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Hydrotec HydroDOS HD550G Operation And Maintenance Manual Download Page 77

 

 

I-77/103 

Last change 04/2016 E-P – AL/TW/PW | Subject to technical modifications

 

 
 

 

 

Caution! 

 

It is to be guaranteed that the plant board is kept closed whilst in 
operation! 

 
 

 

 

The control box and reactor board doors shall be opened by 

                                   authorized personnel only for repair and maintenance work! 

 
 

3. Commissioning record  

 
Attached to the O&M is a commissioning and instruction record (see annex 3). Such record has to 
be duly filled by the service staff after commissioning and start up. 
 

A complete and duly filled commissioning record and operational log book is necessary and 
must be guaranteed since otherwise any warranty claims cannot be accepted.  

 
 
 

 

Summary of Contents for HydroDOS HD550G

Page 1: ...to technical modifications Operation and Maintenance Manual HydroDOS Chlorine Dioxide System Serial number Hydrotec UK Ltd Hydrotec House 5 Manor Courtyard Hughenden Avenue High Wycombe Bucks HP13 5RE...

Page 2: ...VI Chlorine dioxide measuring Chapter VII Electronic control PLC Chapter VIII Commissioning Putting out of operation Chapter IX Control and maintenance Appendices 1 Installation schematics HYDRO DOS c...

Page 3: ...stem Special care must be taken to with regards to hygiene during operation and maintenance if the plant is used in the food industry This operation and maintenance manual includes important informati...

Page 4: ...y of care 3 2 3 Appropriate use 4 2 4 Basic safety measures 4 Maintenance repair and electric work 5 Start up after maintenance and repair work 5 Environmental regulations 5 2 5 Risk in the event of s...

Page 5: ...ght below on each page For information about the chapter contents see index on page 1 of each chapter For any additional information or problems encountered in conjunction with operation please contac...

Page 6: ...fety in operation can only be assured if all necessary measures are taken beforehand It is part of the operator s diligence to plan and monitor such measures and implement them with due care The opera...

Page 7: ...the operating and maintenance manual and applicable local regulations must be strictly adhered to Any malfunctions must be reported and corrected immediately 2 4 Basic safety measures Prior to starti...

Page 8: ...ilst working on the equipment suitable protective clothing shall be worn e g when handling with liquids such as acids and bases alkalis Start up after maintenance and repair work Check all screw conne...

Page 9: ...for the chlorine dioxide unit Operator On request the plant operator shall provide a risk assessment for chemical storage All nameplates and information supplied by the manufacturer with the plant mus...

Page 10: ...es must be worn whilst the chemical tubs are replaced You should not carry out safety technical or functional modification Consequence may cause material damage or injury to persons It is forbidden to...

Page 11: ...ly by authorised specialists Original spare parts by Hydrotec UK Ltd shall be used exclusively No modifications are carried out on the system by users themselves The stipulated operation parameters pr...

Page 12: ...e maximum ambient temperature of 36 C must not be exceeded in storage The chemicals hydrochloric acid and sodium chlorite shipped together with the plant must be stored separatly during transport It i...

Page 13: ...de system 6 2 2 Installation schematic 7 3 Scope of supply 8 3 1 Components 8 Installation cabinet 8 Reactor cabinet 9 Chlorine dioxide reactor 9 Dosing pumps 9 Chemical collection tubs 10 Polymer pis...

Page 14: ...r feed cold water storage tank a part flow volume is fed to the chlorine dioxide system dosing agent added and fed again in the consumer feed or water storage tank Corresponding measuring equipment fo...

Page 15: ...control recognizes the demand and the dosing of reactants into the reactor is initiated whereby there is always a small surplus of hydrochloric acid in order that sodium chlorite reacts totally and d...

Page 16: ...as a ring line inside the plant cabinet and is equipped with corresponding stop and safety fittings The measuring instruments below are installed in the pipe work to control the plant Chlorine dioxide...

Page 17: ...er pressure must not exceed 6 bar static pressure doing so may pose a safety risk and cause operational problems It is recommended that a pressure reducing valve be fitted upstream of the chlorine dio...

