CHEMPOD - cleaningsystemsinc.comincluded in ChemPod Mizer Install Kit P91030002. The check valve...

CHEMPOD®

Cleaning Systems Inc. 2 P59000002 Rev:04

Table of Contents Overview ........................................................................................................................................... 3 Specifications ................................................................................................................................... 3

Dimensions ..................................................................................................................................... 3 Weight ............................................................................................................................................ 3 Electrical Voltage ............................................................................................................................ 3 Capacity ......................................................................................................................................... 3 Product Supply ............................................................................................................................... 3 Pneumatic Supply ........................................................................................................................... 3 Optional Installation Kits ................................................................................................................. 3 Chemical Compatability .................................................................................................................. 3

Locating and Mounting the ChemPod® ........................................................................................... 4 Air and Fluid Connections ............................................................................................................... 6

Application Plumbing with a Mizer® ................................................................................................. 7 Application Plumbing Other than a Mizer® ...................................................................................... 7 Hose Pressure Loss Chart .............................................................................................................. 8

Electrical ......................................................................................................................................... 10 Controller Diagram ....................................................................................................................... 10 Controller Status ........................................................................................................................... 11 Control Wiring ............................................................................................................................... 11 Schematic – ChemPod® Wiring Diagram ...................................................................................... 13 Schematic – ChemPod® To Mizer® Wiring Diagram ...................................................................... 14

ChemPod® Parts Diagram .............................................................................................................. 15 P91030001 ChemPod® Parts Listing ............................................................................................ 16 P91030010 ChemPod® Parts Listing ............................................................................................ 17

Application Examples .................................................................................................................... 20 Wheel Cleaner Application............................................................................................................ 20 High Flow Application ................................................................................................................... 21 Hand Wand Application ................................................................................................................ 22 Self-Serve Bay Application ........................................................................................................... 23

ChemPod® Accessories ................................................................................................................. 24 P91030002 - ChemPod® Mizer® Install Kit .................................................................................... 24 P91030003 - ChemPod® Air Regulator Kit .................................................................................... 25 P20040003 - Sump Wrench for Sump Housing ............................................................................ 26 P91030005 - ChemPod® Accessory 3/8" Valve Plumbing ............................................................. 27

Troubleshooting ............................................................................................................................. 28 ChemPod Controller/Float Switch ................................................................................................. 28 Air Only, Exiting ChemPod ........................................................................................................... 30 Will Not Fill ................................................................................................................................... 30 Overfilling ..................................................................................................................................... 30 Pressure Fluctuating ..................................................................................................................... 30 Air Bleeding/Leaking ..................................................................................................................... 30


Overview The ChemPod is a solution storage reservoir that holds a solution in a pre-charged, ready to apply

state. It has its own control module and fluid level switch to maintain an operable fluid level while

maintaining a consistent output pressure. The unit can be hooked up to multiple application devices.

The ChemPod will provide a consistent fluid flow of product whether in diluted form or non-diluted form

to the applicator creating even coverage allowing an economical application of product. The ChemPod

can also be used to apply products that require air injection agitation of product at the applicator(s)

providing extended coverage on surfaces using less product.

Specifications Dimensions

ChemPod assembly with cover: 11” wide x 26” tall x 8" deep

Weight

8.0 pounds (empty)

Electrical Voltage

24VAC 50/60Hz

Capacity

1 Gallon

Product Supply Maximum Product Temperature: 120°F

Pneumatic Supply

60PSI Maximum @ 0.2SCFM per ChemPod

Optional Installation Kits P91030002 – ChemPod Mizer Install Kit. Kit includes fluid plumbing components to connect

ChemPod to Mizer outlet and tubing to connect to an air source.

P91030003 – ChemPod Regulator Install Kit. Kit includes a pneumatic regulator and tube

fittings to control the air pressure in the ChemPod(s).

Chemical Compatability

Chempod® Model P91030010 may not be compatible with all chemicals. Do not use with CSI

UF104, UF220, UF222, UF280, or UF600-UF609. Consult CSI @ 1-800-225-2231 with any chemical compatibility questions.


Locating and Mounting the ChemPod® The ChemPod location is specific to where and how the product is to be applied. It can be

mounted directly to or at the application mechanism, or out of customers view in an equipment room or some other controlled environment. Consideration to temperature is also a factor in colder or extremely warm environments. The ChemPod can handle temperatures between 32 to 120°F, but preferably around (room temperature) 70°F.

