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Operating instructions
Chlorine dioxide systems
Bello Zon
type CDLb with external pre-storage
®
vessel
Please carefully read these operating instructions before use! · Do not discard!
The operator shall be liable for any damage caused by installation or operating errors!
Part no. 985312
Technical changes reserved.
Original operating instructions (2006/42/EC)
CDLb 6
P_PMA_BEZ_0110_SW
BA LZ 011 02/14 EN
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Summary of Contents for ProMinent ProMaqua Bello Zon CDLb Series
- Page 1 Operating instructions Chlorine dioxide systems Bello Zon type CDLb with external pre-storage ® vessel CDLb 6 P_PMA_BEZ_0110_SW Please carefully read these operating instructions before use! · Do not discard! The operator shall be liable for any damage caused by installation or operating errors! Technical changes reserved.
- Page 2 Supplemental instructions Supplementary information Read the following supplementary information in its entirety! Should you already know this information, you will benefit more from referring to the operating instructions. The following are highlighted separately in the document: Enumerated lists Fig. 1: Please read! - refer to...
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Page 3: Table Of Contents
Table of contents Table of contents Identity code..................5 About this system................6 Safety chapter................. 7 Storage and transport..............12 System overview................13 Functional description..............15 6.1 Chemical principle behind the systems......... 15 6.2 System operating principle............ 15 6.3 Safety equipment..............15 Requirements at the installation site.......... - Page 4 Table of contents 16.2 Over longer periods............. 52 Disposal..................53 Technical data CDLb..............54 Accessories................... 56 EC Declaration of Conformity ............58 Dimensional drawings..............59 Interface list................... 65 Wiring diagram CDLb..............66 Decontamination declaration............70 Chlorine dioxide hazardous substance data sheet......71 25.1 Physical and chemical properties........
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Page 5: Identity Code
Identity code Identity code The identity code is shown on the system nameplate. Product range CDL, Version b CDLb Type Production performance 6 g/h 12 g/h 22 g/h 55 g/h 120 g/h Equipment With internal pre-storage vessel, pump and multifunctional valve (only up to 55 g/h) With internal pre-storage vessel and pump (only up to 55 g/h) With internal pre-storage vessel (only up to 55 g/h) With external pre-storage module... -
Page 6: About This System
About this system About this system The Bello Zon ® CDLb chlorine dioxide generating and metering system is designed for drinking water treatment - especially in respect of water disin‐ fection using chlorine dioxide. The control provides an appropriate amount of diluting water in the mixer vessel and mixes it with precisely measured quantities of hydrochloric acid and sodium chlorite, which are metered using two measuring vessels and two metering pumps. -
Page 7: Safety Chapter
Safety chapter Safety chapter Identification of safety notes The following signal words are used in these operating instructions to denote different severities of danger: Signal word Meaning WARNING Denotes a possibly dangerous sit‐ uation. If this is disregarded, you are in a life-threatening situation and this can result in serious inju‐... - Page 8 Do not allow untrained personnel to operate systems of type CDLb! All other activities should only be carried out by personnel trained by ProMinent or personnel who have been authorised by ProMinent – see the table below! You are obliged to observe the information contained in the operating...
- Page 9 Service The Service department refers to service technicians, who have received proven training and have been authorised by ProMinent to work on the system. Personal protective equipment The following represents the current situation in Germany at the time of...
- Page 10 Safety chapter Chlordioxidgas Chlorine dioxide gas Gaz de dioxyde de chlore Biossido di chloro gas P_PMA_BEZ_0091_SW Fig. 4: Sticker "Chlorine dioxide gas" Chemical drum safety collecting pans (accessories) The safety collecting pans should prevent chemicals escaping in an uncontrolled manner from a defective chemical drum or even mixing with other chemicals.
- Page 11 Safety chapter WARNING! Risk of explosion due to chlorine dioxide without safety measures Under rare fault conditions ClO solution can escape via a leak. – A gas detector must be installed if no other measure is provided to ensure personnel safety in the event of ClO escaping so that the system switches off and an alarm is triggered that can be seen/heard from afar.
