Operating Instructions ProMinent Chlorine Dioxide Generating Systems Bello Zon Type CDVa

Bello Zon Type CDVa for diluted chemicals

Please carefully read through these operating instructions in full. Do not discard! Damage caused by incorrect operation will invalidate the guarantee!

These operating instructions were delivered with following system:

Affix type identification

See Fig. 2 Identification Code System in Annex (page 8) for identification Part No. 987796 ProMinent Dosiertechnik GmbH 69123 Heidelberg Germany BA BEZ 014 12/01 GB

ProMinent

Publishing Details

ProMinent

Publishing details: Operating Instructions Bello Zon Chlorine Dioxide Generating Systems Type CDVa ProMinent Dosiertechnik GmbH ProMinent Dosiertechnik GmbH Im Schuhmachergewann 5-11 69123 Heidelberg P.O. Box 101760 69007 Heidelberg Germany info@prominent.de www.prominent.de Subject to technical modifications Printed in Germany

Page 2

ProMinent

ProMinent
General User Information .................................................................. 4 1 Functional Description ................................................... 5 1.1 Production Process .............................................................. 5 1.2 System Concept ................................................................... 5 1.3 System Description .............................................................. 6 1.3.1 Reactor ................................................................................. 6 1.3.2 Exhaust system .................................................................... 6 1.3.3 Metering Pumps ................................................................... 6 1.3.4 Feed Monitoring ................................................................... 7 1.3.5 Metering Valve ...................................................................... 7 1.3.6 Bypass Line .......................................................................... 7 1.3.7 Systems without Bypass Monitoring .................................... 7 1.3.8 Intake Lances ....................................................................... 7 1.3.9 Safety Trays .......................................................................... 8 1.4 Control .................................................................................. 8 1.4.1 Functional Sequence ............................................................ 8 1.4.2 Display Elements of the Control ........................................... 8 1.4.3 Function Buttons .................................................................. 8 1.4.4 Identity Code, Revision Status (Version), Operating Code ... 9 1.5 Operating Modes .................................................................. 9 1.5.1 Manual Setting of Chlorine Dioxide Rate: Internal Control ... 9 1.5.2 Flow-Dependent Chlorine Dioxide Metering ........................ 10 1.5.3 Measured Value-Dependent Chlorine Dioxide Metering: Controlled Variable-Dependent ............................................ 11 1.5.4 Combined Activation ............................................................ 11 1.5.5 Remote Control Input: Contact (Pause Function) ................ 11 1.5.6 Remote Control Input: Analog .............................................. 12 1.5.7 Outputs for Signalling Facilitites: Alarm and Warning .......... 12 1.5.8 Analog Output ...................................................................... 12 2 Mounting/Installation ..................................................... 12 2.1 Prerequisites and Safety Notes ............................................ 12 2.2 Wall Mounting ....................................................................... 13 2.3 Hydraulic Connections ......................................................... 13 2.3.1 Bypass Line .......................................................................... 14 2.3.2 Water Connection for Exhaust Systems ............................... 14 2.3.3 Venting Line .......................................................................... 14 2.3.4 Intake Lances ....................................................................... 14 2.3.5 Intake Lines .......................................................................... 14 2.3.6 Checking Pipe Screw Fittings and Connections .................. 15 2.4 Electrical Connection ........................................................... 15 2.4.1 Opening the Control ............................................................. 15 2.4.2 Installation of Cable Connections ........................................ 15 2.5 Affixing Information Signs .................................................... 16 3 Initial Operation (Commissioning) .............................. 17 3.1 Information on Applicable Regulations ................................ 17 4 Operation ........................................................................... 17 4.1 Setting the Metering Rate .................................................... 17 4.1.1 Systems with Internal Control .............................................. 17 4.1.2 Systems with Flow-Dependent Metering ............................. 18 4.1.3 Systems with Control Variable-Dependent Metering ........... 18 4.2 Accuracy of Metering Rate ................................................... 19 4.3 Calibrating the Metering Pumps ........................................... 19 4.4 Setting the Feed Monitors .................................................... 20 4.5 Bypass Water Failure ............................................................ 20 4.6 Changing Component Containers ........................................ 20 4.6.1 Bleeding ............................................................................... 21 4.7 Checking the Reaction - Sampling Chlorine Dioxide ........... 21 4.8 Determining Chlorine Dioxide Concentration ....................... 22 4.9 Chlorine Dioxide Metering Rate ........................................... 22

Contents

ProMinent

Page 3

General User Information

ProMinent
4.10 Consequences of Incorrect Setting ...................................... 22 4.10.1 Incorrect Setting of Metering Pumps ................................... 22 4.10.2 Incorrect Setting of Feed Monitoring .................................... 23 4.10.3 Incorrect Setting of Bleeder Cock Valves Acid/Chlorite ....... 23 4.10.4 Incorrect Setting at Bypass .................................................. 23 4.10.5 Incorrect Setting in Control .................................................. 23 5 System Maintenance ...................................................... 23 5.1 Regular Checks .................................................................... 23 5.2 Maintenance Work ................................................................ 24 5.2.1 Maintenance of Metering Pumps ......................................... 24 5.3 Troubleshooting .................................................................... 24 5.4 Shutting Down the Chloride Dioxide System ....................... 26 5.4.1 Shutting Down for a Short Period ........................................ 26 5.4.2 Shutting Down for a Prolonged Period ................................. 26 5.4.3 Shutting Down and Frost-Proof Storage .............................. 26 6 Technical Data .................................................................. 27 6.1 Accessories .......................................................................... 27 6.1.1 Intake Lances ....................................................................... 27 6.1.2 Supplementary Kit and Spare Parts ..................................... 27 6.1.3 Venting Valve Reactor Room ................................................ 27 6.1.4 Fuses .................................................................................... 28 6.1.5 Bello Zon-Acid and Bello Zon-Chlorite ............................. 28 6.1.6 Safety Trays .......................................................................... 28 6.1.7 Set for Determining Chlorine Dioxide ................................... 28 6.1.8 Heating Systems for Chemical Lines ................................... 29 6.1.9 Metering Points .................................................................... 29 6.1.10 Suction Accumulator Bello Zon .......................................... 29 6.2 Protective Filter ..................................................................... 29 6.3 Temperature .......................................................................... 29 6.4 Bypass Pump (Stainless Steel) ............................................. 29 6.5 Spare Parts ........................................................................... 29 7 Conformity Declaration .................................................. 30 Annex

General User Information

These operating instructions describe the technical specifications and functions of the Bello Zon chlorine dioxide generating systems, they provide detailed safety information and are organised in clear steps which are explained by following examples: Device descriptions are identified by normal flowing text: The complete systems are preassembled on a plastic support bracket. Actions/activities to be carried out are identified by bullets (bold type dots): Reset bleeder cock valves to initial position. Cross references are identified by arrows and bold type texts: > Detailed description as of Page 61 Safety notes are set in bold italics and identified by a warning symbol. WARNING: Effective monitoring of the flow of bypass water is a prerequisite for reliable and safe operation of chlorine dioxide systems. Working notes are emphasised and set in italics: NOTE: All machines, fittings and system components must be installed such that they are easily accessible to facilitate operation and maintenance! Wherever possible set up machine at eye level!

Page 4

ProMinent

ProMinent

Functional Description

Functional Description

Bello Zon systems serve the purpose of producing and metering chlorine dioxide. 20 years of experience gained in the construction of these systems ensures a high safety standard and outstanding operational reliability.

1.1

Production Process

Hydrochloric acid-chlorite process: 5 NaClO2 + 4 HCl > 4 ClO2 + 5 NaCl + 2 H2O Sodium chlorite + hydrochloric acid > chlorine dioxide + sodium chloride + water

1.2

System Concept

Type CDV Bello Zon systems produce and simultaneously meter a 2 % chlorine dioxide solution. The chlorine dioxide is produced by combining the two components Bello Zon acid (9 % hydrochloric acid solution) and Bello Zon chlorite (7.5 % sodium chlorite solution). The two components are mixed in the reactor thus producing a chlorine dioxide solution with a concentration of 20 g/l. Under normal operating conditions, this chlorine dioxide solution can be safely managed in the sealed reactor of a Bello Zon system.

WARNING: The sodium chlorite concentration in CDV systems should be 7.5 weight % ( 0.3 %) and the hydrochloric acid concentration 9 weight % (+1 %). If the concentration of sodium chlorite is not maintained in CDV type Bello Zon systems the quantity indicated in the display will be falsified and a risk of accident will be posed in the case of higher sodium chlorite concentrations. Gaseous chlorine dioxide is explosive as from a concentration of 300 mg/m3. At a critical chlorine dioxide concentration, an aqueous chlorine dioxide solution with a concentration of 8 g/l, for example, can be expected. For this reason, the reactor of a Bello Zon system features a completely sealed design. A backpressure valve (approx. 1.5 bar prepressure) that ensures no gas phase can occur is located at the reactor outlet. Particular care must be taken during the installation to ensure that vacuum cannot occur at the metering point under all operating conditions. After the reactor, the chlorine dioxide is substantially diluted with water in a bypass line. The quantity of water required for this dilution should be set such that a concentration of 0.1 to 0.5 g/l is produced in the bypass line. This eliminates the risk of corrosion while this intense dilution (1:100) also reduces the corrosiveness of the chlorine dioxide solution containing hydrochloric acid. WARNING: Mixing of the chemicals outside the Bello Zon reactor must be avoided under all circumstances. (Also refer to: Extract from the hazardous substances information sheet of FIGAWA in the annex, Page 5). The metered quantity can be set manually (internal activation) or fully automatically (external activation). The systems are designed such that chlorine dioxide is produced only in the quantities actually required. Bello Zon systems are manufactured in compliance with the relevant guidelines applicable in Germany, i.e. DVGW working codes of practice W 624 (chlorine dioxide in water treatment) and the accident prevention regulation Chlorination of water (GUV 8.15 or VBG 65). NOTE (for systems installed in Germany): The system operator is obliged to read these guidelines and to use the chlorine dioxide system accordingly.

