Polymaster CAB-SDASY-CL Chemical Dosing Cabinet

Introduction

Congratulations for purchasing one of Polymaster’s quality dosing systems. Ensure this product is correctly installed, operated and regularly maintained and it should give you trouble free service for years to come.
CORRECT SYSTEM INSTALLATION IS THE SOLE RESPONSIBILITY OF THE PURCHASER.
READ OPERATION MANUAL IN DETAIL BEFORE USE & COMPLY WITH ALL INSTRUCTIONS HEREIN. OPERATION MANUAL SHOULD BE KEPT WITH THE EQUIPMENT AT ALL TIMES.
The following content is a guide only. Any vehicle/machinery affected negatively or positively is not covered by the warranty of the system.

Safety Guide

1. This manual contains important information concerning the safe installation and use of this product. Read the manual carefully before installation and use. Pay attention to all safety warnings.
2. Installation and use of this product should only be carried out by properly trained and approved personnel.
3. Users of this product are responsible for the safe and correct use of this product.
4. Any changes to this product, which have been done without consulting the manufacturer, will invalidate all warranties and guarantees.
5. The components must not be altered or tampered with, due to potential risks to personnel.
6. The manufacturer will not be responsible for any accidents or damages caused by incorrect installation or use of this product.
7. This product is only suitable for storage and dispensing of Polymaster approved chemicals.
8. If present, the control board contains electrical devices which are not suited for use in areas where there may be risks of explosion.

overview

ABOUT POLY MASTER
A proud Australian business since 1994, we’ve earned an industry-leading reputation through reliable products and honest, trusted, dependable service. We listen to our clients, and we respond with quality solutions that will help them to thrive. Because at the end of the day, their business is our business.
Polymaster manufactures an extensive range of quality products for industrial, residential and agricultural applications. Over the last two decades, Polymaster has been at the forefront of industry-endorsed, product-certified designs that have advanced the life span and functional capabilities of process vessels, bulk storage, rainwater tanks and animal care products. As an Australian-owned, quality-assured company.

PRODUCT DEVELOPMENT
We continue to extend our manufacturing operations to achieve market diversification and operational longevity. Our Design & Mould team offers custom design solutions and continual scope for new product development, product improvements and modifications. Coupled with
our ability to customize colours to specification and apply brand identities on request, Polymaster delivers on quality and quantity, on time and within budget.

LOGISTICS CAPABILITIES
Polymaster tanks can be delivered direct to any site. We arrange specific delivery times to suit your timetable and on-site requirements. Our logistics team are highly skilled at handling oversized freight – it’s what they do every day. Polymaster’s distribution fleet is experienced in over-dimensional loads, general freight and site handling that provides flexibility and capability to deliver every Polymaster Product.

PROJECT MANAGEMENT
Our dedicated project managers
take full control of all our Engineered Solutions projects to ensure they stay on time and within budget, as well as provide you with the convenience of a single point of contact. At Polymaster our highly experienced project managers have an in-depth knowledge of all projects.

ENGINEERING
Working closely with your engineering team, our own highly skilled engineers are ready to assist with all mechanical, polymer and chemical-related requirements. Drawings are provided ensuring we’ve met your construction brief so there are no surprises with the delivered project. CAD drawings are available to your design team to save them precious time, so they can incorporate them into your overall plant drawings.

Quality Assurance & Certification

Polymaster as a Quality Certified Company has a regimen of quality systems in place. These systems are recognised and certified internationally to ISO9001.

PREMIUM MATERIALS
Insisting on the finest quality components and proven manufacturing procedures, Polymaster exclusively uses premium resins in the manufacture of all Polyethylene products within the range, fully UV stabilised in all colours to AS/NZS 4766.

ENGINEERED
Product Design & Mould operations see the extensive use of FEA testing and engineering, all Polymaster products are thoroughly tested and trialled before being released to the public.

CERTIFICATION
Polymaster Tanks are Independently Certified by BSI Benchmark

THE BENEFITS

• Product Certification by an independent testing authority is your best guarantee of a quality and long lasting product.
• Every tank is labelled with the full manufacturing details including a serial number for complete traceability.
  Granted to : Polymaster Pty Ltd by BSI Benchmark

Product Specification

Polymaster’s Standard Dosing Systems are designed as an ‘essential elements’ dosing system that provides high levels of functionality and practicality

GENERAL SAFETY STATEMENT
This product has the potential to result in injury or worse if not operated in accordance with this guide and industry best practice. Operators shall be sufficiently competent in the operation of such systems prior to commissioning/operating this product. Appropriate PPE is to be worn at all times when operating this equipment, regardless of the chemical being handled.

