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Xylem WEDECO SMOevo PLUS Series Original Manual Download Page 164

 

Manual Ozone Generating System 

SMOevo

PLUS

 

Maintenance 

 

Manual_SMOevoPLUS_eng_01.2019.doc 

page 164 of 179 

 

 

•

 

Depressurize the complete ozone system prior to starting any 
maintenance or repair work on the equipment. 

 

 

 

CAUTION! 

 

Hot surfaces on solenoid valves! 

Risk of burns. 

 

•

 

Allow the components to cool before starting any maintenance work.

 

 

 

 

NOTICE!

 

 

Formation of nitric acid due to condensation 

Damage to the ozone system  

•

 

The ozone generator must cool down to ambient temperature  
(+/- 3 K) prior to opening.

 

 

 

•

 

If using wrong or substandard spare parts, proper operation of 
the ozone generating system cannot be guaranteed and voids 
the warranty! 

•

 

Only use spare and wear parts approved by Wedeco.  

 

 

11.2 Personal Protective Equipment 

In order to avoid injuries, wear the following protective equipment during maintenance and 
repair work: 

 

 

Ear protection 

 

Safety gloves 

 

 

Summary of Contents for WEDECO SMOevo PLUS Series

Page 1: ...Original Manual Manual WEDECO EFFIZON Ozone Generating System SMOevoPLUS Series...

Page 2: ...lem com Version 01 2019 Date 21 01 2019 File Manual_SMOevoPLUS_eng_01 2019 doc Xylem Water Solutions Herford GmbH 2019 The reproduction distribution and utilization of this document as well as the com...

Page 3: ...Signs 15 3 3 Safety Devices 19 3 3 1 Emergency Stop 19 3 3 2 Main Switch 19 3 3 3 Gas Detectors Ambient Air Monitoring 19 3 3 4 Technical Ventilation System 20 3 3 5 Door Switch 20 3 3 6 Protective Co...

Page 4: ...p Cooling Water System 59 5 4 2 Option WOD Residual Ozone Destructor 60 5 4 3 Option CP Custom Positioning 62 5 4 4 Option FH Flashing Light Horn 62 5 4 5 Option M1 and M2 Ozone Monitoring 62 5 4 6 Op...

Page 5: ...ettings Screen 02 01 91 8 9 System Sequence Screen 02 02 93 8 10 Controller Settings Screen 02 03 96 8 11 Production Settings Screen 03 00 01 Power Gas Flow Control 98 8 12 Production Settings Screen...

Page 6: ...11 1 Safety Instructions 162 11 2 Personal Protective Equipment 164 11 3 Requirements for Maintenance Staff 165 11 4 Requirements for Safe Maintenance 166 11 5 Maintenance Schedule 167 11 6 Disposing...

Page 7: ...stions will be appreciated They will help design our manuals even more user friendly 2 1 Contact Addresses If you have any queries please contact your regional Sales Company for Wedeco products also r...

Page 8: ...the contracting country was done by certified translators Any warranty becomes void if the information given in this manual is not or not sufficiently observed the ozone generating system is used not...

Page 9: ...he kind of pictographs used in this manual Pictograph Description Warning signs are triangular with a black pictograph on a yellow background Prohibition signs are round with the safety color red arou...

Page 10: ...cess steps and the layout of the ozone system Transport and Storage section 6 What do I have to observe regarding transport and storage of the system Installation and Initial Start Up section 7 How is...

Page 11: ...to visualize information and to allow the operator to interact with the ozone system PID Controller Proportional integral derivative controller Element of control technology P ID Piping Instrumentati...

Page 12: ...s inadmissible and bears unforeseeable risks for the safety of the operating personnel Disclaimer of warranty The manufacturer is not liable for any damage or consequential damage in terms of the Prod...

Page 13: ...operation and maintenance of the ozone system and its equipment must read and understand this manual including the safety section Depending on the qualification of the personnel additional training mi...

Page 14: ...are preceded with hazard warnings as follows SIGNAL WORD Kind and source of hazard Possible consequences if not avoided Instructions on how to avert the hazard 3 2 2 Signal Words DANGER Indicates a h...

Page 15: ...79 3 2 3 Hazard Signs Warning Signs Pictograph Description Danger Hazardous voltage Warning of ozone Warning of suspended loads when loading and unloading Warning of poisonous toxic substances Warning...

Page 16: ...page 16 of 179 Prohibiton Signs Pictograph Description Smoking and open flames forbidden Do not spray water Do not touch live parts Mandatory Signs Pictograph Description Wear ear protection Wear safe...