The distance the supply lines run from the ChemPod to the applicator is one of the more important considerations. It is recommended to try to keep the length of the lines between the ChemPod and the applicator under 75 feet, although longer connections will work, the response time, pressure losses, and opportunity for larger product loss due to line bleed down become more prevalent in long connections.

The height of the ChemPod and the amount of clearance under it should be reviewed before mounting. The ChemPod must be mounted with a minimum clearance of 22” to allow adequate

room to remove the ChemPod sump for maintenance. The ChemPod must be mounted vertically.

The ChemPod has provisions for two 3/8" diameter fasteners to mount the ChemPod head directly to a wall or structure.

Typical methods for mounting are: Concrete anchors to masonry and block walls, anchoring mounting tracks (Unistrut, Kindorf, etc) horizontal or vertical to catch the mount holes or a fabricated bracket. See illustration on following page.


ChemPod Mounting Example


Air and Fluid Connections The air regulator used must be a relieving type that will relieve the back pressure within 10psi

to maintain operational consistency of the ChemPod integral quick exhaust valve.

View of Air Plumbing


Top view of air and fluid connections. Cover is removed for clarity

Application Plumbing with a Mizer®

The following illustration shows the ChemPod fluid connection to the Mizer using the parts

included in ChemPod Mizer Install Kit P91030002. The check valve connects directly to the injector

outlet on the Mizer (3/8NPT). 1/2" O.D. tube is supplied for the connection from the tee to the

ChemPod. The connection port for the product application line is a ½” O.D. tube compression fitting.

The line routed to the application device should be sized referring to line loss chart. The line sizes

should be sized large enough to prevent less than 20PSI of system back pressure caused by the

plumbing to the applicator. Too large of plumbing to the applicator will cause issues with the

application start up delays and product waste due to system draining down after the application shuts

off.

Application Plumbing Other than a Mizer® The plumbing will follow the same routing as a Mizer connection. An inline check valve will be

required on the pressure end (filling device) to prevent back flow. Take note of the inline check valve

and flow direction in the following illustration. The filling device will have to operate at a higher

pressure than the ChemPod operating pressure. The pressure differential between the filling device

and the ChemPod will determine refill rate (in time). The filling device should be operating at least

20PSI higher.


Mizer® fluid connection. Mizer® cover removed for clarity

Hose Pressure Loss Chart

The chart below shows the pressure drop in PSI per 100FT of hose with typical water flow rates.

Example: A 100' long 3/8” hose flowing 3 gallons of water per minute has a 50PSI pressure loss. A 50’

long piece of the same hose and flow would have a 25PSI pressure loss.

Most installations use a hose or tube from the ChemPod to the applications, the pressure loss chart

can be used as a reference to help size the proper size hose or tube. Note that if tubing is used, the chart

would reference the inside diameter, as an example a standard ½” polyethylene tube will have a 3/8”

inside diameter and the 3/8” column of the chart should be used. Try to keep the plumbing runs from the

Mizer panel to the application as short as possible to prevent pressure loss, heat loss, and improve your

reaction time on and off reducing waste. As an average, most plumbing distances from the Mizer panel

to the applicator are less than 50 ft. runs.

½” O.D. TUBE TO CHEMPOD INLET/OUTLET

½” O.D. TUBE TO APPLICATION

3/8” NPT CONNECTION AT THE INJECTOR OUTLET. NOTE THE CHECK VALVE FLOW DIRECTION


Pressure loss chart


Electrical Controller Diagram

P40050011 - CONTROLLER DUAL I/O 24V CHEMPOD

ITEM # DESCRIPTION NOTES/STATUS

1 24VAC power connections No polarity

2 LED (red) - Fault indicator FLASHING - Controller in Fault. Cycle power to reset

3 LED (green) - Upper float switch indicator ON - No fluid present OFF - fluid present

4 Upper float switch connections Normally closed switch

5 Lower float switch connections Normally closed switch

6 LED (green) - Lower float switch indicator ON - No fluid present OFF - fluid present

7 Relay output 2 connections Not used

8 LED (green) - Relay output 2 indicator Not used

9 LED (green) - Relay output 1 indicator ON - Chempod fill signal ON OFF - Chempod idle

10 Relay output 1 connections Normally Open contact

P40050011 Controller Item Descriptions

L2 L1

K1.1

K1.2

K2.1

K2.2

IN1.1

IN1.2

IN2.1

IN2.2


Controller Status

The ChemPod controller P40050011 has LED’s to visually indicate the state of the (2) inputs, (2)

outputs, and if the controller is in a fault. See the controller diagram above for LED identification.

