Bulletin 4002

Chemical Injection Technologies
Installation/Service Bulletin
SUPERIOR Series CL-16/26/56 Automatic Switchover
Gas Chlorinator - Installation & Operation
IMPORTANT!! READ THESE PRECAUTIONS BEFORE PROCEEDING!!!
They are very important for your personal safety, and for proper chlorinator operation.
1.

Read these precautions and all related instructions thoroughly and follow them carefully. If you do not understand anyof the information, call your local SUPERIOR supplier or Chemical Injection Technologies, Inc. Do not attempt to installor operate any gas chlorination/sulfonation equipment unless you are properly trained.
2. Read the "CHLORINATOR CYLINDER CHANGING PROCEDURE" card supplied with your chlorinator, and be certain you
fully understand the information presented on the card. If you do not have the card, contact your local SUPERIOR
supplier or Chemical Injection Technologies, Inc. and we will supply one.
3. Make certain all required safety equipment is in place and operational.
4. When performing any maintenance or changing cylinders, Chemical Injection Technologies, Inc. strongly recommends
that a gas mask (a pressure-demand type air pack is strongly recommended) should be available in the immediate areaof the chlorination equipment and all operating personnel should be properly trained in its use.
5. Chlorine gas or the fumes from chlorine solutions can be lethal in large enough doses. Therefore, you should always
have a co-worker observe from a safe location when you are working on any type of chlorination equipment.
6. Avoid breathing the gas or fumes of chlorine solutions and avoid contact with your skin. Work only in a well-ventilated
area. Chlorine will bleach clothing.
7. Before working on the chlorination system, make certain that the cylinder valve is shut off. If it seems to be shut off
already, open it one quarter turn and immediately close it to make certain that the valve is not frozen in the open position.
If the valve stem does not turn easily, you may use the heel of your hand to tap the cylinder wrench. Never use a hammer
or other tool to force the valve stem. If you cannot turn the cylinder valve in either direction, always assume it is open.
BE POSITIVE THIS VALVE IS CLOSED BEFORE LOOSENING THE CHLORINATOR MOUNTING YOKE OR VALVE CAP.
If you are not sure, call your chlorine supplier.
8. Do not use wrenches larger than the standard cylinder wrench and do not hit the wrench with a heavy object to open or
close the valve.
9. Do not re-use lead gaskets. THIS IS VERY IMPORTANT! Do not re-use a lead gasket because used gaskets will notproperly seal the chlorinator/cylinder connection and will cause leaks.
10. Use only lead gaskets. Other types may contract with temperature variations resulting in the escape of gas.
11. Check for chlorine gas leaks every time the chlorinator is connected or remounted onto the cylinder. Using a plastic
squeeze bottle of strong ammonia, approximately a full, squeeze fumes under the lead gasket connection and aroundthe cylinder valve bonnet and valve stem. A piece of rag or paper towel wetted with ammonia may also be held under
the connection. Do not pour ammonia onto the valve or connection. A chlorine or Sulfur Dioxide leak will create "smokelike" fumes similar to cigarette smoke. Correct the leak before proceeding.
12. Open the cylinder valve ¼ to ½ turn only, and leave the wrench on the cylinder valve when it is open.
13. The rate valve is not a shut-off valve. To shut-off chlorine, use the chlorine cylinder valve.
14. Always use safety chains or clamps to secure the chlorine cylinders so they may not be accidentally tipped over.
Protective hoods and valve caps must be in place whenever cylinders are not in use.
NOTE: These instructions are also applicable to SUPERIOR Gas Sulfonators. Just substitute "sulfonator" wherever the word
"chlorinator" appears and substitute "sulfur dioxide" wherever "chlorine" appears. Parts for the two types of units, except for
the front and back bodies, the diaphragm front and back plates, and the remote meter panel bodies are interchangeable.
‡

To prevent reliquification or condensing of Sulfur Dioxide (SO2) gas in locations where the temperature may fall below 500F
(100C), sulfonator installations should be inside a heated enclosure. DO NOT apply heat directly to chlorine or sulfur dioxide
cylinders as this will cause a rapid increase in the gas pressure which could rupture the cylinder.