Page 17: ...signs Warning of poisonous substances Ozone plant Access for authorized personnel only No persons with pacemaker Smoking and open flames forbidden Safety Signs on the Ozone System Symbol Description W...

Page 18: ...ription No persons with pacemaker Smoking and open flames forbidden Do not touch live parts Wear ear protection Isolate before working on the system Ozone labeling on pipework Oxygen labeling on pipew...

Page 19: ...e to the system Once the Emergency push button is activated the electrical energy supply and the feed gas flow will stop immediately Prior to re starting the system the Emergency Stop circuit must be...

Page 20: ...e system will turn off immediately Do not remove or bridge the door switch at any time 3 3 6 Protective Covers All system components of the converter all electrical equipment and the system control ar...

Page 21: ...or personnel who have been selected and deemed to be capable by the owner operator are qualified persons Instructed person An instructed person is a person who has been informed and if necessary trai...

Page 22: ...Personal Protective Equipment The owner operator must ensure that an ozone proof breathing protective device in form of a full mask with effective filter is available for and identified with the name...

Page 23: ...on as well as according to its intended use safely and aware of potential hazards Rectify any faults immediately which could impair your safety or the safety of the ozone system 3 5 1 Personal Protect...

Page 24: ...uded Refer to Chapter Operating Room Do not allow permanent workplaces or work stations in rooms housing ozone systems If the installation site of the system cannot be separated from the workplace for...

Page 25: ...measures which are described in the following section Ozone contains three oxygen atoms is heavier than air is a colorless to blue gas has an intensive odor similar to carnations hay or chlorine is di...

Page 26: ...n directly penetrate into deeper sections of the respiratory tract Physical strain and a rise in the ambient temperature increase the toxicity of ozone An increase of the room temperature by e g 8 C d...

Page 27: ...t with oxygen or oxygen ozone mixtures or are soiled with grease or oil Breathing Protective Devices Only enter rooms in which ozone is accumulating or can be expected to accumulate wearing a breathin...

Page 28: ...spontaneous ignition of oil and grease This also applies to clothing soiled by oil and grease An increased oxygen concentration causes a considerable increase in combustion speed Furthermore technica...

Page 29: ...tion of high oxygen concentrations will usually disappear after exposure to fresh air 3 8 2 Precautions Fire naked light and smoking is prohibited in rooms where O2 is handled Ventilation Ensure that...

Page 30: ...ver store combustible or self igniting materials within a safety area of 5 m surrounding possible outlet points of liquid oxygen Rooms in which oxygen is handled must be located in that way that they...

Page 31: ...ary means to prevent unintentional restart 3 Check for absence of voltage 4 Ensure grounding and short circuiting 5 Protect adjacent live parts by covers Inform the operating personnel of the duration...

Page 32: ...es on the ozone system Risk of burns Never touch hot surfaces Turn off the components prior to maintenance and cleaning work Wait until the surface has cooled before starting to work on the system CAU...

Page 33: ...the current state of the art 4 1 Type and Identification of the System The ozone generators of the SMOevoPLUS series are systems for the generation of ozone in the concentration range of up to 15 by...

Page 34: ...Manual Ozone Generating System SMOevoPLUS Technical Data Manual_SMOevoPLUS_eng_01 2019 doc page 34 of 179 4 2 Operating Data Refer to the corresponding data sheet in the Appendix...

Page 35: ...Manual Ozone Generating System SMOevoPLUS Technical Data Manual_SMOevoPLUS_eng_01 2019 doc page 35 of 179 4 3 Signal Transfer example of electrical wiring diagram SMOevoPLUS 410 860...

Page 36: ...Manual Ozone Generating System SMOevoPLUS Technical Data Manual_SMOevoPLUS_eng_01 2019 doc page 36 of 179...

Page 37: ...Manual Ozone Generating System SMOevoPLUS Technical Data Manual_SMOevoPLUS_eng_01 2019 doc page 37 of 179 SMOevoPLUS 910 and 960...

Page 38: ...Manual Ozone Generating System SMOevoPLUS Technical Data Manual_SMOevoPLUS_eng_01 2019 doc page 38 of 179...

Page 39: ...Gas Flow Power setpoint converter 0W100 or gas flow setpoint generator 0WX Nm h Operating mode Required Ozone Concentration Required ozone concentration 0 W X g Nm Operating mode Required Ozone Mass R...