ProMinent

Page 5

Functional Description

ProMinent

1.3

System Description

Series CDVa chlorine dioxide generating systems represent completely assembled turn-key installations ready for connection. > See Fig. 1 and table with performance specifications in Annex The following are always included in the scope of delivery of each Bello Zon system: the intake lances to suit the relevant component tank and supplementary kit with various hardware. The system configuration is defined by the identification code CDVa XA.XXXXXDXX The version of the bypass line and of the control can be varied dependent on the identification code. > See Fig. 2 and Fig. 3 in Annex

1.3.1

Reactor

The reactor is installed separated from the pumps in a closed housing. An inspection window is provided in the line above the reactor. Here the reaction can be observed in the form of a slight yellow discolouration. The chlorine dioxide solution flows through the metering valve into the bypass. Here it is mixed into the flow of water.

1.3.2

Exhaust system

The exhaust system ensures a regular exchange of air in the reactor housing. It consists of an injector and a solenoid valve which is switched by the control system. The fresh air is fed into the reactor room either via a ventilation valve or via a line which leads to atmosphere. The ventilation valve is available as an accessory (see Section 6.1.3).

1.3.3

Metering Pumps

The metering pumps are mounted at the bottom end of the support bracket. The bleeder bottles are arranged between them. On the intake side, a hose leads from the intake lances to the pumps. A rotary knob is provided on the metering pumps to adjust the stroke length. The stroke frequency is calculated by the control and sent by way of pulses to the pumps. One metering stroke is carried out for each incoming pulse. The pumps therefore operate at independent frequencies. The relevant delivery rate is determined by calibrating the capacity. These values are entered in the control. The control then calculates the relevant frequency so that both pumps deliver the same quantity. The stroke length must no longer be varied after gauging capacity in litres. The stroke length of the pumps should be set approximately the same ( 20%). The liquid ends are made of Plexiglas. Various pumps are used dependent on the capacity of the chlorine dioxide system. > See table of performance data in Annex Calibration measuring cylinders are arranged over the pumps. They are used to calibrate (gauge) the capacity of the pumps.

Page 6

ProMinent

ProMinent

Functional Description

1.3.4

Feed Monitoring

The task of the feed monitoring element is to ensure that both chemicals flow constantly during system operation. If the volumetric flow of a component is reduced by more than 30%, the feed monitoring element triggers an alarm and switches off the chlorine dioxide system. The operating point must be set correctly by means of vertical adjustment in order to ensure feed monitoring functions correctly.

1.3.5

Metering Valve

The metering valve is located in the bypass line and is installed in a cross piece fitting. The valve opens at a reactor internal pressure of approx. 1.5 bar.

1.3.6

Bypass Line

The chlorine dioxide solution produced (20 g/l) is diluted in the bypass water line and fed to the main flow of water. The bypass line is made up in various versions depending on the identification code: Bypass line with variable-area flowmeter and minimum contact Bypass with turbine wheel flowmeter and minimum contact Non-return valve Premixing device Bypass pump made of stainless steel or cast iron A flow monitor is installed in the bypass line which signals when the flow drops below a minimum flow rate and then switches off the system. The flow monitor may be a variable-area flowmeter or a turbine wheel flowmeter. The response value of the minimum contact in conjunction with the turbine wheel flowmeter is adjustable in the control system. The current flow in the bypass can also be monitored. The turbine flowmeter can not be used if the bypass water is to be enriched with chlorine dioxide (e.g. in circuit systems). NOTE: If the bypass water is not free of solid particles, a protective filter should be connected downstream of the turbine flowmeter. > See Section 6.2 Protective Filter

1.3.7

Systems without Bypass Monitoring

If the system does not feature bypass monitoring, the operator must ensure the metering system is interlocked with the flow of water in which the chlorine dioxide is fed. This ensures that the system is always switched off immediately if there is no flow of diluting water.

1.3.8

Intake Lances

The intake lances must suit the container size (length of intake lances) and the system capacity (diameter/wall thickness of intake line). > See Section 6.1.1 They feature a two-stage level monitoring facility. If the level of the components drops to the first stage, initially, the control triggers the message Acid level low or Chlorite level low as an initial warning. This is indicated by the red alarm lamp (Fig. 4-L2) flashing. The system, however, continues to operate. In addition, the Warning relay is also activated.

ProMinent

Page 7

Functional Description

ProMinent
When the level reaches the second (lower) stage, the system shuts down and the message Acid container empty or Chlorite container empty is indicated at the control. The alarm relay is now activated. The red alarm lamp (Fig. 4-L2) now lights permanently. If connected, a horn also signals.

1.3.9

Safety Trays

Safety trays are available as accessories in two versions, i.e. with and without leakage warning. They are designed to take up 30 l and 200 l containers. > See Section 6.1.6

1.4

Control

The control with the inputs and outputs, display/indicators as well as the necessary operating elements is located on the right next to the reactor housing. The number of inputs and outputs is defined by selection of the identification code. > See Fig. 4 in Annex

1.4.1

Functional Sequence

A pulse is generated in the control and sent to the metering pump which in turn carries out one stroke. This stroke produces a signal in the feed monitor which is sent back to the control. If the feedback to the control fails, the system is shut down after eight missing pulses in series and the corresponding error message appears in the display. At the same time the red alarm lamp (Fig. 4-L2) flashes. The system can be restarted by pressing the Acknowledge button.

1.4.2

Display Elements of the Control

The operating mode, chlorine dioxide capacity and flow rate, if water meter connected, are indicated in the display. LED indicators at the top of the control unit indicate the control signals for the pumps (Fig. 4-L5 Acid, Fig. 4-L9 Chlorite) by way of a yellow flashing light. They light red in the case of fault. The relevant green feed monitoring LEDs (Fig. 4-L6, Fig. 4-L10) are located next to them. The indicators for a bypass water pump if fitted (Fig. 4-L3) and for monitoring the flow of bypass water (Fig. 4-L4) are located at the top left. The indicator for the diluting water pump (between acid and chlorite) is provided for use in CDK systems and therefore has no function for this series (L7 and L8).

1.4.3

Function Buttons
STOP
START

Start/Stop

With this button, the system can be started or metering stopped from any program level. In Standby mode, it is possible to change the setting data. The green LED (Fig. 4, L1) lights during operation.

Page 8

ProMinent

ProMinent

Functional Description

Discharge The solenoid valve of the exhaust system is opened and the air extracted from the reactor housing. Discharge duration: 5 min by pressing button, during normal operation: 12 sec. Calibrate/Start-Up A certain number of strokes is triggered at maximum frequency. Change Changing a function/mode of operation. Smaller Reduces a displayed numerical value. Back Exits operating menu in steps, back by one setting level at a time. Larger Increases a displayed numerical value. Store Saves a displayed value or status. Acknowledge
R

Acknowledgement of error messages

1.4.4

Identity Code, Revision Status (Version), Operating Code

The ordering system based on the identity code enables easy selection of the system variant to be ordered. The identity code must be specified in the order. When expanding a system, the identity code of the system must also be changed accordingly. Due to the fact that electronics and software are subject to constant update and improvement, the version numbers are used as the means of identification. All systems which are supplied within a certain time interval have the same hardware and software revision statuses irrespective of the identity code. They must be quoted in the case of complaints or when extending systems which are already installed. They can be shown on the display by pressing the change button. To facilitate system setup on site, an operating code has been introduced which makes it possible to activate and deactivate the various options available in the system. This code can also be shown on the display.

1.5

Operating Modes

> Refer to annex for graphic representation of operating modes.

1.5.1

Manual Setting of Chlorine Dioxide Rate: Internal Control

Here, the metering capacity of the system can be set manually from zero to maximum capacity. The control varies the drive frequency of the pumps accordingly. In this mode of operation, the system can be used for treating water at constant volumetric flow rates. The system can be switched on or off externally via the remote control contact (control hardware adaptation necessary).

ProMinent

Page 9

Functional Description

ProMinent

1.5.2

Flow-Dependent Chlorine Dioxide Metering

In this mode, the amount of chlorine dioxide produced is controlled by means of the signal provided by a contact water meter in the main flow of water. The pulse interval is set during the start-up procedure (range: 0.1 - 320 litres). The table below should be used as an aid in selecting the suitable contact water meter.
Type Capacity at 5 bar 46 g/h 66 g/h 130 g/h Reference Maximum feed rate flow rate 0.3 mg/l 0.3 mg/l 0.3 mg/l 153 m /h 220 m3/h 433 m3/h
3

Reference pulse interval 20 30 50

Recommended water meter Part number Pulse interval 30.44.41 30.44.43 30.44.43 25 litres 50 litres 50 litres

CDV 35 CDV 60 CDV 120

The contact spacing should be selected depending on the feed rate and on the flow rate in the main water line of the water meter. The following estimation applies for this purpose: Maximum contact spacing (MaxK) Minimum contact spacing (MinK) = Capacity (g/h) / feed rate (mg/l) = (Max.K) / 10

The contact spacing should always be between MinK and MaxK. This ensures the maximum input frequency is not exceeded and a maximum transmission ratio of 7 is maintained (one water meter pulse = 7 pump strokes of chlorite). Potential-free contact input (via optocoupler) for connection of contacts (e.g. reed) or switching transistors (open collector output). Maximum input frequency: 4 switching operations/second No Namur signal input. It is also possible to connect a water meter with an analog signal (0/4 - 20 mA) (control hardware adaptation necessary). The following table should be used to assist in selecting the analog flow meter. Type CDV 35 CDV 60 CDV 120 Capacity at 5 bar 46 g/h 66 g/h 130 g/h Feed reference value 0.3 mg/l 0.3 mg/l 0.3 mg/l IDM flow meter reference measuring range 0-150 m3/h 0-250 m3/h 0-450 m3/h

The upper limit of the measuring range is specified in the configuration menu. Standardised input (0/4-20 mA) for active (current sources) and passive (variable resistance) signal generators. Terminal assignments Terminals 1(V+),2(+),3(-) Connection Analog input Flow rate Plug-in slot Plug-in slot 1 Plug-in card Current input B Plug-in card Order No.: 725236

Active signal generators (the majority flow meters) are connected to the terminals 2(+), 3(-). A voltage of 20 V is available at terminal 1(V+). Variable resistors (1 k - 5 k) are connected to the terminals 1(V+), 2(+).

