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Safety

Think and act in a safe manner. Always disconnect power and use a lockout before you work on the E-coat system, or any of the related subsystems. Observe any confined space conditions. Use the appropriate safety equipment and clothing for the task. Please carefully read all the instructions listed below to familiarize yourself with the project before attempting to perform any of the work.

Required Materials

• Cell Layout Drawing and Roof Cell Drawing
• See Table Below

Item Description	UFS PN	Qty / Cell
2-1/2” PVC Sch 80 90 degree Elbows	806205	2 Each
2-1/2” PVC Sch 80 pipe x 20 ft long	040035	11ft (max)
1/8” OD coated 304 SS wire rope McMaster Carr PN 8912T344 page #1052 (Catalog #105)	240017	4 ft
304 SS compression clamps McMaster Carr PN 37555T15 page #1068 (Catalog #105)	310020	4 each
3/8” ID x 9/16” OD PVC Tubing (Supply)	060001	15 ft (max)
½” ID x 11/16” OD PVC Tubing (Return)	060002	15 ft (max)
Plastic wire loom		15 ft (max)
AWG #6 Stranded THHN wire	240004	15 ft (max)
#6 round lug for 5/16” bolt	250017	2
2-1/2” metal 2 piece clamps	310015	2
PVC heavy body cement	Z070005	as needed
PVC cement primer	Z070006	as needed

Required Tools

• Screw Driver
• ¼’ Wrench
• Pipe Wrench
• Strap Wrench
• 2 (½”) Wrenches
• Bubble Level

General

PN 701018 is the major portion of the Roof Cell. It is shipped without some of the piping, cable, and tubing in order to reduce the shipping complexity and cost. Hence, some field assembly is required for operation. These instructions are meant to provide general assistance and a sequence of preparation and assembly. It is not practical to provide dimensions for each step since most of the dimensions are only known once the Roof Cell’s initial position is fixed.

Step 1

Determine the approximate location for the Roof Cell. See the layout drawing for general guidance.

Step 2

Determine how the Cell can be supported. There are at least four support points. There is a wire supporting the Cap, another wire supports the Collar, and two clamps secure the vertical portion of the field-installed pipe. [See Figures 1 and 2.]

Step 3

If the 2-½“ PVC Female adapter is attached to the top of the Bulkhead, remove it and set aside. This will make it easier to attach the supply and return tubing.

Step 4

Cut a length of AWG #2 (or as small as #6) THHN, THWN-2, or MTW to length. Place a round lug on one end. Attach this end (with round lug on the electrical connection) to the Bulkhead. [See Figures 3 and 4.] Use the supplied stainless hardware. NOTE: The compression washer must be installed so it goes flat as it is tightened.

Step 5

Cut a piece of 3/8” supply tubing to the desired length. Make the cuts straight. Slip a SS clamp over one end.

Step 6

Dip one of the cut ends into a cup of DI water and push it over the 3/8” inlet hose barb (smaller and lower hose barb). Push the tubing in as far as it will go.

Step 7

Slide SS clamp over the part of the tubing that covers the hose barb.

Step 8

Tighten the clamp until it is snug. NOTE: If the clamp is not snug, there is a chance that the tubing will come off the hose barb. Do not let any part of the clamp touch the electrical connection.

Step 9

Repeat steps 5-8 to install the ½” ID return tubing. [See Figure 5.]

Step 10

Take note of the location of the outlet Hose Barb. This must be at the 12:00 o’clock position in order for oxygen to be purged. [See Figure 3.]

Step 11

Cut three pieces of plastic wire loom about 5’ long (enough to extend past Elbow #2 by 1 foot) and place over each of the Supply, Return, and electric lines. This will protect these items from the PVC primer and glue that can cause problems. [See Figure 6.]

Step 12

After installing the wire and the supply/return tubing, attach the female adapter to the bulkhead. NOTE: Be sure the Bulkhead does not twist. The diamond on the Bulkhead should be in the 12:00 o’clock position. [See Figure 7.]

Step 13

Cut a piece of 2-½“ PVC Sch 80 pipe called out as “Pipe #1.” Glue this into the Female adapter.

Step 14

Glue a 2-½” PVC Sch 80 Elbow (Elbow #1).

Step 15

Cut a piece of 2½” PVC Sch 80 pipe called out as “Pipe 2.” Glue this into Elbow #1.

Step 16

Take the next Elbow, called out as “Elbow #2”, and glue it to the other end of “Pipe #2.”

Step 17

Cut a length of pipe, called out as “Pipe #3”, and attach to the other side of Elbow #2.

Step 18

Raise the unit by supporting at the Cap, Collar, and vertical pipe portion.

Step 19

Hold the unit in place while another person attaches the two support cables and two clamps.

Step 20

Place the bubble level on the top side of the Membrane Shell. The Cap end must be lower than the Collar end by 1 or 2 degrees. Adjust as necessary. Tighten all support cables and clamps after proper slope is confirmed.

Step 21

Attach the other end of the 3/8” ID line to a Flow Indicator and shut off valve (UFSc PN 225044).

Step 22

Attach ½” ID opening in the anolyte trough.

Step 23

Attach the electric cable lead to the appropriate bus bar with a second round lug. If you want to use quick connects or need to use a diode, then follow the instructions called out in Bulletin #993105.

Step 24

After the fluid has been turned on for about 60 minutes, use a flashlight to look inside the vertical portion of the piping and look for evidence of a leak. Repair if needed.

BULLETIN 99XXXX