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Chlorine Dioxide Generator
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!
LOTUS MINI
Operation Manual
DOWNLOAD ERMES COMMUNICATION SOFTWARE
www.ermes-server.com
English
R5-02-16
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Summary of Contents for Emec LOTUS MINI
- Page 1 Chlorine Dioxide Generator LOTUS MINI Operation Manual DOWNLOAD ERMES COMMUNICATION SOFTWARE www.ermes-server.com 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.
- Page 2 NORME CE EC RULES(STANDARD EC) NORMAS DE LA CE ⎬ Direttiva Bassa Tensione 2014/35/UE Low Voltage Directive Directiva de baja tensión ⎬ Direttiva EMC Compatibilità Elettromagnetica 2014/30/UE EMC electromagnetic compatibility directive EMC directiva de compatibilidad electromagnética GENERAL SAFETY GUIDELINES Danger! In emergencies the instrument should be switched off immediately! Disconnect the power cable from the power supply! When installing always observe local regulations!
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Page 3: Table Of Contents
Directory General Safety Guidelines Symbols Safety instructions CE-Conformity General Description Construction Construction overview Description and details „LOTUS“ - Controller Start display Main display Control element „Click-Wheel“ Status displays Logbook Help Adjustment of production capacity Proportional mode Constant mode Analog mode Batch mode Replacement of chemical cans and pump priming LOTUS Terminal board... -
Page 4: General Safety Guidelines
General Safety Guidelines General remarks This manual includes basic directions for the assembling, operation and maintenance. Therefore it is obligatory for the assembly technician as well as for the operator to study the complete manual before starting with the installation and start-up. This manual must be present at the generator at any time. It is also obligatory for the operator to consider the general directions in chapter “Safety instructions”... - Page 5 • Drain and flush the pump-heads with clean water before starting the service. • Take attention to the chemical safety data sheets! • Wear protection clothes for the handling with unknown and hazardous chemicals. WARNING: INSTALL NFIL/60 BEFORE WATER INPUT TO AVOID OCCLUSIONS Pulse sender water meter Multivalve ECL1...
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Page 6: Ce-Conformity
Directions for the operator (Specific information for applicable regulations in Germany): • Accident prevention regulation (UVV) „Chlorination of water“, GUV V-D5 E. • „Dosing plants for chlorine dioxide“, DVGW guideline W 624 (latest version respectively). • „Chlorine dioxide in water treatment“, DVGW worksheet W 224 (latest version respectively). •... -
Page 7: General Description
General Description The chlorine dioxide generator is used for the production of liquid chlorine dioxide. This disinfection agent kills all bacteria, germs, viruses and fungi within shortest time – and it works with very low concentration. The generator is working with the hydrochloric acid – chlorite process and uses diluted chemicals like hydro- chloric acid (HCl 9%) and sodium chlorite (NaClO 7.5%) in accordance to the following chemical equation: Hydrochloric acid... -
Page 8: Construction
Construction Construction overview HCl 9% NaClO 7,5% Description and details 1 LOTUS-controller 10 Drain nozzle ½“ 2 Dosing pump for hydrochloric acid (HCl 9%) 11 Level switch „Dilution water tank empty“ 3 Dosing pump for dilution water 12 Can with hydrochloric acid 9 % (ca. 95 g/l) 4 Dosing pump for sodium chlorite (NaClO 7,5%) 13 Suction lance with level-switch „Hydrochloric acid“... -
Page 9: Lotus" Controller
When the power supply is switched on the start display appears and shows the actual software release for some seconds. LOTUS Rel: x.x.x After approx. 3 seconds the program goes onto the main display. Main display 02-12-10 EMEC 09:10:55 LOTUS 25.9° C Chlorine Dioxide Generator Stand-by Status Menu Logbook Help... -
Page 10: Status Displays
Status Displays 02-12-10 EMEC 09:10:55 LOTUS 25.9° C Chlorine Dioxide Generator Stand-by Status Menu Logbook Help Status Push the click-wheel on “Status” to open 4 different operation displays: Status LOTUS Status LOTUS Check : Mode: Production [g/h] : 4.25 Mode:... -
