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1
OPERATING INSTRUCTIONS FOR THE
"LOTUS AIR" SYSTEM
Il biossido di cloro, come tutti gli agenti ossidanti, potrebbe produrre fenomeni di
corrosione dell'impianto. Si consiglia di effettuare verifiche cadenzate e di trattare
l'impianto con prodotti chimici specifici. Si consiglia, inoltre, di utilizzare nel punto
d'iniezione del prodotto materiali resistenti al biossido di cloro.
Chlorine dioxide, like all oxidizing agents, could produce corrosion phenomena of the
plant. It is advisable to perform cadenced checks and to treat the plant with specific
chemical products. It is also advisable to use chlorine dioxide resistant materials at
the point of injection of the product.
Le dioxyde de chlore, comme tous les agents oxydants, pourrait produire des
phénomènes de corrosion de l'installation hydraulique. Il est conseillé d'effectuer des
contrôles cadencés et de traiter l'installation avec des produits chimiques spécifiques.
Il est également conseillé d'utiliser des matériaux résistants au dioxyde de chlore au
point d'injection du produit.
This manual contains important information about
safe installation and operation of the unit. Strictly
comply with this information to avoid harming people
or damaging property.
It is strictly prohibited to use this equipment with radi-
oactive chemicals!
Before switching this instrument on, read this manual
in its entirety.
Keep the manual near the instrument for future
reference
ERMES REMOTE CONTROL
www.ermes-server.com
ENGLISH edition
R34-02-19
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Related Manuals for Emec LOTUS AIR Series
Summary of Contents for Emec LOTUS AIR Series
- Page 1 This manual contains important information about safe installation and operation of the unit. Strictly comply with this information to avoid harming people or damaging property. It is strictly prohibited to use this equipment with radi- oactive chemicals! Before switching this instrument on, read this manual in its entirety.
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Page 2: General Notes On Safety
This manual contains important information about SAFE installation and operation of the unit. Read and retain for future reference. Strictly comply with this information to avoid harming people or damaging property. The information contained in this manual may contain inaccuracies or typographical errors. The information contained in this manual is subject to change at any time without prior notice. -
Page 3: Additional Notes
Safety This manual contains basic instructions for installation, operation and maintenance. It is therefore mandatory for the installation technician and the equipment administrator to study the entire manual prior to installing and commissioning. The manual must be found near the generator at all times. It is also mandatory for the operator to consider the general rules listed in the "Safety standards"... - Page 4 PART ON THE DOSING PUMPS IN THE "LOTUS AIR" SYSTEM The pump must only be used for dosing liquid products. It should not be used in explosive atmospheres (EX). It should not be used to dose flammable chemicals. It should not be used with radioactive chemicals. Attention Use the pump only after installation.
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Page 5: General Safety Regulations
General safety regulations The manual describes the proper use of the "LOTUS AIR" generator. Improper use of the generator compromises its safety function and that of the other devices connected to it and therefore such use is strictly forbidden. Installation and maintenance must only be carried out by authorised technicians. -
Page 6: Operating Safety Instructions
Operating safety instructions Strict compliance with all national and local regulations is required when using the "LOTUS AIR" generator. The operator is responsible for compliance with safety-related local instructions. Danger The generator must be installed and operated in accordance with the instructions in this manual. - Page 7 Safety regulations in case of chemical spills I If the odour of chlorine dioxide (a penetrating odour similar to that of chlorine) can be smelt, access is allowed only with the required personal protective equipment. Danger If the odour of chlorine dioxide is smelt, immediately turn off the system from a safe position, for example with an emergency stop switch away from the system In rare error cases, the hazardous ClO solution can leak.
- Page 8 Safety regulations in case of chemical spills II The following personal protective equipment is required to access the "LOTUS AIR" device Face shield Rubber or plastic boots Attention Protective gloves (ClO sealed model) Protective apron Full face respirator The composition and the type of personal protective equipment required may vary from one country to another and change over time.
- Page 9 Storage, transport and repairs In case of repairs, return the unit after having cleaned it and having washed the hydraulic components. Attach the material decontamination declaration to be sent for repairs. The unit can be damaged due to non-compliant storage or transport. Additional notes Store or transport the unit adequately packed, preferably in its original packaging.