Page 40: ...Manual Ozone Generating System SMOevoPLUS Technical Data Manual_SMOevoPLUS_eng_01 2019 doc page 40 of 179 If necessary four other Emergency push buttons contacts can be included...

Page 41: ...of 179 4 4 Vibrations To reduce vibrations generated by the ozone system various vibration damping components are included Amongst others the following components are installed Vibration damping adjus...

Page 42: ...tally friendly oxidizing agent in many areas of application Ozone is technically produced through silent electrical discharge from oxygenic feed gases typically air or oxygen by special ozone generato...

Page 43: ...zone generator in which ozone is produced from oxygenic gas converter in which the medium voltage required for ozone production is generated system control process measuring and safety controls self s...

Page 44: ...be fed to the relevant application Coolant The ozone generator must be cooled with water in order to reduce the high temperature developing during the ozone generation process Ozone generator The ozo...

Page 45: ...Manual Ozone Generating System SMOevoPLUS System Description Manual_SMOevoPLUS_eng_01 2019 doc page 45 of 179 5 3 Process Description of the System P I Diagram complete SMOevoPLUS 410 860...

Page 46: ...Manual Ozone Generating System SMOevoPLUS System Description Manual_SMOevoPLUS_eng_01 2019 doc page 46 of 179 P I Diagram complete SMOevoPLUS 910 960...

Page 47: ...01 1 50 Safety Pressure Limiter Combination Two pressure limiters with integrated pressure transmitter Via the analog signal of the pressure transmitter the PLC receives the current pressure in the g...

Page 48: ...ressures while simultaneously triggering a fault message Refer to section Operating Data The safety pressure limiters are prescribed safety elements for the ozone generator They switch off the system...

Page 49: ...t dew point is reached 01 1 85 Flow meter Option Air Measures the gas volume flow during purging phase until the correct dew point is reached 01 1 86 Silencer Option Air Reduces the noise of exiting f...

Page 50: ...ise to 3 5 bar g in order to prevent excess pressure due to thermal expansion in the ozone generator during operation as well as during OFF state 02 1 10 Ozone generator In the ozone generator the oxy...

Page 51: ...utomatically 03 1 20 Check valve To secure the system against flow in opposite direction 03 1 25 Ball valve Open in normal operation To be closed manually only in case of shutting down the system for...

Page 52: ...tance The specified water quantity and quality must be ensured by all means Refer to Chapter Technical Data 07 1 05 Butterfly valve Customer interface for cooling water flow Must be fully open during...

Page 53: ...0 SMOevo 860 From type SMOevoPLUS 610 on in addition to the ozone generator the converter is water cooled too 07 1 20 Butterfly valve To be throttled to the extent that a sufficient amount of cooling...

Page 54: ...ting contact which switches off the system and triggers a fault message if the value falls below 2l min set point 4l min 07 1 50 Heat exchanger The heat exchanger transfers the heat of the converter c...

Page 55: ...expansion tank with shut off valve For isolation with hose connection Allows checking the primary pressure of the tank and replacing the tank without draining the system The shut off valve must be ope...

Page 56: ...entration is expected in case of a malfunction The ambient air sensor has a built in self test function for daily checking the functionality of the sensor Sensor replacement is recommended every six m...

Page 57: ...e system generates a medium frequency single phase alternating voltage from 3 phase power supply with a fixed frequency of 50 60Hz The generated single phase AC voltage is transferred to a medium volt...

Page 58: ...complete converter unit is mounted on one half of the skid The electrical interfaces of the FU cabinets are designed in the form of two connector sets type Harting so that the two framework halves do...

Page 59: ...or circuit to the coolant circuit provided by the customer 07 1 120 Pressure gauge Pressure in the cooling circuit is approx 1 bar g and is displayed via the pressure gauge 07 1 125 Pressure switch In...

Page 60: ...consists of an internal diameter expansion in which a fine wire mesh is attached Small drops carried along with the gas are segregated in this way 06 1 125 Catalyst tank The offgas from the ozone tre...

Page 61: ...ually optionally also electrically operated ball valve for isolating the WOD 06 1 305 Ozone measuring device Option MC400 for determining the amount of residual ozone in the offgas of the ozone treatm...

Page 62: ...34 Ambient Air Monitoring 5 4 5 Option M1 and M2 Ozone Monitoring The option Ozone Monitoring is available in two versions M1 Measurement and display of ozone concentration by ozone monitor HC 400 plu...