Page 11: Logbook
Logbook 02-12-10 EMEC 09:10:55 LOTUS 25.9° C Chlorine Dioxide Generator Stand-by Status Menu Logbook Help Logbook Turn the click-wheel onto the field “Logbook” and push it to open the sub-menu. Logbook Logbook ˄ ˄ 07-12-10 23:59:59 Mode: Proportional 07-12-10 12:35:55 Failure level acid Acid:109.0 l Chlorite: 109.7 l Water: 298.6 m³... -
Page 12: Adjustment Of Production Capacity
Adjustment of production capacity Depending to the operation mode the production capacity of LOTUS can be changed. 02-12-10 EMEC 09:10:55 LOTUS 25.9° C Chlorine Dioxide Generator Stand-by Status Menu Logbook Help Menu Push the click-wheel “Menu” to open the display for the adjustment of the production capacity. -
Page 13: Proportional Mode
0,90 22.2 1,00 The overriding of the maximum possible production capacity caused by the water flow is shown on the display with a special blinking message “Overflow”: 02-12-10 EMEC 09:10:55 LOTUS 25.9° C Chlorine Dioxide Generator Overflow Status Menu Logbook Help... -
Page 14: Constant Mode
Constant mode In this mode LOTUS is producing chlorine dioxide with a constant and adjustable capacity as long as input “Stand-by” is not activated. Two different capacities can be adjusted depending to the digital inputs “Batch tank empty” [terminal 34 and 35] and “Stand-by” [terminal 44 and 45]. Constant Mode Capacity 1: 50 %... -
Page 15: Batch Mode
< ESC > < ESC > In case one of the level-switch failed or the cable is damaged a failure message appears: Failure Level-switch: Status 02-12-10 EMEC 09:10:55 LOTUS 25.9° C Level Tank full Mode: Level Tank empty : Batch... -
Page 16: Replacement Of Chemical Cans And Pump Priming
Replacement of chemical cans and pump priming Warning: Wear protective clothes for the handling with hazardous chemicals! • Replace the chemical can. 02-12-10 EMEC 09:10:55 LOTUS 25.9° C Chlorine Dioxide Generator Status Menu Logbook Help Status • Use the click-wheel, go to „Status“ and then to „Priming“. Push the click-wheel and open the sub-display for the manual mode. -
Page 17: Lotus Terminal Board
LOTUS Terminal board Optic coupled Outputs mA Outputs RS485 for pump type …-IS (Option) F2 F1 Relay Outputs + – – + – + – + – + – + – A1 A2 A3 A4 A5 L 01 02 03 04 05 06 Relay Outputs 01 02... - Page 18 LOTUS Terminal board SEPR module for proximity switch Slot 1 To set the proximity switch enter into configuration menu and select Probe Flow Alarm Flow contact can be enabled to stop a dosing procedure using a N.O. contact mode (normally open) or N.C. contact mode (normally clo- MDSEPR sed) when status on blocks changes.
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Page 19: Technical Data
Technical Data LOTUS MINI 8 LOTUS MINI 20 production capacity Maximum operation pressure Chemical consumption at max. production each 0.2 each 0.5 Concentration of ClO stock solution approx. 2 - 20 Power supply 90 – 265 V, 50/60 Hz Energy consumption... -
Page 20: Failure Messages
Failure messages In case of a malfunction a message appears on the display and LOTUS stops. Failure: 07-12-10 14:35:42 Level Acid Restart Remove the malfunction and restart LOTUS. Message Problem Solution Change the chemical can and prime the Level Acid pump. -
Page 21: Communication
COMMUNICATION... - Page 22 COMMUNICATION MENU (TCP/IP - GPRS with MODEM OR ETHERNET MODULE This instrument can be controlled and programed remotely using the system called ERMES and a standard web browser (i.e.: Google Chrome or Safari). In order to use this service an internet connection is required (lan or wan) and user must configure the instrument to obtain a valid IP address (through a valid DHCP service or manually).
- Page 23 COMMUNICATION (MESSAGES Setup - RS485) This instrument can send emails and / or sms when a system failure or warning happens. If instrument is configured to operate through the LAN only email messages can be send. Otherwise if instruments has a mobile modem both SMS and emails messages can be send.
- Page 24 COMMUNICATION (LOG MENU & LOGBOOK MENU) This function, when enabled, allows to record and send to ERMES server all instrument activities (date, time, temperature, levels, alarms, totalizers, outputs status) for a set period (EVERY) and starting from a certain time (TIME) . Note: SET TIME AND DATE PRIOR TO ENABLE THE LOG.
