MAINTENANCE MANUAL DI 16 0.2 - 1.6%...1:500 (0.2%) to 1:64 (1.6%) • Water Flow Range: 0.05 to 11 GPM • Operating Water Pressure: 4.3 to 85 PSI • Maximum Water Temperature: 104

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MAINTENANCE MANUALMAINTENANCE MANUALDI 16 DI 16

0.2 0.2 -- 1.6%1.6%

© COPYRIGHT, DOSATRON INTERNATIONAL SA, 2002

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STANDARD INSTALLATIONSTANDARD INSTALLATION


200 Mesh/ 80 micron filter

Union ball check/

check valve or water hammer arrestor

Inlet Outlet

Concentrate

Optional accessories:

•Pressure regulator

•Solenoid valves

•Water meter

•Flow restrictor

Optional accessories


MAIN MENUMAIN MENU• CHAPTER 1 Removing the dispenser from the installation• CHAPTER 2 Disassembling the dispenser • CHAPTER 3 Reassembling the dispenser • CHAPTER 4 Maintenance of PX piston• CHAPTER 5 Maintenance of air bleed• CHAPTER 6 Troubleshooting guide


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SPECIFICATIONSSPECIFICATIONS• Injection Range:

1:500 (0.2%) to 1:64 (1.6%)1:500 (0.2%) to 1:64 (1.6%)• Water Flow Range:

0.05 to 11 GPM0.05 to 11 GPM• Operating Water Pressure:

4.3 to 85 PSI4.3 to 85 PSI• Maximum Water Temperature:

104°F 104°F –– 40°C40°C

Note: Normal safety precautions should be practiced when Note: Normal safety precautions should be practiced when working with chemicals and equipment.working with chemicals and equipment.


5© COPYRIGHT, DOSATRON INTERNATIONAL SA, 2002

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CHAPTER 1CHAPTER 1REMOVING THE DISPENSER FROM INSTALLATIONREMOVING THE DISPENSER FROM INSTALLATION


DISASSEMBLING OF THE DISPENSER FROM THE DISASSEMBLING OF THE DISPENSER FROM THE INSTALLATIONINSTALLATION


After turning off the water and relieving the pressure on the unit, unscrew the dispenser inlet/outlet couplings and allow it to drain.

Unscrew the suction tube nut and remove the hose.




CHAPTER 2CHAPTER 2DISASSEMBLING THE DISPENSERDISASSEMBLING THE DISPENSER


DISASSEMBLING THE DISPENSERDISASSEMBLING THE DISPENSER

Unscrew middle retaining nut.




Pull the injection stem assembly out of the injection sleeve, and let

the solution drain out of it.

CautionCaution: Stem may be full of undiluted chemical. Be aware of

hazardous materials and take the necessary precautions for

protection.


WATCH OUT FOR SPLASHING !WATCH OUT FOR SPLASHING !



With the injection stem assembly in your hands, unscrew the check valve nut.





Gently push the check valve out of the dosing stem with a pencil or similar object.

Do not scratch the inside of the dosing stem.




Separate the check valve assembly. Remove the check valve retainer with the help of small flat head screw driver. Then, remove the

cone and the spring.


DISASSEMBLING THE Y OF DISPENSERDISASSEMBLING THE Y OF DISPENSER


Unscrew the bell housing and remove it.




Unscrew the plunger by pushing the piston down as far as possible. Use the narrow end of the suction tube nut as a

tool to unscrew the plunger.




Remove the piston assembly.




Unscrew the injection sleeve from the body of

the dispenser.

Check that the O-ring, retainer and seal are on the injection sleeve. If not, remove them from the

inside of the dispenser.




Remove the screen from the body, put the dispenser body on a table, hold it firmly and at the same time lift the screen with your fingers.

Remove the bell housing seal.


DISASSEMBLING THE DISPENSERDISASSEMBLING THE DISPENSERDisassembly of the diffuser assembly is only necessary if a leakDisassembly of the diffuser assembly is only necessary if a leak develops.develops.

Unscrew the diffuser nut.

Push the diffuser towards the interior of the dispenser. Bump it with your palm if

necessary.

Remove the diffuser assembly.