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Page 12: Storage And Transport
The "Decontamination Declaration Form" can be found in the Appendix or under www.prominent.com . CAUTION! Danger of material damage The device can be damaged by incorrect or improper storage or transportation! –... -
Page 13: System Overview
System overview System overview System Fig. 5: System overview CDLb 6 Solenoid valve diluting water Acid measuring vessel Active carbon filter Mixer vessel Solenoid valve acid Solenoid valve ClO Acid metering pump Control not shown Safety collecting pan (option) not shown 3-way valve For the sake of clarity, only device parts of the acid metering line are identified. - Page 14 System overview Pre-storage module CDLb P_PMA_BEZ_0081_SW Fig. 6 30 ClO solution supply line (connect to CDL) 31 ClO extraction 32 Set of level switches 33 Receiver tank 34 Safety bund 35 Gas phase pressure equalising line (connect to CDL) 36 Box for exhaust gas "lung"...
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Page 15: Functional Description
Functional description Functional description 6.1 Chemical principle behind the systems Operate chlorine dioxide systems Bello Zon ® according to the hydrochloric acid-chlorite process: Hydrochloric acid + sodium chlorite = chlorine dioxide + sodium chloride + water (4HCl + 5NaClO = 4ClO + 5NaCl + 2H The Bello Zon CDLb systems produce a 0.2 % chlorine dioxide solution (2... -
Page 16: Requirements At The Installation Site
Requirements at the installation site Requirements at the installation site Safety notes CAUTION! Warning against illegal operation Observe the regulations that apply where the device is installed. 7.1 Requirements for the installation site The chlorine dioxide system must not be located outdoors. It must be possible to protect the chlorine dioxide system against unauthorised access. -
Page 17: Requirements For The Water
Requirements at the installation site 7.2 Requirements for the water CAUTION! Warning of operating disruptions and corrosion damage Severe system operating disruptions and corrosion of your piping system can occur. – Always fulfil requirements in respect of the diluting water and the water to be treated. -
Page 18: Assembly
Assembly Assembly Safety notes WARNING! Danger due to the sudden unexpected escaping of toxic chlorine dioxide solution The seals which are exposed to chlorine dioxide solution, will start to leak if they are not replaced early enough. – The system must be set up so that it can be accessed easily for maintenance. - Page 19 Assembly Fig. 8: Fastening of welded bracket Rawlplug Hanger bolt Panel Hexagon nut Washer (metal) Protective cap After fitting, brush the metallic fastenings with Vaseline to prevent corrosion. Fasten the external pre-storage module to the floor using clamps. Attach the warning signs according to the national regulations at the access to the chlorine dioxide system and the chemical stores or any other locations so that they are clearly visible (Warning signs according to German regulations (08/2012) form part of the scope of...
- Page 20 Assembly Warning sign * Warning label * Included text Sodium chlorite Sodium chlorite NaCIO NaClO P_BEZ_0003_SW * Mandatory in Germany c) Attach this sign in rooms in which sodium chlorite (Bello Zon ® chlorite) is handled: Warning label * Included text Do not interchange storage tanks Do not use storage tank and devices.
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Page 21: Installation
Installation Installation CAUTION! Warning against illegal operation Observe the regulations that apply where the device is installed. A wiring diagram is contained in the appendix. 9.1 Installation, hydraulic P_PMA_BEZ_0117_SW Fig. 9: Typical installation of CDLb with external pre-storage module Filter insert Sample water line (or sampling tap) Shut-off valve Measuring station... -
Page 22: System Isolator
Installation 9.1.2 System isolator WARNING! Warning against unchecked through-suction If the line that is carrying the water to be treated is subject to a vacuum pressure, then unchecked through-suction of the solution can occur. – Fit a system isolator. – Fit a backpressure-free back pressure valve upstream of the injection point, if a constant back pressure of 1.5 bar is not ensured in any other way. - Page 23 Installation WARNING! Personnel danger If during installation work an electrically conducting pipe has been interrupted, personnel and devices are placed under substantial risk, e.g. if a lightning strike occurs. – Provision must then be made to ensure suitable potential equalisation (e.g. connect the pipe ends at the point of separation using a suitable metal bridge or strap) WARNING! Warning against through-suction...