- Page 25 EMEC instruments with ETHERNET or GSM/GPRS Configuration will be immediatly connected and available for remote control. Furthermore, with ERMES you can receive alarm messages via email, with different report option on instrument status. If instrument has been bought with the GSM/GPRS option it’s possible to receive SMS reports on any mobile phone.
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Page 26: Troubleshooting
Troubleshooting Problem Possible solution Check best signal coverage for operator choice. Modem is compatible with the following GSM frequencies: 900 -1800 -1900 MHz (three-band). Not compatible with 3G only operators. What to do before to install the SIM into instru- SIM type is: ment’s modem Mini-SIM (classica SIM card in uso nei telefoni) - Page 27 MODBUS Modbus is a serial communications protocol originally published by Modicon (now Schneider Electric) in 1979 for use with its programmable logic controllers (PLCs). Simple and robust, it has since become a de facto standard communication protocol, and it is now a commonly available means of connecting industrial electronic devices. From main menu select COMMUNICATION then MODBUS to access the options.
- Page 28 ADDENDUM DIOXIDE PROBE SAFETY SYSTEM Dioxide Probe Use this function to setup sensor that detects dioxide into air. This option is useful during a plant’s dioxide leakage to prevent dangerous high dioxide concentration. To set this valure refer to the sensor sensitiveness as printed on head’s label (see below picture).
- Page 29 Appendix A: Test Certificate Order No.: LOTUS type: Serial No.: Software release: Chamber: Test pressure: Test temperatur Test period: ° C hours Dosing pumps: Acid Water Chlorite Type: Calibration value: Calibration pressure: Number of strokes: System settings: Dos-Check: Pass-Code 2: Default: Pass-Code 1: Default:...
- Page 32 R3-10-14...
- Page 33 Chlorine Dioxide Generator LOTUS MINI Installation and Operation Manual Read this manual completely before you start with the installation and start-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.
- Page 34 R3-10-14...
- Page 35 Directory General Safety Guidelines Symbols Safety instructions CE-Conformity General Description Construction Construction overview Description and details Installation General requirements for the installation location Requirements to the water Assembly Hydraulic installation 4.4.1 Installation to a pressure system 4.4.2 Installation to a batch tank Electric Installation 4.5.1 Power supply...
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Page 36: General Safety Guidelines
General Safety Guidelines General remarks This manual includes basic directions for the assembling, operation and maintenance. Therefore it is obligatory for the assembly technician as well as for the operator to study the complete manual before starting with the installation and start-up. This manual must be present at the generator at any time. It is also obligatory for the operator to consider the general directions in chapter “Safety instructions”... - Page 37 • Before starting service at the dosing pumps 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 handling with unknown and hazardous chemicals.
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Page 38: Ce-Conformity
Directions for the operator (Specific information for applicable regulations in Germany): • Accident prevention regulation (UVV) „Chlorination of water“, GUV V-D5 E. • „Dosing plants for chlorine dioxide“, DVGW guideline W 624 (latest version respectively). • „Chlorine dioxide in water treatment“, DVGW worksheet W 224 (latest version respectively). •... -
Page 39: General Description
General Description The chlorine dioxide generator is used for the production of liquid chlorine dioxide. This disinfection agent kills all bacteria, germs, viruses and fungi within shortest time – and it works with very low concentration. The generator is working with the hydrochloric acid – chlorite process and uses diluted chemicals like hydro- chloric acid (HCl 9%) and sodium chlorite (NaClO 7.5%) in accordance to the following chemical equation: Hydrochloric acid... -
Page 40: Construction
Construction Construction overview HCl 9% NaClO 7,5% Description and details 1 LOTUS-controller 10 Drain nozzle ½“ 2 Dosing pump for hydrochloric acid (HCl 9%) 11 Level switch „Dilution water tank empty“ 3 Dosing pump for dilution water 12 Can with hydrochloric acid 9 % (ca. 95 g/l) 4 Dosing pump for sodium chlorite (NaClO 7,5%) 13 Suction lance with level-switch „Hydrochloric acid“... -
Page 41: Installation
Installation Warning: • For the operation of the LOTUS generator the absolute observance of the national and local regulations is required. The operator is liable for the observance of the local safety instructions. • The generator must be installed and started up in accordance to the regulations in this manual. •... -
Page 42: Requirements To The Water
Requirements for the water Warning: Serious malfunctions at the plant or corrosion damages in the pipe-work of the treated wa- ter should be possible in case the following requirements to the water the chlorine dioxide is produced for as well as for the dilution water are not fulfilled: Dilution water: Temperature: 10 –... -
Page 43: Hydraulic Installation
Hydraulic Installation 4.4.1 Installation to a pressure system Systems with more than 0.5 bar operation pressure like drinking water treatment for hospitals, municipal build- ings, retirement homes as well as cooling water treatment etc. Connection for dilution water (PE-hose 4x6 mm) Chlorine dioxide injection point (PVDF-hose 4x6 mm) Overflow dilution water storage tank (20 mm PVC adhesive sleeve) -
Page 44: General Information
General information: Warning: In accordance to DIN 1988 a system separator is required in the main building feed line. Notice: • Take equal pipe dimensions and connections for the contact water meter and the intermixture device to ensure optimal hydraulic conditions. •... - Page 45 Injection and intermixture device [ 24 ] Caution! Don´t install the injection valve direct into a metal tube. The chlorine dioxide will destroy the tube by corrosion in a short time. Select one of the following devices for the installation into metal pipe- works: •...