When the disassembly of the Dosatron unit is complete, soak it in lukewarm soapy water. A soft bristled brush may be used to break residue.

Change seal kit every 12 months. Seal kit part No. EDDI002 includes: JDI012 - Top O-ring JDI011 - Top sealJDI010 - Plunger sealJDI009 - Injection stem O-ringMDI028 - Check valve springPDI032 - Check valve coneJDI011 - Check valve seal JDI012 - Check valve O-ring

CLEANING & MAINTENANCE PROCEDURECLEANING & MAINTENANCE PROCEDURE





CHAPTER 3CHAPTER 3REASSEMBLING THE DISPENSERREASSEMBLING THE DISPENSER


REASSEMBLING THE DISPENSERREASSEMBLING THE DISPENSER

Place the screen inside the body. Then, reseat or replace the bell

housing O-ring. Replace the O-ring if leaking.





Install the diffuser nut hand tight.

If the diffuser is leaking, replace the diffuser O-ring. Install the diffuser assembly into the body. Be sure to

align the notch in the diffuser with the tooth that is molded in the body.


REASSEMBLING THE DISPENSERREASSEMBLING THE DISPENSERInjection AssemblyInjection Assembly


Replace the check valve seal on the barb fitting with the

raised portion facing upward.

Replace the check valve O-ring.


REASSEMBLING THE DISPENSERREASSEMBLING THE DISPENSERInjection AssemblyInjection Assembly


Replace the check valve cone and spring. Insert them in the check valve guide. Then, put the check valve retainer to hold the cone and the spring in

place.

Caution: Small, spring loaded parts are easily lost!Caution: Small, spring loaded parts are easily lost!




Assemble the check valve assembly by firmly pushing the guide and the barbed fitting together.

Injection AssemblyInjection Assembly



Replace the injection stem O-ring.






Insert the check valve assembly into the injection stem.


Slide the middle nut on the stem and thread the check valve nut.




Injection Sleeve AssemblyInjection Sleeve Assembly

Put the top seal retainer with the ridge toward the seal.

Replace the injection seal on the injection sleeve. Make sure

the raised part is facing up.




Thread the injection sleeve assembly into the body of

the dispenser.

Replace the sleeve O-ring on the top of the retainer.

Injection Sleeve AssemblyInjection Sleeve Assembly




Plunger AssemblyPlunger Assembly

Replace the plunger seal. Make sure not to damage the seal or plunger.




Plunger AssemblyPlunger Assembly

Push the piston down as far as possible and screw the plunger onto

the plunger rod. Use the narrow end of the suction tube nut as a tool to screw the plunger all the way until it stops.



Insert the piston assembly.




Screw the bell housing onto the body of the dispenser. It should be hand tight.




Insert the injection stem assembly into the sleeve.

Insert the stem ring into the sleeve assembly until flush.

Align tooth on sleeve with a notch in clear adjusting nut.





Thread the middle nut onto the injection sleeve.



The dispenser is ready to be reinstalled.




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CHAPTER 4 CHAPTER 4 MAINTENANCE OF PX PISTONMAINTENANCE OF PX PISTON


MAINTENANCE OF PX PISTONMAINTENANCE OF PX PISTON


Insert upper portion of piston into the bell housing half way down, turn the bell housing upside down and hold the smaller part of the piston ONLY, then lift it. The piston should be snug in the bell housing and the bell housing should not fall off, if it does the upper piston shell needs to be replaced. Also inspect the inside of the bell housing and look for deep vertical scratches. If this is the case, the bell housing needs to be replaced.

Piston “Fit” TestPiston “Fit” Test



Insert the lower part of the piston half way down the body. Holding onto the top of the piston, let go of the body. The piston should be snug in the body, and the

body should not fall off, if it does the lower piston shell needs to

be replaced.

Also inspect the inside of the body and look for deep vertical

scratches. If this is the case, the body needs to be replaced.

MAINTENANCE OF PX PISTONMAINTENANCE OF PX PISTONPiston “Fit” TestPiston “Fit” Test Note: It is best to remove the plunger (page 14) prior to Note: It is best to remove the plunger (page 14) prior to

doing this test so it will not interfere.doing this test so it will not interfere.


