Emec LOTUS MINI Operation Manual

Chlorine Dioxide Generator

LOTUS MINI

Operation Manual

Read this manual completely before you start LOTUS. Do not trash this manual and store it nearby the generator for later use.

This manual contains important information about the installation and operation safety. Take care about the following instructions to avoid personal injuries and material damages! The operator is responsible in case of damages caused by installation and operation failures!

English

R5-02-16

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NORME CE EC RULES(STANDARD EC) NORMAS DE LA CE

Direttiva Bassa Tensione Low Voltage Directive Directiva de baja tensión

Direttiva EMC Compatibilità Elettromagnetica EMC electromagnetic compatibility directive EMC directiva de compatibilidad electromagnética

2014/35/UE

2014/30/UE

⎬

Danger!

GENERAL SAFETY GUIDELINES

In emergencies the instrument should be switched off immediately! Disconnect the power cable from the power supply!

When installing always observe local regulations!

Manufacturer is not liable for any unauthorized use or misuse of this product that may cause injury,

damage to persons and / or materials.

Caution!

Instrument must be accessible at all times for both operating and servicing. Access must not be obstructed in any way!

Feeder should be interlocked with a no-ﬂow protection device to automatically shut-off the pumps when there is no ﬂow!

Pumps and accessories must be serviced and repaired by qualiﬁed and authorized personnel only!

Always discharge the liquid end before servicing the instrument!

Empty and rinse the liquid end before work on a pump which has been used with hazardous or unknown chemicals!

Always read chemical safety datasheet!

Always wear protective clothing when handling hazardous or unknown chemicals!

Instrument must be operated / serviced by trained technicians only!

All connection operations must be performed while the instrument is not connected to main supply!

Directory

General Safety Guidelines

1.1

Symbols

1.2

Safety instructions

1.3

CE-Conformity

General Description

Construction

3.1

Construction overview

3.2

Description and details

„LOTUS“ - Controller

4.1

Start display

4.2

Main display

4.3

Control element „Click-Wheel“

4.4

Status displays

4.5

Logbook

4.6

Help

Adjustment of production capacity

5.1

Proportional mode

5.2

Constant mode

5.3

Analog mode

5.4

Batch mode

Replacement of chemical cans and pump priming

LOTUS Terminal board

Technical Data

17 9.18

Failure Messages

Communication

NOTE:

WHEN CHANGING WORKING MODE, SETPOINT PARAMETERS SHOULD BE ENTERED AGAIN.

1. General Safety Guidelines

1.1 General remarks

This manual includes basic directions for the assembling, operation and maintenance. Therefore it is obligatory for the assembly technician as well as for the operator to study the complete manual before starting with the installation and start-up. This manual must be present at the generator at any time.

It is also obligatory for the operator to consider the general directions in chapter “Safety instructions” as well as the specific safety instructions included in the other chapters of this manual.

Notice:

• For some of the following described functions additional accessories (not included in the delivery

scope of LOTUS) may be required.

• Depending to the software release of the LOTUS-controller some of the described features may

not be available. Or some functions are available, but not described in this manual. Please contact your dealer in case of the requirement for more information.

1.2 Symbols

In accordance to the guideline DIN 4844-W9 about the characterization of special risks all safety instructions in this manual are labeled with the following symbols:

Warning:

This symbol is waring about risks. Disregarding may cause heavy personal injuries and material damages.

Caution!

This symbol is warning about troubles caused by incorrect operation.

Notice or advice:

This symbol shows important additional information.

1.3 Safety instructions

The appropriate use of the LOTUS generator is described in this manual.

Warning:

• The un-appropriate use affects the safety function of this generator and other connected devices

and is therefore strictly forbidden.

• Assembling and maintenance has to be done by authorized technicians only.

• Maintenance repairs have to be executed only by the manufacturer or authorized technicians. Inter-

ventions or changes at the device in opposite to the regular maintenance in accordance to this manual are incorrect and make the all warranty claims nugatory.

• The operator is liable for the observance of the local safety instructions.

• For the operation and service the device must be accessible at all times.

• Before starting service at the dosing pumps make the pump-heads pressure-less.

Warning: risk of explosion

• Drain and flush the pump-heads with clean water before starting the service.

• Take attention to the chemical safety data sheets!