Pub. No. 496-1

Copyright © 1996, Chemical Injection Technologies, Inc

Printed in U.S.A.

Contents
1.0 INSTALLATION
1.1 Handling of Chlorine Cylinders
1.2 Mounting Vacuum Regulator
1.3 Installation of Remote Meter Panel
1.4 Installation of Ejector
1.5 Piping of Ejector
1.6 Installation of Pressure Relief/Vent Valve
1.6 Connecting Vacuum Regulators to Pressure Relief
Valve, Remote Meter and to Ejector.
1.8 Additional Installation Suggestions

2.0 START-UP
2.1 Check Ejector
2.2 Check Chlorinator
3.0 SHUT DOWN
4.0 RESETTING TO "STAND-BY" AFTER A CYLINDEREMPTIES

1.0 INSTALLATION(See Drawing No. 1)
IMPORTANT: Before proceeding, read "Precautions"
1.1 Handling of Chlorine Cylinders

1.2.6 Place 1/16" thick lead gasket over the chlorine inlet ofthe vacuum regulator. Never use other types of gaskets
or gasket materials. Never re-use the lead gasket.
Replace the lead gasket each time the chlorine cylinder
is changed.

Chlorine gas is potentially dangerous. The following rules
must always be adhered to:
1.1.1 Never move a cylinder unless the valve protection cap
is screwed on tightly.

1.2.7 Mount vacuum regulator on cylinder valve by placing
the yoke over the valve, engage the vacuum regulator
inlet properly with the valve outlet, and tighten the yokescrew, compressing the lead gasket. Excessive
tightening will squeeze the lead gasket out of the joint
and should be avoided. Do not open the chlorine
cylinder valve until all components are installed. See
section 2.0 "Start-Up".

1.1.2 Locate the cylinders where they will not be bumped ordamaged.
1.1.3 A safety chain should be placed around the cylinders
and secured to a wall or support.
1.1.4 When the vacuum regulator is mounted directly on thechlorine cylinder valve, the cylinder and chlorinatorneed not be in a heated room. For outdoor installation,
when temperatures exceed 1000 F., the cylinder should
be shaded from direct sunlight.

1.3 Installation of Remote Meter Module
1.3.1 Install remoter meter panel right side up in a locationthat is convenient for the operator and/or affords
greatest security. Connect vacuum tubing from thevacuum regulator to the remote meter panel and fromthe remote meter panel to the ejector as shown inDrawing No. 1.

1.1.5 Do not open the cylinder valve more than ¼ to ½ turn.
Note: The term "Chlorinator", as used in this publication, refers to
the Vacuum Regulator, the Remote Meter Tube/Rate Valve Panel,and the Ejector Assembly, as a complete system.

1.4 Installation of Ejector(See Photo Nos. 1.2, 1.3, 1.4)

1.2 Mounting Vacuum Regulators(See Photo No. 1.1)

1.4.1 The check valves in the ejector are designed in such amanner that the ejector may be installed in any position.

Follow these steps to mount vacuum regulators onto two separate
chlorine cylinder valves.

1.4.2 The point of injection should be carefully chosen so thatthe water pressure at this point is as low as possible.
Vacuum is created in the ejector by the nozzle which isactually a precision designed venturi. Water pressure to
the nozzle must be high enough to overcome the backpressure and create a strong jet in the nozzle.

1.2.1 Unscrew the valve protection cap from the chlorine
cylinder.
1.2.2 Check to make sure the cylinder valve is closed.
Carefully unscrew the cap nut which covers the chlorine
cylinder valve outlet.

1.4.3 The standard ejector is designed to withstand staticback pressures in excess of 250 psig (17.5 kg/cm2).
However, due to possibilities of water line "torque" inhigh pressure on-off systems, as well as special booster
pump considerations, it is recommended that a factory
representative, or Chemical Injection Technologies, Inc.
be consulted regarding installation details in systems
over 100 psig (7 kg/cm2).