Page 63: ...The ozone mass per norm cubic meter depends on the set converter output and the set gas volume flow VG Gas volume flow Nm h NTP The gas volume flow in norm cubic meter per hour is adjustable by the mo...

Page 64: ...ely due to very low or very high ozone mass to be required the PLC independently corrects the preset setpoints in order to ensure optimum operation of the Ozone System The value correction is displaye...

Page 65: ...ntial in the process water When falling below or exceeding a certain limit value the ozone production is reduced or increased in pre defined stages in order to ensure a process optimized ozone product...

Page 66: ...se lifting aids and slings permitted to the total weight Never stand under suspended loads Secure the ozone system against tilting Make sure that nobody stands under suspended loads Secure the hazard...

Page 67: ...udes transportation by crane forklift and lift truck The weight of the ozone system is indicated in Chapter Technical Data The weight of the separate packages is indicated in the Packing List Only use...

Page 68: ...t purposes observe the following instructions In order to prevent damage pack and unpack the different System Components according to their function and depending on their sensitivity with regard to d...

Page 69: ...g system 7 1 Installation 7 1 1 Safety Instructions DANGER Live components Danger to life due to electric shock Prior to installation work ensure that the ozone system is disconnected from the power s...

Page 70: ...installed by qualified persons refer to Chapter Classification of Operating Staff only 7 1 4 Requirements for Safe Installation Ensure the complete civil construction work is finished Check all the oz...

Page 71: ...e installation surface must be straight and even Ventilation In order to ensure good ventilation of the system provide a free area around the system Ensure sufficient room ventilation during normal op...

Page 72: ...es are possible with special option 2 For higher altitudes above sea level consulte Wedeco for assistance Ensure that the air humidity does not exceed 90 during continuous operation higher values are...

Page 73: ...otherwise ozone decays at the weld seams which are not treated When installing the system in an in house pipework system make sure that only ozone resistant connecting parts like cables fittings and s...

Page 74: ...distribution of all supporting points to avoid stress on the system 3 Ensure stress free connection of the system to in house piping for the gas pipes 4 Ensure stress free connection of the system to...

Page 75: ...g Out Purposes Prior to commissioning the ozone system for the first time or after carrying out modifications to the connection lines ensure that all moisture is removed from the gas lines Purge the g...

Page 76: ...ating the operating room with the converter switched off no ozone production look for the cause of the leak Maybe not all the connections are sufficiently tightened Although the system was factory tes...

Page 77: ...nd enabled 4 Set all manual valves to operating position 5 Let the cooling water flow into the system and bleed the pipe work 6 Set the cooling water flow according to the instructions given in Chapte...

Page 78: ...System On Off Starting and Stopping the Ozone Production Process This section describes the following 1 Switching the ozone system on off 2 Starting the ozone production 3 Stopping the ozone producti...

Page 79: ...piping and valves must be dry after purging and may not contain any dirt particles If there is any uncertainty as far as the dryness of the piping and valves are concerned carry out the purging proces...

Page 80: ...e Production The following picture shows the operating controls 1 Identify the setting parameters before starting the ozone production 2 Open the cooling water flow valve and set the flow according to...

Page 81: ...has occured A fault can be acknowledged by means of the system switch turn to position R or via the HMI Refer to Chapter Alarms Events Current After successful acknowledgment the system can be restar...

Page 82: ...g points It may vary depending on the options included in the respective system Message line Every screen containing the message line navigates the operator to the screen Alarm messages current by pre...

Page 83: ...nus from main menu 5 Navigation Opening submenus from main menu option not available 6 Navigation Opening parameter settings of the Dose Trim from submenu 7 Navigation Opening display of current alarm...

Page 84: ...l Mode 19 Visualization Status indication Ozone system faulty 20 Visualization Status indication Local mode 21 Visualization Status indication Remote mode 22 Visualization Status indication Service mo...

Page 85: ...l SP setpoint PV actual value 31 Operation Display process values AI Analog input P ID number 32 Operation Periphery settings 33 Operation Process value graph time axis 34 Operation Process value grap...

Page 86: ...Manual_SMOevoPLUS_eng_01 2019 doc page 86 of 179 8 6 Main Menu Screen 01 00 The main menu shows all screens required for operating the system Every screen is accessed by pressing the relevant pushbutt...

Page 87: ...process control system connection The status of the external commands can be checked in the Customer Interface screen Local The system is switched on or off via the system switch only Remote Hardwire...

Page 88: ...the manual purge mode is carried out OFF The converter is not released the ozone generation process is not in operation When the system is started the system is automatically started up to the Start...

