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Emec LOTUS MINI, Operation Manual

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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 

R

5

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02

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6

 

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Summary of Contents for LOTUS MINI

Page 1: ...r 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 op...

Page 2: ...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...

Page 3: ...8 4 2 Main display 8 4 3 Control element Click Wheel 8 4 4 Status displays 9 4 5 Logbook 10 4 6 Help 10 5 Adjustment of production capacity 11 5 1 Proportional mode 12 5 2 Constant mode 13 5 3 Analog...

Page 4: ...bout 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...

Page 5: ...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 MF Multivalve Pulse...

Page 6: ...ration instruction 1 4 CE Conformity The LOTUS generator is corresponding to the following EU standards The following standards are considered Machinery directive 89 392 EWG IIA inclusive all actual c...

Page 7: ...pumps 2 and 4 Each stroke from each pump is triggered by the LOTUS controller 1 and counter controlled by a SEFL 6 Inside the chamber vessel the chemicals are reacting to chlorine dioxide with a conc...

Page 8: ...h 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...

Page 9: ...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...

Page 10: ...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 LOTU...

Page 11: ...Help Turn the click 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...

Page 12: ...s soon as the fourth correct digit is selected the next display opens automat ically Notice The factory default for the operator passcode is 0 0 0 0 In case you like to change your passcode please ask...

Page 13: ...ation 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 th...

Page 14: ...mpty 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...

Page 15: ...rising 2 Tank full 3 Level falls down 4 Tank empty 1 Step 1 Step 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 L...

Page 16: ...ng hose back into the cans Let the pumps keep on running for some more seconds to be sure that rely all gas bubbles leaved the suc tion hose and the pump head in direction to the chamber Push the clic...

Page 17: ...wer Supply 90 265 VAC Relay Outputs current free Relay Outputs NC C NONC C NO 12 VDC Signal GND Green Brown White Yellow Pump Acid Pump Chlorite Pump Water Common GND GND Signal A Signal B Optic coupl...

Page 18: ...y open or N C contact mode normally clo sed when status on blocks changes Rotate wheel to choose between DISABLE REVERSE N O contact or DIRECT N C contact Furthermore Flow contact can starts after a s...

Page 19: ...pressure bar 10 10 Chemical consumption at max production l h each 0 2 each 0 5 Concentration of ClO2 stock solution g l approx 2 20 Power supply 90 265 V 50 60 Hz Energy consumption w h 50 Protection...

Page 20: ...ing control is recognizing lack of or no dosing Prime the corresponding pump Readjust the flow sensitivity at the dosing control Call the service in case priming is not successful Flow control Water F...

Page 21: ...COMMUNICATION...

Page 22: ...on requires the presence of a ROUTER with automatic IP address assignment from TCP IP menu select IP MODE and set it to DYNAMIC If local LAN needs to provide static IP address then from TCP IP menu se...

Page 23: ...r must be notified see below table MSG warning MSG alarm MAXIMUM TIME REACHED PROBE FLOW ALARM HCl LEVEL CHLORINE DIOXIDE IN STORAGE NO LONGER USABLE NaClO2 LEVEL SYSTEM NOT READY ST Tank Full SYSTEM...

Page 24: ...arting from a certain time TIME Note SET TIME AND DATE PRIOR TO ENABLE THE LOG If not fed after 30 days the instrument will lose current date and time TIME log starting time format 23h 59min EVERY fre...

Page 25: ...t can display the instruments activity log as line graphs and charts and it can download it to your pc in excel or pdf format HOW TO USE WEB ERMES Enter the website www ermes server com and after regi...

Page 26: ...l roaming DATA if the connection is abroad The instrument is unable to obtain a valid IP ad dress from the LAN or the software does not connect to it Make sure the pre existing network allows auto ass...

Page 27: ...nd it is now a commonly available means of connecting industrial electronic devices From main menu select COMMUNICATION then MODBUS to access the options Set the communication speed according to the P...

Page 28: ...sage Use exclusively if no sensor is connected MAIN MENU SHOW to enable warning message and related alarm on main screen Enabled by default Attention this procedure assumes that the instrument is conf...

Page 29: ...emperatur Test period bar C hours Dosing pumps Acid Water Chlorite Type Calibration value ml ml ml Calibration pressure bar Number of strokes System settings Dos Check Pass Code 2 Default Pass Code 1...

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Page 33: ...rt up 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 inst...

Page 34: ...R3 10 14 2...

Page 35: ...ypes of Control 15 5 First Startup 16 5 1 Preparations 16 5 2 Hydraulic start up 16 6 LOTUS Controller 17 6 1 Start display 17 6 2 Main display 17 6 3 Control element Click Wheel 18 6 4 Status display...

Page 36: ...cordance 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 risk...

Page 37: ...mps make the pump heads pressure less 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 hand...

Page 38: ...ration instruction 1 4 CE Conformity The LOTUS generator is corresponding to the following EU standards The following standards are considered Machinery directive 89 392 EWG IIA inclusive all actual c...

