Severn Trent NXT3000 Series Training manual

- 1 - 105.6605.0

Instruction Bulletin - Series High Capacity

NXT3000 Wall Mounted Vacuum Regulator

1,000 - 3,000 PPD (30-60 Kg/h) Maximum

105.6605.0 - 2 -

Theseinstructionsdescribetheinstallation,operationandmaintenanceofthesubjectequipment. Failure to strictly follow

these instructions can lead to an equipment rupture that may cause signiﬁcant property damage, severe personal injury

and even death. If you do not understand these instructions, please call Severn Trent Water Puriﬁcation for clariﬁcation

before commencing any work at 215-997-4000 and ask for a Field Service Manager. Severn Trent Water Puriﬁcation,

Inc. reserves the rights to make engineering reﬁnements that may not be described herein. It is the responsibility of the

installer to contact Severn Trent Water Puriﬁcation, Inc. for information that cannot be answered speciﬁcally by these

instructions.

Any customer request to alter or reduce the design safeguards incorporated into Severn Trent Water Puriﬁcation

equipment is conditioned on the customer absolving Severn Trent Water Puriﬁcation from any consequences

of such a decision.

Severn Trent Water Puriﬁcation has developed the recommended installation, operating and maintenance procedures

with careful attention to safety. In addition to instruction/operating manuals, all instructions given on labels or attached

tags should be followed. Regardless of these efforts, it is not possible to eliminate all hazards from the equipment or

foresee every possible hazard that may occur. It is the responsibility of the installer to ensure that the recommended

installation instructions are followed. It is the responsibility of the user to ensure that the recommended operating and

maintenance instructions are followed. Severn Trent Water Puriﬁcation, Inc. cannot be responsible deviations from the

recommended instructions that may result in a hazardous or unsafe condition.

Severn Trent Water Puriﬁcation, Inc. cannot be responsible for the overall system design of which our equipment may

be an integral part of or any unauthorized modiﬁcations to the equipment made by any party other that Severn Trent

Water Puriﬁcation, Inc.

Severn Trent Water Puriﬁcation, Inc. takes all reasonable precautions in packaging the equipment to prevent shipping

damage. Carefully inspect each item and report damages immediately to the shipping agent involved for equipment

shipped “F.O.B. Colmar” or to Severn Trent Water Puriﬁcation for equipment shipped “F.O.B Jobsite”. Do not install

damaged equipment.

SEVERN TRENT SERVICES, COLMAR OPERATIONS

COLMAR, PENNSYLVANIA, USA

IS ISO 9001: 2000 CERTIFIED

- 3 - 105.6605.0

Table of Contents

1 INTRODUCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

1.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

1.2 Warranty. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

1.3 Standard Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

1.4 Speciﬁcations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

2 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

2.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

2.2 Safety Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

2.3 Principles of Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

2.4 Capacity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

2.5 Typical Gas Feed Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

3 INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

4 OPERATING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

4.1 Initial Start-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

4.2 Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23

5 SHUTDOWN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

5.0 Shutdown for Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

5.1 Shutdown for Extended Period . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

6 SERVICE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

6.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29

6.2 Cleaning Agents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

6.3 Lubricating Agents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

6.4 O-Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

6.5 Diaphragms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30

6.6 Check Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

6.7 Hose Lines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

6.8 Inlet Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30

6.9 Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

7 TROUBLESHOOTING CHART. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31

FIGURES

1 Basic System Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

2 Cylinder Mounted Vacuum Regulators. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

3 Ton Container and Wall Mounted Vacuum Regulators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

4 Mounting Cylinder Mounted Vacuum Regulators. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

5 Mounting Ton Container Mounted Vacuum Regulators. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

6 Mounting Wall Mounted Vacuum Regulators. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

7 Connections - Wall Mounted Vacuum Regulators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14

8 Out-of-Gas Alarm Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

9 SO2Cylinder Adaptor Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

10 Wall Mounted Vacuum Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16

11 Vacuum Regulator Exploded View. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17

12 Meter Exploded View. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18

105.6605.0 - 4 -

1 INTRODUCTION

1.1 General

The vacuum regulators are engineered and carefully tested to assure years of satisfactory operation. Correct

installation and proper care will ensure continued trouble free operation. Read instructions carefully and save

for future reference.