Page 89: ...tely The entire system remains in operation Automatic Restart Option Release of the Automatic Restart including status indication When the system is in operation and mains fluctuations of the main sup...

Page 90: ...ork Remote Wedecontrol Converter Power Production Settings 03 00 01 X X 4W20 mA 0W100 Converter Power X X Gas Flow Generator X X 4W20 mA 0WX Nm h Gas Flow X X Ozone Concentration Production Settings 0...

Page 91: ...urge Mode When turning the system switch from Normal Operation position I to position 0 the system stops via the automatic stop sequence The Purge Mode in which the system is purged with the feed gas...

Page 92: ...arning or Breakdown ON If a warning status occurs the fault indicator flashes OFF The fault indicator goes on only if a fault status resulting in a breakdown occurs Ozone Alarm Indication A function t...

Page 93: ...essure If the pressure is not higher than the start level after 30 minutes the system stops and a fault message is generated The system is waiting for feed gas dew point option If the dew point is abo...

Page 94: ...screen System Settings is in position OFF A manual purge mode is carried out The converter switches on if the converter button in the screen System Settings is in position ON Start of the cooling sys...

Page 95: ...19 doc page 95 of 179 Turn off Periphery optional The air preparation system turns off after a preset Turn off Delay optional The cooling water system turns off after a preset Turn off Delay optional...

Page 96: ...OevoPLUS Operation Manual_SMOevoPLUS_eng_01 2019 doc page 96 of 179 8 10 Controller Settings Screen 02 03 The following settings are available for the PID Controllers Converter Power Gas Flow Generato...

Page 97: ...rameters and the setpoint Normal operation condition of the controller Manual The PID Controller operates with a fixed setpoint for the controller output Input parameters and setpoint are not taken in...

Page 98: ...Power Gas Flow Control With this control mode the setpoints Converter Power and Gas Flow Generator must be preset Signal Setpoint Local Remote Hardwired Remote Network Remote Wedecontrol Converter Po...

Page 99: ...nt Gas Flow Generator The external setpoint via the 4W20 mA signal corresponds to 0W100 Gas Flow of the Generator Refer to System Specification Converter Power The external setpoint via the 4W20 mA si...

Page 100: ...rol mode the setpoint for the ozone concentration in the gas must be specified The system automatically modulates the converter power according to the required ozone concentration The gas flow control...

Page 101: ...Generator The gas flow is controlled remotely The gas flow control valve on the ozone generator opens completely The resulting Gas Flow is displayed as follows PV Actual value in Nm h showing the actu...

Page 102: ...produce the Required Ozone Mass Signals Setpoint Local Remote Hardwired Remote Network Remote Wedecontrol Gas Flow x x x Ozone Conzentration X X X Required Ozone Mass X X 4W20 mA 0WX g h Ozone product...

Page 103: ...xample calculations Variable Gas Flos Required Ozone Mass Constant Concentration 49 02 Nm h 5000 g h 102 0 g Nm 39 22 Nm h 4000 g h 102 0 g Nm Variable Concentration Required Ozone Mass Constant Gas F...

Page 104: ...ch ozone is required the variable system setpoint remains at a fixed minimum or maximum parameter Depending on the required ozone mass the constant setpoint is automatically corrected to produce the r...

Page 105: ...n of the required ozone mass no internal calculation depending on the process water flow In this operating mode it is not possible to correct the dose using the trim function if available See section...

Page 106: ...in addition to the main setpoint Ozone Dose another constant setpoint must be specified Ozone Concentration or Gas Flow Generator Depending on the Required Ozone Mass the non constant setpoint is chan...

Page 107: ...decided which parameter should be the constant setpoint and which the variable parameter The setpoint highlighted in green is always the constant setpoint The setpoint highlighted in gray is always th...

Page 108: ...utomatically corrected to produce the required ozone mass After about 30 seconds a warning message is displayed in the HMI Warning setpoint corrected due to limits Ozone Dose Trim Option The correctio...

Page 109: ...ual value comparison setpoint actual value comparison after exchange of the reaction volume depending on the process water flow The operating mode and trim parameters of the function can be adapted to...

Page 110: ...e read in the output field Operating Mode Time Control Mode Interval After the start delay time the timer for the control interval starts The setpoint actual value comparison is not carried out contin...

Page 111: ...arison is carried out by the Dose Trim function Depending on the difference determined there are changes in the trim output The correction level is displayed graphically via the correction bar The cor...