Remove the plunger rod. To do so, turn the nut 1/8 turn counter clockwise. Pull on nut once, then, turn again the

nut 1/8 turn counter clockwise.


MAINTENANCE OF PX PISTONMAINTENANCE OF PX PISTONDisassembly of pistonDisassembly of piston


Remove the upper valves by squeezing the upper area of the valve.




Unscrew the 4 screws that connect the piston rod retainer to piston shell. Remove the piston

rod retainer.



Pull out the actuator assembly

from the top.


Remove screws from outer perimeter of piston

shell.

Separate the upper piston shell from the lower piston shell.

Remove the seal between the two piston shells.





MAINTENANCE OF PX PISTONMAINTENANCE OF PX PISTONReassembly of pistonReassembly of piston

Screw the screws from outer perimeter of piston

shell.

Put together the upper and the lower piston

shells.

Replace the seal between the two piston shells.


Insert the piston assembly into the piston shell. Make sure that the two guides are aligned with

the piston shell columns.



Replace the lower valves O-rings if

they are missing or deteriorating.

Replace the toggle spring.


Put together the piston rod retainer, the two feet

should face downward.


Install the piston rod retainer in the piston shell. Attach it with the four screws.



Replace the O-rings on the upper piston valves if they are

missing or deteriorating. Insert the two upper piston

valves.© COPYRIGHT, DOSATRON INTERNATIONAL SA, 2002


The splits in the valves should line up.




Install plunger rod in the rod retainer. The pin in the head of the rod should be aligned with the slot inside the rod retainer.

Lock it in to place by turning the lock nut clockwise 1/8 turn,

pushing it down and 1/8 turn clockwise again.



MAINTENANCE OF PX PISTONMAINTENANCE OF PX PISTONReset PistonReset Piston

To reset the piston, remove the bell housing, push the piston all the way down, it may click, pull the piston all the way up. Holding it in up position, push down on the vertical posts and it should click. Push the piston back down and screw the bell housing on.




CHAPTER 5CHAPTER 5MAINTENANCE OF AIR BLEEDMAINTENANCE OF AIR BLEED



MAINTENANCE OF AIR BLEEDMAINTENANCE OF AIR BLEEDDisassembly of air bleedDisassembly of air bleed

Remove the rubber cap from the top of the air bleed button.



MAINTENANCE OF AIR BLEEDMAINTENANCE OF AIR BLEED

Remove the ribbed collar by pulling it straight up.

Disassembly of air bleedDisassembly of air bleed

Using a small flat blade screwdriver, gently pry loose

the ribbed collar.



MAINTENANCE OF AIR BLEEDMAINTENANCE OF AIR BLEEDDisassembly of air bleedDisassembly of air bleed

Gently twist the air bleed button with pliers (if necessary) until the two tabs on the air bleed button align with the corresponding grooves in the bell housing.

Remove the air bleed button by pushing it through the bell housing.



MAINTENANCE OF AIR BLEEDMAINTENANCE OF AIR BLEEDReassembly of air bleedReassembly of air bleed

Replaced the O-ring.

The only serviceable part on the air bleed is the O-ring.




Align the two tabs on the air bleed with the

corresponding grooves in the bell housing.



MAINTENANCE OF AIR BLEED

Install the air bleed button from the inside of the bell

housing. Make sure the two tabs get out of the bell

housing.Rotate the air bleed button

a quarter turn.

Reassembly of air bleedReassembly of air bleed




Install the ribbed collar so that the tabs fit into the

slots in the collar.

Re-install the rubber cap on the air bleed button.




CHAPTER 6 CHAPTER 6 TROUBLESHOOTING GUIDETROUBLESHOOTING GUIDE


TROUBLESHOOTINGTROUBLESHOOTING

© COPYRIGHT, DOSATRON INTERNATIONAL S.A. , 2002

Do piston “fit” test (pages 38-39). Replace piston shells, body and bell housing as necessary. Make sure your installation has a 200 mesh filter before the Dosatron.

Worn piston shells, bell housing or body

Clean the in line water filter. Clean the inside screen (see pages 17 and 21).

In-line water filter or inside screen is clogged

1. Reduce the flow rate and restart the unit slowly.2. Open bell housing, check O-rings around the four piston valves (2 at the top, 2 at the bottom) to see if they are missing or dislodged. 3. Reset the piston (see page 49 for instructions) screw bell housing back on.