Page 10

ProMinent

ProMinent

Functional Description

1.5.3

Measured Value-Dependent Chlorine Dioxide Metering: Controlled Variable-Dependent

There are two different input positions available for selection: Contact input - for connection of controller with potential-free frequency output (e.g. WS controller, DULCOMETER D1C) Analog input (0/4-20 mA) - for connection of controller with standardised current output (e.g. DULCOMETER D1C, dialog) Contact input Terminal assignments 41(+), 42(-) This option is set as standard in the device. Signal frequency: 0 - 4 Hz The pulse frequency output for pump activation of the DULCOMETER D1C controller can be connected to this input. Analog input Terminal assignments Terminals 6(V+),7(+),8(-) Connection Analog input Flow rate Plug-in slot assignment Plug-in slot 3 Plug-in card Currrent input B Plug-in card Order No.: 725236

The controlled variable signal output (0/4-20 mA) of DULCOMETER D1C controllers can be connected to this input. Terminals 7(+), 8(-).

1.5.4

Combined Activation

It is possible to combine flow-dependent and measured value-dependent activation. Both signals are processed multiplicatively.

1.5.5

Remote Control Input: Contact (Pause Function)

The system can be switched on and off externally via the remote control contact input. For connection to: - Controller with limit contact - Locking contact Terminal assignments Terminals 30 (+), 31 (-) Connection Contact input Plug-in slot assignment Plug-in slot 6 Plug-in card Order No.: 725321

Remote control Plug-in card digital input three-conductor It is also possible to operate the system with basic load metering in this mode of operation. The required basic load metering rate can be set in the configuration menu.

ProMinent

Page 11

Mounting/Installation

ProMinent

1.5.6

Remote Control Input: Analog

With this function, the system capacity can be set from an external point with the aid of an analog signal. When combined with other input signals, both are processed multiplicatively. Terminal assignments Terminals Connection Plug-in slot assignment Plug-in slot 5 Plug-in card Order No.: 725236

27(+),28(E),29(-) Analog input

Remote control Plug-in card current input B

1.5.7

Outputs for Signalling Facilities: Alarm and Warning

The control system can output signals at two different signalling devices. Operating faults can be output in the form of a warning signal via the terminals 64, 65: e.g., in the case of the level switches in the component tanks responding to the first stage or if the bypass water does not flow correctly. Operating faults can be output as an alarm signal, which can implement system shutdown, via terminals 61, 63: e.g., if the metering monitor responds or if the supply voltage fails. > See Fig. 15 Error messages

1.5.8

Analog Output

This option comprises up to 3 outputs: Flow rate, controlled variable and capacity. Terminal assignments in addition to the basic unit: Terminals 4(+), 5(-) Connection Analog output Flow rate Plug-in slot assignment Plug-in slot 2 Plug-in card, current output B 9(+), 10(-) Analog output Controlled variable Analog output Capacity Plug-in slot 4 Plug-in card, current output B Plug-in slot 8 Plug-in card, current output B Order No.: 725240 Order No.: 725240 Plug-in card Order No.: 725240

35(+), 36(-)

2
2.1

Mounting/Installation
Prerequisites and Safety Notes

> See safety and installation hints for Bello Zon systems The installation hints stipulate that a separate room need not necessarily have to be provided for chlorine dioxide systems, i.e. under certain preconditions, installation can take place in operating rooms: If the system is necessary for the process taking place there If small quantities of diluted chemicals are in the system If the system and chemicals are secured to prevent access by unauthorized persons.

Page 12

ProMinent

ProMinent

Mounting/Installation
NOTE: Persons who have access to the room, in which the chlorine dioxide system is installed, must have participated in appropriate safety instruction. The place of installation must be protected from sunlight, frost and renewing the air must be possible. The permissible ambient temperature must be observed for drinking water applications. (Refer to table Capacity data, Annex, Page 7.) It should be possible to transfer chemical containers to the system without obstruction. It must be possible to safely dispose of any spilt chemicals with the aid of a water connection and floor drain. Following connections are necessary: Connection of the bypass water line Water line min. 1 bar (free of solids and turbidity substances) Floor drain Electrical connection

2.2

Wall Mounting

The installation kit contains anchor bolts, wall plugs, washers and nuts. > See Fig. 5 in Annex The Bello Zon system should be mounted on a suitable wall as close as possible to the metering point. The mounting height should be selected such that the chemical containers still have sufficient room under the system and the control display is convenient to read of. When full, the liquid level of the chemical container should always be below the metering pump. > See 6.1.1 for container height of Bello Zon components

2.3

Hydraulic Connections

WARNING: The system must be installed such that a vacuum cannot occur at the metering point under any circumstances, i.e. also during operation downtimes, inspections etc. If this requirement cannot always be ensured, a bleeder valve (refer to accessories, Chapter 6) or a pipe bleeder with backpressure valve should be installed after the premixing stage in the bypass line. In addition, the maximum permissible operating pressure for the system must not be exceeded under any operating conditions. Particular care must be taken to ensure that metering does not take place if the water to be treated fails (no flow). This can be achieved, for instance, in that the system is controlled by a flowmeter or the system operates parallel to a delivery pump and is interlocked with it (via the remote control contact input). NOTE: The entire installation should be checked for leaks at maximum operating pressure. A protective filter should be used if there are solid particles or turbidity substances in the water of the bypass line, in the water line for the discharge device or in the measuring water line. > See Section 6.2 Protective Filter

ProMinent

Page 13

Mounting/Installation

ProMinent

2.3.1

Bypass Line

The volumetric flow rate through the bypass should be 1-1.5 m3/h. The bypass flow rate should be approx. 2 - 2.5 m3/h for metering rates greater than 120 g/h. A bypass pump must be used if this flow rate is not achieved by installation of a control valve in the main water line. For this purpose, a slanted seat valve (refer to Accessories, Chapter 6) should be installed to control the volumetric flow in the bypass. Nominal diameter of bypass line DN 25, material: PVC If it is necessary to dismantle the bypass line, simply release the expanding studs used for securing the line: Slide a knife blade between the white dome head and the grey PVC tab and carefully lift off. Replacement studs are contained in the supplementary kit (included in scope of delivery, see Section 6.1.3). The reactor must be flushed before carrying out maintenance. As a rule, it is not possible to discharge the entire contents of the reactor into the process water within a short space of time. Installation of a flushing device (refer to Accessories, Chapter 6) is recommended for this purpose.

2.3.2

Water Connection for Exhaust System

Water line nominal diameter DN 10, minimum pressure: 1 bar, run from left to solenoid valve Arrange waste water line over constant downward slope. Do not connect to other waste water lines before the drain. A screw fitting should be provided just before and after the system to facilitate disassembly.

2.3.3

Venting Line

If no venting valve is installed, a venting line can be fitted from the reactor housing, ascending and as short as possible to the outside. > See Section 6.1.3

2.3.4

Intake Lances

Fix supplied labels as far as possible above the end cover on the pipe (arrow tip first) so that the chemical names Acid and Chlorite are clearly legible. Fit intake lances in corresponding containers, the foot valve should hang just above the base, firmly screw on end cap. Cut intake hoses to length, make sure that they are arranged on a constant ascent to the pumps in order to counteract gasification (note permissible intake height). > See table of performance data in Annex NOTE: The intake hoses must be arranged such that connection free of mechanical stresses is ensured at the liquid end.

2.3.5

Intake Lines

NOTE: Only use suitable hoses otherwise the durability of the connection cannot be guarantied. Check the diameter of the intake line.

Page 14

ProMinent

ProMinent

Mounting/Installation
Slide union nut and clamping ring over the hose, then slide end of hose as far as it will go over the connection sleeve, slightly widen hose end if necessary. > See Fig. 6 in Annex The clamping effect is achieved by firmly tightening the nut while at the same time pressing down the hose. You will obtain a firm hose connection if you now briefly pull the line secured to the liquid end and then tighten the union nut once again.

2.3.6

Checking Pipe Screw Fittings and Connections

Before initial operation, all screw fittings on the system as well as the connections should be checked for leaks and retightened if necessary.

2.4

Electrical Connection

Electrical installation must be carried out by a trained electrician in accordance with the documents (wiring diagram) provided.

WARNING: The system must not be under voltage (live) when working on it. NOTE: A lockable repair switch with overload and short-circuit trigger should therefore be provided on site for the system. A flexible electrical cable 3 x 1 mm2 should be used as the mains power supply line. All other cables used by the customer for the alarm, contact water meter etc. should be flexible.

2.4.1

Opening the Control

Before opening the unit, particular care must be taken to ensure that power supply to the unit is disconnected. Release the four screws in the upper section of the housing. The housing can be opened by pressing with the index finger on the front edge of the upper section. The retaining hooks are unlocked by pulling forward. The entire upper section can now be detached by pulling forward. > See Fig. 7 in Annex WARNING: Carefully separate the upper section and lower section from each other both sections are connected by a ribbon cable! With the aid of both guide rails, the upper section can now be fitted in the approx. 80 mm high slide-in unit. All connection terminals are now freely accessible.

2.4.2

Installation of Cable Connections

To facilitate electrical connection of the terminals, closed holes are provided on the underside of the control which must be punched out in order to pass through the connection lines. The leadthroughs must be broken out on the control corresponding to the system configuration. > See Fig. 8 in Annex NOTE: First connect the cables of the rear row. The leadthroughs in the rear row are allocated to Pg 9 and Pg 11 screw fittings (Fig. 9). Special punch tools are available for breaking out the holes to ensure the pcboard and thread are not damaged (Fig. 10 and 11).

ProMinent

Page 15

Mounting/Installation

ProMinent
Slide screw fitting, thrust ring and seal from the installation kit onto the cable, screw into threaded hole and hand tighten. NOTE: The 9 leadthroughs in the front row are for Pg 7 screw fittings. > See Fig. 10 in Annex Fit Pg 7 screw fittings over the cable and lock in position with locknut. Run wires to the terminals corresponding to the electrical wiring diagram. > See Fig. 19 in Annex NOTE: Various cable identification rings are fitted in order to differentiate between equivalent cables (e.g. power supply). (S for acid and C for chlorite.) Unused terminals must be connected to the corresponding pin strips before closing the unit.

2.5

Affixing Information Signs

The two signs below must be displayed together at entrances to rooms, in which Bello Zon chlorine dioxide systems are installed.

Chlorine dioxide systems Access for authorized persons only

The two signs below must be displayed together at entrances to rooms, in which the component Bello Zon-chlorite is stored or used.