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Page 46: Installation To A Batch Tank
4.4.2 Installation to a batch tank HCl 9% NaClO 7,5% Connection for dilution water (PE-hose 4x6 mm) Connection for chlorine dioxide outlet (PVDF-hose 4x6 mm) Overflow of dilution water storage tank (PVC 20 mm adhesive muffle) to drain 20 Shut-off valve 21 Protection filter (like NFIL/60) 22 LASP suction-lance for hydrochloric acid 23 LASP suction-lance for sodium chlorite... - Page 47 Caution! Take care that the “MFKTS” – multifunction valve on the top of the reactor (inside LOTUS) is adjusted with a counter-pressure of minimum 1 bar! Dilution water connection [ A ] Inside LOTUS is a storage tank [ 8 ] for the dilution water. The automatic refill is controlled by a float valve [ 9 ]. The float valve has to be connected to the water line with a 4x6 mm PE-hose (2 m included in the delivery scope).
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Page 48: Electric Installation
Electrical Installation Caution! • Installation only made from an authorized expert! • In Germany: Take the instructions of VDE 0165 into consideration. In foreign countries: Consider the current national regulations! • Risk of electric shock! • Take care that the power supply meets the power requirements of LOTUS (see plant-label). •... -
Page 49: Preparations
Wear protective clothes for the handling with hazardous chemicals! Hydraulic startup • Plug the power supply into the socket. The LOTUS-controller starts with the start-display and shifts to the main-display after some seconds. 02-12-10 EMEC 09:10:55 LOTUS 25.9° C Chlorine Dioxide Generator Status Menu Logbook Help Status •... -
Page 50: Lotus" Controller
When the power supply is switched on the start display appears and shows the actual software release for some seconds. LOTUS Rel: x.x.x After approx. 3 seconds the program goes onto the main display. Main display 02-12-10 EMEC 09:10:55 LOTUS 25.9° C Chlorine Dioxide Generator Stand-by Status Menu Logbook Help... -
Page 51: Control Element „Click-Wheel
Control element „Click-Wheel“ On the right side of the display a turning- and push-button is located. It is called „Click-Wheel“. You can turn the click-wheel into both directions to scroll through the menus or select a function. The selected function is shown in an inverse color. Main Menu Proportional Pumps... -
Page 52: Status Displays
Status Displays 02-12-10 EMEC 09:10:55 LOTUS 25.9° C Chlorine Dioxide Generator Stand-by Status Menu Logbook Help Status Push the click-wheel on “Status” to open 4 different operation displays: Status LOTUS Status LOTUS Check : Mode: Production [g/h] : 4.25 Mode:... -
Page 53: Logbook
Logbook 02-12-10 EMEC 09:10:55 LOTUS 25.9° C Chlorine Dioxide Generator Stand-by Status Menu Logbook Help Logbook Turn the click-wheel onto the field “Logbook” and push it to open the sub-menu. Logbook Logbook ˄ ˄ 07-12-10 23:59:59 Mode: Proportional 07-12-10 12:35:55 Failure level acid Acid:109.0 l Chlorite: 109.7 l Water: 298.6 m³... -
Page 54: Main Menu
Main Menu 02-12-10 EMEC 09:10:55 LOTUS 25.9° C Chlorine Dioxide Generator Stand-by Status Menu Logbook Help Menu Push the click-wheel to open the main menu. The access to the main menu is protected by a passcode: Passcode * * * *... -
Page 55: Pumps - Calibration Of The Dosing Pumps
Pumps – Calibration of dosing pumps For an accurate production of chlorine dioxide a proper calibration of the dosing pumps is essential. The exact calibration ensures the maximum yield of the chemicals and the minimization of the chemical consumption. For this a periodic maintenance with a pumps calibration is required. -
Page 56: Contact Water Meter
