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I-1/103 

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

Tel: 01494 796 040 

email: [email protected]

 

 

Содержание HydroDOS HD550G

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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 ______________________________...

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

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

Страница 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...

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

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

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

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

Страница 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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