Sodium chlorite NaCIO2

The following sign must be displayed in rooms, in which sodium chlorite (component Bello Zon-chlorite) is used: These include storage and filling rooms as well as the room, in which tanks are installed and connected to the Bello Zon systems.

Do not use containers and equipment alternatively Sodium chlorite + acid = Highly toxic chlorine dioxide gas DANGER OF FATAL INJURY!

Page 16

ProMinent

ProMinent

Initial Operation (Commissioning)/Operation

3
3.1

Initial Operation (Commissioning)

Information on Applicable Regulations

As stipulated in valid accident prevention regulations in Germany, chlorine dioxide systems must not be placed into operation before they have been checked by an authorized inspector to ensure they are in a condition appropriate to their intended purpose. In addition, before restarting operation, the safety of chlorine dioxide generating systems must be checked by an approved inspector. In compliance with regulations applicable in Germany, this inspection must be repeated at least every 6-12 months. Only specially instructed persons who can be expected to perform their work reliably are permitted to operate and maintain chlorine dioxide systems and handle chemicals. > See Accident Prevention Regulations GUV 8.15 and VBG 65 Chlorination of Water For this reason, commissioning is carried out by ProMinent service or by specially trained personnel in accordance with the corresponding commissioning instructions. Operating and maintenance personnel of the chlorine dioxide system receive instructions as part of the commissioning procedure.

Operation

Directly after switching on with the Start-Stop button, the system identification code is indicated in the top line of the display. It begins with CDVa. Below this, the relevant hardware/software version is indicated on the left and the active code on the right. The active code (= operating status of the system) is adapted as part of the commissioning procedure. After 30 seconds, the display switches over to the normal operating status. The operating mode and metering rate are then displayed.

4.1

Setting the Metering Rate

> Refer to Annex for graphic representation of the software menu page 2-4 The system must be shut down in order to make entries in the control. If the system is in operation: Press the Start/Stop button Standby appears in the display Press the Store button The message Standby parameter? appears in the display

4.1.1

Systems with Internal Control

Press the Store button The message Parameter max. metering appears in the display Press the Store button The message Max. metering xx g/h appears in the display The required system capacity can now be set with the Smaller button or the Larger button. Press Store button

ProMinent

Page 17

Operation

ProMinent
A smaller stroke length can also be set if the frequency of the metering strokes is not sufficient to ensure the chlorine dioxide is mixed optimally with the main flow of water. NOTE: Correct calibration (capacity gauging) in accordance with Section 4.3 and readjustment of the feed monitoring system in accordance with Section 4.4 are necessary every time the stroke length is adjusted.

4.1.2

Systems with Flow-Dependent Metering

Systems controlled dependent on the flow rate are set similar to that described above. See Section 4.1.1. In this case, however, in contrast to the above, the feed rate is referred to the main flow of water: Example 0.1 mg/l. The maximum and minimum flow rates of the main water flow are entered at the controler of the system. The systems shuts down if the flow rate drops below the minimum set value in the main water line. Press Store button Parameter feed rate ClO2 appears in the display Press Store button Feed rate ClO2 xx mg/l appears in the display The required concentration after mixing in the main flow of water can now be set with the Smaller button or the Larger button. Press Store button Parameter max. flow rate appears in the display Press Store button Max. flow rate xx m3/h appears in the display The maximum flow rate at the water meter can now be set with the Smaller button or Larger button. Press Store button

4.1.3

Systems with Control VariableDependent Metering

In this case, the input signal is a control variable from a controller output. The maximum value for metering capacity (control variable 100 %) is entered in the parameter menu. Press Store button Parameter max. metering appears in the display Press Store button Max. metering xx g/h appears in the display The maximum system capacity can now be set with the Smaller button or Larger button. Press Store button

Page 18

ProMinent

ProMinent

Operation

4.2

Accuracy of Metering Rate

The accuracy of the metering rate depends on following parameters: Backpressure in bypass Intake head Stroke length and frequency of pump Pump temperature Conveyed medium: Its concentration, density, vapour pressure The pump reaches its operating temperature after one hour of operation at maximum frequency. A cold pump delivers more than a warm pump. The metering accuracy at maximum stroke length and maximum backpressure is -5 % +15 %. The reproducibility under constant conditions and at ~ min. 60 % stroke length in CDV 35 and ~ min. 50 % stroke length in CDV 60 and 120 is better than 2 %. All data are referred to water (20 C).

4.3

Calibrating the Metering Pumps

The pumps should be at operating temperature before calibrating (gauging capacity). After storing the metering rate, the following message appears in the display Pump calibration acid tt min (depending on the size of the system). Press Store button The message Acid tt min. xxx ml appears in the display On the basis of the metering rate as set above, there is a minimum volume which the acid pump must deliver. This value can be called up: Press and hold Smaller button until the value indicated in the display no longer changes. NOTE: The value now indicated is the minimum volume which the pumps must deliver in order to ensure the required metering rate. The stroke length must be increased if this volume is not obtained during calibration (capacity gauging). Fill both calibration cylinders with water exactly up to marking. Place calibration cylinders on even, horizontal surface to facilitate read-of. The liquid level should be at eye level. Remove both intake lances from the containers and place in separate buckets of water. This removes residual chemicals on the outside and prevents the intake lances running empty. Slowly lift the intake lances, hold vertically and carefully place in the calibration cylinders. The symbol for the start-up button should appear at the bottom right of the display. The calibration procedure can then be started. Press Calibrate/start-up button. The system completes a number of strokes corresponding to its size and switches off automatically. Remove intake lances from the measuring cylinders (lift slowly and hold vertically), read off the new values at the calibration cylinders. Calculate the difference between 500 ml resp. 1000 ml and the new values (in ml). Enter the measured value for the acid pump with the Larger/smaller buttons.

ProMinent

Page 19

Operation
Press Store button

ProMinent

Enter the measured value for the chlorite pump with the Larger/smaller buttons. Press Store button Rescrew intake lances in the containers. If the value is 20% higher than the minimum volume shown in the display mixing of the chlorine dioxide in the main water line can be improved by a smaller stroke length setting. The calibration procedure must then be repeated.

WARNING: The stroke length must not be less than 50 % in CDV 60 and CDV 120 systems and not less than 60 % in the CDV 35 system otherwise effective operability of the feed monitoring system and operational reliability are no longer guarantied.

4.4

Setting the Feed Monitors

The normal operating pressure should be applied in the bypass line when setting the feed monitoring elements. Set control to Standby. The feed monitoring elements (Fig. 1-7) are adjusted with the aid of two knurled screws. In order to set a feed monitoring element, the upper knurled screw must be turned upward as far as it will go. Start pumps with Calibrate/start-up button. The system performs 20 strokes at max. frequency in this menu position. By turning the lower knurled screw, the feed monitoring element is slowly shifted upward until the green LED flow monitoring Acid (Fig. 4-3) or Chlorite (Fig. 4-5) just still lights during each stroke. Now turn back the screw so that the feed monitoring element is set approx. 2 mm below its switching point. The feed monitoring element is locked in position with the upper knurled screw.

WARNING: The feed monitoring element must be reset if the stroke length of a pump is varied or the backpressure changes at the metering point.

4.5

Bypass Water Failure

The minimum contact on the bypass monitor is set such that the monitoring function responds as soon as the flow rate is too low. In this case, the red LED (Fig. 4-L3) comes on and the system shuts down. The warning relay is activated. The system resumes operation automatically as soon as the flow rate increases once more.

4.6

Changing Component Containers

Switch off system by pressing the Start/stop button. Place new component containers under system. (Left side: Bello Zon-acid, right side: Bello Zon-chlorite)

Page 20

ProMinent

ProMinent

Operation
Place intake lances in corresponding containers such that they hang slightly above the bottom of the containers. Firmly tighten screw cap. Check whether there are any air bubbles in the intake line, bleed if necessary. (See Section 4.6.1).

WARNING: Particular care must be taken when refilling or replacing the component containers to ensure that under no circumstances are the containers confused or interchanged. If sodium chlorite is poured into the hydrochloride acid tank (or vice versa), large quantities of chlorine dioxide gas are immediately produced. Chlorine dioxide is unstable and as from a concentration of more than 10 vol.% (= 300 g/m3) in the gas phase it tends to explosive decomposition. In such cases, potentially, an explosion can occur even after a period of 15 to 30 minutes. To avoid confusion, the component containers, safety trays, tank store, place of installation and storage should be identified with a clear colour marking (acid = red, sodium chlorite = blue). Safety can be further improved particularly in the case of the storage tanks by the use of different connections systems. The operating personnel is to be instructed in the safe and responsible handling of chemicals.

4.6.1

Bleeding

NOTE: After changing the containers, air may be trapped in the intake line. Pump intake is impaired by pressure. It is therefore necessary to bleed the system until the intake line and liquid end are free of bubbles. The stroke length should be set to 100 % during the suction procedure. Only adjust stroke length while pumps are in operation. If the manual operation stroke length is not 100 %, note the value before changing it in order to proceed. Set ball cocks for bleeding (Fig. 14, Ill. 1+2, note symbol on control levers). Press Calibrate/start-up button several times if necessary. The delivered liquid is now collected in the bleeder bottles. Operate pumps until the intake lines and liquid ends are filled free of bubbles. Stop procedure by pressing Calibrate/start-up button. Reset ball cocks and stroke length to normal operation (Fig. 14, Ill. 3+4). WARNING: Do not pour together the liquids in the bleeder bottles and do not fill back into the chemical containers. Pour out contents and flush with large volumes of water.

4.7

Checking the Reaction Sampling Chlorine Dioxide

The reaction to chlorine dioxide results in slight yellow discolouration which can be observed at the inspection window of the reactor outlet. Approx. 1 hour after successful conversion in the reactor (possibly longer in the case of larger supply tanks) a sample should be taken from the main water line. This water sample is then examined for excess chlorine dioxide (colorimetric determination in accordance with DPD method). Change operating parameters of the system until the excess chlorine dioxide has reached the required value.