1.2.3 Remove any dirt that may be in the valve outlet or on theoutlet gasket surface.
1.2.4 Remove all shipping material from the vacuum
regulator. (DO NOT remove the porous, white highefficiency filter which is inserted in the vacuum regulator
inlet).

1.4.4 Generally, the amount of water (GPM) required tooperate the ejector depends upon the chlorine flow rate
(lbs./24 hrs. or gr./hr.). The higher the chlorine flow rate,
the greater the water flow needed.

1.2.5 Unscrew the yoke screw until the sliding valve plate canbe pushed all the way back.
2

1.1

1.3

1.2

..
..

1.4

1.5

3

1.4.5 Ejector water supply pressure must be greater than thepressure into which solution is ejected. The amount ofpressure differential may vary with the particularapplication. Generally, the greater the pressure into
which the chlorine will be injected, the greater therequired differential pressure. However, the minimumpressure differential and water flow for your installation
should be determined prior to installation and start-up.

1.5.4 Connect hose between the hose adaptor and theejector nozzle. Clamp the hose securely at both ends
with single or double hose clamps.
(Photo No. 1.5).
1.5.5 When rigid piping is used all the way up to the ejector
inlet instead of hose, cut off the hose adaptor "barbs" on
the nozzle where the 1" NPT threads start. Be certain to
install pipe unions to allow maintenance.

1.4.6 Follow these steps for installing close-coupled diffuserand ejector.
1.6 Installation of Pressure Relief / Vent Valvea. Unscrew the diffuser from the assembly. DO NOT
install the diffuser when the ejector is assembled ordamage may occur.
b. Put Teflon tape on the 1" pipe threads and screw thediffuser into the pipe. These are high-strength plastic
parts, but like all plastic pipe fittings, care should be
exercised in tightening. Tighten carefully withproperly adjusted wrench. Make sure that the holes
in the spray type diffuser are in the main stream. The
end of an open type diffuser should not allow strong
chlorine solution to come into contact with metal
pipe or fittings, as this will cause serious cor- rosion.
(Photo No. 1.2).
c. Place a gasket (GK-125) into the recess on each sideof the check valve body. Insert the nozzle throughthe check valve body (Photo No. 1.3). Hold thecheck valve body against the diffuser at ¼ turn
COUNTER CLOCKWISE from its final position (up,down, side- ways).
d. Screw the nozzle into the diffuser, by HAND ONLY,
until contact is made against both gaskets. Turn the
check valve body and the nozzle, at the same time,¼ turn clockwise to the final, tight position (PhotoNo. 1.4). Attach water supply hose and tighten
clamps. (Photo No. 1.5).
1.4.7 Other types of diffuser and ejector installations may bedesired for certain applications:a. The ejector (nozzle and check valve assembly) may
be located near the vacuum regulator. A wall
mounting bracket can be provided for the assembly,
and the outlet can be supplied with various sizes ofadaptors for solution hose or pipe.
b. If the ejector is to be remotely installed with solution
piping or hose running to the point of application, becertain to cut off the tip of the diffuser before
installing into the pipe or hose. Failure to do this will
result in excessive back- pressure being created in
the diffuser, causing chlorine feed rate to drop off or
stop.