• Wear protection clothes for the handling with unknown and hazardous chemicals.

HCl 9% NaClO2 7,5%

PEF1/E Probe holder

ECL1 Chlorine probe

Multivalve

Pulse sender water meter

WARNING: INSTALL NFIL/60 BEFORE WATER INPUT TO AVOID OCCLUSIONS

Directions for the operator

(Specific information for applicable regulations in Germany):

• Accident prevention regulation (UVV) „Chlorination of water“, GUV V-D5 E.

• „Dosing plants for chlorine dioxide“, DVGW guideline W 624 (latest version respectively).

• „Chlorine dioxide in water treatment“, DVGW worksheet W 224 (latest version respectively).

• Guidelines for the protection of groundwater against polution.

(§ 19 Federal Water Act – WHG dated 23.9.1986).

• Ordinance of hazardous substances (GefStoffV) – especially § 17 (obligatory protection)

and § 20 (operation instruction).

1.4 CE - Conformity

The LOTUS gener

ator is corresponding to the following EU-standards:

The following standards are considered:

• Machinery directive 89/392/EWG IIA inclusive all actual changes within the year of

Manufacturing 91/368/EWG – Mod. 1

, and 93/44/EWG – Mod. 2.

• Guideline 2004/108 EG about the electromagnetic tolerance of electric equipment.

• Low-voltage directive 2006/95/EG.

• EC – Pressure Equipment Directive (97/23/EG)

The following harmonized safety guidelines are considered:

• UNI EN 292/1 – Safety of machines

• UNI EN 292/2 – Safety of machines; technical principles.

• CEI EN 60204-1-98 – General requirements for electric equipment in machines.

Notice:

A declaration of conformity can be ordered from the manufacturer.

2. General Description

The chlorine dioxide generator is used for the production of liquid chlorine dioxide. This disinfection agent kills all bacteria, germs, viruses and fungi within shortest time – and it works with very low concentration.

The generator is working with the hydrochloric acid – chlorite process and uses diluted chemicals like hydrochloric acid (HCl 9%) and sodium chlorite (NaClO

7.5%) in accordance to the following chemical equation:

Hydrochloric acid + Sodium Chlorite = Chlorine dioxide + Sodium chloride + Water

4 HCl + 5 NaClO

= 4 ClO2 + 5 NaCl + 2 H2O

In the process each chemical is pumped with a specific proportion into a chamber vessel [ 5 ] by two dosing pumps [ 2 and 4 ]. Each stroke from each pump is triggered by the LOTUS-controller [ 1 ] and countercontrolled by a “SEFL” [ 6 ].

Inside the chamber vessel the chemicals are reacting to chlorine dioxide with a concentration of 2% (= 20 g/l).

In the next step a specific proportion of water is pumped into the chamber by a third dosing pump [ 3 ] to dilute the chlorine dioxide down to a concentration of approx. 2 g/l.

The finished chlorine dioxide leaves the chamber vessel through a back pressure valve [ 7 ] on the top of the chamber.

The advantages are:

• The chlorine dioxide can be pumped direct into pressurized systems with the pressure of the pumps and likewise into pressure-less storing tanks, to distribute the disinfection to different points of use.

• The System can work in proportional mode with contact water meter, current signal or chlorine dioxide measurement.

3. Construction

3.1 Construction overview

3.2 Description and details

1 LOTUS-controller 10 Drain nozzle ½“ 2 Dosing pump for hydrochloric acid (HCl 9%) 11 Level switch „Dilution water tank empty“ 3 Dosing pump for dilution water 12 Can with hydrochloric acid 9 % (ca. 95 g/l) 4 Dosing pump for sodium chlorite (NaClO

2 7,5%) 13 Suction lance with level-switch „Hydrochloric acid“

5 Chamber 14 Can with sodium chlorite 7,5 % (ca. 80 g/l) 6 Dosing control “SEFL” 15 Suction lance with level-switch „Sodium chlorite“

each for hydrochloric acid, sodium chlorite and dilution water 7 PVDF check-valve with hose-connection 4x6 mm 8 Storage tank for dilution water

(located behind the dosing pumps) 9 Floating valve

A Hose-connection 4x6 mm for dilution water B Hose-connection 4x6 mm for chlorine dioxide (for PVDF hose) C Dilution water storage tank overflow

HCl 9%

NaClO2 7,5%

4. „LOTUS“ Controller

4.1 Start display

When the power supply is switched on the start display appears and shows the actual software release for some seconds.