ProMinent

Page 21

Operation

ProMinent

4.8

Determining Chlorine Dioxide Concentration

The chlorine dioxide concentration can be determined easily and reliably with the DPD method. The DT1 photometer can be used for this purpose, order no. 1003473.3 > See chapter 6.1.7 The reagents are prepared in tablet or liquid form and specific volumes are then added to the sample water. The water will then turn a red colour which is evaluated in the photometer by comparing it to a control sample (sample water without reagent). Measurement with DPD 1 tablets comprises following substances: Chlorine dioxide (ClO2) and free chlorine (Cl2, HOCl, OCl). Chlorine compound (e.g. chloramine), chlorite (ClO2) and chloride (Cl) are not determined by this method. > Extremely high chlorite content can cause problems (e.g. in bottle washing machines). The measured value will increase continuously after addition of reagents. In this case the measured value reading taken directly after the addition of the reagent is to be viewed as the correct one. The present of manganese can also falsify measurements and indicate a deceptively high chlorine dioxide content.

4.9

Chlorine Dioxide Metering Rate

In view of the various applications of chloride dioxide systems, a generally applicable statement cannot be made with regard to recommended metering rates. In the treatment of drinking water, the total chlorine dioxide feed rate must not exceed the limit value of 0.4 g/m3. The overall drinking water concept must therefore be adapted to the use of chlorine dioxide. Higher feed rates are used for industrial water treatment (e.g. in bottle cleaning machines).

4.10 Consequences of Incorrect Setting 4.10.1 Incorrect Setting of Metering Pumps 4.10.1.1 Different stroke length of metering pumps and
feed monitoring element set accordingly and not calibrated or incorrect values entered during calibration.
Consequences: Excess feed of acid or chlorite Excess acid simply increases the excess which already exists and is of little consequence. Excess chlorite, however, can impair the production process and result in the limit value being exceeded. NOTE: Always set both metering pumps to the same stroke length. Set the metering monitoring element correctly. Do not forget the calibration (capacity gauging) procedure! Enter calibrated values in the control and store.

4.10.1.2 Setting Stroke Length when Metering Pump is not

in Operation
Consequence: Stroke difficult to adjust. NOTE: Only adjust stroke length with the pump in operation.

Page 22

ProMinent

ProMinent

System Maintenance

4.10.2 Incorrect Setting of Feed Monitoring

If the feed monitoring element is set too low, it is possible that the monitoring function no longer detects a reduction in the flow rate of >30 % and the system continues to operate. Consequence: See 4.10.1.1 If the feed monitoring element is set too high, the system shuts down after eight pump strokes.

4.10.3 Incorrect Setting of Bleeder Cock Valves Acid/ Chlorite

Ball cock set to bleeding during system operation. Consequence: The feed monitoring element sends no signal since there is no flow of chemicals. System switched off. NOTE: Observe symbol on control lever of ball cock!

4.10.4 Incorrect Settings at Bypass 4.10.4.1 Ball Cock Before the Bypass Monitor or
After the Metering Valve Closed
Consequence: No flow in bypass, pressure increases. Bypass monitor or feed monitor no longer sends signal. System shuts down. NOTE: Check setting of ball cock and set to correct position if necessary.

4.10.4.2 Flow Rate and Limit Contact in Bypass Set

Incorrectly
Consequence if flow rate is too low: The chlorine dioxide concentration in the bypass becomes excessively high thus reducing operational reliability. Consequence if flow rate is too high: Operating pressure increases possibly above the maximum permissible operating pressure.

4.10.5 Incorrect Setting in Control

Parameter values entered incorrectly. Consequence: See 4.10.1.1

5
5.1

System Maintenance
Regular Checks

Determine chlorine dioxide concentration in the treated water. Compare levels of component containers, if applicable, observe initial warning Level low in display. Check flow rate at the bypass. Document consumption of Bello Zon Chlorite and Bello Zon Acid.

ProMinent

Page 23

System Maintenance

ProMinent

5.2

Maintenance Work

NOTE: In accordance with Accident Prevention Regulations GUV 8.15 and VGB 65 19 (2), the safety of chlorine dioxide systems must be checked by an approved inspector regularly, however, once a year at a minimum and before resuming operation. This inspection can be carried out as part of the routine maintenance carried out twice a year by customer service. It is therefore advisable to conclude a maintenance agreement. > See Fig. 15 and 16 in Annex The system is checked for leaks on completion of maintenance work. Control lines or mains power connection lines must only be installed by service technicians. Only the corresponding special lines must be used.

WARNING: Before starting any maintenance work (replacement of parts etc.) on the chlorine dioxide system, the system must be flushed out with water in order to remove all traces of chemicals. The contents must be discharged before opening the reactor. Press the Discharge button (Fig. 4) for this purpose.

5.2.1

Maintenance of Metering Pumps

Check following points during maintenance: Firm fit of liquid end screws Firm fit of metering lines (delivery and intake side) Firm fit of pressure control valve and of intake valve. Check for moisture at leakage hole on head. If moisture is found, this indicates a probable diaphragm breakage.

5.3 5.3.1

Troubleshooting Feed Monitoring LED (Fig. 4-L6 or L10) does not Flash during Pump Stroke (Fault 5.3.4 Occurs after 8 Strokes)

Cause 1: Feed monitoring element not set correctly. > See Section 4.4 Cause 2: Air in intake line from container to pump. > See Section 4.6

5.3.2

Liquid Escapes from head Disc of a Pump

Cause: Diaphragm leaking Remedy: Retighten socket head cap screws on liquid end. If tightening the socket head cap screws is not successful, notify ProMinent Service.

Page 24

ProMinent

ProMinent

System Maintenance

5.3.3

Metering Pump does not Delivers although the Yellow LED of the Metering Pump (Fig. 4-L9 or 4-L10) Flashes

Cause 1: Air may be trapped in the liquid end. Remedy: Bleed system as described under Commissioning Section 4.6.1. Cause 2: The stroke length is set to too small a value. Remedy: Increase stroke length with adjustment.

5.3.4

Red LED - Metering Pump (Fig. 4-L9 or 4-L10) Lights Up

The message in the display indicates the pump concerned or - in the case of chemical level low - which container is empty. Cause 1: Delivery rate has been reduced (by more than 30 %) due to an increase in the operating pressure or due to an increase in the intake head. Remedy: Readjust feed monitoring (explained in Section 4.4 Setting Feed Monitoring). Cause 2: Function connector on pump worked loose or cable is not connected correctly. Remedy: Check orange cable from pump to control. Cause 3: Ball cock in metering line set incorrectly. Remedy: Check setting of ball cocks, note symbol on control lever. Cause 4: Component container empty. Remedy: Change container, bleed intake lines.

5.3.5

Red LED of Bypass Pump (Fig. 4-L3) Lights Up

Cause 1: Ball cock (Fig. 1-12) set incorrectly. Remedy: Check setting of ball cocks in bypass. Cause 2: Cable not connected correctly. Remedy: Check cable from bypass monitor to control. Cause 3: Bypass pump no longer delivers Remedy: Check bypass pump. Cause 4: Float or turbine wheel is blocked. Remedy: Remove deposits. Cause 5: Limit contact defective. Remedy: Check limit contact and replace if necessary.

5.3.6

Metering Pump is not Primed Despite Full Stroke Movement and Bleeding

Cause: Crystalline deposit on ball seat due to valves drying out. Remedy: Briefly lift up intake hose, thoroughly flush through pump, if not successful, remove and clean valves.

ProMinent

Page 25

System Maintenance

ProMinent

5.3.7

Metering Pump was in Operation for a Prolonged Period of Time and Suddenly no Longer Delivers

Bleed metering line, check level in container, if not successful Cause: Pump diaphragm probably defective. Remedy: Notify service.

5.3.8

Metering Pump does not Move, Indicator Lamp (Fig. 4-L5 or 4-L9) does not Light

Check power supply, if power applied: Cause: Fuse defective. Remedy: Have fuse checked by service and replaced if necessary. NOTE: Only use the specified fuse ratings (see Section 6.1.4) If the fault cannot be rectified by changing the fuse, notify ProMinent Service.

5.4 5.4.1

Shutting Down the Chloride Dioxide System Shutting Down for a Short Period

If the chlorine dioxide system is to be shut down only for a short period, switching off the system via the Start/Stop button will be sufficient. The power supply for system control and chlorine dioxide measurement should not be disconnected.

5.4.2

Shutting Down for a Prolonged Period

Chlorine dioxide is an unstable compound that disintegrates over time. Therefore, if the system is to be shut down for a prolonged period (several days), it is advisable to flush out the reactor with water. The installation of a flushing device in the bypass line is recommended for this purpose (refer to Accessories, Chapter 6.1.3). Switch off system by pressing the STOP button. Open the configuration menu in the control display. Set the start-up time parameter to min. 30 minutes in the Start menu. Remove the intake lances from the chemical containers and place separately in a bucket filled with water. Press Start button and set the stroke length of both metering pumps to 100%. Allow system to operate until the pump heads, reactor and lines up to the metering valve are completely filled with water (this ensures no chlorine dioxide can flow out of the reactor during disassembly). Disconnect system from power supply.

5.4.3

Shutting Down and Frost-Proof Storage

If the chlorine dioxide system is to be prepared for winter, it will be necessary to completely discharge the reactor and bypass line. After flushing with water, the system can be discharged by opening the back pressure valve on the reactor outlet/bypass and by removing the inlet valves on the underside of the reactor. Switch on the discharge system by pressing the Discharge push button before disassembling the reactor inlet valves.

Page 26

ProMinent

ProMinent

Technical Data

6
6.1 6.1.1

Technical Data
Accessories Intake Lances

As necessary accessories, the intake lances are included in the scope of delivery of a Bello Zon chlorine dioxide generating system. They are adapted to the various container heights and to the intake hose diameter used in the corresponding size of system. When ordering the system, the relevant intake lances are selected depending on the container sizes used by the operator. Table: Intake lances for various container sizes 30 litre Intake lance PN 790650 200 litre 791563 940 mm 500 litre 791612 970 mm Flexible intake line 792195 variabel

Container height 420 mm

NOTE: To ensure trouble-free operation, only ProMinent intake lances with twostage float switches should be used.