LED (red) - Fault Indicator – LED will flash red to indicate the controller is in a fault state if either of the

following conditions are met:

1. Float switch error. The upper float switch is OFF (fluid present), and the lower float switch is ON (fluid

not present). This state is not possible if all components are functioning properly and indicates there

is an issue with the float switch or wiring.

2. The Chempod calls for a fill < 15 seconds after it finishes a fill cycle and reaches full. The ChemPod

should not be draining quick enough to require a fill within 15 seconds of reaching full and shutting off.

LED (green) - Upper Float Indicator – LED is ON when fluid is not present. OFF when fluid is

present. The float switch is a normally closed switch.

LED (green) - Relay Output 1 Indicator – LED is ON when the normally open relay contact closes

to send a signal to the filling control device to fill the ChemPod. OFF when the ChemPod is full or

Idle. The relay contact is open when the LED is OFF.

LED (green) - Relay Output 2 Indicator – Not used for the ChemPod configuration.

Control Wiring

The ChemPod comes assembled with the control board and float switch wiring in place. The supplied

wiring harness will connect to the right-hand side of the control board as shown in the following

illustrations.

L1 - 24VAC PHASE POWER IN - BLACK

L2 - 24VAC NEUTRAL POWER IN - WHITE

K1.1 - N.O. COMMON GREEN

K1.2 - N.O. OUTPUT RED

IN1.1 - RED WIRE LOWER FLOAT SWITCH

IN1.1 - BLK WIRE LOWER FLOAT SWITCH

IN2.1 - GRN WIRE UPPER FLOAT SWITCH

IN2.2 - WHT WIRE UPPER FLOAT SWITCH


Float switch and control module


Schematic – ChemPod® Wiring Diagram

Schematic – ChemPod Connections


Schematic – ChemPod® To Mizer® Wiring Diagram

Schematic – Reference of ChemPod to Mizer Connection


ChemPod® Parts Diagram


P91030001 ChemPod® Parts Listing

ITEM QTY NUMBER DESCRIPTION

1 1 P17020005 COVER CHEMPOD GRAY ABS

2 1 P18000005 BRACKET CHEMPOD-CONTROLLER ALUMINUM

3 1 P20030001 CHEMPOD HEAD WHITE

4 1 P20030002 CHEMPOD HEAD EXHAUST CAP

5 1 P20040002 SUMP 20" BLUE

6 1 P21020003 VALVE RELIEF 75PSI 1/4NPT BRASS

7 1 P23010007 TEE 1/4NPT FEMALE x MALE x FEMALE BRASS

8 1 P23090006 ADAPTOR .50TUBEx.50MPT 90DEG COMP PP



11 1 P23090009 ADAPTOR 1/2SLIP x 1/2MNPT SCH40 PVC WHITE

12 1 P28010004 O-RING .210x5.60ID SILICONE 70D ORANGE

13 1 P28060002A DIAPHRAGM 1.96 ODx.060" SILICONE 70D RED

14 1 P28060002B GASKET 1.96 IDx0.06"THK SILICONE 70D RED

15 1 P40030006 SWTCH FLOAT MULTIPOINT NC-3.0", NC-14.0"

