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Read this manual completely before you start with the installation and start-up. Do not discard this manual and store it nearby the generator for later use. English...
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Directory General Safety Guidelines Storage and Transport Construction Installation First Startup „LOTUS“ - Controller „Click-Wheel“ Configuration Menu LOTUS Terminal board Failure Messages...
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General Safety Guidelines General remarks • • Notice: • • Symbols in the manual Warning: Caution! Notice or advice: Symbols at the installation site Warning: Danger! Prohibition!
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Safety chapter The three basic rules: Correct and proper use: • • • • • • • • • • • • • •...
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Qualification of personnel: Warning! Activity Qualification level Technical expert: Qualified personnel: Instructed personnel: Customer service department: Personal protective equipment...
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Safety information: Warning! Danger from incorrect operation • • Warning! Danger due to toxic and explosive ClO • Instructions for entering • a room where a chlorine dioxide system is installed • • Notes You got into contact with acid: for the system operator •...
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• The LOTUS system was supplied with concentrated chemicals but the dosing pumps have not yet started: Directions for the operator • • • • • EU Declaration of Conformity • • • • • • • Notice:...
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Storage and Transport Safety information: Warning! • • Notice: Danger of material damage • • • Packaging: Ambient conditions: Data Value...
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Construction General description • • WARNING: follow European directive DIN EU 939 concerning HYDROCHLORIC ACID follow European directive DIN EU 938 concerning SODIUM CHLORITE...
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Installation Safety information: Warning! • • • • • • • • General requirements for the installation site Notice: • • • • • • • • • • • General requirements for the plant installation Notice: • • • •...
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Requirements for the water Safety information: Warning! Serious malfunctions at the plant or corrosion damages in the pipe-work of the treated water should be possible in case the following requirements to the water – the chlorine dioxide is produced for – as well as for the dilu- tion water are not fulfilled: •...
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Hydraulic Installation Safety information: Warning! Warning against illegal operation Danger! Warning of toxic chlorine dioxide vapour • • • • Warning! The reactor can explode Main components: • • • • • • • •...
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Chlorine Dioxide Generator LOTUS D 4.5.1 Installation example A • Point of injection (34) direct in the main water supply. • Operation mode: “Proportional” Fig. 4.1 Reactor outlet valve Main water supply Flushing unit with vacuum relieve valve Water meter (frequency or analog signal) Acid tank in safety tub Bypass line Chlorite tank in safety tub...
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Chlorine Dioxide Generator LOTUS D 4.5.2 Installation example B • The reactor outlet valve (9) of the LOTUS system is located beneath the point of injection (34). • Operation mode: “Proportional” h > 0 Fig. 4.2 Reactor outlet valve Main water supply Flushing unit with vacuum relieve valve Water meter (frequency or analog signal) Acid tank in safety tub...
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Chlorine Dioxide Generator LOTUS D 4.5.3 Installation example C • The reactor outlet valve (9) of the LOTUS system is located beneath the point of injection (34). • Operation mode: “Proportional” h < 0 Fig. 4.3 Reactor outlet valve Main water supply Flushing unit with vacuum relieve valve Water meter (frequency or analog signal) Acid tank in safety tub...
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Chlorine Dioxide Generator LOTUS D 4.5.4 Installation example D • Batch tank filling with water supply module • Operation mode: “Batch” Fig. 4.4 Flushing unit with vacuum relieve valve Batch or storage tank Acid tank in safety tub Back pressure valve Chlorite tank in safety tub Module “Water Supply”...
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Hydraulic Installation of accessories and options 4.6.1 Bypass line Safety information: Danger! Warning of toxic chlorine dioxide vapour • • • • Warning! The reactor can explode • • Function: 4.6.2 Safety equipment bypass line Safety information: Warning! The reactor can explode Risk of explosion in the bypass line Function:...
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4.6.3 Flushing unit with vacuum relieve valve Safety information: Warning! Degassing ClO solution can still vaporize in the bypass line. Danger! Poisonous ClO solution can escape Function:...
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4.6.4 Back pressure valve Function: 4.6.5 Flow generator for bypass line Function: • •...
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4.6.8 Suction lances Safety information: Danger! Warning of toxic chlorine dioxide gas Warning! Warning of corrosive acid or toxic chlorite solution Assembly: Caution! The suction hoses must not be plugged into the chemical tanks yet! Caution!
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4.7.6 Installation of a gas detector Notice: Placing of warning labels Danger! Toxic substances Chlorine dioxide Access only for authorized personnel! Prohibition! No Fire, naked light and smoking Sodium Chlorite NaClO...
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Startup Warning! For the first startup it is strongly recommended to use water instead of the chemicals to avoid accidents with hazardous chem.s because of leakages! So in the following explanations the water is called Preparations • “6. LOTUS Controller” “Click-Wheel”...
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7.5.1 Proportional mode Prod. Capacity: Warning: • “Prod. Capacity” • • “Prod. Capacity” General Notices: But for very low water flows, resp. water consumption it can be dangerous to do this and should be absolutely avoided! “Overflow” LOTUS Overflow...
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7.5.2 Constant mode “Stand-by” “Stand-by” Capacity 1: “Batch tank empty” Capacity 2: “Stand-by” Situation STAND-BY (44, 45) MD DI (5,6) “STAND-BY” Notice: “Capacity 1” 7.5.3 Analog mode Capacity at 20 mA: Notice: “Stand- by” Notice: “Analog”...