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Page 24: Pre-Storage Module
Installation 9.1.4 Pre-storage module Hydraulic and electrical connections for an external pre-storage module 21b 21a P_PMA_BEZ_0080_SW Fig. 10: Plan view of the external pre-storage module extraction 21a Level switch LLL 21b Level switch LL 21c Level switch HL Level switch overflow OF supply line Connector pressure equalising line gas phase mixer vessel - simulta‐... -
Page 25: Suction Lances / Suction Assemblies For Acid And Chlorite
Installation 9.1.5 Suction lances / suction assemblies for acid and chlorite Safety notes WARNING! Warning of toxic chlorine dioxide gas Toxic chlorine dioxide can arise outside the mixer vessel. – Allocate parts correctly to the acid and chlorite sides. WARNING! Warning of corrosive acid or toxic chlorite solution Corrosive acid or toxic chlorite can escape at the connectors. -
Page 26: Water Supply Diluting Water
Installation Fig. 11: Installing the hose Pump suction valve Nozzle Clamp ring Union nut Hose 9.1.6 Water supply diluting water The diluting water is fed to the system via a tube connection. Use particle-free potable water that is non-corrosion inducing! 9.1.7 3-way valve Only valid for Bello Zon ®... - Page 27 Installation The system can be vented and drained via connector (3). Fig. 12: 3-way valve: A) "Flush" position; B) "Active" position From Bello Zon ® system To external pre-storage module To collecting vessel P_PMA_BEZ_0119_SW Fig. 13: Installing 3-way valve tubes Nozzle of the screw-in piece Clamp ring Union nut...
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Page 28: Chemical Supply Instructions
Installation 9.1.8 Chemical supply instructions WARNING! Chemicals may escape If the filling level of the chemical drums lies above the top edge of the Bello Zon ® system or the point of injection, then if a leak occurs on the suction side of a metering pump, chemi‐ cals can escape. - Page 29 Installation To break out the holes, puncture the slit in the middle of the holes using a medium-sized screwdriver (tip width 3.5 - 4 mm) and lever the material out - see figure. P_PMA_BEZ_0082_SW Fig. 14 Smooth the edges. Ä on page 28 , 2) Screw in the appropriate threaded cable glands ( using suitable lock nuts (1) and tighten firmly.
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Page 30: Connecting The Terminals
Installation Fit the front part on the rear part. WARNING! Danger of an electric shock If moisture penetrates into the control, an electric shock may occur. – Once again check the seating of the seals to ensure an IP 65 degree of protection rating is cor‐ rectly achieved. - Page 31 Installation Remove the cable insulation according to Fig. 16 and crimp on the corresponding cable end sleeves. Connect the cables according to the wiring diagram. Check all of the cabling using the wiring diagram. Tighten the clamping screws of the cable glands until they are leak- tight.
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Page 32: Installing An Emergency Stop Switch
Warning against illegal operation Observe the regulations that apply where the device is installed. - - - Preparation of the Bello Zon ® system is now so far advanced as to permit its starting up by a ProMinent service technician! - - -... -
Page 33: Controlling The System
Controlling the system Controlling the system This chapter summarises which elements can be used to control the system. 10.1 Control elements Fig. 18: CDLb 6 Control Stroke adjustment dials Solenoid valve ClO 10.2 Key functions STOP ST AR T P_PMA_BEZ_0071_SW... -
Page 34: Operating Menu, Schematic
Controlling the system Name Function [Change] To change within a menu level and to move from a changeable variable to another within a menu option. [Jump back] Back to the continuous display or to the start of the respective setting menu. [Down] To lower a displayed numerical value and to change the variables (flashing display). - Page 35 Controlling the system Operation Operation Operation: 24 h ClO2 production ClO2: before 3:45 h:m B0474 Fig. 19: Alternating display "Active" (default setting) Explanation of the symbols of the alternating display Symbol Meaning Comment ↓ Level warning HCl or Place filled chemical NaClO drum drums ready...