1.6.1 Mount the pressure relief (vent) valve on the wall using
the mounting bracket provided. Install with the "cross"fitting on top.
1.6.2 It is preferable to locate the pressure relief valve so it isapproximately equidistant from the two vacuum
regulators.
However, this is not an absolute
requirement.
1.6.3 Connect d" tubing to the bottom (vent) fitting and run
the tubing outside the building to a safe location.
Should the system become pressurized, the vent will
expel excess chlorine gas into the atmosphere. An
insect screen is provided for the outside of the vent line,
and MUST be installed to prevent insects from entering
the tubing and plugging the vent.
1.7 Connecting Vacuum Regulators to Pressure Relief Valve,
Remote Meter, and to ejector
1.7.1 Appropriate size plastic tubing is normally used for thevacuum line between the vacuum regulators andpressure relief/vent valve; pressure relief valve andremote meter; and the remote meter and ejector. Useenough length for each line to allow for movement of
the vacuum regulators from one cylinder to another.
1.7.2 Remove connector nut from connector and slip onto
tube. Push tube onto connector and tighten connector
nut HAND TIGHT.
1.7.3 The connector on chlorinator vacuum regulator is forconnecting the vacuum tubing to one of the sideconnectors on top of the pressure relief valve. The top
connector on the pressure relief valve is connected to
the lower connector on the remote meter panel. The
upper connector on the remote meter is for connecting
the vacuum tubing to the ejector.
1.8 Additional Installation Suggestions
1.8.1

Many operators find it convenient to install a "hook" on
the wall behind the chlorine cylinder, slightly above thevacuum regulator. When changing cylinders, thevacuum regulator can easily be hung on this "hook"while moving new cylinders into place.

1.8.2

A beam-type scale should be used to weigh chlorine
cylinders while in use to determine the amount ofchlorine remaining.

c. The entire diffuser-ejector assembly may besubmersed in an open channel or tank.
d. Diffuser tubes with corporation cocks can be supplied for either close coupled or remote ejectors.
e. Special diffusers can be supplied for use with PVC
Ball valves.
1.5 Piping of Ejector
1.5.1 For most installations, the ejector water supply line
should be brought to within 3-5 feet of the nozzle withrigid copper or iron pipe, or schedule 80 PVC pipe.
1.5.2 A shut-off valve followed by a Y-type strainer and theejector is desirable as a service tool, and is highly
recommended.
1.5.3 A pressure gauge installed between the Y-type strainer
and the ejector is desirable as a service tool, and isrecommended very strongly.

2.0 START-UP
2.1 Check Ejector
2.1.1 The ejector, with its water supply and solution lines,
must be properly installed and operating before
checking the chlorinator: IMPORTANT: do not connect
ejector to the chlorine vacuum tubing before applying
water pressure to the ejector assembly. Dirt or debris
can become lodged in the check valve during
installation. Cycle the ejector on and off several times toinsure tight closing. Failure to follow this procedure cancause water to enter the chlorinator, requiring
disassembly.

2.1.2 Unless the ejector is creating a vacuum, the chlorinator5will not work. Follow these steps:
a. Make sure the plastic vacuum tube is disconnectedfrom the ejector.
b. With the booster pump running, or pressurized watersupply connected, open the ejector water supply
valve. The ejector should be in operation andcreating a vacuum.
c. Put your finger on the vacuum connector opening ofejector and feel the vacuum. This is a strong vacuum
and there should be no doubt that a vacuum exists.
If there is no vacuum, refer to Section 1.4 and be
certain the supply pressure is sufficient and that thenozzle or piping is not plugged. Correct thecondition and obtain proper vacuum before
proceeding.
d. Be sure that no water is coming out of the vacuum
tube fitting when the ejector is shut off. If water isobserved leaking past the check valve, see Service
Section 5.1 and correct before proceeding.
e. Re-connect the vacuum tube to check chlorinator.
Leave the ejector running.
2.2 Check Vacuum Regulators. Leave Chlorine Cylinder Valves
Closed.
(Have strong household ammonia and a piece of cloth
available to check for chlorine leaks. Avoid breathing thefumes).
2.2.1 Make sure that the knobs on both vacuum regulators
are in the "ON" position by turning them counterclockwise until they "bottom out". DO NOT FORCEKNOBS.
2.2.2 With the cylinder valves closed, turn on water supply tothe ejector.
2.2.3 Turn the rate valve in the remote flowmeter/rate valve
panel counter-clockwise a few turns.
2.2.4 With the ejector operating, and the chlorine cylinders
still closed, the ball in the metering tube will remain at
the bottom. If the ball does not remain at the bottom, or
bounces up and down, there is either a leak at the leadgasket where the vacuum regulator connects on thecylinder or a loose connection in the system. Check andcorrect.
2.2.5 Close the ejector water supply valve or turn off thebooster pump to stop operation of the ejector.
2.2.6 Disconnect the plastic vacuum tube from one of thevacuum regulators and pull off the tube to allow air toenter system. Reconnect tubing.
2.2.7 Reset one of the vacuum regulators to STAND-BY by
turning the "Reset" knob clockwise until the knob
“ratchets” freely and does not unscrew any more . Thenturn the knob counter-clockwise until it bottoms out.
DO NOT FORCE THE KNOB. The lock nut on the endof the center pin should project completely past the endof the knob when the vacuum regulator is in "STAND-BY'
mode. (See Drawing No. 2).
IMPORTANT: Before proceeding, read "Precautions".
2.2.5 Open chlorine cylinder valve 1/4 turn and close
immediately.
2.2.6 Wet small piece of cloth in household ammonia (avoid
breathing fumes) and hold below the lead gasket inlet
connection and below the cylinder valve bonnet.