HOW IT WORKS
The primary function of the Polymaster standard dosing system is to provide a safe and efficient means of providing
a measured and controlled volume of fluid to a process. This is achieved by an engineered dosing system. All Polymaster standard dosing systems provide an operating environment suitable to
the pump, and functionality to the operator to be able to effectively control and adjust the pump and associated equipment.
All Polymaster standard dosing systems comprise of the following features

• A means of calibrating the dosing pump (calibration systems).
• A means of draining or flushing the contents of the system (drain valves).
• A means of proving an alternate path for fluid in the event of a blockage upstream (pressure relief valve).
• A means of providing the minimum required backpressure for the pump to properly operate.
• A method of determining back pressure/pressure relief setpoints (Pressure gauge).
• A convenient means of connection to the dosing system (outlet valve)

Dosing System Components (Duty)

1. Isolator valve – Supply Tank
2. Strainer – system input
3. Isolator valve – Strainer
4. Drain valve with 1/2″ male Camlock – System inlet side (suction)
5. Calibration cylinder
6. Isolator valve – Calibration cylinder
7. Vent/ Overflow return – Calibration Cylinder
8. Pump – Duty cycle
9. Isolator valve – Duty cycle pump inlet side (suction)
10. Isolator valve – Duty cycle pump outlet side (pressure)
11. Regulator valve – Pressure relief
12. Pressure Gauge – system
13. Isolator valve – pressure gauge
14. Regulator valve – Back pressure
15. Check valve – none return output
16. Isolator valve – system output
17. Drain valve with 1/2″ male Camlock – System outlet side (pressure)
18. Drain valve with 1/2″ male Camlock – System inlet side (suction)

Dosing System Components (Duty/Standby)

1. Isolator valve – SupplyTank
2. Strainer – system input
3. Isolator valve – Strainer
4. Drain valve with 1/2″ male Camlock – System inlet side (suction)
5. Calibration cylinder
6. Isolator valve – Calibration cylinder
7. Vent/ Overflow return – Calibration Cylinder
8. Pump – Duty cycle
9. Isolator valve – Duty cycle pump inlet side (suction)
10. Isolator valve – Duty cycle pump outlet side (pressure)
11. Regulator valve – Pressure relief
12. Pressure Gauge – system
13. Isolator valve – pressure gauge
14. Regulator valve – Back pressure
15. Check valve – none return output
16. Isolator valve – system output
17. Drain valve with 1/2″ male Camlock – System outlet side (pressure)
18. Drain valve with 1/2″ male Camlock – System inlet side (suction)
19. Pump – standby cycle
20. Isolator valve – Standby cycle pump inlet side (suction)
21. Isolator valve – Standby cycle pump outlet side (pressure)

Scope of Supply

determination (contact Polymaster for assistance for further information)
Pulsation Dampener:| Not included
Y-Strainer:| Included as standard (x1)
Dosing Pump:| Grundfos DDA FCM series pump(s) (Pumps supplied loose)
Dosing pump materials/seals:| Standard (PVDF, Teflon, Ceramic)
Pump mounting:| (Direct to cabinet backboard or via Polymaster pump shield)
Pressure relief valve:| Included as standard (x1)
Back Pressure Valve:| Included as standard (x1)
Check Valve:| Included as standard (x1)
Pressure Gauge:| Included (63mm S/Steel 0-1000kpa)
Pressure gauge guard:| Included PVC / PTFE
Piping:| Georg Fischer – PVC-U
Ball Valves:| Georg Fischer – Type 546
Connection in:| (clearance hole in cabinet – not sealed) Single
Connection out:| Single – finishing inside cabinet#
Calibration Cylinder:| Included (0 – 500ml)
Drain Valves:| Included as standard
Flow Meter:| Not included (Flow metering can be achieved via Grundfos DDA FCM pump)
Valve Tags:| Not Included
Vented ball valves:| Standard
GPO for Pumps:| Not Included as standard (GPO/signal cable kits available on request)
Input Signal Cables:| Not Included as standard (GPO/signal cable kits available on request)
Pump Output Signal Cables:| Not Included as standard (parts available on request)
Pipe Pressure Test:| Included as standard
Construction Drawings:| Included as standard for client approval
Cabinet Drain:| Not included (available on request)
Pipework Painting:| Not included (available on request)
Cabinet return pipework:| Included as standard

Not included as part of the standard offer – can be optioned as part of a custom order if required.

End user to penetrate the cabinet in an appropriate location for external

connection and ensure its adequate weather seal.
Out of Scope

• Installation
• Handling on site
• On site electrical works
• Any equipment not specifically outlined in the above equipment summary

Setup & Installation

INITIAL INSPECTION
On initial arrival and during commissioning of the dosing system, a thorough check must be conducted to ensure equipment is free from damage and is fit for use. If any damage is found, please contact Polymaster for further direction.
Whilst all systems are pressure tested during manufacturing, a check must also be conducted prior to the system being commissioned to ensure all fittings and connections are secure and have not come loose during transport.