Page 112: ...een percentage and absolute comparison levels Furthermore the main operating mode of the setpoint actual value comparison interval is defined Operating Mode Percent The setpoint actual value compariso...

Page 113: ...completion of the Time Control Mode Volume Control Mode interval with the result that the Dose Trim output needs not to be corrected since the actual value is in the dead zone of the controller The T...

Page 114: ...voPLUS_eng_01 2019 doc page 114 of 179 the next setpoint actual value comparison can be read in the output field Interval in the Dose Trim screen screen 03 01 SP Reaction volume in m PV Current proces...

Page 115: ...ting Mode Status and Turn off Delay after stopping the ozone production Operating Mode Automatic The external auxiliary may always be operated in Automatic Mode i e start and shutdown is carried out a...

Page 116: ...eration and waiting for the start signal Manual Operation is operated in Manual Mode Normal Operation is operated in Automatic Mode Fault General periphery or System Fault Start up Delay starts after...

Page 117: ...omatic Mode i e start and shutdown is carried out automatically via the start and stop sequence If the periphery is stopped in Automatic Mode it turns off not before the preset delay time has elapsed...

Page 118: ...erter For operating data refer to the data sheet Status The operational status of the periphery is displayed Disabled Is turned off Stand by is ready for operation and waiting for the start signal Man...

Page 119: ...d shutdown is carried out automatically via the start and stop sequence If the ozone destructor is stopped in Automatic Mode it turns off not before the delay time has elapsed Manual The Manual Mode i...

Page 120: ...ration and waiting for the start signal Manual Operation is operated in Manual Mode Normal Operation is operated in Automatic Mode Fault General periphery or System Fault Start up Delay starts after d...

Page 121: ...Press the Process Values field to access the curve progression graph Screen 05 03 Ozone Concentration Ambient Air 0W1 ppm Gas Flow Inlet Generator 0WX Nm h External Setpoint system specific depending...

Page 122: ...5 01 Display of the following current Process Values with PLC address and P ID number Press the Process Values field to access the curve progression graph Screen 05 03 Ozone Concentration in Gas optio...

Page 123: ...Screen 05 02 Display of the current enery values Press the Process Values field to access the curve progression graph Screen 05 03 Power Consumption Converter 0WX kW Mains Frequency 0WX Hz Voltage Ne...

Page 124: ...ss and P ID number The curve progression graph shows the process values over a period of 0 5 32 h The recording of the measured values can be stopped and started via the buttons The resolution of the...

Page 125: ...are diplayed including PLC address date and status Status K Fault message appears Fault is present Status K Q After successful remedy of the fault the fault message has been acknowledged Status KQ G F...

Page 126: ...ual Ozone Generating System SMOevoPLUS Operation Manual_SMOevoPLUS_eng_01 2019 doc page 126 of 179 Pop up window The pop up window can be closed by pressing x in the top right corner of the pop up win...

Page 127: ...term Alarms buffer Fault messages are always displayed in clear text including PLC address All messages are provided with a time stamp Press the Delete button to delete the messages from the buffer P...

Page 128: ...Date and Time synchronization with control Change Language Available languages German English Italian French Spanish and Chinese Clean HMI Shut down 30sec The Runtime of the HMI is stopped for 30 sec...

Page 129: ...l Status Relay Information External Release 1 2 DI1 0 External release signal of the system External Setpoint 5 6 4W20 mA External setpoint for controlling the system Normal Operation 9 10 11 25K2 Dis...

Page 130: ...communication bit heartbeat by the Wedeco system green communication bit from the higher level controller to the Wedeco system 5s true 5s false This provides a simple visualization whether the commun...

Page 131: ...orized personnel Work on live components may only be carried out by electrically qualified persons or by specially instructed personnel under the supervision of an electrically qualified person WARNIN...

Page 132: ...s for handling oxygen Refer to section Safety 9 2 Fault Rectification The system is equipped with a control unit generating the fault messages These messages allow the user to localize non complex fau...

Page 133: ...ating System SMOevoPLUS Troubleshooting Manual_SMOevoPLUS_eng_01 2019 doc page 133 of 179 Re start the converter the ozone production Refer to Chapter Switching on the system Starting and Stopping the...

Page 134: ...ck the devices peripheral settings System not ready for operation Remote mode selected and system switch not in position I The converter ozone production cannot be started externally because an extern...

Page 135: ...10 Opening the gas inlet valve and release to PID controller Start Ozone Destruct Start Step Chain 11 optional Residual Ozone Destructor is started Start Converter Ozone Production Start Step Chain 12...