6.1.2

Supplementary Kit and Spare Parts

The supplementary kit is included in the scope of delivery of a Bello Zon system. It consists of the parts which are necessary for installation at the customer. Cable screw fittings Pg 7, Pg 9 and Pg 11 including sealing rings, thrust rings and lock nuts Dummy discs, plugs and lock nuts for stamped out and no longer required leadthroughs in the control so that the specified type of enclosure is retained. Wall plugs, anchor bolts and washers for mounting the system on a wall. Expanding studs in two sizes (as replacement) Clamping length 7, mm for securing metering lines, tab thickness 1 mm Clamping length 8 mm, for securing bypass line and cable duct, tab thickness 3 mm Supplementary kit Part No. 791388 > See Fig. 16 Spare Parts Sets in Annex.

6.1.3

Valves and Flushing Device

Bleeder valve for reactor chamber (can be used instead of a bleeder line that is routed to the outside), Part No. 791801. Bleeder valve for bypass line (to prevent the breakthrough of chemicals in long bypass lines or vacuum), Part No. 1001260. Slanted seat valve, DN 25 (for adjusting the bypass flow rate with bypass pump installed), Part No. 1001877. Flushing device (for installation in bypass line for discharging reactor before maintenance), Part No. 1000525, see Fig. 13.

ProMinent

Page 27

Technical Data

ProMinent

6.1.4
Control:

Fuses

A 5x20 mm fine-wire fuse must be used to provide fuse protection. Mains voltage 200-240 V: 0.2 A super slow-blow PN: 712057 Mains voltage 100-120 V: 0.4 A slow-blow PN: 712021 The fuse is located in a fuse holder with bayonet catch in the terminal box of the control. Metering pump: Fine-wire fuse 6.3 x 32 mm for 230 V: 0.25 A slow-blow for 115 V: 0.5 A slow-blow

6.1.5

Bello Zon -Acid and Bello Zon -Chlorite

30 l 200 l 500 l 30 l 200 l 500 l PN: 950130 PN: 950131 PN: 950132 PN: 950135 PN: 950136 PN: 950137

Bello Zon-acid

Bello Zon-chlorite

6.1.6

Safety Trays

Safety trays with leak monitor Leakage in the safety tray is monitored by means of a level switch. Order number: Scope of delivery: 40 l 250 l PN: 791728 PN: 791729

2 trays plus pc-board

Terminal assignments in addition to basic unit: Terminals 47(+)(br), 48(-)(w) 49(+)(br), 48(-)(w) Connection Plug-in slot assignment Plug-in card Order No.: 725275

Leakage Plug-in 9 monitoring acid Leakage monitoring chlorite Plug-in card digital input Bello Zon

Safety trays without leak monitor Order number: Scope of delivery: 40 l 250 l 1 tray PN: 791726 PN: 791727

6.1.7

Set for Determining Chlorine Dioxide

PN: 1003473

Photometer DT 1

Page 28

ProMinent

ProMinent

Technical Data

6.1.8

Heating Systems for Chemical Lines

(For the case that the ambient temperature about the chlorine dioxide system or the chemicals is below 10 C) Intake hose diameter 6/4 mm Intake hose diameter 8/5 mm Intake hose diameter 12/9 mm Intake hose diameter 19/16 mm Part No. 1001636 Part No. 1001637 Part No. 1001638 Part No. 1001639

6.1.9

Metering Points
Part No. 1001823 Part No. 1001822

Metering tube, DN 25, PVC (can be used up to pipe diameter DN 80) Immersion tube, DN 25, PVC (can be used up to pipe diameter DN 100)

6.1.10 Suction Accumulator Bello Zon

Used for CDVa 35 to CDVa 120 Suction accumulator CDVa Acid Suction accumulator CDVa Chlorite > See Fig. 12 in Annex Part No. 1001820 Part No. 1001821

6.2

Protective Filter
Part No. 911056 4 m3/h Part No. 143076

DULCOFILT protective filter G 1 Nominal flow rate at delta p = 0.2 bar: Replacement strainer element Pore size 100 m

6.3

Temperature
+10 to +40 C + 2 to +40 C +10 to +40 C

Permissible ambient temperature: Permissible treatment water temperature: Permissible component temperature (chemicals):

6.4

Bypass Pump (Stainless Steel)

220 - 240 V 2.2 A 540 W 2880 rpm

Motor data Rated voltage: Rated current: Motor: Speed:

Electrical protection: Integrated overload protection

6.5

Spare Parts

> See Bello Zon parts list, Part No. 987902

ProMinent

Page 29

Conformity Declaration

ProMinent

EC Declaration of Conformity
We,

ProMinent Dosiertechnik GmbH Im Schuhmachergewann 5-11 D-69123 Heidelberg

hereby declare that, on the basis of its functional concept and design and in the version brought into circulation by us, the product specified in the following complies with the relevant, fundamental safety and health stipulations laid down by EC regulations. Any modification to the product not approved by us will invalidate this declaration.

Product description:

Chlorine dioxide generator

Product type:

CDV ...

Serial number:

see type identification plate overleaf and on device

Relevant EC regulations:

EC - machine regulation (89/392/EEC) subsequently 93/44/EEC EC - low voltage regulation (73/23/EEC) EC - EMV - regulation 89/336/EEC subsequently 92/31/EEC

Harmonised standards used, in particlar:

EN 292-1, EN 292-2; EN 60335-1 A6, EN 60335-2-41, EN 61010-1 EN 50081-1/2, EN 50082-1/2, EN 60801-2, EN 55011 EN 60555-2, EN 60555-3

National standards and other technical specifications used, in particular:

DIN VDE 0700 T1 DIN VDE 0700 T41 DIN VDE 0700 T500

DIN VDE 0110 DIN VDE 0106

DVGW - compilation of rules, job sheet W224

Date/manufacturers signature:

19.07.1996

The undersigned:

Mister Manfred Hholt, factory manager

Page 30

ProMinent

ProMinent

Annex

Contents Graphical representation of software menus Properties of chlorine dioxide and information on the handling of aqueous solutions Performance data

Page 2-4 5 6

Fig. 1 Fig. 2 Fig. 3 Fig. 4 Fig. 5 Fig. 6 Fig. 7 Fig. 8 Fig. 9 Fig. 10 Fig. 11 Fig. 12 Fig. 13 Fig. 14 Fig. 15 Fig. 16 Fig. 17 Fig. 18 Fig. 19

Design of a Bello Zon system CDVa Identification code system Operating code Bello Zon Control Wall mounting of support bracket Mounting of intake hose Bello Zon control inputs and outputs Arrangement of Pg screw fittings Installation of Pg 7 screw fittings Installation of Pg 9 screw fittings Suction accumulator Bello Zon CDVa acid/chlorite Flushing device d32/d20 Bello Zon Setting of ball cocks Error messages in control and corresponding output signals Part No. - Overview of spare parts sets Measurements Bello Zon chlorine dioxide system CDVa 35-120 Measurements Bello Zon chlorine dioxide system CDVa 220-600 Measurements Bello Zon chlorine dioxide system CDVa 2000 Electrical wiring diagramm

7 8 9 10 11 11 12 13 13 13 14 14 15 16 17 18 19 20 21

ProMinent

Page 31

Annex

ProMinent

Operating Mode: Internal Activation

The system capacity is constant and is set in the parameter menu. Startup Operating code: AKTIV xxNNDxxx Set the other features based on the existing options. If necessary, vary intake interval and intake duration. Parameter setting Set the required capacity as the maximum metering rate. Gauge pump capacity in litres. Find the minimum limit value in the "Acid tt min." menu point using the "less than" button. Place the moist intake lances in the measuring cylinder filled with water. Press the "start" button and gauge the pump capacity in litres. The gauged value must be greater than the displayed minimum value. Enter gauged values of the pumps. Operation The current and maximum set capacity values are displayed. These values are not equal in systems with analog remote control. In systems with a turbine flow meter in the bypass, the bypass flow rate is also indicated.

OPERATION
STOP
START

PARAMETER SETTING

ClO2 = 52.7 g/h Internal control CDVa xAxxxxxDxx H01S01 xxNNDxxx maxClO2 = 52.7g/h Internal control 52.7 76 current value set value Metering OFF

Metering OFF Parameter ?

Parameter max. metering Gauge pump capacity in litres Acid tt min. Gauge pump capacity in litres Chlorite tt min.

Max. metering xxx ,x g/h Acid tt min. xxx ,x ml Chlorite tt min. xxx ,x ml Gauge pump capacity in litres

Metering OFF Configuration ?

Configuration xxxx Feed.Code AKTIV XXNNDXXX

Metering during pause Intake Intake interval ? Intake Intake duration ?

Pause metering xx % Intake interval* xxx minutes Intake duration xx seconds Start

STARTUP

Start ?

ttt minutes Start

remote contact *For pause option only

Page 32

ProMinent

ProMinent

Annex

Operating Mode: Flow-Dependent Activation

The system capacity is proportional to the measured flow rate. Startup Operating code: activecode (4) = K, F, 0 or 4; Set the other features based on the existing options. If activecode (4) = K Enter pulse duration of water meter If activecode (4) = F Enter pulse value (frequency) of the flow meter If activecode (4) = 0, 4 Enter flow rate at 20 mA (maximum measured flow rate) Flow rate at 0 (4) mA is assumed to be 0. If necessary vary intake interval and intake duration. Parameter setting Set the required feed rate (compensate for wear) Find the maximum limit value in the "max. flow rate" menu point with the "greater than" button. This corresponds to the maximum capacity of the system. In the case that the real maximum flow rate is far below this value, the real value should be entered. The maximum system capacity is calculated internally from the feed value and the maximum flow rate, thus deriving the minimum pump capacity value. Set minimum flow rate - this must be 0 for analog flow meter (0 - 20 mA). Gauge pump capacity in litres: Find the minimum limit value in the "acid tt min." menu point with the "less than" button. Place the moist intake lances in the measuring cylinder filled with water. Press "start" button and gauge pump capacity in litres. The gauged value must be greater than the displayed minimum value. Enter gauged values of the pumps. The maximum flow rate value is recalculated internally from these values. Operation The flow rate, current system capacity and the set feed value are displayed. If the flow rate exceeds the maximum value, the system capacity remains constant and the feed value drops. Metering cuts out if the flow rate drops below the minimum value. The bypass flow rate is also indicated for systems with a turbine flow meter in the bypass.