If chlorine is leaking, a smoke will appear similar tocigarette smoke. Tighten bonnet or replace gasket andeliminate leaks. (NOTE: Do not pour ammonia solution
on the vacuum regulator or cylinder valve).
2.2.7 Open chlorine cylinder valve 1/4 turn, leave open, andrecheck for chlorine leaks.
2.2.8 Repeat procedure for the second vacuum regulator. If
no leaks are observed around the pressurized
connections, check the vent outlet with ammonia fumes.
If chlorine is detected at the vent, the inlet valve on oneof the vacuum regulators is unable to close completely
due to dirt or impurities from the chlorine, and must be
cleaned before proceeding.
2.2.9 When you are certain that there are no chlorine leaks,
turn on water supply valve to ejector and adjust rate
valve to desired chlorine flow rate. Flow rate in lbs./24
hrs., or gr./hr. is read on the meter scale at the center ofthe ball for all flow rates except 200 to 500 PPD which
are read at the top of the ball.
NOTE: NEVER use the rate valve to shut off the chlorine
supply. This valve is for adjusting flow rate while thesystem is in operation. To shut off chlorine flow close thecylinder valve.
2.2.10 Make certain that both chlorine cylinder valves are open
¼ turn, that one vacuum regulator is reset to "STAND-BY", andthe reset knobs are turned fully counter-clockwise so that it isbottomed out against the face of the regulator.

3.0 SHUT-DOWN
IMPORTANT: Before proceeding, read "Precautions".
3.1 Shut off water supply valve and/or booster pump.
3.2 Shut off the chlorine cylinder valve - not the rate valve.
3.3 When changing cylinders, follow the procedure on the cylinderchanging chart supplied with your SUPERIOR Gas Chlorinator.
Make certain that the cylinder valve is closed before removing
the vacuum regulator.

4.0 RESETTING TO "STAND-BY" AFTER ACYLINDER HAS EMPTIED
4.1 Be certain the chlorine cylinder valve is turned off. If the valve
will not turn clockwise, try to open the valve by turning
counter-clockwise. If it will not turn in either direction, assume
the valve is stuck in the open position and call your chlorine
supplier.
4.2 Before removing the vacuum regulator from an empty cylinder,
reset the regulator to "STAND-BY" by turning the Reset knob
clockwise to engage the latching mechanism (See 2.2.5).
4.3 Turn the reset knob counter-clockwise until it bottoms against
the regulator face. DO NOT FORCE KNOB.
4.4 Follow the procedure for changing cylinders on the"CHLORINATOR CYLINDER CHANGING PROCEDURE"
supplied with the chlorinator.

Chemical Injection Technologies, Inc.
835 Edwards Road, Ft. Pierce, FL, 34982, USA(772) 461-0666
Fax: (772) 460-1847
Email: Superior@chlorinators.com
www.chlorinators.com