BWT Safeshower M Operating Instructions Manual
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BWT Safeshower M Operating Instructions Manual

BWT Safeshower M Operating Instructions Manual

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BWT Safeshower M
Operating Instructions

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  • Page 1 BWT Safeshower M Operating Instructions...

  • Page 2: Table Of Contents

    Communication ............................23 5.2.10 Configuration ............................. 26 5.2.11 Dosing ............................27 5.2.12 Proportional Dosing ........................28 5.2.13 ORP Application ........................29 5.2.14 Softener settings ........................32 BWT Denmark A/S, Geminivej 24, 2670 Greve, Tel.: 43 600 500 2 / 68...
  • Page 3 Machine and Work Area - Order and Cleaning ................60 Safety During Normal Operation ....................60 8.5.1 Test of Safety Functions ..........................60 8.5.2 Startup After Normal Stop ......................... 61 BWT Denmark A/S, Geminivej 24, 2670 Greve, Tel.: 43 600 500 3 / 68...
  • Page 4 ................67 10.3 MI2540 – Neuthox dosing status ..................... 68 ® Appendix 2 – Documentation ......................68 11.1 BWT Documentation ........................68 11.2 Party Documentation ......................68 BWT Denmark A/S, Geminivej 24, 2670 Greve, Tel.: 43 600 500 4 / 68...

  • Page 5: Preface

    It is necessary to read the instructions before installing or using the BWT Safeshower M for the first time. It may be necessary to continually re-read to maintain knowledge and skills. If the safety instructions are not followed, it might lead to personnel injury and result in loss of any claims for damages.

  • Page 6: Definitions

    Module network Short Message A text messaging service component of most Service telephone, internet, and mobile device systems BWT Denmark A/S, Geminivej 24, 2670 Greve, Tel.: 43 600 500 6 / 68...

  • Page 7: Notifications And Icons/Pictograms

    Operating Instructions 2.2 Notifications and Icons/Pictograms NOTICE General information that should be read before using the BWT Safeshower M. CAUTION Safety related information. Inattention can result in malfunction or damage to the BWT Safeshower M or installation! WARNING Safety related information. Inattention can result in serious injuries! BWT Denmark A/S, Geminivej 24, 2670 Greve, Tel.: 43 600 500...

  • Page 8: Signs And Markings On Bwt Safeshower M

    3.1 Marking Plate/Machine Type Plate The CE marking plate is located on the side of the BWT Safeshower M cabinet. The marking plate must not be removed and must be replaced if it is missing or damaged, to a degree where it has become unreadable (Figure 1 and Figure 2).

  • Page 9: Safety Signs

    Operating Instructions 3.2 Safety Signs The safety-related signs for the BWT Safeshower M, as well as their meaning. Pictogram Definition ISO reference number Warning; General warning ISO ref.: W001 Warning; Explosive material ISO ref.: W002 Warning; Toxic material ISO ref.: W016 Warning;...

  • Page 10: Description Of Bwt Safeshower M

    ® electrochemical process (the electrolysis of salt and water), during which hypochlorous acid is produced. The BWT Safeshower M comes in 2 different tank configurations depending on the machine's production capacity: Configuration 1: Internal tanks • Configuration 2: External tanks for brine and Neuthox, 33 L •...
  • Page 11 Operating Instructions The soft water tank is placed inside the cabinet in all BWT Safeshower M configurations, and the soft water tank is connected to the brine tank. The BWT Safeshower M comes standard without salt in the brine tank.

  • Page 12: Ec-Declaration Of Conformity/Declaration Of Incorporation

    Operating Instructions 4.1 EC-Declaration of Conformity/Declaration of Incorporation BWT Denmark A/S, Geminivej 24, 2670 Greve, Tel.: 43 600 500 12 / 68...

  • Page 13: Function Description

    Operating Instructions 4.2 Function Description A simplified P&I diagram shows the process: Soft water enters the tank in the BWT Safeshower M from an external water softener where the water hardness is removed. The soft water is pumped with a precise flow to the cell and brine is mixed into the water before it enters the electrolysis cell.