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Page 36: Operating Menu, Overview
Controlling the system 10.4 Operating menu, overview Operation: 24 h CIO2: 120 g/h system CDL-B1 FW 01.00.00 HW 01 language? user code? User code: xxxx Change alarm relay contact type? Expert code: xxxx External storage module? Expert code: xxxx Rinse system? Expert code: xxxx... -
Page 37: Start Up
Start up Start up Safety notes WARNING! Only a ProMinent service technician or a competent person authorised by ProMinent may start up the Bello Zon ® system. This person must check whether the system is correctly assembled and installed. The person must instruct the operator and the operating per‐... -
Page 38: Setting The Language
Start up 11.1 Setting the language Select Language language? German B0476 Change to the ‘Select language?’ setting menu by pressing the [Change] key and press the [ENTER] key. Select the operating language ( [arrow keys] ) and press the [ENTER] key. -
Page 39: Configuring Alarm Relay Contact Types
Start up 11.3 Configuring alarm relay contact types Set alarm relay Alarm relay contact type? contact type: Expert code: xxxx B0587 Configuring how the alarm relay is to behave. Setting Normal mode Fault NC (normally closed)* closed open NO (normally open) open closed * recommended... -
Page 40: Carrying Out Commissioning
Start up 11.5 Carrying out commissioning Begin Runtime and Really reset runtime Runtime and start-up? reset and ClO reset Expert code: Operation: 24 h Operation: 5000 ClO2: ClO2: Produce Pre-batch Pre-batch pre-batch? HCl vessel HCl vessel NaClO2 vessel NaClO2 vessel Start! 05:23 mm:ss Stop pump? - Page 41 Start up [Arrow Keys] ) and press [Enter] . Enter the access code ( It is possible to jump from one display to an underlying display by pressing the [CHANGE] key. This prevents resetting of the operating time. If the ‘Runtime’...
- Page 42 Start up WARNING! Warning of too-low ClO concentration A depletion effect can reduce the ClO concentration in the treated water by too much. – Check the ClO value in the treated water, correct if nec‐ essary and record the value in the operating log after the Bello Zon system has been metering for a certain time.
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Page 43: Operation
Operation Operation WARNING! At no operating status may the maximum permissible oper‐ ating pressure for the system be exceeded. WARNING! The entire installation should remain leak-tight when oper‐ ating at maximum operating pressure. 12.1 Changing the chemical drums WARNING! Danger of explosion If the two chemicals hydrochloric acid and sodium chlorite come together, toxic ClO gas forms almost instantaneously... - Page 44 Operation WARNING! Never interchange sodium chlorite (NaClO ) with sodium-cal‐ cium hypochlorite (sodium hypochlorite, NaOCl). Only use Bello Zon chlorite. ® WARNING! Warning against leaks Technically impure hydrochloric acid can contain organic chlorine compounds that strongly corrode the seals and render PVC components brittle.
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Page 45: Flush System
Operation 12.2 Flush system Rinse Rinse system Rinse system system? Empty Expert code Outlet v. open all vessels! - Confirm! 00:00 mm:ss 5000 Rinse system Rinse system Emptying Vessels empty? all measuring vessels! Outlet v.closed - Confirm! 05:00 mm:ss Rinse system Rinse system Emptying all vessels! - Page 46 Operation Turn the 3-way valve to the "Flush" position. Only CDLb 6 ... 55: - see figure. Fig. 20: 3-way valve: A) "Flush" position; B) "Active" position Lead the tube into a collecting vessel of sufficient volume in which a removal agent has been mixed, see the "Accessories"...