OPERATION
STOP
START

PARAMETER SETTING
Metering OFF Metering OFF Parameter ? Parameter Feed rate ClO2 Parameter max. flow rate Parameter min. flow rate Gauge pump capacity in litres Acid tt min. Gauge pump capacity in litres Chlorite tt min. Feed rate ClO2 xxx mg/l Max. flow rate xxx m3/h Min. flow rate xx ,x m3/h Acid tt Min. xxx ,x ml Chlorite tt Min. xxx ,x ml Guage pump capacity in litres Flow signal AKTIV XXXKDXXX water meter ? Flow signal or AKTIV XXXFDXXX Frequency ? Flow signal or AKTIV XXX0DXXX Analog ? Metering during pause Intake Intake interval ? Intake Intake duration ? Water meter xxx .x Liter Frequency xxx pulse./l Q at 20 mA xxx .x m3/h Pause metering xx % Intake interval* xxx minutes Intake duration xx seconds Start Start ? remote contact *For pause option only tt minutes Start

Q=

47 m3/h

ClO2 = 52.7 g/h CDVa xAxxxxXDxx H01S01 xxNXDxxx Feed = 0.61mg/l External Control 52.7 0.61

current value set value

Metering OFF Configuration ?

Configuration xxxx Feed.Code

STARTUP

ProMinent

Page 33

Annex

ProMinent

Operating Mode: Controlled Variable-Dependent Activation

The system capacity is proportional to the value of the controlled variable signal. Startup Operating code: Activecode (3) = K, 0 or 4; Set the other features based on the existing options. If active code (3) = K Enter pulse value of controlled variable. If necessary vary intake interval and intake duration. Parameter setting Set required maximum capacity (in g/h). The minimum pump capacity value is calculated internally from the maximum system capacity. Gauging pump capacity in litres: Find the minimum limit value in the "acid tt min." menu point with the "less than" button. Place the moist intake lances in the measuring cylinder filled with water. Press "start" button and gauge pump capacity in litres. The gauged value must be greater than the displayed minimum value. Enter gauged values of the pumps. Operation The current capacity and the maximum capacity are displayed. The bypass flow rate is also indicated for systems with a turbine flow meter in the bypass.

OPERATION
STOP
START

PARAMETER SETTING

ClO2 = 52.7 g/h max. ClO2 76 g/h CDVa xAxxx1xDxx H01S01 xTKNDxx max.ClO2 = 76 g/h External control 52.7 76 current value set value Metering OFF

Metering OFF Parameter ?

Parameter max. metering Gauge pump capacity in litres Acid tt min. Gauge pump capacity in litres Chlorite tt min.

Max. metering xxx .x g/h Acid tt min. xxx .x ml Chlorite tt min. xxx .x ml Gauge pump capacity in litres

Metering OFF Configuration ?

Configuration xxxx Feed.Code AKTIV XXXXDXXX

Controlled vatiable max. contact ? Metering during pause Intake Intake interval ? Intake Intake duration ?

Max. contact xxx pulse/min Pause metering xx % Intake interval* xxx minutes Intake duration xx seconds Start

STARTUP

Start ?

tt minutes Start

remote contact *For pause option only

Page 34

ProMinent

ProMinent

Annex

Properties of chorine dioxide and guidelines for working with aqueous solutions (Extract from the safety data sheet for chlorine dioxide by FIGAWA, April 1998)
1. Physical and Chemical Properties of Gas-form Chlorine Dioxide
Colour: Orange-yellow Odour: Pungent Boiling point: 11 C Stability: Gas-form chlorine dioxide decomposes explosively at concentrations above 300 g/m3 (= 10 % by volume) into chlorine and oxygen. Dilution reduces the explosive tendency; at concentrations below 10 % by volume in gases with which chlorine dioxide does not react (e.g. air, nitrogen, carbon dioxide) there is no longer any danger of explosion. A critical chlorine dioxide concentration is for instance an aqueous chlorine dioxide solution with a concentration of more than 8 g/l chlorine dioxide (at a temperature of 20 C) within the gas room. A significant to explosive reaction will also result with oxidising materials.

2. Characteristics of the Aqueous Solutions of Chlorine Dioxide

The gas phase which forms over the aqueous solution of chlorine dioxide is decisive. Stability: Outside a gas room aqueous chlorine dioxide solutions from a concentration of around 30 g/l are explosive, i.e. they can decompose explosively without external influences such as heat, spark, dirt or rust. Chlorine dioxide is stable for several days in a dilute aqueous solution if the solution is pure and is kept dark and/or if the temperature of the solution is below 25 C and its pH value is less than 7.

3. Measures in the Event of Spillage, Leakage, Gas Leak and Fire

Hose the gas with a water jet. Leaked solution should be doused with sodium thiosulphate and then diluted with plenty of water and rinsed into the drainage system. Chlorine dioxide is not inherently flammable but has fire-stimulating properties. Decomposes explosively at temperatures above 100 C. Chill a tank of water and hose leaked chlorine dioxide gas with a water jet. There are no fire extinguisher constraints in the event of fires in the vicinity.

4. Health and Safety 4.2 MAK value (MAK = max. admissible concentration in the workplace) and odour threshold
MAK value: 0.1 ppm (ml/m3) and/or 0.3 mg/m3 Odour threshold: chlorine dioxide gas is perceptible by odour from concentrations of around 15 mg/m3.

4.2 Health Hazards

A chlorine dioxide gas concentration above 45 mg ClO2/m3 causes respiratory difficulties and leads to irritation of the mucous glands and headaches. Respiratory protection: gas mask, filter B/grey In general chlorine dioxide causes severe irritation in the region of the mucous glands of eyes and respiratory organs. Depending on the concentration and duration of the effect this can lead to danger of suffocation, coughing attacks occasional vomiting, conjunctivitis and severe headaches. In serious cases it can cause lung oedema with breathlessness, oxygen shortage and circulation failure. In the event of short periods of exposure to high concentrations there is a threat of glottal cramp and/or reflexive breathing or heart stoppage. Harmful to nerves (e.g. eye muscle failure).

4.3 First Aid

Clothing which has come into contact with chlorine dioxide or its aqueous solution should be removed immediately. Wash skin thoroughly with soap and plenty of water. If solution has splashed into the eyes, rinse under running water with the eyes wide open. After inhalation of chlorine dioxide provide fresh air, absolute rest, lay patient horizontally, maintain body heat. Inform a doctor immediately even if complaints do not appear straight away. If necessary, remove to hospital quickly and carefully.

ProMinent

Page 35

Annex

Page 36
Max. operating pressure Operating temperature Max. stroke frequency Metering rate per component* Metering pump Type Max. intake head metering pump** m wc G/4 - 1601 1.65 2.35 0.93 1.3 1.9 7 7 G/4 - 1201 G/4 - 1002 G/5 - 1605 G/4 - 1310 Vario 12017 Sica 12050 230 V 1.8 A 1.8 A 1.8 A 6.9 A 6.9 A 1.7 A 3.4 A l/h ml/stroke 0.16 0.23 0.45 0.9375 1.66 3.2 11.4 1.15 1.65 3.25 5.625 10 15 50 Stroke/h 7200 7200 7200 6000 6000 4620 4380 C 10 - 40 10 - 40 15 - 40 10 - 40 10 - 40 15 - 40 15 - 40 bar 10 8 8 10 10 8 7 Max. current input*** 115 V 3.5 A 3.5 A 3.5 A 12.2 A 12.2 A 3.4 A 6.8 A

Performance data

System Type

Metering Chlorine dioxide*

g/h

mg/Hub

CDV 35

46

6.4

CDV 60

66

9.1

CDV 120

130

18

CDV 220

225

37.5

CDV 400

400

66.6

CDV 600

600

130

CDV 2000

2000

456

= The metering rates are reffered to a mean operating pressure of 5 bar and an operating temperature of 20 C and determined with the pump at operating temperature (min. 3 hours at max. frequency)

** = Intake head with clean, moist valves. Intake head at 100 % stroke.

*** = For systems without bypass pump.

ProMinent

ProMinent

ProMinent

Annex

1 2

10

13

16 9 15 3 14 12 7 8

11 17
Bypass Bypass Sure Acid Wasser Water Chlorit Chlorite
Bello Zon
STOP
START

12 24 25
STOP
START

20
230 V, 50/60 Hz

23 5

6 22

80

60

40

25

l/h

21

4
Bello Zon Sure Acide Bello Zon Chlorit Chlorite

Bello Zon Chlorine Dioxide Plant with Flow-Dependant Control

18

19

1 2 3 4 5 6 7 8

water meter (contact, analogue) main water pipe bypass pipe 1-2 m3/h bypass pump water monitoring pipe solenoid dosing pump flow sensor reactor

9 10 11 12 13 14 15 16

reactor housing dosing valve (pressure sensitive) mixer stop valve ventilation valve suction device bypass monitor non-return-valve

17 18 19 20 21 22 23 24 25

control with production level display Bello Zon acids in safety vessel Bello Zon chlorite in safety vessel D1C - chlorine dioxide meter chlorine dioxide probe water readings monitor interlocking contact rinsing connector holding tank (reaction time 10-15 min.)

Fig. 1: Installation example of a Bello Zon chlorine dioxide generating system CDVa
ProMinent

Page 37

Annex

ProMinent

Please note here the Identcode from the front page: 0 1 2 3 4 5 6 7 8 9

CDVa
System type: Series Version

1A = CDV 35 = 46 g/h 2A = CDV 60 = 66 g/h 3A = CDV 120 = 130 g/h 4A = CDV 220 = 225 g/h 5A = CDV 400 = 400 g/h 6A = CDV 600 = 600 g/h 8A = CDV 2000 = 2000 g/h
Default language: Bypass monitoring:

Operating voltage:

0 1

= 230 V 50/60 Hz = 115 V 50/60 Hz

Bypass version:

0 1 2 3 4

= without bypass and without premixer = without bypass, with premixer = with bypass, with premixer = with bypass, without premixer = with bypass, with premixer with bypass pump made of stainless steel = with bypass, without premixer with bypass pump made of stainless steel = with bypass, with premixer with bypass pump made of cast iron = with bypass, without premixer with bypass pump made of cast iron

0 1 2 3

= None = Turbine flowmeter = Variable-area flowmeter = Variable-area flowmeter and PVC solenoid valve

D E F I S 0 1

= German = English = French = Italien = Spanish

Analog outputs: = None = Analog (0/4-20 mA for recorder) Remote control input:

Control variable input:

0 1 2

= None = Contact (max. 4 sec.) = Analog (0/4-20 mA) + contact, reversible

0 1 2 3

= None = Contact = Analog (0/4 - 20 mA) = Contact and Analog

Flow input:

0 1 2 3

= None = Contact (max. 4 sec.) (water meter) = Frequency = Analog (0/4-20 mA) (Analog flowmeter + reversible contact)

The hatched options are not included in the standard control. The mixer is supplied separately for CDVa 220 to 2000.