This instruction manual covers the High Capacity NXT3000 Series vacuum regulator and it's function within a

gas feed system. The complete gas feed system consists of a vacuum regulator, a gas ﬂow meter assembly

with a manual or automatic rate valve and an ejector. Refer to the following instruction manuals for other

system components:

Meter Assemblies 105.6610

Ejectors 122.6051, 122.6060

Also, the following literature is referenced throughout:

Vacuum Line Size Requirements 100.4601 and 121.3003

Chemical feed equipment technical information 010.3650

1.2 Warranty

See Bulletin 005.9001 for Severn Trent Services equipment warranty.

NOTE: The High Capacity NXT3000 vacuum regulator is designed for use in systems where the feed rate

is manually or automatically set and operation is either continuous or start/stop. The Severn Trent Services

equipment warranty and service policy is null and void, as it pertains to user protection, if the High Capacity

NXT3000 Series vacuum regulator is misapplied.

1.3 Standard Equipment

The NXT3000 Series gas feeder system consists of the following major components and accessories:

1.3.1 Vacuum regulator, which connects to the gas manifold.

1.3.2 Ejector assembly. See Instruction Manuals 122.6051, 122.6060.

1.3.3 Metering or multiple feed points, separate meter assemblies. See Instruction Manual 105.6610.

1.3.4 Accessories

a. (1) - Ammonia leak test bottle

b. (1) - Insect screen for vent line

c. (4) - Spare lead gaskets

d. (1) - Multi purpose wrench

NOTE: This instruction manual covers the vacuum regulator only. Since the vacuum regulator is one part

of a gas feed system, references will be made within this bulletin to meter assemblies, ejectors and

other ancillary equipment that complete the various systems. Installation of a complete system

is covered within.

- 5 - 105.6605.0

1.4 Speciﬁcations

Capacity: Chlorine - 1000 to 3000 PPD (20 kg/h to 60 kg/h)

Sulfur Dioxide - 1000 to 2000 PPD (20 kg/h to 40 kg/h)

Ammonia - 500 to 1000 PPD (10 kg/h to 20 k/gh)

Carbon Dioxide* - 750 to 1500 PPD (15 kg/h to 30 k/gh)

*Due to the high gas pressure in the carbon dioxide storage cylinders, a two stage pressure regulator is

required between the gas source and the vacuum regulator.

Temperature limits: 35° to 130°F (2° to 54°C)

Maximum inlet pressure: 300 PSIG

Manifold heater power: 25 Watt, 120 or 240 VAC, 50/60 Hz

105.6605.0 - 6 -

2 OPERATION

2.1 General

A. Vacuum Regulator

The vacuum regulator serves to reduce the gas supply pressure to a regulated vacuum for safe transport of

the gas to the point of application. Aleak in any portion of the vacuum transport line simply allows air to be

pulled into the system. A substantial vacuum line break will stop gas feed from taking place. The vacuum

regulator is a spring opposed diaphragm type that uses vacuum to operate the gas inlet valve. The vacuum

regulator can control maximum gas ﬂow rates from 1000 to 2000PPD without any component changes. (Up

to 3,000 for chlorine with different components)

For manually controlled systems, the ﬂow rate of gas through the regulator is set and indicated by a meter

assemblywhichcontainsa manuallyadjustedneedlevalve,called aratevalve. Oneormore meterassemblies

may be furnished with each vacuum regulator and they are wall mounted. The operating vacuum that pulls

the gas through the system is created by a separately mounted ejector, one normally being required for

each meter assembly.