Page 136: ...spare Stop Injection System Stop Step Chain 10 optional Injection system is stopped Stop Step 11 Stop Step Chain 11 spare Stop Air Preparation System Stop Step Chain 12 optional Air preparation is sto...

Page 137: ...Manual_SMOevoPLUS_eng_01 2019 doc page 137 of 179 9 4 Fault Messages In the event of an alarm a pop up window opens automatically in every HMI screen The window shows current alarms in clear text inc...

Page 138: ...cooling water temperature generator high Water temperature 50 C downstream ozone generator Check cooling water supply Check cooling water temperature Check cables and connections De aerate cooling wa...

Page 139: ...Cable break Pressure reducer defective or set incorrectly Acknowledge pressure switch Check cables and connectionss 10 SYS DI1 1 Alarm cooling water flow generator low Insufficient cooling water supp...

Page 140: ...13 SYS DI1 4 Alarm overload PSU Overload air condition Current consumption too high Incorrect limit value Motor protective circuit breaker defective Overload Rittal air condition units Eco mode activa...

Page 141: ...Check cables and connections De aerate cooling water line Clean cooling water circuit Use suitable cooling medium 16 SYS DI1 7 Alarm fault UPS 24V Fault message from UPS Cable break Incorrect wiring...

Page 142: ...the system Check cooling water flow and temperature by customer reduce pressure if necessary 20 SYS DI2 3 Alarm fault ozone destructor Main switch at WOD turned to Off Overload motor protective circui...

Page 143: ...unit refer to manufacturer s manual 23 SYS DI2 6 Warning fault nitrogen boost compressor Fault message from compressor Cable break Incorrect wiring Check cables and connections Check input voltage Che...

Page 144: ...e in injection system Process water in outlet blocked Injector dirty Check process water pre filter provided by customer Check process water in outlet Check injector for dirt Contact regional Wedeco S...

Page 145: ...Refer to Chapter Contact Addresses 65 PSU DI20 0 Alarm no operation message from DICON Door electrical cabinet open Cable break Connection plug between cabinets not fixed 24V supply of Dicon missing...

Page 146: ...high Temperature capacitor too high Ambient temperature too high Cable break Check air cooling Check chiller cleaning Check cables and connections 69 PSU DI20 4 Alarm powerblock temperature high Powe...

Page 147: ...he display take countermeasures according to the operating instructions of the unit refer to manufacturer s manual 75 PSU DI21 2 Alarm fault air condition 2 Fault message from air condition Cable brea...

Page 148: ...te IO is missing Check cables and connections Check input voltage Contact Wedeco Service Fault rectification only by qualified staff Refer to Chapter Contact Addresses 98 Alarm communication fault to...

Page 149: ...int corrected due to limits The calculated setpoints are not within tolerance The system corrects to min max setpoints Check Required Ozone Mass setting Change setpoint if necessary to operate the sys...

Page 150: ...t temperature cooling water generator Signal 4 mA or signal 20 mA Cable breakage Measuring device or transducer input PLC defective Replace sensor Check signal Check cables and connections 133 SYS AI1...

Page 151: ...Alarm signal fault gas flow line 1 Signal 4 mA or signal 20 mA Cable breakage Measuring device or transducer input PLC defective Replace sensor Check signal Check cables and connections 139 SYS AI120...

Page 152: ...as flow inlet generator low Gas flow volume too low Measuring device defective Check gas flow volume Check manual valve setting Check gas supply Check introduction system back pressure too high Check...

Page 153: ...y 180 SYS AI108 Alarm feed gas pressure low Inlet pressure too low Check valve setting Check gas supply 185 SYS AI112 Alarm feed gas dew point high Feed gas has bad dew point quality 50 C Start up tim...

Page 154: ...centration ambient air high Oxygen concentration in ambient air too high Ambient air sensor defective Search for leakage and rectify Calibrate ambient air sensor Replace if necessary 195 SYS AI116 War...

Page 155: ...ective Check gas flow volume Check manual valve setting Check gas supply Check introduction system back pressure too high 204 SYS AI120 Alarm gas flow line 2 low Gas flow rate too low Measuring device...

Page 156: ...ferrite core high Temperature step up transformer 120 C Temperature in control cabinet too high Temperature Ambient too high Check transformer fan Check function of cooling unit Check cables and conn...

