IOM 3000 Dolphin Watercare 6-30-08

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Dolphin WaterCare is a Division of Clearwater Systems Corporation, Essex, CT. Copyright 2008. All Rights Reserved.

TECHNICAL MANUAL INSTALLATION, OPERATION, AND MAINTENANCE

DOLPHIN SERIES 3000

Superior Performance Chemical-Free Energy Savings Minimal Maintenance Water Savings

DESIGNED, DEVELOPED, MANUFACTURED, AND MARKETED BY:

CLEARWATER SYSTEMS CORPORATION145 DENNISON ROAD P.O. BOX 463 ESSEX, CT 06426 PHONE: 860-767-0850 FAX: 860-762-8972 Email: service@dolphinwatercare.com Internet: www.dolphinwatercare.comThe Dolphin SystemTM is covered by the following patents: U.S. Patents 6,063,267 and 6,641,739, Canadian Patent 2335496, and Japanese Patent 3595505. Other patents applications pending.

Document No. CWSTL0204 Rev. 6-30-08

The Dolphin SERIES 3000

List of Ongoing Appendixes or AddendaNew information may be issued in the form of an appendix or as an addendum to your manual. Please store such items with your acknowledgment of receiving them in the following table.

Appendix/Addendum Designation and Title

Issue Date

Date Received Acknowledged By

This document supports the following Clearwater System Corporation products.

Dolphin System 3000 Dolphin System 3000-G Dolphin System 3000-REF

This device is registered with the U.S. EPA as a Pesticide, Device or Active Ingredient Producing Establishment EPA Est. 73323-CT-0001

This product conforms to the requirements of CFR 47(FCC) PART 18, 2006 for radiated emissions.

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The Dolphin SERIES 3000

Table of ContentsSubject Page

List of Ongoing Appendixes or Addenda .....................................................ii 1.0 INTRODUCTION....................................................................................... 11.1 The Dolphin Series 3000 ......................................................................................... 1

2.0 PRINCIPLES OF OPERATION ................................................................ 22.1 Scale Prevention..................................................................................................... 2 2.2 Bacterial Control ..................................................................................................... 4 A. Encapsulation......................................................................................................... 4 B. Electroporation ....................................................................................................... 4 C. Biofilm or Slime ...................................................................................................... 4 2.3 Corrosion Control.................................................................................................... 5 A. Localized Corrosion Corrosion ............................................................................... 5 B. Uniform Corrosion .................................................................................................. 5

3.0 COOLING TOWER OPERATIONS ...........................................................................63.1 Cleaning, "Passivation," and Galvanized Conditioning........................................... 6 A. Cleaning ................................................................................................................. 6 B. Passivation of Iron Piping ....................................................................................... 6 C. Conditioning Galvanized Tower to Prevent White Rust ......................................... 6 3.2 Tower Startup ......................................................................................................... 7 3.3 Transition to Dolphin System Treatment................................................................. 7 A. System Totally Drained .......................................................................................... 7 B. System Not Drained ............................................................................................... 7 C. Dolphin Installation on One Cooling Cell or Chiller at a Time ................................ 7 3.4 Algae....................................................................................................................... 8 3.5 Monitoring ............................................................................................................... 9

4.0 SERVICE AND WARRANTY.................................................................... 94.1 4.2 4.3 4.4 Service ..................................................................................................................... 9 Limited Warranty...................................................................................................... 9 Legionella Statement ............................................................................................. 10 Safety Instructions and Warnings .......................................................................... 12

5.0 DOLPHIN SERIES 3000 MAJOR COMPONENT DESCRIPTIONS ..... 135.1 The Signal Generator ............................................................................................ 13 5.2 The Treatment Module .......................................................................................... 16 5.3 Operating Temperatures and Pressures for the Dolphin System .......................... 18

6.0 INSTALLATION INSTRUCTIONS .......................................................... 196.1 Proper Lifting of the Treatment Module ................................................................. 19 6.2 Installation Location of the Treatment Module on Evap Condenser Tower .......... 20

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The Dolphin SERIES 3000

6.3 6.4 6.5 6.6 6.7

Installation Location of the Treatment Module on Cooling Tower.......................... 21 Installation Guidelines............................................................................................ 22 Installation of the Signal Generator ....................................................................... 23 System Status Relay/Building Management System Connection ......................... 28 Remote Start/Stop ................................................................................................. 28

7.0 TESTING AND TROUBLESHOOTING .................................................. 29 8.0 ROUTINE MAINTENANCE..................................................................... 308.1 Inspection .............................................................................................................. 30 8.2 Cleaning................................................................................................................. 31

9.0 PREPARATION FOR SHIPMENT .......................................................... 32 10.0 OUTSIDE INSTALLATION - RAIN HOODS......................................... 33 11.0 BOILER APPLICATION OF THE DOLPHIN......................................... 3511.1 Dolphin System Boiler Installation and Operation ............................................... 35 11.2 Dolphin System Boiler Installation Guidelines ..................................................... 35

APPENDIX A: MAINTENANCE SCHEDULES ............................................ 37 APPENDIX B: DOLPHIN WATERCARE CHEMISTRY LOGS .................... 41 APPENDIX C: GLOSSARY OF TERMS ...................................................... 45

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IllustrationsSubjectFigure 1. Figure 2. Figure 2A. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 8A. Figure 8B. Figure 8C. Figure 8D. Figure 9. Figure 9A. Figure 9B. Figure 9C. Figure 10. Figure 11. Figure 12. Figure 13. Figure 14. Figure 15.

PageOverview: The Dolphin 3000 Series System.......................................... 1 Signal Generator 1 6 Small Panel .................................................... 13 Signal Generator 8 16 Large Panel.................................................. 15 Treatment Module .. 17 Proper Lifting of the Treatment Module................................................. 19 Evaporative Condenser Tower ............................................................. 20 Typical Evaporative Cooling Tower Installation .................................... 21 Support of the Treatment Module for Pipe Sizes 6" or Larger............... 22 Signal Generator 1"- 6" Small Panel Call-Out....................................... 23 Signal Generator (Bottom View) AC Power and Serial Number Label . 24 Treatment Module Serial Number Label............................................... 24 Signal Generator (Front View) 8"-16" 230 Volt Large Panel Call-Out... 25 Signal Generator (Front View) 8"-16" 480 Volt Large Panel Call-Out... 25 AC Power Wiring Diagram 1" to 6" - 115 Volt ....................................... 26 AC Power Wiring Diagram 1" to 6" - 230 Volt ....................................... 26 AC Power Wiring Diagram 8" to 16" - 230 Volt ..................................... 27 AC Power Wiring Diagram 8" to 16" - 480 Volt..................................... 27 Status Relay/Building Management System Connection ..................... 28 Outside Vertical Installation with Rain Hood ..................................... 33 Outside Horizontal Installation with Rain Hood ................................. 34 Heat Tracing of the Treatment Module ................................................ 34 Insulation of the Treatment Module ..................................................... 34 Typical Steam Boiler Installation .......................................................... 35

TablesSubjectTable 1. Table 1A. Table 1B. Table 1C. Table 1D. Table 1E. Table 2. Table 3. Table 4. Table 5. Table 6.

PageSignal Generator Small Panel 1"- 6" 115/1/60 Specifications ................ 13 Signal Generator Small Panel 1