  • Page 14: Technical Specifications

    BWT Safeshower M 3LC internal 3LC external Unit 15LC Dimensions tanks tanks Cabinet dimensions 600×600×250 (W×H×D) Weight, dry Brine tank capacity Neuthox® tank capacity Sound level dB(A) BWT Denmark A/S, Geminivej 24, 2670 Greve, Tel.: 43 600 500 14 / 68...

  • Page 15: Product Warranty

    If the safety instructions are not followed, it might lead to personnel injury and result in loss of any claims for damages. A guarantee claim in accordance with BWT's general terms of sale and delivery is only valid if the following requirements are fulfilled: The BWT Safeshower M is used in accordance with the information within this manual.

  • Page 16: Intended Use

    - Lifting, loading, and packing dismantling, and recycling - Transporting - Unloading 4.5.2 Intended Use The intended use of the BWT Safeshower M is to produce the disinfection fluid Neuthox ® dosing the Neuthox ® into the user’s water system. Neuthox ®...

  • Page 17: Hmi Controller

    Red flashing in case of a critical alarm, process will stop. Inactive buttons are shown in grey with grey writing. If a function button is inactivated, then try stopping the BWT Safeshower M to activate it (Figure 8). Figure 8 - Start button The Menu button navigates directly to the Menu screen (Figure 9).

  • Page 18: Functions

    5.2 Functions 5.2.1 Start Screen (Logo) When the BWT Safeshower M is powered on, then the BWT logo is displayed as the start screen. The start screen contains information on the generator size and software version. Pressing the logo will navigate to the operation screen (Figure 12).
  • Page 19 Operating Instructions Figure 13 - Operation screen (1) with dosing NOT activated Figure 14 - Operation screen (2) with dosing activated BWT Denmark A/S, Geminivej 24, 2670 Greve, Tel.: 43 600 500 19 / 68...

  • Page 20: Menu

    • shown. Logo: Navigates to the start screen. • The possible settings on the BWT Safeshower M are divided into four levels, as shown in the right column of buttons. Settings: Operator settings to be used in day-to-day operation. •...

  • Page 21: Flowchart

    The flowchart screen contains two shortcuts that navigates directly to operation screen: Cell • Brine pump or cell current • BWT Denmark A/S, Geminivej 24, 2670 Greve, Tel.: 43 600 500 21 / 68...

  • Page 22: Information

    By pressing the display, it is possible to toggle between the different values. 5.2.7 Language Choose the required local language by pressing the appropriate flag (Figure 18). Figure 18 - Language selection BWT Denmark A/S, Geminivej 24, 2670 Greve, Tel.: 43 600 500 22 / 68...

  • Page 23: Settings

    5.2.8 Settings The settings menu contains settings and functions appropriate for operators during normal day to- day handling. Some buttons are inactive in the BWT Safeshower M version of the software. The buttons below provide the following options (Figure 19): Neuthox/Cathox internal pH settings - Enabled.
  • Page 24 Operating Instructions 5.2.9.2 SMS Message If the BWT Safeshower M is equipped with a modem for mobile phone messages, then SMS communication is possible. Insert a SIM card into the modem. To utilize the SMS function: Insert SIM-card with known phone number into any available cell phone and change PIN code to “4323”.
  • Page 25 Operating Instructions 5.2.9.3 PC to PLC Communication It is possible to setup the BWT Safeshower M for Modbus TCP/IP communication over Ethernet, hereby allowing supervisory control and data acquisition systems (SCADA) to start/stop the BWT Safeshower M and receive alarm messages. BWT will only offer support on the HMI controller software, all other support concerning communication is to be handled by the sales partner.

  • Page 26: Configuration

    BWT Safeshower M. Buffer tank: Configure the size of the attached Neuthox buffer tank. ® • Figure 24 - Configuration menu BWT Denmark A/S, Geminivej 24, 2670 Greve, Tel.: 43 600 500 26 / 68...