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Page 47: Paging Through The Protocol
Operation Only CDLb 120: Route the tube back into the external pre-storage module. Only CDLb 6 ... 55: Remove the PVC tube from the 3-way valve and fit the plug. CAUTION! Only CDLb 6 ... 55: Always refit the plug in the flushing connector of the 3-way valve! Carefully insert the acid suction lance in the red "acid"... -
Page 48: Perform Service
All error messages See "Troubleshooting" chapter 12.4 Perform service Perform service? Service code: 5000 B0485 This setting menu is only for service teams authorised by ProMinent - see "Operating instructions Chlorine dioxide systems Bello Zon Type CDLb, ® service instructions". -
Page 49: Maintenance
CDLb must be inspected at least weekly by a trained person. This must include checking all metering pumps and tube connec‐ tions for leak-tightness. In the event of leaks, inform ProMinent's author‐ ised service department and switch off the system! -
Page 50: Repairs
Only the fuses in the control can be replaced by the opera‐ tor's qualified employees! All other repair work on the Bello ® CDL system may only be performed by ProMinent's authorised service. WARNING! Only qualified personnel may open the controller... -
Page 51: Troubleshooting
"External fault", reports a fault (e.g. flow meter bypass or ClO measuring point) All other faults Please contact the responsible ProMinent branch or representative! In the event of a power failure, the control stores the parame‐ ters and the status of the Bello Zon ®... -
Page 52: Decommissioning
Decommissioning Decommissioning WARNING! Toxic ClO2 gas can escape – Never pour the contents of the chemical drums together. – Never place both suction lances together or one after the other in the same bucket. WARNING! Corrosive liquids may escape Do not inadvertently interchanges the different valves 16.1 For a short period [Start/Stop] key. -
Page 53: Disposal
Disposal Disposal Safety notes WARNING! The Bello Zon ® system could still contain hydrochloric acid (HCl), sodium chlorite (NaClO ) and chlorine dioxide (ClO – The entire Bello Zon ® system must be thoroughly rinsed through with water - see chapter 12 "Decommissioning". –... -
Page 54: Technical Data Cdlb
Technical data CDLb Technical data CDLb General CDLb 6 g/h 12 g/h 22 g/h 55 g/h 120 g/h Power: 6 g/h 12 g/h 22 g/h 55 g/h 120 g/h Diluting 3-6 bar 3-6 bar 3-6 bar 3-6 bar 3-6 bar water: Concen‐... - Page 55 Technical data CDLb External storage module: PVD-U (collection pan: PE) Control housing: PPE GF10 Membrane keypad: Polyester PET membrane Pump housing: PPE, fibreglass-reinforced Pump liquid ends: PP, PVDF Technical data, electrical System Power supply Data Value Unit Nominal voltage, ± 10 % 230 or 115 V Mains supply frequency 50 / 60 Hz...
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Page 56: Accessories
Accessories Accessories Chemicals Accessories Part no. 1027594 Bello Zon ® acid in 25 l single-use drum 1027595 Bello Zon ® chlorite in 25 l single-use drum Chemical additives for removal of chlorine 1029256 dioxide during system flushing Collecting pan Accessories Part no. - Page 57 Accessories Multifunctional valve Accessories Part no. Multifunctional valve with wall bracket type MFV- 1027652 DK Size I, 16 bar, with wall bracket, hose con‐ nector 10x8...
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Page 58: Ec Declaration Of Conformity
In accordance with DIRECTIVE 2006/42/EC OF THE EUROPEAN PAR‐ LIAMENT AND OF THE COUNCIL, Appendix I, BASIC HEALTH AND SAFETY REQUIREMENTS, section 1.7.4.2. C. ProMinent GmbH Im Schuhmachergewann 5 - 11 D - 69123 Heidelberg, hereby declare that the product specified in the following, complies with... -
Page 59: Dimensional Drawings
Dimensional drawings Dimensional drawings (Dimensions in mm) Dimension sheet Bello Zon ® CDLb 6 to 22 in minimum version P_PMA_BEZ_0113_SW... - Page 60 Dimensional drawings (Dimensions in mm) Dimension sheet Bello Zon ® CDLb 55 in minimum version 12/9 P_PMA_BEZ_0114_SW...
- Page 61 Dimensional drawings (Dimensions in mm) Drilling template Bello Zon ® CDLb 55 14 (6x) P_PMA_BEZ_0112_SW...
- Page 62 Dimensional drawings (Dimensions in mm) Dimension sheet Bello Zon ® CDLb 120 in minimum version blind...
- Page 63 Dimensional drawings (Dimensions in mm) Drilling template Bello Zon ® CDLb 120 14 (6x) P_PMA_BEZ_0152_SW...