Page 157: ...ety Instructions DANGER Live components Danger to life due to electric shock Do not use water for cleaning live components Do not spray rooms housing ozone generating systems with water DANGER Live co...

Page 158: ...t by qualified persons Ensure sufficient room ventilation Do not smoke and avoid open flames It is essential to follow the guidelines for handling ozone Refer to section Safety WARNING Escaping oxygen...

Page 159: ...em SMOevoPLUS Cleaning Manual_SMOevoPLUS_eng_01 2019 doc page 159 of 179 10 1 2 Personal Protective Equipment In order to prevent injuries wear the following protective equipment during cleaning work...

Page 160: ...ng to the applicable rules of electrical engineering only are electrically instructed and under the supervision of an electrically qualified person have read and understood this manual 10 3 Requiremen...

Page 161: ...y Preparation Ensure the system is isolated from the power supply Secure the system against unintended restart Close all openings to prevent cleaning agent from ingressing into the system Cover all sy...

Page 162: ...for the container by an approved accreditation body zugelassene ber wachungsstelle Z S 5 years after commissioning the system If the periodic test does not detect any defects the test time for the oz...

Page 163: ...o opening ozone containing System Components purge the system until no more ozone can be detected however at least 4 hours with nominal gas flow Work in which the ozone generator must be opened may on...

Page 164: ...nance work NOTICE Formation of nitric acid due to condensation Damage to the ozone system The ozone generator must cool down to ambient temperature 3 K prior to opening If using wrong or substandard s...

Page 165: ...LUS Maintenance Manual_SMOevoPLUS_eng_01 2019 doc page 165 of 179 11 3 Requirements for Maintenance Staff Maintenance work on the ozone system may be carried out by qualified persons refer to Chapter...

Page 166: ...er cable from the socket Wait 30 minutes before starting any work Secure the system against unintentional restart Secure all upstream and downstream devices and operating media e g feed gas supply aga...

Page 167: ...as inlet 01 1 35 Microfilter Visual inspection weekly 01 1 40 Pressure reducer Visual inspection Adjusting required operating pressure if necessary Refer to Chapter System Description Assembly 01 Gas...

Page 168: ...thly 07 1 55 Solenoid valve Visual inspection monthly Piping Visual inspection weekly Assembly Ambient Air Monitoring 34 1 10 Ozone Sensor Check Sensor replacement every 6 months every 6 months 2 Asse...

Page 169: ...ance Manual_SMOevoPLUS_eng_01 2019 doc page 169 of 179 11 6 Disposing of Components and Materials Dispose of all the components and materials which have been replaced in a proper and environmentally f...

Page 170: ...ies and external voltages prior to starting any work on it WARNING Hazard due to not sufficiently qualified personnel Danger to life or serious injury may result Work on electrical system components m...

Page 171: ...aids and slings permitted to the total weight Never stand under suspended loads Secure the ozone system against tilting Make sure that nobody stands under suspended loads Secure the hazard area agains...

Page 172: ...l the piping and system components 3 Close the feed gas inlets 4 Seal the gas lines 5 Discharge the cooling water 6 Disconnect the system from the media supply connections Make sure that no leakages o...

Page 173: ...safety observe the following instructions Observe all local regulatory requirements regarding the environment Dispose of materials in a safe and environmentally friendly manner Separate materials by m...

Page 174: ...al_SMOevoPLUS_eng_01 2019 doc page 174 of 179 13 Appendix 13 1 Confirmation of Briefing I hereby confirm that I have completely read and understand the manual related to the ozone generating system SM...

Page 175: ...of 179 13 2 Operating Directives Operating Directives must be issued by the owner operator of the ozone system The Directives must be attached well visible for the personnel in the operation room The...

Page 176: ...Manual Ozone Generating System SMOevoPLUS Appendix Manual_SMOevoPLUS_eng_01 2019 doc page 176 of 179 Example Directive Handling of Ozone...

Page 177: ...Manual Ozone Generating System SMOevoPLUS Appendix Manual_SMOevoPLUS_eng_01 2019 doc page 177 of 179 13 3 Swagelok Installing Instructions for External Connections...

Page 178: ...and or passive safety characteristics Any damage caused by the use of parts other than the original Wedeco spare parts and accessories will void all liability and guarantee obligations on the part of...

Page 179: ...following torques arising M 7 allowable torque 2 Nm 17 7 lbf in M 10 allowable torque 35 Nm 310 lbf in M 12 allowable torque 60 Nm 531 lbf in M 14 allowable torque 94 Nm 832 lbf in M 16 allowable torq...

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