Each vacuum regulator is equipped with a vacuum actuated, manually reset, three position, “status” lever

markedRESERVE,OPERATING, and EMPTY. When a systemisplacedinto operation, the lever ismanually

set to the operating position. When the gas in the cylinder or ton container is exhausted, or has been

inadvertently interrupted, the lever automatically moves to the EMPTY position. The RESERVE position is

used when a dual regulator type gas dispensing system is furnished, The RESERVE position indicates that

the gas cylinder is full and is in stand-by condition. When the operating tank is exhausted, its status lever

moves to EMPTY and the reserve tank status lever moves to the OPERATING position. This provides an

automatic changeover of gas feed from the exhausted to the full gas supply container.

B. Meter-Rate Valve Assembly

The meter assembly is a variable area type meter and provides visual indication of the gas ﬂow rate set

by the rate valve. Since the systems operates under sonic conditions a D/P Regulator is not required to

maintain constant ﬂow under varying vacuum conditions.

The rate valve is located at the meter outlet (top) to provide manual selection of the desired gas ﬂow rate.

The capacity range of each meter-rate valve assembly is clearly indicated by a calibrated scale, direct

reading in pounds per day (PPD) and kilograms per hour (kg/h), etched on the meter assembly tube.

For systems requiring automatic feed control, an automatic valve is provided to be piped between the

ejector and the meter assembly. The manual valve on the meter assembly is not supplied for this mode

of operation.

C. Ejector

The ejector, operated by the ﬂow of water or process liquid under sufﬁcient pressure and velocity, creates

the necessary vacuum to operate the regulator. In some instances, a booster pump is required to provide

sufﬁcient water pressure and ﬂow rate.

2.2 Safety Features

The gas inlet valve of the vacuum regulator provides positive shut-off in the absence of operating vacuum.

Therefore, the regulator is sealed off from the gas supply if a major leak should develop in the vacuum portion

of the gas dispensing system during normal operation or at shutdown when the water supply to the ejector is

shut off. This valve is protected by a cartridge type ﬁlter located within the gas manifold.

A pressure relief valve, within the vacuum regulator, provides for venting gas, through a vent connection, to a

remoteand suitable location should gas at greater than atmospheric pressureentertheregulator. This abnormal

condition could occur if liquid chemical enters the regulator; or, the gas inlet valve of the regulator does not close

tightly due to the accumulation of foreign matter not removed by the ﬁlter.

- 7 - 105.6605.0

The manifold assembly has a liquid chemical trap, a wrap-around type heater and a cartridge type ﬁlter. The

trap catches any condensed gas vapors (liquid chemical) which may form in the gas supply line to prevent its

entrance into the regulator. The heater vaporizes any liquid chemical and prevents any gas from condensing in

the manifold, thereby permitting only gas to enter the regulator. The ﬁlter cartridge serves to remove entrained

foreign particles from the gas entering the manifold assembly.

2.3 Principle of Operation

When the ejector is operating, gas enters the regulator, being reduced from supply pressure to a constantly

regulated vacuum by the throttling action of the regulator, the meter assembly rate valve assembly and into

the ejector. Within the ejector, the gas is thoroughly mixed with the water or process liquid to form a chemical

solution which is delivered via solution hose or piping to the point of application.

WARNING

All components of the gas dispensing system are constructed of materials

capable of withstanding the corrosive action of the particular gas for which

the system has been speciﬁed. Never attempt to use any component

for handling a gas different from that for which it has been purchased.

Failure to observe this warning can result in equipment failure and bodily injury.

2.4 Capacity

The vacuum regulators can be provided with maximum capacities of either 2,000 PPD or 3,000 PPD as chlorine.

The actual system maximum is determined by the ﬂowmeter-rate valve combination and the commensurate

ejector sizing. The capacity of an installed system may be changed by changing the meter assembly and/or

ejector capacity components. Refer to the vacuum regulator parts list 100.7609, the meter assembly parts list

105.7226, and ejector parts lists Section 122, for the speciﬁc part numbers associated with each ejector.