Page 18: ...erature C 5 30 Ambient temperature C 10 40 no direct sun radiation Relative humidity 70 not condensing Performance data Chlorine dioxide preparation efficiency g h 215 Max water flow l h 300 Reactor v...

Page 19: ...I 19 103 Last change 04 2016 E P AL TW PW Subject to technical modifications 2 2 Installation schematics...

Page 20: ...ydrochloric acid 8 Tub for hydrochloric acid HCl 9 positioned in a collection tank 9 Chlorine dioxide measuring control 10 Flow volume measuring control 11 Pressure control 12 Discharge Equipment Desc...

Page 21: ...Height 190 mm Quantity 1 Including connections for hydrochloric acid 1 sodium chlorite 2 chlorine dioxide 3 water used for start up of system 4 Dosing pumps Suited for dosing the reactant chemicals i...

Page 22: ...impulse module Flow volume 2 5 m h Connection G AG external thread Impulse frequency 1 litre impulse Quantity 1 Weight 0 57 kg Pressure measuring control Suited to control the pressure in the drinkin...

Page 23: ...esign protection type IP 66 including assembly plate of sheet steel Material Polyester Dimensions Width 300 mm Height 400 mm Depth 200 mm Quantity 1 Fittings The below fittings are required for the op...

Page 24: ...lorine dioxide Concentration 7 5 purity as per DIN EN 938 Tub volume 25 litres Neutralising agent Neutralising agent DESULAN EX for chlorine dioxide solutions Measuring instrument chlorine dioxide for...

Page 25: ...n 2 2 Installation site 4 3 Pre assembly 4 Control of shipment 4 Input and output lines 4 Other preparation 5 Use of chemicals 5 4 Hydraulic connections 5 Installation input output 5 Wash and discharg...

Page 26: ...integrated and connection to the local installation Connection of required pipe work is to be realized at inputs and outputs of unit Control of plant parameters is by the control unit The plant is con...

Page 27: ...I 27 103 Last change 04 2016 E P AL TW PW Subject to technical modifications Installation example HydroDOS Chlorine dioxide disinfection plant Ill 1 Split Compartment Tank Installation...

Page 28: ...I 28 103 Last change 04 2016 E P AL TW PW Subject to technical modifications Ill 2 Single Compartment Tank Installation...

Page 29: ...ns The installation surface shall be designed within an even surface tolerance as per DIN 18202 2 mm at 0 1 m up to 15 mm at 15 m A water discharge bottom discharge for the chemical residues shall be...

Page 30: ...uld be applied on request Protective clothing shall be provided at installation site Any warning and information plates included in the delivery shall be attached and clearly visible Use of chemicals...

Page 31: ...d not used for any other application Note All pipe connections shall be provided strain free All subsequent pipes must be equipped with clamps and supports where necessary Hoses must not be squeezed o...

Page 32: ...ection cable is prepared for the local connection and reaches outside the unit This cable is to be installed in a switchable fused spur with a 5a fuse Control The PLC control is mounted in the cabinet...

Page 33: ...connection is provided in the system control A 2 m long connection cable reaching to the outside of the cabinet is equipped as well Circulation pump The system is designed to supply voltage to an ext...

Page 34: ...e and pressure pipe 4 Connection overflow and ventilation 4 5 Electrical connections 5 Connection schematics and connector engagement 5 6 Control unit operation 7 Control and monitor elements 7 Functi...

Page 35: ...will invalidate any warranties 2 Construction Pump connections 1 Intake connection 2 Pressure connection 3 Dosing head with manual ventilation 4 Ventilation screw for manual de airing 5 Ventilation l...

Page 36: ...Noise level 60 dB A Ambient temperature 0 C bis 40 C Protection type with mains plug IP 65 Nema 4X Electrical mains supply 1 x 100 240 V 50 Hz Power input P1 14 W Weight 2 4 kg Pump efficiency at max...

Page 37: ...top Connect intake and pressure line Intake line to be connected to intake valve 1 The intake lance must be installed in the tub so that the foot valve is about 5 10 cm above tub base The pressure lin...