Excessive water flow

PISTONPiston is not clicking

Reset piston (see page 49 for instructions) and install water hammer arrestor in the appropriate location.

Water hammer

Do piston “fit” test (pages 38-39). replace piston shells, body and bell housing as necessary. Make sure your installation has a 200 mesh filter before the Dosatron.

Scratched/scored piston shells, bell housing and/or body

Bleed out the air by pushing the air bleed button until constant flow of water comes out from around the button.

Presence of air inside the bell housing

Reset piston. See page 49 for instructions. Flip bypass to ON position if dispenser is equipped with manual bypass

Piston locked up/not clicking or bypass is in OFF position.

The arrow on the unit should point in the same direction as the water flow. Water supply and demand valve should be open.

The unit is installed in the wrong direction

REMEDYCAUSESYMPTOM




Clean or replace check valve parts and reassemble check valve correctly. Be sure the check valve seal is in proper position. Pages 23-25.

Check valve dirty, worn, assembled incorrectly or missing

DOSING Water flowing back into solution container.

Check suction tube connection. Inspect suction tube for pin holes or cracks.Check tightness of connection nuts.Cut ½” of top of the hose and reattach it correctly.

Air leak in the suction tube

No suction of solution

Clean or replace plunger seal.If plunger seal is missing, check incoming water pressure; refer to unit manual for specifications.

Plunger seal is damaged, swollen or missing

Clean or replace check valve parts. In particular the seal and the cone. Pages 23-25.

Check valve worn, improperly assembled, dirty or damaged

Do piston “fit” test (pages 38-39). If necessary replace piston shells, body and bell housing. Make sure your installation has a200 mesh filter before the Dosatron.

Worn piston shells, bell housing or body

Clean suction tube and strainer or replace hose assembly.Raise strainer 2” off the bottom of stock tank solution.

Suction tube or strainer clogged

Reset piston. See page 49 for instructions. Flip bypass to ON position if dispenser is equipped with manual bypass

Piston locked up/not clicking or bypass is in OFF position

REMEDYCAUSESYMPTOM




Do piston “fit” test (pages 38-39). If necessary replace piston shells, bell housing and/or body. Make sure your installation has a 200 mesh filter before the Dosatron.

Worn or scratched piston shells, bell housing and/or body

Check suction tube connection. Inspect suction tube for pin holes or cracks. Check tightness of connection nuts. Cut ½” off top of the hose and reattach it correctly.

Suction of air

Under-Injection

Listen to the unit clicking, count the individual clicks, should not exceed 36 clicks in 15 seconds otherwise is excessive flow. If excessive flow reduce the flow rate and restart the unit slowly.

Excessive water flow

Replace plunger seal.Worn plunger seal

Replace injection stem.Worn or cracked injection stem

Clean or replace check valve parts. In particular the seal and the cone. Pages 23-25.

Check valve worn, improperly assembled, dirty or damaged

REMEDYCAUSESYMPTOM




Position correctly or replace the diffuser seal.Check tightness of the nut. Pages 18 & 22.

Diffuser seal is damaged or positioned incorrectly

Position correctly or replace the diffuser if damaged. Align notch in the diffuser with tooth molded in the body. Pages 18 & 22.

Diffuser is installed incorrectly

Position correctly, clean the seal seat, or replace the bell housing seal.

Bell housing seal is damaged, positioned incorrectly or missing

Leaks between the body and the bell housing

Check and replaced the body if necessary.Body may be cracked

LEAKSLeaks in the vicinity of the black nut under the body

REMEDYCAUSESYMPTOM



Thank you for using Dosatron liquid dispensers.

Please contact us at (800) 523-8499 for further assistance or visit our website at

www.dosatronUSA.com

2090 Sunnydale Blvd., Clearwater, Florida 33765

www.dosatronusa.com

Documents

MAINTENANCE MANUAL DI 16 0.2 - 1.6%...1:500 (0.2%) to 1:64 (1.6%) • Water Flow Range: 0.05 to 11 GPM • Operating Water Pressure: 4.3 to 85 PSI • Maximum Water Temperature: 104