INSTALLATION
The dosing cabinet should be securely fixed to the foundation on which it is placed to ensure stability whilst in operation. Consideration of placement should be given to ensure ease of integration/connection with site pipework/processes without creating distortion to new/existing equipment.

INITIAL SETUP NOTES
It is recommended that during the installation/commissioning of the dosing system, that the maximum pressure limit of the pump is set to a conservative value to safeguard system/operator – This control measure is only possible
if the FCM variant of the pump is being used, for pumps with no pressure monitoring capability, it is recommended that pressure relief and backpressure valves are set to the low possible value and adjusted to the appropriate value during commissioning.

PUMP CALIBRATION
Calibration may be checked or adjusted using the provided calibration cylinder.(From Grundfos user manual) The pump is calibrated in the factory for media with a viscosity similar to water at maximum pump backpressure (see section 3.1 Technical data). If the pump is operated with a backpressure that deviates or if dosing a medium whose viscosity deviates, the pump must
be calibrated. For pumps with FCM control variant, it is not necessary to calibrate the pump if there is deviating or fluctuating backpressure so long as the “AutoFlowAdapt” function
has been enabled (see section
6.10 AutoFlowAdapt). Polymaster recommends that the calibration is ran for the chemical being dosed.

SETTING BACK PRESSURE
The recommended minimum backpressure for a Grundfos DDA FCM pump is 2 bar. Using the supplied pressure gauge, the systems backpressure valve be adjusted accordingly.

Setup & Installation (continued)

SETTING PRESSURE RELIEF
Like the setting of the back pressure valve, the pressure relief valve can be set using the provided pressure gauge. With the pressure relieve valve fully
‘backed off’ (opening at the lowest possible pressure), and the outlet valve in the almost (or fully) closed position, adjust the pressure relief valve
to open at the desired pressure. Note that if the system becomes blocked or the pressure relief valve does not function, the pump is capable of generate pressure sufficiently high to damage the system or worse.

The Grundfos DDA FCM pump
does have the ability to have a pre-programmed max pressure set, it is recommended a conservative max pressure is set during commissioning as a safeguard to the system and operators.

JUNCTION BOX – SITE CONNECTION (If applicable)
If dosing system has been supplied with a junction box, a qualified electrician will be required to connect mains power to the junction box, a wiring diagram for the junction box is available on request.

OPERATION
Please refer to relevant Grundfos DDA pump installation and operating instruction document for operation and control modes.

STRAINER
It is recommended that the strainer is positioned with the basket facing up, to minimise the loss of fluid when the basket is removed.
To clean y-strainer, it is necessary
to pause pump and then isolate the strainer via the immediate upstream and downstream valves, with an appropriate container in place to collect any spilled liquid remove the strainer and clean, then reinstall the strainer, ready for use.
Operators may wish to use the closest drain valves to drain the majority of fluid prior to removing the strainers basket.
Operators may look to use the calibration cylinder as a temporary draw down reservoir through the opening/closing of appropriate ball valves to keep the pump on-line whilst cleaning out strainer, it is recommended that the fluid is completely drawn down, leaving the cylinder empty once strainer has been reinstalled and the system can be reconnected to main fluid reservoir. Regular maintenance and inspections should be a normal part of any dosing systems operation, please refer to the below as a starting point for suggested maintenance intervals. This section serves as a guide only, end users should look to develop and maintain their own maintenance and servicing schedules. Appropriate PPE is to be worn whilst conducting maintenance or repairs.
Important Note: Dosing system
can expose operators to dangerous chemicals under high pressure.
Care must be taken to ensure that

Maintenance/Servicing & Care

appropriate PPE and shutdown procedures are used to avoid chemical spills and or exposure. Contact with some chemicals can lead to extreme burns or worse. Consult with relevant SDS before handling.

PUMP DIAPHRAGM
(Grundfos DDA pump manual) –Warning If the diaphragm leaks or is broken, dosing liquid will escape from the drain opening on the dosing head
Please refer to relevant Grundfos DDA pump installation and operating instruction document (available via web download)

WARRANTY
Standard warranty for non-consumable parts is 12 months from date of receiving unit.

Description| Recommended Inspection/Service Interval|
---|---|---
General system inspection (visual inspection)| Daily
Pump Diaphragm| Replacement at 12-24 months
Pressure relief valve function| Check every 6 months
Ball valve function| Check monthly
Y strainer clean out| Visual inspection monthly

Activate your Warranty

Please activate your warranty online at polymaster.com.au/warranty
Alternatively, if you do not have access to the online warranty page, contact us onWe would love to hear about your experience with Polymaster. Please
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References

• Warranty - Polymaster

Read User Manual Online (PDF format)

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