  • Page 27: Dosing

    Operating Instructions 5.2.11 Dosing The following dosing types are available on the BWT Safeshower M: The ORP application with water meter is used for hot water systems in buildings (Figure 25). • ORP application without water meter is used for any other setup where a specific ORP value should be targeted.

  • Page 28: Proportional Dosing

    Required capacity dosing pump: Not user configurable. The minimum dosing pump capacity • necessary to meet the configured dosing requirements. Max capacity dosing pump: The actual capacity of the installed dosing pump. • BWT Denmark A/S, Geminivej 24, 2670 Greve, Tel.: 43 600 500 28 / 68...

  • Page 29: Orp Application

    5.2.13 ORP Application Figure 30 - Settings, ORP with water meter Figure 31 - Settinges, ORP w/o water meter BWT Denmark A/S, Geminivej 24, 2670 Greve, Tel.: 43 600 500 29 / 68...
  • Page 30 Chloride in water: Salt concentration in the supply. Can be retrieved from the local water • supplier or measured with strip test, that can be supplied by BWT upon request. Corrosion limit: There is a defined upper limit to avoid chloride build-up in the system with •...
  • Page 31 ORP process value: The value measured by the ORP sensor. Load Default will set the • default value to 1.000 if the sensor has not been calibrated. Figure 35 - Calibration screen BWT Denmark A/S, Geminivej 24, 2670 Greve, Tel.: 43 600 500 31 / 68...

  • Page 32: Softener Settings

    Softener: An external water softener conditions the water before it enters the BWT • Safeshower M. RO water: The BWT Safeshower M is supplied with water from a reverse osmosis water • purification system. If this option is selected, no further configuration is possible.
  • Page 33 BWT Safeshower M. If "Delta Simplex 3,3L" is selected (Figure 39) and Softener monitoring is enabled, the BWT Safeshower M will alert the user if regeneration is not performed correctly. The only parameter that needs to be configured is water hardness.

  • Page 34: Installing New Cell

    It is thus incumbent on the user to ensure water of a satisfactory purity. CAUTION If the BWT Safeshower M is not supplied water of sufficient purity, the electrolysis cell will be damaged. Such damage is not the responsibility of BWT Danmark. 5.2.15 Installing New Cell Figure 40 - New cell installation Use this screen to configure the BWT Safeshower M following replacement of the electrolysis cell.

  • Page 35: Manual Operation

    Operating Instructions 5.2.16 Manual Operation Descriptions for manual operation of the BWT Safeshower M can be found in section 6.5.1.1. Manual operation is to be performed exclusively by the installer and the service technicians. 5.2.17 Buffer tank Figure 41 - Configuration of Neuthox® tank If the Neuthox ®...

  • Page 36: Handling, Installation, Connection, And Testing

    If in doubt, then contact BWT for support. Never attempt to assemble or connect if there is any doubt as to how to do it, or if faults and defects are present in the BWT Safeshower M and its associated equipment.

  • Page 37: Installation Safety Instructions

    • The BWT Safeshower M is vulnerable to the surrounding atmosphere. • Do not install the BWT Safeshower M anywhere that may be considered as a corrosive environment. WARNING The BWT Safeshower M is not approved for operations in potentially explosive atmospheres.

  • Page 38: Installation Procedure

    6.3.2 Installation Procedure NOTICE • Mount the BWT Safeshower M in such a way, that it allows the operator easy access, during both operation of the HMI controller and maintenance inside the cabinet. • The BWT Safeshower M should be mounted so the PLC is within eye level of operator and should always be mounted above the external tanks.

  • Page 39: Attachment To Mounting Rack

    If there is no clear wall-space at the installation site, then a mounting rack can be constructed for the BWT Safeshower M. Specifications for an acceptable mounting rack is provided in Figure 43. All measurements are provided in millimeters.

  • Page 40: Peristaltic Pumps

    Figure 44 - Water pump as delivered from factory Figure 45 - Pump cover When the BWT Safeshower M is delivered from the factory, the water pump will have its cover removed and the internal hose detached. Before connecting the generator to water or electrical supply, the hose and the included pump cover must be reinstalled.