Contact water meter For the proportional production of the chlorine dioxide the connection of a contact water meter is required. The LOTUS-controller can work with the following types of water meters: • Contact water meter with Reed-contact (like type CTFI) •... -
Page 57: Analog Outputs
Analog outputs Optional there are 2 analog outputs available for the chlorine dioxide and the temperature measuring values. In case LOTUS is equipped with the option you can select the output resolution in this sub-menu. Enter the main menu and open the sub-menu “Analog Outputs”. Main menu Analog Outputs Water Meter... -
Page 58: Operation Mode
Operation mode LOTUS can work in different operation modes. Enter the main menu and open the sub-menu “Operation Mode”. Main Menu Operation Mode Water Meter Proportional ü Proportional Analog Outputs Constant Betriebsmodus Operation Mode Batch Analog Select operation mode Operation Mode Prop. -
Page 59: Proportional Mode
0,90 22.2 1,00 The overriding of the maximum possible production capacity caused by the water flow is shown on the display with a special blinking message “Overflow”: 02-12-10 EMEC 09:10:55 LOTUS 25.9° C Chlorine Dioxide Generator Overflow Status Menu Logbook Help... -
Page 60: Constant Mode
7.5.2 Constant mode In this mode LOTUS is producing chlorine dioxide with a constant and adjustable capacity as long as input “Stand-by” is not activated. Two different capacities can be adjusted depending to the digital inputs “Batch tank empty” [terminal 34 and 35] and “Stand-by” [terminal 44 and 45]. Operation Mode Constant Mode Proportional... -
Page 61: Batch Mode
< ESC > < ESC > In case one of the level-switch failed or the cable is damaged a failure message appears: Failure Level-switch: Status 02-12-10 EMEC 09:10:55 LOTUS 25.9° C Level Tank full Mode: Level Tank empty : Batch... - Page 62 7.5.5 Prop. & Reading mode In this mode LOTUS produces an adjustable capacity of chlorine dioxide proportional to a water flow recorded by a water meter. In addition an internal chlorine dioxide measurement controls the concentration and down- sizes the production capacity in case of an set-point overriding. Operation Mode Prop.
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Page 63: System Settings
System settings This menu is for basic settings. Main Menu System Settings Proportional System Settings Dos-Check: Pass-Code 2: 0916 Exit Pass-Code 1: 0000 Language: English System Settings System Settings Time: 10:47:55 Date: 07-12-10 Reset Dos-Check: Here you can preset the number of failed strokes from the dosing pumps without response from the dosing controls. -
Page 64: Lotus Terminal Board
LOTUS Terminal board Optic coupled Outputs mA Outputs RS485 for pump type …-IS (Option) F2 F1 Relay Outputs + – – + – + – + – + – + – A1 A2 A3 A4 A5 L 01 02 03 04 05 06 Relay Outputs 01 02... - Page 65 LOTUS Terminal board SEPR module for proximity switch Slot 1 To set the proximity switch enter into configuration menu and select Probe Flow Alarm Flow contact can be enabled to stop a dosing procedure using a N.O. contact mode (normally open) or N.C. contact mode (normally clo- MDSEPR sed) when status on blocks changes.
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Page 66: Technical Data
10. Technical Data LOTUS MNI 8 LOTUS MINI 20 production capacity Maximum operation pressure Chemical consumption at max. production each 0.2 each 0.5 Concentration of ClO stock solution approx. 2 - 20 Power supply 90 – 265 V, 50/60 Hz... -
Page 67: Failure Messages
11. Failure messages In case of a malfunction a message appears on the display and LOTUS stops. Failure: 07-12-10 14:35:42 Level Acid Restart Remove the malfunction and restart LOTUS. Message Problem Solution Change the chemical can and prime the Level Acid pump. - Page 72 R3-10-14...
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