16 1 P40050011 CONTROLLER DUAL I/O 24V CHEMPOD

17 1 P49020002 HARNESS CHEMPOD INTERFACE 15'LONG

18 4 P49050009 TERM DISC 22-16AWG FEM .250 FULL-INSU PK

19 1 P51000024 DECAL CHEMPOD

20 2 P51000028 DECAL CAUTION PRESSURIZED DEVICE

21 1 P51000031 DECAL CHEMPOD CONTROLLER DIAGRAM

22 1 P52020005 LABEL SPEC CHEMPOD

23 1 P52020006 LABEL SPEC ELECTRICAL CHEMPOD

24 1 P61000002-20 PIPE 1/2 SCH40 PVC WHITE 20"CUT LENGTH

25 6 P70010010 SCREW 8x3/8LG PHIL PAN THRD-FORMING SST


27 3 P71040002 CABLE TIE 4.00x.100 NATURAL


P91030010 ChemPod® Parts Listing


1 1 P17020005 COVER CHEMPOD GRAY ABS

2 1 P18000005 BRACKET CHEMPOD-CONTROLLER ALUMINUM

3 1 P20030001 CHEMPOD HEAD WHITE

4 1 P20030002 CHEMPOD HEAD EXHAUST CAP

5 1 P20040008 SUMP 20" CLEAR

6 1 P21020003 VALVE RELIEF 75PSI 1/4NPT BRASS

7 1 P23010007 TEE 1/4NPT FEMALE x MALE x FEMALE BRASS




11 1 P23090009 ADAPTOR 1/2SLIP x 1/2MNPT SCH40 PVC WHITE

12 1 P28010013 O-RING .210x5.35ID VITON 75A BLACK

13 1 P28060002A DIAPHRAGM 1.96 ODx.060" SILICONE 70D RED

14 1 P28060002B GASKET 1.96 IDx0.06"THK SILICONE 70D RED

15 1 P40030006 SWTCH FLOAT MULTIPOINT NC-3.0", NC-14.0"

16 1 P40050011 CONTROLLER DUAL I/O 24V CHEMPOD

17 1 P49020002 HARNESS CHEMPOD INTERFACE 15'LONG

18 4 P49050009 TERM DISC 22-16AWG FEM .250 FULL-INSU PK

19 1 P51000024 DECAL CHEMPOD

20 2 P51000028 DECAL "CAUTION" CONTENTS UNDER PRESSURE

21 1 P51000031 DECAL CHEMPOD CONTROLLER DIAGRAM

22 1 P52020005 LABEL SPEC CHEMPOD

23 1 P52020010 LABEL INFO CHEMPOD ELECTRICAL CLEAR

24 1 P61000002-20 PIPE 1/2 SCH40 PVC WHITE 20"CUT LENGTH



27 3 P71040002 CABLE TIE 4.00x.100 NATURAL


Application Examples

Wheel Cleaner Application


High Flow Application


Hand Wand Application


Self-Serve Bay Application


ChemPod® Accessories

P91030002 - ChemPod® Mizer® Install Kit


1 1 P21000019 VALVE CHECK .375FPTx.375FPT PP 125PSI

2 2 P23090012 ADAPTOR .50TUBEx.38MPT COMP PP

3 1 P20010003 TUBING .50x.375 LDPE NATURAL 15' LONG

4 1 P20010008 TUBING .25X.125 LDPE NATURAL 15' LONG

5 1 P23090018 ADAPTER TEE-BRANCH .50TUBEx.38MPTCOMP PP

6 1 P23090019 ADAPTER ELBOW 90DEG .50TUBEx.38FPT COMP PP

P91030002 Part Listing


P91030003 - ChemPod® Air Regulator Kit


1 1 P21010001 REGULATOR MINI 1/8&1/4NPT PORTS 0-60PSI

2 3 P23090002 ADAPTOR .25TUBEx.25MPT PP PUSHLOCK

3 1 P21010002 REGULATOR BRKT & NUT MINI PLATED-STEEL

4 1 P21040001 GAUGE 0-100 1.00DIA .125MPT CBM

P91030003 Part Listing


P20040003 - Sump Wrench for Sump Housing

Wrench P20040003 used to remove the sump


P91030005 - ChemPod® Accessory 3/8" Valve Plumbing


1 3 P20010003 TUBING .50x.375 LDPE NATURAL , 10FEET

2 1 P21000021 VALVE SOLENOID .375FPT SST 24VAC SPADE

3 2 P21000025 VALVE BALL .25MPTx.25FPT PLSTC

4 1 P23000016 NIPPLE .38NPTx2.50"LONG SCH40 SST

5 1 P23010011 TEE .38FPTx.38FPTx.38FPT SST

6 1 P23010013 TEE .50T COMP PP

7 1 P23070004 PLUG .375MPT SST 302 SOCKET

8 2 P23090012 ADAPTOR .50TUBEx.38MPT COMP PP

9 2 P23090014 ADAPTER .50x.25MPT PP

10 1 P49020003 HARNESS SOLENOID SPADE 20-2 CABLE 6'LONG

11 1 P71000013 CLAMP HANGING 3/8&1/2"CONDUIT SST

P91030005 Parts Listing

This is an example. Each component can be purchased separately or as kit #P91030005.