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7.5.4 Batch mode “Batch tank empty” “Stand-by” MD DI MD DI Level tank Level Situation Step Terminal Terminal empty tank full 1, 2 Notice: “Tank empty/full” Step 1: Step 2: Step 3: Step 4:...
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System settings Dos-Check: “0” Pass-Code 2: the main menu Default value: “0 9 1 6”. Caution! Write the new passcode down in your documents or into the „Test Certificate” (appen- dix A) for later using! Notice: “Reset” “0 9 1 6” Pass-Code 1: Default value: “0 0 0 0”.
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8. LOTUS Terminal board 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- sed) when status on blocks changes.
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Configuration Menu Summary PUMP CALIBRATION SENSORS WATER METER ANALOG OUTPUT mA INPUT BYPASS ALARM PROBE FLOW ALARM...
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Inputs: Block, Terminal Function Electrical data Outputs: Block, Terminal Function Electrical data...
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10. Failure messages “RESTART” Message Problem Solution Leave the room immediately and shut the door! Shut down the plant with emergency There is a massive leakage inside stop switch. Reactor Leakage the reactor housing (3). Wear complete personal protective equipment. Take attention to chapter “1.4 Safety Chapter”...
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Message Problem Solution Notice: “Restart”...
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COMMUNICATION (TCP/IP & GPRS) 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).
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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.
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COMMUNICATION (LOG & LOGBOOK and time. Note: To view on instrument’s display the archived logs select LOGBOOK...
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Enter the website and, after registration, set plants. 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.
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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. SIM type is: What to do before to install the SIM into instru- ment’s modem Mini-SIM (classica SIM card in uso nei telefoni) Lenght 25 (mm) - Width 15 (mm) - thickness 0,76 (mm)
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Read this manual completely before you start with the installation and start-up. Do not discard this manual and store it nearby the generator for later use. English R1-10-12...
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Directory General Safety Guidelines Storage and Transport Construction Installation 5…… Manual Part 2: Startup and Operation … LOTUS Terminal board Technical Data R1-10-12...
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General Safety Guidelines General remarks • • Notice: • • Symbols in the manual Warning: Caution! Notice or advice: Symbols at the installation site Warning: Danger! Prohibition! R1-10-12...
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Safety chapter The three basic rules: Correct and proper use: • • • • • • • • • • • • • • R1-10-12...
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Qualification of personnel: Warning! Activity Qualification level Technical expert: Qualified personnel: Instructed personnel: Customer service department: Personal protective equipment R1-10-12...
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Safety information: Warning! Danger from incorrect operation • • Warning! Danger due to toxic and explosive ClO • Instructions for entering • a room where a chlorine dioxide system is installed • • Notes You got into contact with acid: for the system operator •...
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• The LOTUS system was supplied with concentrated chemicals but the dosing pumps have not yet started: Directions for the operator • • • • • EU Declaration of Conformity • • • • • • • Notice: R1-10-12...
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Storage and Transport Safety information: Warning! • • Notice: Danger of material damage • • • Packaging: Ambient conditions: Data Value R1-10-12...
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Construction General description • • R1-10-12...
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System overview HCl 9% NaClO 7,5% R1-10-12...
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Installation Safety information: Warning! • • • • • • • • General requirements for the installation site Notice: • • • • • • • • • • • General requirements for the plant installation Notice: • • • •...
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Requirements for the water Safety information: Warning! Serious malfunctions at the plant or corrosion damages in the pipe-work of the treated water should be possible in case the following requirements to the water – the chlorine dioxide is produced for – as well as for the dilu- tion water are not fulfilled: •...
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Hydraulic Installation Safety information: Warning! Warning against illegal operation Danger! Warning of toxic chlorine dioxide vapour • • • • Warning! The reactor can explode Main components: • • • • • • • • R1-10-12...
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4.5.1 Installation example A • • R1-10-12...
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4.5.2 Installation example B • • h > 0 R1-10-12...
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4.5.3 Installation example C • • h < 0 R1-10-12...
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4.5.4 Installation example D • • R1-10-12...
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Hydraulic Installation of accessories and options 4.6.1 Bypass line Safety information: Danger! Warning of toxic chlorine dioxide vapour • • • • Warning! The reactor can explode • • Function: 4.6.2 Safety equipment bypass line Safety information: Warning! The reactor can explode Risk of explosion in the bypass line Function: R1-10-12...
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4.6.3 Flushing unit with vacuum relieve valve Safety information: Warning! Degassing ClO solution can still vaporize in the bypass line. Danger! Poisonous ClO solution can escape 4.6.4 Back pressure valve Function: 4.6.5 Flow generator for bypass line Function: • • R1-10-12...
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4.6.8 Suction lances Safety information: Danger! Warning of toxic chlorine dioxide gas Warning! Warning of corrosive acid or toxic chlorite solution Assembly: Caution! The suction hoses must not be plugged into the chemical tanks yet! Caution! R1-10-12...
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4.7.3 Connection of the bypass pump Caution! 4.7.4 Installation of a gas detector (accessory) Notice: Placing of warning labels Danger! Toxic substances Chlorine dioxide Access only for authorized personnel! Prohibition! No Fire, naked light and smoking Sodium Chlorite NaClO R1-10-12...
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