Page 38: ...lectrical connections must be made by qualified experts only The mains supply must be switched off prior to connecting the mains supply and relay contacts The pump casing may only be opened by authori...

Page 39: ...I 39 103 Last change 04 2016 E P AL TW PW Subject to technical modifications...

Page 40: ...are switched on for 3 seconds and the software version is shown on the display for 2 seconds Operating state The dosing pump is started or stopped by the respective Start Stop button Failure records...

Page 41: ...p is operated in constant operation with maximum stroke frequency if the value exceeds the maximum pump capacity Excessive contacts are ignored as long as the memory function is not active Pump is dos...

Page 42: ...at maximum stroke frequency The pump must be allowed to run as long as the dosing material is coming out from the ventilation pipe free from bubbles Close the ventilation valve carefully The dosing pu...

Page 43: ...I 43 103 Last change 04 2016 E P AL TW PW Subject to technical modifications Calibration...

Page 44: ...low a position in tub Position intake line higher Bent intake line Correct position of intake line and check for damage Crystalline deposits in valves Clean valves Burst membrane or membrane pestle d...

Page 45: ...unter pressure Installation of pressure hold valve Leaking or porous intake line or pressure pipe Replace intake line or pressure pipe Components coming in contact with the material not resistant Repl...

Page 46: ...tive gloves Switch off plant and pump from plant control and isolate from mains The pressure must be allowed to escape via the ventilation hose Appropriate measures must be taken to collect returning...

Page 47: ...to technical modifications Chapter VI Chlorine dioxide measuring control Page 1 General information 2 2 Construction and function 2 Components measuring instrument 2 Probe cleaning 3 3 Operation 3 4...

Page 48: ...r with integrated backing electrode suited to measure chlorine dioxide by potentiostatic double gold sensor Diaphragm zircon Shaft material glass Electrode material 2 gold rings Reference system Ag Ag...

Page 49: ...xide is shown on the display of the control unit The volume of chlorine dioxide solution that must be added to the drinking water in order to achieve an optimum disinfection is calculated by the contr...

Page 50: ...feed and membrane valve after ClO2 measurement assembly must be closed 3 Open the discharge ball cock to release the pressure 4 Screw connection A must be released and the cable removed 5 Screw conne...

Page 51: ...ring and control device chlorine dioxide 6 General 6 4 1 Technical Data 6 4 2 Connection plan chlorine dioxide measuring instrument 7 4 3 Operation 8 Setting of parameters 9 4 4 Control settings 10 4...

Page 52: ...ble Connection of an external circulation pump possible Gas warning failure record gas warning Output of volt free alternating contact for transmitting a collective failure record to the BMS 2 Indicat...

Page 53: ...ion can be retrieved on the display Operation Operation hours Time interval to next maintenance Software version Extended failure diagnosis see menu point 4 8 Error acknowledgment with ESC Retrieval o...

Page 54: ...must have mains voltage applied Any national safety regulations must be followed Work on the control and cables must be carried out by authorized electrical experts only Only our service engineers ca...

Page 55: ...I 55 103 Last change 04 2016 E P AL TW PW Subject to technical modifications 3 1 Terminal plan control unit BMS Connection terminals 26 NC normally closed 27 Common 28 NO Normally open...

Page 56: ...on There is no control for setting failures system failures and handling failures Setting of operation parameters and programming may be carried out by Hydrotec staff only 4 1 Technical Data A measuri...

Page 57: ...be bridged in case of 2 electrode sensors Pt 100 7 9 10 7 T1 Pt 100 9 T2 Pt 100 10 RL three phase line resistance Pt 1000 8 9 10 8 T1 Pt 1000 9 T2 Pt 1000 10 RL three phase line resistance Digital in...

Page 58: ...3 Time 4 Event messages 5 Display of temperature 6 Operation mode AUTO controller ON Standard operation MAN controller OFF Manual operation of relay HOLD locking up freezing analogue outputs and limit...

Page 59: ...s can be displayed on the screen view a scroll bar will appear on the right You can move the scroll bar either by pulling the scroll bar or pressing the arrow keys below or above the scrollbar Setting...