2.5 Typical Gas Feed Systems

Figure1 illustrates several basic system arrangements. The meter-rate valve assembly must always be mounted

remotely on a wall. The gas ﬂow from the vacuum regulator may be divided to feed more than one application

point with the ﬂow to that point being either manually or automatically controlled. The sum of the ﬂows to each

application point cannot exceed the capacity of the vacuum regulator.

Automatic switchover may be achieved by adding a second vacuum regulator and connecting the outlets to a

tee connected to the meter assemblies and following the procedures outlined further in this manual.

105.6605.0 - 8 -

Figure 1 - Basic System Schematics

Single Regulator System

Manual Control

Automatic Change-Over

Dual Regulator System

Manual Control

Single Regulator System

Automatic Control

Automatic Change-Over

Dual Regulator System

Automatic Control

- 9 - 105.6605.0

3 INSTALLATION

Select a location which can be isolated from unauthorized personnel. Outdoor installations for wall mounted

regulators are not recommended (especially if the gas supply system consists of two or more containers) since a

suddendecreaseinambient temperature will result in the formation of condensed gas vapors (liquidchemical) in

the gas supply line. This liquid will be swept into the manifold and if sufﬁcient in volume to exceed the vaporizing

capacity of the manifold heater, will ﬂood the manifold and enter the regulator.

CAUTION

The corrosion resistant plastics used in the construction of all

regulators and meter-rate valve assemblies, regardless of the particular

gas service for which they have been supplied, will soften and distort

above 130°F (54°C). Therefore, the ambient temperature, in every instance,

must never exceed this maximum allowable limit.

If you must install outdoors, select an area which will provide natural protection for the gas supply against direct

sunlight. If this is not possible, erect an open type structure to provide this protection. Observe the upper and

lower temperature limits. (Upper limit 130°F (54°C), Lower limit 40°F (5°C))

Forindoor installations, select a well ventilated enclosureprovidedwitha source of heat, if necessary,tomaintain,

acomfortableambienttemperature. Additionally, the enclosure should beof sufﬁcient size to permit easy access

for inspection and maintenance of the regulator and gas supply. And ﬁnally, to provide for maximum safety

of operating personnel, the enclosure should be equipped and ﬁtted as described under the Personnel Safety

Section of Instruction Bulletin 010.3550.

The relative locations of the regulator(s); the remote mounted meter-rate valve assemblies, if used; and the

ejector(s) must be chosen so that the length(s) of the vacuum line(s) does not exceed the value(s) shown in

100.4601 and 121.3003. Maximum gas ﬂow to the point(s) of application will not be achieved if these limits are

exceeded.

The vent line(s), one required for each regulator, must be extended to a suitable area (outside the building

for indoor installations) where gas fumes cannot cause damage or endanger personnel. Although there is

no restriction (within practical limits) to the distance over which the vent line(s) can be extended, each line, if

applicable, must be run individually. Multiple vent lines cannot be manifolded. The end of the vent line(s) must

beturneddownwardto prevent the entrance of water. Theﬁne mesh plastic screen(s) (supplied in the accessory

package) must be installed over the outlet(s) to prevent insects from entering the line(s).

When extending vent lines, eliminate low spots to prevent trapping condensed water vapor and arrange to

prevent crimping.

Allthreaded plastic-to-plastic pipe joints must be lubricatedtopreventgalling of the threads, provide a perfectseal

and to permit ease of disassembly. The recommended lubricating agent is Teﬂon (self lubricating) tape. Apply

tape to the male pipe threads, one thread from the end, only to prevent it from entering the piping. Exercise care

not to overtighten the joints as this may crack the plastic. Slightly more than hand tight is usually sufﬁcient.

The vacuum regulator shall be wall mounted or mounted on a multi-container manifold only.

Wall Mounting refer to Figure 2 & 3.

105.6605.0 - 10 -

Figure 2 - Wall Mounted Vacuum Regulators

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