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Page 10: First Start
Introduction & First Start The chlorine dioxide generator named "LOTUS AIR" is used to produce liquid chlorine dioxide. This disinfectant kills all bacteria, germs, viruses and fungi very rapidly and works at very low concentration. The generator works according to the hydrochloric acid - chlorite process and uses diluted chemicals such as hydrochloric acid (HCl 9%) and sodium chlorite (NaClO 7.5%) in accordance with the following chemical formula:... -
Page 11: Main Components
Main components “LOTUS AIR” is made of the followings components: “LOTUS AIR” Version 1 “LOTUS AIR” Version 2... -
Page 12: Hydraulic Connections
Hydraulic connections The hydraulic components to be installed for the pumps to work properly are: Suction Hose with a level probe and bottom filter x 2 Delivery Hose with injection valve Discharge hose x 3 Suction Hose. Unscrew the suction ring nut completely on the pump body and draw the components required to assemble the hose: tightening ring nut, Holding ring and hose holder. -
Page 13: Discharge Hose
Discharge hose. Insert one end of the Discharge hose on the drain hose connection as shown in figure A (page 12). Place the other end directly into the tank containing the product that is to be dosed. In this way, the liquid that leaked during the priming phase will return into the tank. - Page 14 Assembling the bottom filter with a level probe. The level probe must be assembled using the relative kit with the supplied foot valve. The foot valve is made to be installed at the bottom of the product container without sediment priming issues. Connect the BNC on the level probe on the level input on the right side of the instrument.
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Page 15: Operating Logic
Operating logic The "LOTUS AIR" chlorine dioxide generator consists of the following main components: a production management tool, 4-filling level reaction tank, 2-filling level storage tank, HCl dosing pump, NaClO dosing pump, chlorine dioxide dosing pump, reaction tank emptying solenoid valve and reaction tank with water filling solenoid valve. Note: during first startup use water instead of chemicals (e.g.: priming, seal check, calibration) Dioxide production cycle, the 7 main phases... -
Page 16: Electrical Connections
Connections to the motherboard Before performing any operation on the terminal board of the instrument, it is mandatory to disconnect it from the mains. To facilitate the connections to the motherboard, it has been divided into two blocks: electrical connections and I/O connections. Unplug power cable from main power supply before operate on controller’s board Danger... - Page 17 I/O Connections: OUTPUTS FOR A DIGITAL SIGNAL PROPORTIONAL PUMP: 1(-) ; 2(+): ClO pump signal output OPTO ISOLATED 3(-) ; 4(+): Pump retainer 2 ext SIGNALS open manifold 5(-) ; 6(+): Pump retainer 3 ext 7(-) ; 8(+): Pump retainer 4 ext 9(-) ;...
- Page 18 Probe modules connection At the top of the motherboard there are 4 adaptors for the installation of the probe modules and inputs. Upon request, these modules are installed by the manufacturer. For proper installation, check the installed modules and implement the required connections. A standard Ethernet cable (RJ45) is required for the ETHERNET version (module with red circle).
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Page 19: Main Screen
Browsing the menus At the top right of the "LOTUS AIR", there is the knob to browse and programme the instrument. The knob can be ro- tated in both directions to move the cursor through the menus and the selection. The function is confirmed by pressing the relative function. -
Page 20: Language / Time / Date
"LOTUS AIR" system setting For the "LOTUS AIR" system to work properly all the settings listed below must be configured properly. It is recommended to primarily set the DATE & TIME. “System Settings”, “Mode Selection” “Probes”, “Water Meter”, “mA Input” “Clean”, “Service”... - Page 21 View pH or ORP* / Cl / Temp The instrument can only display a few items on the main screen, including the 3 main parameters: pH, chlorine dioxide and temperature. Set YES or NO to enable or disable the display of these items. Feeding The distribution of the dioxide from the storage tank it’s launched by using an internal relay.
- Page 22 PROBES Enter this menu by selecting “MENU’” from the main screen, enter the PASSCODE and select “PROBES”. Save the settings by selecting “ESC”, then confirm the changes by moving to “YES” and pressing the knob. Chlorine Dioxide & Select Probe Before calibrating the chlorine dioxide probe (Ch3) verify that the selected model is the correct one.