Page 60: ...thin the input limits only after confirming the entry with the OK button If the value is within the input limits then the keyboard will close If the value is instead beyond the input limits it will no...

Page 61: ...Digital Digital 1 Selection of event message and contact of digital input 1 Digital 2 Selection of event message and contact of digital input 2 o mA Off mA Off 1 Input of relevant parameters for anal...

Page 62: ...eration A water sample must be taken just behind the measuring fitting sample tap The actual chlorine content is determined photometrical by comparison measuring Open the main menu Press CAL symbol to...

Page 63: ...d Run cleaning is shown and the calibration function is locked to be on the safe side The automatic sensor cleaning is switched off if Cleaning day is set to 0 Cleaning starts as soon as a setting is...

Page 64: ...it values must only be carried out by our service staff The settings are shown in the commissioning record Caution Operation settings and programming is to be carried out by experts only Any illegal o...

Page 65: ...perature sensor Signal failure at input 2 Check temperature sensor and cable Failure record is even shown if no or a not suited temperature sensor is connected Limit value 1 2 Limit value 1 exceeded o...

Page 66: ...egarded Fault Limit ClO2 Limit value 1 exceeded or Limit value 2 not reached Failure measuring system Check dosing Call our service staff Fault GAS SENSOR Sensor recognized chlorine dioxide gas Check...

Page 67: ...2 3 Filling and de airing of dosing pumps 6 2 4 Filling of system 7 2 5 Calibration gauging of dosing pumps 7 2 6 Placing of chemical tub 8 2 7 Installation of intake lances 9 2 8 Putting plant contr...

Page 68: ...l cock in the water feed to the reactor closed and tight Is the discharge ball cock and the membrane valve in the drinking water ring line closed and tight Chemical barrels It must be guaranteed that...

Page 69: ...contact integrated already in the control unit with an external cable provided ex works Is the K 1 or K 10 ratio provided A plant operated with an external water meter is recommended The impulse cabl...

Page 70: ...e shall not exceed or fall below the following values Min pressure 2 0 bar flow pressure Max pressure 6 0 bar static pressure Control unit settings Standard setting code and language Setting of measur...

Page 71: ...g process is started prior to the reactor vessel being filled with water Sequence for commissioning 2 1 Pre commissioning The intake lances shall not be installed in the chemical tub Tubs 2 with a vol...

Page 72: ...g pumps Requirement The intake lances are immersed into the water tubs a Open discharge ball cock in the ring line of the plant b Open discharge to drain outside the plant Fittings to consumer outlet...

Page 73: ...er the plant and the water circuit be guaranteed Residual air is displaced from the pipe c The display Observe pressure measuring Display must react d Open reactor board The ball cock for drinking wat...

Page 74: ...filled with water a The dosing pumps have to be stopped with the Start Stop button and the plant must be switched off with OFF button red LED lights b The chemical tubs shall be placed in the respect...

Page 75: ...pty tub b The intake lance shall be immersed into the respective tub c The intake lance shall be connected firmly screw connection with the tub The below has to be connected to the intake lance Intake...

Page 76: ...free liquid is coming out of the ventilation hose The ventilation valve at the dosing head of the dosing pumps shall be closed carefully c Setting dosing pumps Both dosing pumps have to be set to the...

Page 77: ...ened by authorized personnel only for repair and maintenance work 3 Commissioning record Attached to the O M is a commissioning and instruction record see annex 3 Such record has to be duly filled by...

Page 78: ...on LED FAILURE lights the plant is switched off automatically after failure record The selector switch has to be put in 0 position Removal of intake lance Unscrew intake lance and remove carefully fro...

Page 79: ...ort term operational interruption No special measurements are required for short term operational interruptions of ca 1 to 2 hours The plant must be switched off with button OFF LED FAILURE lights The...

Page 80: ...st be provided The stop fitting to the neutralizing tub outside the plant must be opened The fittings to the consumer output must be closed Start switch on plant The plant shall be restarted with the...

Page 81: ...ed 5 3 Putting the plant out operation Plant flushing The plant must be flushed according to point 5 2 Caution Reactor and pipes must be totally flushed and free from any chemicals Putting the control...