  • Page 41: Connection To Supply Sources

    When producing Neuthox at low pH, the BWT Safeshower M forms chlorine gas. A ventilation pipe ® must be installed from the buffer tank and the buffer tank must not be sealed. BWT support will be able to advise on this. •...

  • Page 42: Water Supply Connection

    If the water softener is not equipped with an ion-exchanger, then the user must ensure to supply one to the system. • The content of FAC in the supply water for the BWT Safeshower M must never exceed 0,2 ppm, as this will damage the softener. •...

  • Page 43: Electrical Supply Connection

    Figure 49 - Connection point for water supply The soft water tank is placed inside the cabinet on the BWT Safeshower M. The tank is connected to the brine tank. The level sensor in the tank is connected to the plug NI01 on the PCB and the leak sensor is connected to the plug NI03 on the PCB.

  • Page 44: Neuthox ® Tank Connection

    In spaces with insufficient ventilation, the gas venting hose should be fitted with a hose outlet, which discharges the gases to an outdoor area. For the Neuthox ® tank connections, only use the following materials: BWT Denmark A/S, Geminivej 24, 2670 Greve, Tel.: 43 600 500 44 / 68...

  • Page 45: Dosing Pump Installation On Bwt Safeshower M

    The BWT Safeshower M can supply power for an external dosing pump, by connecting it directly to the terminals inside the cabinet (Figure 52). Refer to Electrical Circuit Diagram in section 11.1 for further information on connections.
  • Page 46 Connect the dosing pump and water meter: Set the dosing pump for pulse control, and set the same ml/pulse on the pump, as in the PLC. BWT Denmark A/S, Geminivej 24, 2670 Greve, Tel.: 43 600 500 46 / 68...

  • Page 47: Orp Hot Water Supply Hardware Installation

    If the water meter uses a transistor output be aware of polarity (Figure 52). The water meter is connected to the relay coil and 24 VDC from the BWT Safeshower M. The BWT Safeshower M is connected to a relay contact.
  • Page 48 Figure 55 - Injection valve installation 6.4.6.2 ORP Sensor The ORP-sensor must be calibrated by start-up, and the calibration can be done in the BWT. When the ORP-sensor is calibrated, then it can be installed in the water pipe. The ORP-sensor must be installed vertically or at most 45° from vertical with the ORP sensor wire facing upward (Figure 56).
  • Page 49 The ORP-sensor must be looped into the system to make sure that it can be taken out biannually for calibration, without shutting down the hot water supply. BWT Denmark A/S, Geminivej 24, 2670 Greve, Tel.: 43 600 500 49 / 68...

  • Page 50: Proportional Dosing Hardware Installation

    Operating Instructions 6.4.6.3 ORP-transmitter The process ORP-value is supplied to the BWT Safeshower M as an analogue 4-20 mA signal, from the supplied transmitter. The cable from the transmitter is connected directly to the terminals inside the cabinet. The ORP-transmitter and sensor are sensitive to EMI. To ensure proper function, they must not be installed near any other power source.
  • Page 51 Press the corresponding Up or Down button to set the frequency for either process (water pump) or brine pump (Figure 61). Figure 61 - Up and Down buttons BWT Denmark A/S, Geminivej 24, 2670 Greve, Tel.: 43 600 500 51 / 68...
  • Page 52 If it is needed to check the state of the inputs, then click on I/O button (Figure 63). Figure 63 - I/O button Ensure Input/Output values are as required (Figure 64). • • • • • BWT Denmark A/S, Geminivej 24, 2670 Greve, Tel.: 43 600 500 52 / 68...