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Page 23: Orp Probe
pH Probe Before you calibrate the pH probe (Ch2) verify that you have two buffer solutions with values close to those found in the plant (e.g. 7pH and 4pH). Select "pH PROBE" in the "PROBES" menu to calibrate 2 points of the probe. ... -
Page 24: Temperature Probe
Temperature Probe To calibrate the temperature probe select “Calibration Temp” from the “Probe” menu. In order to complete this task, it is necessary to use a professional thermometer to take the temperature of the plant. Warning: this procedure can be completed only if the instrument is correctly installed and the temperature probe is in good condition. -
Page 25: Water Meter
WATER METER This menu allows you to set the operation mode of a pulse emitting water meter connected to the "LOTUS AIR" system. Enter this menu by selecting “MENU’” from the main screen, enter the PASSCODE and select “WATER METER”. Save the settings by selecting “ESC”, then confirm the changes by moving to “YES”... -
Page 26: Working Mode
WORKING MODE This menu allows you to set the operation mode of the system. Enter this menu by selecting “MENU’” from the main screen, enter the PASSCODE and select “WORKING MODE”. Save the settings by selecting “ESC”, then confirm the changes by moving to “YES”... - Page 27 PROPORTIONAL (mA) This function allows you to set the operation mode proportional to the PUMP output based on current received from mA input. The PUMP CL output (based on 180 strokes per minute) is referred to as “P1” on the main board of the instrument. Example: set PUMP CL to 180p/m @ 20mA and 0p/m @ 0mA The chlorine dioxide pump will dose to its full capacity (180 strokes per minute) for ma reading values greater than or equal to 20mA.
- Page 28 Alarms Probe flow alarm (contact) can be enabled to stop a dosing procedure using a N.O. contact mode (normally open) or N.C. contact mode (normally closed) when status on blocks changes. Rotate wheel to choose between: “DISABLE”, “REVERSE” (N.O. contact) or “DIRECT” (N.C. contact). Furthermore “Flow contact”...
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Page 29: Pump Calibration
Pump Calibration This function allows the calibration of the “chlorine dioxide” dosing pump based on strokes capability. To calibrate, proceed as follows: 1. Set strokes of the metering pump according to its capability (eg 100) 2. Place an additional suction hose in a graduated beaker 3. -
Page 30: Service & Clean
Service & Clean Enter this menu by selecting “MENU’” from the main screen, enter the PASSCODE and select “SERVICE” or “CLEAN”. Save the settings by selecting “ESC”, then confirm the changes by moving to “YES” and pressing the knob. Service From this menu it is possible to view the functions of the inputs relative to: pH or ORP Probe (as specified when ordering) Cl2 Probe... - Page 31 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).
- Page 32 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 33 COMMUNICATION (LOG & LOGBOOK) 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 34 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.
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Page 35: Status Messages
STATUS MESSAGES On main screen, the instrument displays the status of the dosing activities and bioxide chlorine dioxide production. See table below to better understand and solve any problems. Shown Message EXPLANATION / What to do Product ready and storage tank full. Chlorine dioxide is ready to STORAGE TANK FULL be used. - Page 36 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.
- Page 37 SAFETY OPTIONAL 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 38 mA CURRENT OUTPUTS Use this menu to set mA current outputs for dioxide pump (PROD, production) and dioxide probe (READING). mA values can be set between: 0/20 mA or 4 / 20mA based on pulsers per minute (PROD.) and parts per million (READING).
- Page 39 ALARM CONTACT SETUP WHEN WARNING To enable or disable the controller to stop in case of WARNING (non-blocking case) for each type of alarm, scroll through the settings menu to the end and select the required function, then enable to stop the controller with YES ore leave the warning message on with NO.
- Page 40 Logical working scheme...
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Page 41: Maintenance
Maintenance OPERATOR PROTECTION. Use safety equipment according to the company regulations. Use this safety equipment within the work area during installation, service and when handling chemicals: • protective mask • protective gloves • safety goggles • ear plugs or hear muffs •... - Page 43 Index Safety page 3 Introduction and first start page 10 Hydraulic connections page 12 Electrical connections page 16 Main screen page 19 System Settings page 20 Probes page 22 Water Meter page 25 Mode Selection page 26 Alarms page 28 Pump Calibration page 29 Service...
- Page 44 All materials used in the construction of the instrument and for this manual can be recycled and therefore supporting the invalua- ble environmental resources of our planet. Do not dispose of harmful materials in the environment! Check with the competent authority on the recycling programs for your area!
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