Fig. 2: Identification code system Bello Zon CDVa 35-2000

Page 38 8

ProMinent

ProMinent

Annex

AKTIV
Bypass pump

N N N N D N N N

N Inactive P Drive active

Bypass monitor

Language

N Inactive T Turbine Q NO contact C NC contact

Controlled variable input Flow input

N Inactive K Contact (0-3.3 Hz) 0 Analog 0-20 mA 4 Analog 4-20 mA

N Inactive K Contact (0-3.3 Hz) F Frequency 0 Analog 0-20 mA 4 Analog 4-20 mA

B Portuguese C Czech D German E English F French H Hungarian I Italian N Dutch P Polish R Rumanian S Spanish
Analog output

Remote control input, analog

N Inactive 0 0-20 mA 4 4-20 mA

Remote control input, contact

N Inactive O NO C NC

N Inactive 0 0-20 mA 4 4-20 mA

Fig. 3: Operating code Bello Zon CDVa

ProMinent

Page 39

Annex

ProMinent

L7 L6 L5 L4 L3 12 L2 11 10 17 18 L1 15 14
2971-3

L8 A L9 L10 16

13

L1 green Device in operation L2 red Fault (flashing light), warning (steady light) A Display for operating parameters, error messages, setting menu

LED-lamps
L3 yellow Bypass pump activation red Bypass monitoring, fault L4 green Bypass monitoring OK L5 yellow Activation metering pump acid (stroke) red Feed monitoring pump acid fault L6 green Feed monitoring pump acid OK L9 yellow Activation metering pump chlorite (stroke) red Feed monitoring pump chlorite fault

PUSHBUTTON
STOP
START

START/STOP (in conjunction with L1) Changeover between operating and setting status ACKNOWLEDGE (in conjunction with L2) Acknowledgement of fault signals CALIBRATE/START-UP Pump operation for bleeding or start-up DISCHARGE button Start one single discharge cycle STORE OPERATING STATUS CHANGE

L10 green Feed monitoring pump chlorite OK

L7 and L8 not used in CDV systems

Standby

SMALLER

Internal control BACK

LARGER

Access code

Fig. 4: Control
Page 40 10

CIO2=52.7 g/h

STOP
START

Parameter setting Commissioning menu (configuration menu)

ProMinent

ProMinent

Annex

3034-3

1 Support bracket 2 Wall plug 3 Anchor bolt 4 U-washer (plastic) 5 U-washer (metal) 6 Hexagon nut 1 Intake connection 2 Union nut 3 Bite ring 4 Hose sleeve 5 Intake hose
3037-4

Fig. 5: Wall mounting of support bracket

ProMinent

Fig. 6: Mounting of intake hose

11 Page 41

Annex

Page 42

Control inputs and outputs

Complete configuration

Fig. 7: Bello Zon control inputs and outputs

Flow RS 232 output Solenoid valve discharge output Warning output Supply voltage Pump Pump acid chlorite input input Input level signal chlorite Input flow monitoring bypass Input flowmeter contact frequency analog Output external control pump acid/chlorite Input feed monitoring acid/chlorite Output bypass pump Output alarm Input mains power
2968-3

Fault Control variable or pulse remote control or Analog Contact analog CLO2-conc. input input input output

12

Input leak warning safety container acid/chlorite

Input level signal acid

ProMinent

ProMinent

ProMinent

Annex

Fig. 8: Arrangement of Pg screw fittings

Fig. 9: Installation of Pg 7 screw fittings

Fig. 10: Installation of Pg 9 screw fittings

ProMinent

13

Page 43

Annex

ProMinent

3
Acid Chlorite
3403-4

Fig. 11 Suction accumulator Bello Zon CDVa acid/chlorite

(22)

203

Pipe d32

Pipe d20 Sleeve d32

192

Delivery hose socket d20

3328-4

39

Fig. 12: Flushing device d32/d20 Bello Zon

Page 44 14

ProMinent

ProMinent

Annex

Bleeding position
Reactor Reactor

Pump

Pump Bleed Bleed

Ill. 1

Ill. 2

Normal operating position

Reactor Reactor

Pump

Pump Bleed Bleed

Ill. 3

Ill. 4
2984-4

Fig. 13: Setting of ball cocks

ProMinent

15

Page 45

Annex

ProMinent

Error messages
Fault Feed monitoring acid pump Feed monitoring chlorite pump Acid level initial warning Chlorite level initial warning Acid level Chlorite level Qby < Qbymin Qby < Q Signal Acid pump Error Chlorite pump Error Acid level low Chlorite level low Acid container EMPTY Chlorite container EMPTY Bypass fault Bypass fault Effect Metering stops Metering stops Metering continues Metering continues Metering stops Metering stops Metering stops Metering stops Delay Red LED Acknowledge manual manual manual manual manual manual auto auto Warn. Alarm relay relay ON ON ON ON ON ON flashes flashes ON ON ON ON Corrective measure Bleed or set monitoring element Bleed or set monitoring element Change container Change container Change container Change container Find cause Find cause

after 8 flashes strokes after 8 flashes strokes ON ON flashes flashes 0.7 sec. ON 5 sec. ON

PC-board failed or 3.7 mA > current signal > 23 mA PC-board failed or 3.7 mA > current signal > 23 mA PC-board failed or 3.7 mA > current signal > 23 mA PC-board failed PC-board failed PC-board failed

Flow input fault Remote control input fault Remote control output fault Remote control contact fault Feed monitoring fault Bypass monitoring fault

Metering stops

5 sec. flashes

manual

ON

ON

Check pc-board Check signal Check pc-board Check signal Check pc-board Check signal Check pc-board Check pc-board Check pc-board

Metering stops

5 sec. flashes

manual

ON

ON

Metering stops

5 sec. flashes

manual

ON

ON

Metering stops Metering stops Metering stops

5 sec. flashes 5 sec. flashes 5 sec. flashes

manual manual manual

ON ON ON

ON ON ON

Supply voltage failed

Metering stops

OFF

OFF

ON

Find cause

NOTICE If a fault message appears in the display an attempt should be made to remedy the problem by reinitialising before replacing the circuit board. To do this, disconnect the Bello Zon from the power supply for a few seconds and then switch on again.

Fig. 14: Error messages in control and corresponding output signals

Page 46 16

ProMinent

ProMinent

Annex

System type Spare parts set 230 V 115 V Replacement set liquid end Replacement set metering line Pumps Fuses Control 230 V 115 V 230 V 115 V Spare part pipe section without bypass and without premixer Spare part pipe section without bypass and with premixer Spare part pipe section with bypass and without premixer Spare part pipe section with bypass and with premixer Spare part connection piece turbine flowmeter/non-return valve Spare part connection piece variable-area flowmeter/non-return valve Spare part connection piece turbine flowmeter/ball cock Spare part connection piece variable-area flowmeter/ball cock Spare part bypass input Spare part tray cover 0.4 l Bello Zon Spare part tray cover 0.4 l Divosan

CDV 35 791842 791860 791659

CDV 60 791913 791914 791660 791723 712040 712051 712057 712021 791918 791919 791920 791921 791924 791925 791926 791927 791928 791931 740181

CDV 120 CDV 220 CDV 400 CDV 600 CDV 2000 791915 791916 791661 740824 740825 740738 740765 740819 740820 740739 712051 712038 712051 712038 712032 712033 740826 740827 740742 1005333 1005344 1000854 1005345 712027 712070

712057 712021 740696 740697 740695 740693 740694 740693

Fig. 15: Part No. Overview of spare parts sets

ProMinent

17

Page 47

Annex

ProMinent

5 Bypass water 3

1030

1090

Bypass water

220

840 900

Depth = 220 approx. measurements in mm

1 2 3 4 5

3 = Adhesive sleeve DN 25; d 32; PVC; PN 16; bypass water approx. 1.5 m /h; p = 10 bar (CDV 35) / 8 bar (CDV 65 and CDV 120)

= Adhesive sleeve DN 10; d 16; PVC; PN 16; mains water with p = 1-7 bar; consumption rate approx. 7 l/h = Adhesive sleeve DN 25; d 32; PVC; PN 16 = Power connection: 230 V 50/60 Hz; 2.1 A (4.3 A with bypass pump) = Adhesive sleeve DN 10; d 16; PVC; PN 16; vent line ascending into atmosphere or vent valve

Fig. 16: Measurements Bello Zon chlorine dioxide system CDVa 35-120
Page 48 18

485

1125

995

Mains water

Waste water

ProMinent

ProMinent

Annex

55 455 161.5

950 840 DN10/d16 PVC-U

CDV 220 = 572 CDV 400 = 954 CDV 600 = 1054 38

67.5 14 1350 1140

DN25/d32 PVC-U

mains

DN25/d32 PVC-U 39.5

DN10/ d16 PVC-U waste water open outlet

DN10/d16 PVC-U 212 380 deep water

324.5 50

acid

chlorite
3274-2

Fig. 17: Measurements Bello Zon chlorine dioxide system CDVa 220-600
ProMinent

19

Page 49

Annex

ProMinent

flowmeter 1268.5 754.5 venting line

injection fitting

DN10 d16 PVC-U

DN40 d50 PVC-U

108

rinsing device

contact min. setting range 1000-10000 l/h

CDVxxXxx2xxXxx

dimensions 3353-3

1190

DN40 d50 PVC-U

1850

mains

60

40 DN10 d16 PVC-U 14 waste water open outlet

560

50

55

212

1190 1300 dillution water 1-7 bar, max. 120 l/h

90.5

11

DN10 d16 PVC-U

521 110

81_01-401_00_13-74

Fig. 18: Measurements Bello Zon chlorine dioxide system CDVa 2000
Page 50 20

deep 430

195.5

ProMinent

ProMinent

Annex

81-01-401-00-05-42

Fig. 19: Electrical wiring diagram

ProMinent

21

Page 51