IOM 3000 Dolphin Watercare 6-30-08

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<p>Dolphin WaterCare is a Division of Clearwater Systems Corporation, Essex, CT. Copyright 2008. All Rights Reserved.</p> <p>TECHNICAL MANUAL INSTALLATION, OPERATION, AND MAINTENANCE </p> <p>DOLPHIN SERIES 3000</p> <p>Superior Performance Chemical-Free Energy Savings Minimal Maintenance Water Savings</p> <p>DESIGNED, DEVELOPED, MANUFACTURED, AND MARKETED BY:</p> <p>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.</p> <p>Document No. CWSTL0204 Rev. 6-30-08</p> <p>The Dolphin SERIES 3000</p> <p>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.</p> <p>Appendix/Addendum Designation and Title</p> <p>Issue Date</p> <p>Date Received Acknowledged By</p> <p>This document supports the following Clearwater System Corporation products.</p> <p>Dolphin System 3000 Dolphin System 3000-G Dolphin System 3000-REF</p> <p>This device is registered with the U.S. EPA as a Pesticide, Device or Active Ingredient Producing Establishment EPA Est. 73323-CT-0001</p> <p>This product conforms to the requirements of CFR 47(FCC) PART 18, 2006 for radiated emissions.</p> <p>ii</p> <p>The Dolphin SERIES 3000</p> <p>Table of ContentsSubject Page</p> <p>List of Ongoing Appendixes or Addenda .....................................................ii 1.0 INTRODUCTION....................................................................................... 11.1 The Dolphin Series 3000 ......................................................................................... 1</p> <p>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</p> <p>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</p> <p>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</p> <p>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</p> <p>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</p> <p>iii</p> <p>The Dolphin SERIES 3000</p> <p>6.3 6.4 6.5 6.6 6.7</p> <p>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</p> <p>7.0 TESTING AND TROUBLESHOOTING .................................................. 29 8.0 ROUTINE MAINTENANCE..................................................................... 308.1 Inspection .............................................................................................................. 30 8.2 Cleaning................................................................................................................. 31</p> <p>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</p> <p>APPENDIX A: MAINTENANCE SCHEDULES ............................................ 37 APPENDIX B: DOLPHIN WATERCARE CHEMISTRY LOGS .................... 41 APPENDIX C: GLOSSARY OF TERMS ...................................................... 45</p> <p>iv</p> <p>The Dolphin SERIES 3000</p> <p>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.</p> <p>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</p> <p>TablesSubjectTable 1. Table 1A. Table 1B. Table 1C. Table 1D. Table 1E. Table 2. Table 3. Table 4. Table 5. Table 6.</p> <p>PageSignal Generator Small Panel 1"- 6" 115/1/60 Specifications ................ 13 Signal Generator Small Panel 1"- 6" 230/1/60 Specifications................ 14 Signal Generator Small Panel 1"- 6" 230/1/50 Specifications................ 14 Signal Generator Large Panel 8"- 16" 230/1/60 Specifications ............. 15 Signal Generator Large Panel 8"- 16" 230/1/50 Specifications ............. 15 Signal Generator Large Panel 8"- 16" 480/1/60 Specifications.............. 16 Treatment Module Specifications ............................................................ 17 Maximum Fluid Operating Pressure........................................................ 18 Temperature Derating Factor for PVC .................................................... 18 Maximum Flow Rates.............................................................................. 21 Troubleshooting Chart............................................................................. 29</p> <p>v</p> <p>The Dolphin SERIES 3000</p> <p>Table A-1. Dolphin-Equipped Cooling Tower Maintenance Schedule .................... 38 Table A-2. Dolphin-Equipped Boiler Maintenance Schedule.................................. 39 Table B-1. Cooling Tower Water Analyses Log...................................................... 42 Table B-2. Boiler Water Analyses Log.................................................................... 43 Table C-1. Glossary of Terms ................................................................................ 46 Table D-1. Notes .................................................................................................... 48</p> <p>vi</p> <p>The Dolphin SERIES 3000</p> <p>1.0 INTRODUCTIONThe Dolphin Series 3000 (or Dolphin SystemTM) equipment has been designed for superior performance, ease of installation, minimal maintenance, longevity, and low-cost operation. Please take a few minutes to read the basic instructions and warnings in this manual before attempting any installation of or adjustment to the Dolphin System. If you have any questions about any aspect of installing or attending to the system, please contact our service center through any of the means listed on the cover of this manual.</p> <p>1.1 The Dolphin Series 3000The Dolphin System consists of two main components. The Signal Generator houses the power and control components in a NEMA 3R and IEC IP24 rated enclosure. Any serviceable items (fuses, fan filters) are located in the enclosure. The Treatment Module is connected to the Signal Generator via an umbilical cable. There are no customer serviceable parts in the Treatment Module.</p> <p>Figure 1. Overview: The Dolphin Series 3000 SystemOperating Status LEDs External Mounting Flanges</p> <p>Lock</p> <p>Fan Inlet/Filter Ventilation Exhaust/Filter</p> <p>AC Power Connection Knockout Umbilical Cable</p> <p>Signal Generator</p> <p>Serial No. &amp; Voltage Nameplates</p> <p>Serial No. Label 1</p> <p>Treatment Module</p> <p>The Dolphin SERIES 3000</p> <p>2.0</p> <p>PRINCIPLES OF OPERATION</p> <p>The Dolphin imparts pulsed, high frequency electric fields into flowing water. The characteristic waveform is shown below.</p> <p>2.1 Scale PreventionWhen evaporation or steam production occurs in a cooling tower or boiler, the water exits as water vapor and leaves the dissolved minerals behind, causing increased concentration. Upon sufficient concentration, the dissolved minerals such as calcium carbonate (i.e., limestone) become solid in a process known as precipitation. The Dolphin System changes the form of precipitated solids from hard lime scale to a harmless powder. The Dolphin System accomplishes this change by activating naturally occurring, smallsuspended particles in the water. These tiny suspended particles exist in large quantities in all city water or well water that is used as cooling tower or boiler make-up water. Under Dolphin System treatment, the suspended particles (suspended meaning that they neither sink nor float because of their small size) act as seeds for precipitation of dissolved minerals. The Dolphin System activates the suspended particles by removing the static electric charge on their surface. A powder of calcium carbonate (limestone) grows by coating or adhering to the suspended seed particles. The powder formation relieves the ever-growing pressure to form solids that occur from the increasing mineral concentration, before scale has a chance to form on equipment surfaces. Without Dolphin System treatment, the pressure to form solids is relieved by the formation of scale on equipment surfaces. The process is much like seeding a cloud to produce rain when weather conditions are building up water concentration in the atmosphere.2</p> <p>The Dolphin SERIES 3000</p> <p>In removing the surface charge on suspended particles, the Dolphin System makes those particles the preferred sites for precipitation to occur. Thus, the minerals coat or adhere to the suspended particles rather than equipment surfaces. These coated particles or powder can be easily removed from a cooling tower basin by manual means, filtration, or centrifugal separation. The quantity of powder is typically about 15% of normal blown-in dirt in a cooling tower. In a boiler, the powder exits through normal bottom blowdown.</p> <p>Photomicrographs of the two mineral formations are shown in the following magnifications:</p> <p>Typic...</p>