Page 82: ...and discharged as above if opened or within the course of reconstruction measurement If the plant has been out of operation for a longer time also for maintenance repair and reconstruction a re start...

Page 83: ...rmation 2 2 Control to be carried out by the operator inspection 2 Control of ClO2 content 3 Volume flow 3 Operation pressure 3 Filling level chemical tub 3 Operational display control unit 3 Check fo...

Page 84: ...dependent on the actual operation hours of the plant since wear and tear caused by chemicals is evident in standstill as well The manufacturer of the measuring electrode recommends to exchange the chl...

Page 85: ...trol unit An empty tub causes a failure record and the plant is stopped automatically A replacement of the respective tub is absolutely necessary to guarantee a further perfect operation Operation dis...

Page 86: ...ginal spare parts shall be used only The plant must be flushed carefully discharged and put out of operation properly prior to opening as well as repair and maintenance work see chapter VIII point 5 2...

Page 87: ...removed anymore It is recommended to check the intake lances after every chemical tub replacement at the latest however if the intake capacity is reduced Reactor Check for leakage Replace O ring on re...

Page 88: ...ried out by Hydrotec UK Ltd or by an authorised specialist company since otherwise we cannot accept any warranty claim For queries regarding operation and handling of softener please contact our servi...

Page 89: ...I 89 103 Last change 04 2016 E P AL TW PW Subject to technical modifications Appendices 1 Installation schematics HYDRO DOS Chlorine dioxide system 1 Schematics plant cabinet...

Page 90: ...r water meter x chlorine dioxide nominal concentr K litre ppm _________________________________________________ 40 Example Water meter 10 K ltrs Chlorine dioxide nom concentration 0 4 ppm Contact ml C...

Page 91: ...ed yes no Intake lancets checked yes no Operation of plant checked yes no The operator was informed and instructed that a mixing of chemicals must be avoided at all Note ______________________________...

Page 92: ...me drinking water tank external ______________________________m Frequency for electric connection ______________________________ Chemicals Hydrochloric acid HCl 9 yes no Sodium chlorite solution NaClO...

Page 93: ...values Top limit value LW 1 ____________________________ ppm Lower limit value LW 2 _____________________________ ppm Delay _____________________________ sec Controller setting Nom value S1 Sensor __...

Page 94: ...Imp h Efficiency direction S1 Sensor lifting Efficiency direction S2 water meter lowering lifting Switch on delay Switched on yes no Switching delay _____________________ sec Average determination Sw...

Page 95: ...on system Site ______________________________________________________________ Time period ______________________________________________________________ Date Chlorine dioxide measuring value mg l Volu...

Page 96: ...on system Site ______________________________________________________________ Time period ______________________________________________________________ Date Chlorine dioxide measuring value mg l Volu...

Page 97: ...izing materials shall be used It is not allowed that chemicals get untreated into drain surface water ground water or earth First Aid Measurement When the skin gets in contact it is necessary to wash...

Page 98: ...I 98 103 Last change 04 2016 E P AL TW PW Subject to technical modifications Technical documents...

Page 99: ...TW PW Subject to technical modifications Volume flow distribution for chlorine dioxide systems Hydrotec UK Ltd Hydrotec House 5 Manor Courtyard Hughenden Avenue High Wycombe Bucks HP13 5RE Tel 01494 7...

Page 100: ...DN15 Material PVC U 2 Connection piping Chlorine dioxide system for volume flow distribution Nominal size DN15 Material PVC U Nom pressure PN 16 3 Membrane valve Nominal size DN15 Material PVC U Nom...

Page 101: ...pport of a connection piping The volume flow distribution enables a distribution of the drinking water with chlorine dioxide into separate piping networks or storage tanks The membrane valves are used...

Page 102: ...I 102 103 Last change 04 2016 E P AL TW PW Subject to technical modifications 4 Installation drawing...

Page 103: ...________________________________________________________________ Publisher HYDROTEC E P AL TW PW kb All rights reserved 04 2016 by HYDROTEC Subject to technical modification All information dimensions...

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