- Page 64 Dimensional drawings Dimension sheet pre-storage module (Dimensions in mm) CDLb Ø13 (4x) 81_03-403_00_88-72x01 P_PMA_BEZ_0079_SW...
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Page 65: Interface List
Interface list Interface list CDLb interface list with external pre-storage module CDLb 6 g/h 12 g/h 22 g/h 55 g/h 120 g/h Water inlet: ProMinent/Neutral: 12x9 12x9 12x9 12x9 Di20/DN15 Switzerland: Di20/DN15 Di20/DN15 Di20/DN15 Di20/DN15 Di20/DN15 outlet: without pump 12x9... -
Page 66: Wiring Diagram Cdlb
Wiring diagram CDLb Wiring diagram CDLb Wiring diagram Bello Zon ® type CDLb with external pre-storage vessel CDLb 6 - 120 g/h with external storage module INTERNAL INPUTS OUTPUTS Metering container acid full Metering container chlorite full Pre-storage module overflow Pre-storage module new batch Acid vessel low... - Page 67 Wiring diagram CDLb Terminal arrangement ClO valve XR3:7 XR3:11 XP1:11 230 V XP1:7 XP1:3 24 V Terminal arrangement Bello Zon ® type CDLb without internal pre-storage vessel Control inputs Signal Terminal identi‐ LED identifier Type of contact Remarks fier / Pin Metering vessel acid full XK2/1,2 XK2/2 = GND...
- Page 68 Wiring diagram CDLb Signal Terminal identi‐ LED identifier Type of contact Remarks fier / Pin External fault (gas XK7/3,4 XK7/4 = GND; detector) Jumpered as supplied Pre-storage module full XK8/1,2 Pulse outputs Signal Terminal identi‐ LED identifier Type of contact Remarks fier / Pin HCl metering pump...
- Page 69 Wiring diagram CDLb Control input other device Signal Terminal identifier / Pin LED identifier Remarks Pre-storage module empty At input level switch min‐ imum limit stop or chlorine dioxide metering pump or higher-level control...
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Page 70: Decontamination Declaration
Decontamination declaration Decontamination declaration... -
Page 71: Chlorine Dioxide Hazardous Substance Data Sheet
Chlorine dioxide hazardous substance data sheet Chlorine dioxide hazardous substance data sheet (The text is based on the hazardous substances data sheet issued by the Bundesvereinigung der Firmen im Gas- und Wasserfach e.V. FIGWA, 50968 Cologne, dated 16.4.1998.) Properties of chlorine dioxide and instruc‐ The chlorine dioxide solutions used for water treatment have a concentra‐... -
Page 72: Handling Aqueous Chlorine Dioxide Solutions
Chlorine dioxide hazardous substance data sheet 25.2 Handling aqueous chlorine dioxide solutions 25.2.1 Labelling and characters Label the workplace and surrounding area using characters conforming to the (German) Accident Prevention Regulation "Chlorination of Water" (GUV 8.15, appendix 3). 25.2.2 Storage Chlorine dioxide cannot be stored or transported either as a gas or as con‐... -
Page 73: Health Hazards
Chlorine dioxide hazardous substance data sheet Eye protection: Safety goggles, face visor Hand protection: Rubber gloves Other: Protective clothing 25.3.3 Health hazards A chlorine dioxide gas concentration of over 45 mg ClO causes breathing difficulties and leads to irritation of the mucous membranes and headaches. -
Page 74: Index
Index Index Accessories..............56 Key functions..............33 Ambient conditions............12 Applied harmonised standards........58 Level switch on pre-storage module......24 Assembly............... 18 LL.................. 24 LLL................24 Basic rules............... 7 Multifunctional valve............57 Carrying out commissioning.......... 40 Changing the user code..........38 Notes for the System Operator........ - Page 76 ProMinent GmbH Im Schuhmachergewann 5-11 69123 Heidelberg Germany Telephone: +49 6221 842-0 Fax: +49 6221 842-612 email: info@prominent.com Internet: www.prominent.com 985313, 3, en_GB © 2012...
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