  • Page 53: Safety At Commissioning

    Configuration of the water softening system is explained in section 5.2.14 of this manual. Prior to start-up, the local water hardness must be measured and entered into the HMI controller. The local water hardness can be measured with the hardness measuring kit supplied with the BWT Safeshower M.
  • Page 54 Operating Instructions 6.5.3.2 Salt Filling BWT recommends using food grade salt specified according to one of following standards, which both are suitable for electrolyzes and softener regeneration: EN 14805. Chemicals used for treatment of water intended for human consumption. Sodium •...
  • Page 55 When the BWT Safeshower M has been running for some time, the amount of free chlorine in the system is measured with a water testing instrument.
  • Page 56 Number of pulses from the water meter determines the speed of the dosing pump, the water meter informs the BWT Safeshower M of the water consumption in the system and ensures that the amount of Neuthox ®...

  • Page 57: Safety

    It is important to make reservations for visitors and other people who are not used to moving about in the area around the BWT Safeshower M and are therefore not aware of the general safety measures or the signage of the BWT Safeshower M.

  • Page 58: Residual Risks

    • The content of FAC in the supply water for the BWT Safeshower M must never exceed 0,2 ppm, as this will damage the softener. FAC chock dosing in supply water at max. 2 ppm, should not be done more than twice a year.

  • Page 59: Bwt Safeshower M Operation

    8.1.1 Visual Information/Warnings The BWT Safeshower M is optionally equipped with a light beacon on top of the cabinet. Once the start button is pressed, a green light is emitted and will stay lit when the process is running and when it is stopped.

  • Page 60: Water Softener Cartridge

    8.4 Machine and Work Area - Order and Cleaning To ensure the correct functions and usage of the BWT Safeshower M, the BWT Safeshower M and work area around it must be kept clean and orderly regularly.

  • Page 61: Startup After Normal Stop

    Any servicing or repairs, as well as maintenance beyond replenishment of consumables is to performed by qualified service technicians. No part of the BWT Safeshower M can be serviced or repaired by the end user, other than replenishment of consumables.

  • Page 62: Troubleshooting

    High transformer or cell Reset the alarm and restart. If the problem persists, contact your temperature authorized service and maintenance technician. BWT Denmark A/S, Geminivej 24, 2670 Greve, Tel.: 43 600 500 62 / 68...

  • Page 63: Dosing

    If the problem persists, contact your authorized service and maintenance technician. BWT Denmark A/S, Geminivej 24, 2670 Greve, Tel.: 43 600 500 63 / 68...

  • Page 64: Storage/Scrapping Of Bwt Safeshower M

    Always disconnect water and power supply before working inside the BWT Safeshower M. Dismantle and handle with care for own safety. WARNING Dismounting the BWT Safeshower M is a two persons’ job. Do not try to mount it alone. Dismantle and handle with care for own safety. 9.3 Transportation In case transportation of the BWT Safeshower M is necessary, please fasten it up right on a transport pallet.

  • Page 65: Scrapping Of The Bwt Safeshower M And Neuthox

    9.4 Scrapping of the BWT Safeshower M and Neuthox ® The BWT Safeshower M or parts of it must be sorted and disposed off in accordance with applicable national and regional regulations regarding health, safety, and the environment. Use appropriate waste collection services, and if this is not possible, then contact the BWT ECA- machine seller in corresponding country.

  • Page 66: Appendix 1 - Modbus

    Total Neuthox production ® MI2534 Total water usage MI2535 Total water usage MI2536 Total water usage 1 000 m MI2540 Dosing status See table below for explanation BWT Denmark A/S, Geminivej 24, 2670 Greve, Tel.: 43 600 500 66 / 68...

  • Page 67: Mi2519 - Neuthox ® Production Process Status

    Softener is not regenerating Softener regeneration took longer than expected Softener regeneration was quicker than expected No cell current High cell current High temperature in transformer or cell BWT Denmark A/S, Geminivej 24, 2670 Greve, Tel.: 43 600 500 67 / 68...

  • Page 68: Mi2540 - Neuthox ® Dosing Status

    Party Documentation Manual for soft water cartridge (Delivered by vendor and comes with the equipment) • Manual for the supplied dosing pump – if any. • BWT Denmark A/S, Geminivej 24, 2670 Greve, Tel.: 43 600 500 68 / 68...

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