After approx. 3 seconds the program goes onto the main display.

4.2 Main display

The mai

n display is separated into 5 lines::

1: Date and time

2: Measuring value for temperature (in case this option is implemented)

3: Type of plant

4: Information line for operation, status or failure messages (blinking)

5: “Click-Wheel” operation and duty line.

A constant running bar shows that LOTUS is active.

4.3 Control element „Click-Wheel“

On the right side of the display a turning- and push-button is located. It is called „Click-Wheel“.

You can turn the click-wheel into both directions to scroll through the menus or select a function. The selected function is shown in an inverse color.

The actual position is shown .

Push the click-wheel for selection.

Inverse

LOTUS

Rel: x.x.x

3 4 5

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LOTUS 25.9° C

Chlorine Dioxide Generator

Stand-by

Status Menu Logbook Help

Status

02-12-10 EMEC 09:10:55

LOTUS 25.9° C

Chlorine Dioxide Generator

Stand-by

Status Menu Logbook Help

Status

Turn for scroll

Push for selection

4.4 Status Displays

Push th

e click-wheel on “Status” to open 4 different operation displays:

Check: The signal lights are showing the function of the dosing controls.

At stagnant production the signal light shows . During production the signal lights from the dosing controls “Check” are blinking inverse corresponding to the signals from the „Pump“. That means: in the moment when a pump is doing a stroke (light = ), the light of the dosing control has to show .

Pump: See also „Check“.

Mode: Shows the activated operation mode.

Production: Shows the actual chlorine dioxide production capacity.

Water Meter: Shows the actual flow capacity of the contact water meter.

Next Service: Shows the remaining time until the next service is required.

Operating hours: Shows the operating hours counter.

In the operation displays you have different options:

ON/OFF Start/Stop LOTUS

STAND-BY Switches LOTUS into the “Stand-by” mode,

independent to the function of the “Stand-by” – Input

PRIMING Opens the display for dosing pumps priming resp. for manual mode

ESC Go back to the main display

< or > Scroll in the operation displays

Status LOTUS

Production [g/h] : 4.25 Mode: Water Meter [m³/h]: 42.5 Proportional

< ESC >

Totalizer

Acid [ltr.] : 9123.5 Mode: Chlorite [ltr.]: 9124.9 Proportional Water Meter [m³]: 99999.9 < ESC

Status LOTUS

Next Service in [h]: 4375 Mode: Operating hours [h]: 9999999 Proportional

< ESC >

02-12-10 EMEC 09:10:55

LOTUS 25.9° C

Chlorine Dioxide Generator

Stand-by

Status Menu Logbook Help

Status

Status LOTUS

Check : Mode: Pump : Proportional

Acid Water Chlorite

ON Stand-by Priming ESC >

4.5 Logbook

Turn th

e click-wheel onto the field “Logbook” and push it to open the sub-menu.

The LOTUS-controller has an internal logbook-memory. Two different types of data are stored together with a time-stamp: Operation data in periodic intervals and failure messages as soon as they appear.

Turn the click-wheel to scroll forward and backwards through the logbook.

Push the click-wheel on “ESC” for return to the main display.

4.6 Help

Turn the c

lick-wheel onto the field “Help” and push it to open the “Help” display.

The “Help” display shows the contact data of your dealer.

Push the click-wheel on “ESC” for the return to the main display.

Logbook

07-12-10 23:59:59 Mode: Proportional Acid:109.0 l Chlorite: 109.7 l Water: 298.6 m³

ESC

Logbook

07-12-10 12:35:55 Failure level acid 07-12-10 13:10:20 Restart

ESC

LOTUS

LIQUID Water Treatment

Phone: 01234-567890

ESC

02-12-10 EMEC 09:10:55

LOTUS 25.9° C

Chlorine Dioxide Generator

Stand-by

Status Menu Logbook Help

Logbook

02-12-10 EMEC 09:10:55

LOTUS 25.9° C

Chlorine Dioxide Generator

Stand-by

Status Menu Logbook Help

Help

5. Adjustment of production capacity

Depending

to the operation mode the production capacity of LOTUS can be changed.