Page 39: ...pumps 2 and 4 Each stroke from each pump is triggered by the LOTUS controller 1 and counter controlled by a SEFL 6 Inside the reactor vessel the chemicals are reacting to chlorine dioxide with a conc...

Page 40: ...ch Hydrochloric acid 5 Reactor 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 dilutio...

Page 41: ...Disconnect the power supply before opening the controller housing Take care of all national regulations during installation 4 1 General requirements to the installation location Notice The plant must...

Page 42: ...cals for the increase of the pH level is required In case the carbonate hardness is lower 19 dH German hardness the installation place of the injection valve for the chlorine dioxide already made of P...

Page 43: ...hlorine dioxide injection point PVDF hose 4x6 mm C Overflow dilution water storage tank 20 mm PVC adhesive sleeve 20 Valve 21 Protection filter 22 System separator 23 Contact water meter like type CTF...

Page 44: ...after the system separator 22 and before the point of injection 24 He must gather the complete amount of water which has to be injected with chlorine dioxide Use the following formula for the calcula...

Page 45: ...essure and priming hose is laid to the dilution water storage tank In case of an overpressure the chlorine dioxide flows into the tank and will be diluted From there it overflows into the drain Diluti...

Page 46: ...ter like NFIL 60 22 LASP suction lance for hydrochloric acid 23 LASP suction lance for sodium chlorite 24 Power supply controlled by a level control in the batch tank 27 for overflow emergency 25 Batc...

Page 47: ...E hose 2 m included in the delivery scope Notice In case the pressure in the water line is more than 5 bar a pressure regulator valve in the re filling line is required The adjusting range should be 0...

Page 48: ...y disconnection in case of emer gency stop or maintenance The electric socket must be placed free for easy access from all sides An overload protection for the power supply is stringent required 4 5 2...

Page 49: ...e Stop button Shut the priming valves as soon as the chemicals flow out without gas bubbles back into the cans Let the pumps keep on running to fill up the reactor with chemicals and dilution water un...

Page 50: ...The main 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 mess...

Page 51: ...osition is shown Push the click wheel for selection When you leave a sub menu with or you will be asked if you want to save the inputs or changes Select Yes to accept the inputs and changes Select No...

Page 52: ...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 LOTU...

Page 53: ...Help Turn the click 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...

Page 54: ...y defaults Sub menues Calibration of the dosing pumps Calibration of the chlorine dioxide and temperature probe Configuration of the input for a water meter Configuration of the analog outputs Selecti...

Page 55: ...the calibration cylinder with water 4 Go into the Priming mode and vent the suction hose of the calibration cyl inder 5 Refill the calibration cylinder until the 0 ml tag 5 Enter the Main menu and ope...

Page 56: ...ase the option Analog was ordered Timeout The Timeout function acts as an optimizer for the proportional mode in case a contact water meter is connected to LOTUS and a The flow is fluctuating very str...

Page 57: ...Here you have to select the analog output value based on production gr h Choose between 0 20 or 4 20 mA Main menu Water Meter Analog Ausg nge Operation Mode Analog output configuration Analog Outputs...

Page 58: ...20 mA Notice The Analog mode is available only in case the option is ordered Prop Reading In this mode LOTUS produces an adjustable capacity of chlorine dioxide proportional to a water flow recorded...

Page 59: ...al 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 av...

Page 60: ...and by Situation STAND BY 44 45 BATCH TANK EMPTY 34 35 LOTUS STAND BY Capacity 1 Capacity 2 7 5 3 Analog mode In this mode the chlorine dioxide production capacity is controlled by an external analog...

Page 61: ...of the level switch failed or the cable is damaged a failure message appears Failure Level switch Operation Mode Proportional Constant Batch Analog Batch Status Level Tank full Mode Level Tank empty B...

Page 62: ...in case of an set point overriding Set Point Here you can adjust the requested chlorine dioxide concentration before LOTUS is readjusting the production capacity Limit value Here you can adjust the m...

Page 63: ...en the main menu again Notice Executing a Reset see below sets the passcode back to the default value 0 9 1 6 Pass Code 1 This passcode is for the operator It activates an additional display where he...

Page 64: ...ply 90 265 VAC Relay Outputs current free Relay Outputs NC C NONC C NO 12 VDC Signal GND Green Brown White Yellow Pump Acid Pump Chlorite Pump Water Common GND GND Signal A Signal B Optic coupled Outp...

Page 65: ...sed when status on blocks changes Rotate wheel to choose between DISABLE REVERSE N O contact or DIRECT N C contact Furthermore Flow contact can starts after a speci fied time when contact status chan...

Page 66: ...pressure bar 10 10 Chemical consumption at max production l h each 0 2 each 0 5 Concentration of ClO2 stock solution g l approx 2 20 Power supply 90 265 V 50 60 Hz Energy consumption w h 50 Protection...

Page 67: ...tion of the level switch Flow control Acid A dosing control is recognizing lack of or no dosing Prime the corresponding pump Readjust the flow sensitivity at the dosing control Flow control Water Flow...

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