Troubleshooting ChemPod Controller/Float Switch

The controller receives the fill signal from the float switch and closes the normally open contact

(K1.2) to call for product to fill the ChemPod. The float switch has an upper and lower normally closed

contact. When empty, the lower float contact is closed, calling for fill until the upper (normally closed)

contact opens and stops the fill process. The switch must operate in that sequence or the controller will

fault out and will need to be reset (by cycling the 24VAC power).

It is important to keep in mind that whenever manually operating the float switches out of

sequence, the controller must be reset because it has faulted out (indicated with a flashing red LED)

and will not function until it is reset. To clear/reset the ChemPod controller, unplug or shut off the

power source to the controller for at least 10 seconds. The power source is located on the lower right

hand corner of the control module (black or white wire will disrupt power to controller).

Test Float Switch: Remove the ChemPod sump to access and test the float switch. Use CAUTION

and relieve any system pressure in the ChemPod before removing the sump. Check to ensure that the

floats move freely. Test each float separately using an Ohm meter or continuity tester. The upper float

uses the green and white wires and the lower float uses the red and black wires. They are normally

closed circuits, so with the float at rest (down position) the circuit will be closed.

Use P20040003 or a standard strap wrench to remove sump.


Air Only, Exiting ChemPod: 1. ChemPod is empty.

2. Cracked or loose pick up tube inside ChemPod.

3. ChemPod is empty and not able to fill because air inlet pressure is higher than the pressure from

the device filling the ChemPod.

4. Check to make sure that the device that is filling the ChemPod is operating properly.

Will Not Fill: 1. ChemPod is in a fault. This is indicated with a flashing red LED. The controller must be reset by

removing the 24VAC powering the controller for about 10 seconds.

2. Check to see if you have power to the controller. Check for 24VAC to the controller (at L1 and L2

on the controller) with a voltage meter.

3. Check to make sure that the device that is filling the ChemPod is operating properly. Check the

controller output contact.

4. If the ChemPod is being filled by an injection system, check that the injector supplying product to

the ChemPod is not clogged. Remove the injector and make sure you can see through the orifice.

5. Not enough pressure on the fill device to overcome the ChemPod operating pressure.

6. ChemPod level switch cannot be operated out of sequence. If so, the controller will time out and

have to be reset by removing the 24VAC power supply for about 10 seconds. Sequence of switch:

The fluid level switch must call for fill. The lower float (normally closed contact that opens when

raised) will activate the fill device and when the upper level switch is satisfied, (upper float is a

normally closed contact that opens when raised) it will deactivate the fill device.

Overfilling: 1. Product is foaming up inside ChemPod. Verify that air is not getting mixed in from the device filling

the ChemPod (i.e. An injector pulling air instead of solution).

2. Inlet valve from external filling device stuck open.

3. Fill device stuck on.

4. Float switch functioning incorrectly. Test switches: Ensure that the floats move freely and both

switch contacts are opening when the switch is in the up position and closing in the down position

using an Ohm meter or test light.

5. Controller failure.

Pressure Fluctuating: 1. Regulator not relieving properly. When the ChemPod is filling, it should be exhausting air out of the

exhaust port. Air regulator must be the relieving type for the exhaust valve to operate properly.

2. Exhaust valve not exhausting or leaking all the time. Disassemble, check for debris, and clean the

sealing area of the diaphragm.

Air Bleeding/Leaking: 1. Safety valve is leaking:

a. Operating or system pressure set too high. Note: the safety valve is set to relieve at 75 PSI.

2. Check to see if the air regulator supplying the air is relieving properly.

3. Check to see if air is exhausting at exhaust port during fill up is normal.

4. Leaking steady at exhaust port:

a. Dirty or defective diaphragm.

CHEMPOD - cleaningsystemsinc.comincluded in ChemPod Mizer Install Kit P91030002. The check valve...

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