Push the click-wheel “Menu” to open the display for the adjustment of the production capacity.

The access is protected by an operator passcode:

Select a four-digit number-code. As soon as the fourth correct digit is selected the next display opens automatically.

Notice:

The factory default for the operator passcode is “0 0 0 0”. In case you like to change your passcode please ask your dealer and his technician will do the implementation for you.

Depending to the selected operation mode, different displays are available:

Passcode

0 1 2 3 4 5 6 7 8 9 ESC

Enter Passcode

* * * *

02-12-10 EMEC 09:10:55

LOTUS 25.9° C

Chlorine Dioxide Generator

Stand-by

Status Menu Logbook Help

5.1 Proportional mode

In the proportional mode LOTUS produces an adjustable capacity of chlorine dioxide proportional to a water flow recorded by a water meter.

Prod. Capacity: Here you can adjust the requested chlorine dioxide concentration.

Warning:

• The controller takes the inserted value in “Prod. Capacity” for the calculation of the required stroke

frequency of the dosing pumps for the production of chlorine dioxide proportional to the flow.

This

means that it is a theoretically value and not the real concentration in the water!

• The operator is responsible by its own for the proper adjustment of this control-value!

• The operator has to countercheck the chlorine dioxide concentration in the connected water system

with a suitable photometer to verify the real concentration and to readjust the “Prod. Capacity” until the required concentration is stable achieved.

General Notices:

Theoretically it is possible to adjust the production capacity up to 9.99 mg/l.

But for very low water flows, resp. water consumption it can be dangerous to do this and should be absolutely avoided!

In case the water flow exceeds the maximum production capacity a proportional production is not longer possible. In the following table you can find the maximum water flow corresponding to the maximum production capacity:

LOTUS

Production capacity

[mg/l]

Water flow

[m³/h]

0,10

200

0,20

100

0,30

26.6

66.6

0,40

0,50

0,60

13.3

33.3

0,70

11.4

28.5

0,80

0,90

8.8

22.2

1,00

The ove

rriding of the maximum possible production capacity caused by the water flow is shown on the display

with a special blinking message “Overflow”:

As soon as the water flow drops down under the maximum acceptable value, the message disappears.

Proportional Mode

Prod. Capacity: 0.15 mg/l Mode:

Proportional

ESC

02-12-10 EMEC 09:10:55

LOTUS 25.9° C

Chlorine Dioxide Generator

Overflow

Status Menu Logbook Help

5.2 Constant mode

In this mode LOTUS is producing chlorine dioxide with a constant and adjustable capacity as long as input

“Stand-by” is not activated. Two different capacities can be adjusted depending to the digital inputs “Batch tank empty” [terminal 34 and 35] and “Stand-by” [terminal 44 and 45].

Capacity 1: Here you can adjust the production capacity for the digital input “Batch tank empty”.

Capacity 2: Here you can adjust the production capacity for the digital input “Stand-by”.

Situation

STAND-BY (44, 45)

BATCH TANK EMPTY (34, 35)

LOTUS “STAND-BY”

Capacity 1

Capacity 2

5.3 Analog mode

In this mode the chlorine dioxide production capacity is controlled by an external analog signal (0/4 – 20 mA).

Capacity at 20 mA: Here you adjust the maximum production capacity for a 20 mA input signal.

Notice:

Independent to the selected operation mode LOTUS stops as soon as the digital input “Standby” appears!

Constant Mode

Capacity 1: 50 % Capacity 2: 100 %

ESC

Analog Mode

Capacity at 20 mA: 100 %

ESC

5.4 Batch mode

In this mode LOTUS fills up a level-controlled batch tank with chlorine dioxide in an adjustable concentration. The two digital inputs “Batch tank empty” [terminal 34 and 35] and “Stand-by” [terminal 44 and 45] are used for the level-control.

Because LOTUS runs always wit 100% production capacity as soon as it starts, no extra display for the capacity adjustment is available.

Situation

Step

Terminal

34, 35

Level tank

empty

Terminal

44, 45

Level

tank full

Tank empty

Level is rising

Tank full

Level falls down

Tank empty

Step 1: St

ep 2:

Step 3: Step 4:

In case one of the level-switch failed or the cable is damaged a failure message appears:

Failure Level-switch:

Status