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Summary of Contents for Lutz-Jesco EASYZON L 5
- Page 1 62005XXX_1 Translation of the original instructions Chlorine dioxide system EASYZON L 5 EASYZON L 10 EASYZON L 20 EASYZON L 40 Please read this manual before starting up! To be retained for future reference.
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Page 3: Table Of Contents
Table of contents Table of contents Other data ..............Dimensions..............About these operating instructions ........ Target groups..............Installation..............General non-discrimination .......... Components ..............Warnings............... Installation location............Action steps ..............Mounting the system on the wall ......... References to intellectual property rights..... Installation examples ........... - Page 4 Table of contents 11.7 Display menu: Functions and settings ......33 11.7.1 Chlorite usage counters........33 11.7.2 Acid usage counters........33 11.7.3 Site flow meter..........33 11.7.4 Valve states ............. 33 11.7.5 Generating hours ........... 33 11.7.6 Fault log ............33 11.7.7 Language selection.........
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Page 5: About These Operating Instructions
1 | About these operating instructions 1 About these operating instructions Signal words These operating instructions use the following signal words to em- This document: phasise the severity of possible injuries if the danger is ignored: • Is part of the product. •... -
Page 6: Action Steps
1.8 Example of training course topics thorised persons should have access to this document. It may only be given to third parties with the written consent of Lutz-Jesco GmbH. For safety: All documents are protected in the sense of the copyright law. It is •... -
Page 7: Safety
2 | Safety 2 Safety CAUTION The following warnings are intended to help you to eliminate the dangers that can arise while handling the product. Risk prevention System damage due to incorrect maintenance! measures always apply regardless of any specific action. Incorrect maintenance can lead to irreversible damage to equipment Safety instructions warning against risks arising from specific activit- and the preparation process. -
Page 8: Personal Protective Equipment
2 | Safety • Provide personal protective equipment to all users of the sys- • Sufficient training to work on the product under the supervision tem. and guidance of a qualified specialist These operating instructions differentiate between the following user groups: 2.5 Personal protective equipment Based on the degree of risk and the type of work you are carrying... -
Page 9: Intended Use
• People operate the product who are not adequately qualified to carry out their respective activities. • No original spare parts or accessories of Lutz-Jesco GmbH are used. • Maintenance and inspection intervals are not adhered to as re- quired or not adhered to at all. -
Page 10: Product Description
Contact the supplier and/or carrier regarding any questions concerning the delivery and/or transport damage. Do not operate defective products. • EASYZON L 5 / 10 / 20 / 40 • Wall mounting kit • Wall mounting kit for pressure control valve •... -
Page 11: Design And Function
4 | Product description 4.3 Design and function The product is a fully automatic batch system for producing a diluted chlorine dioxide solution ranging from 5 g/h to 40 g/h. The system con- sists of a plastic cabinet in which the instruments are mounted and the product tank and reactor vessel are housed; these are protected by a plastic cover that can be secured with a padlock on a toggle latch. -
Page 12: Technical Data
5 | Technical data 5 Technical data Description (all models) General protection class of the system IP64 Table 8: Electrical specifications 5.1 Connections NOTICE! The power supply cable may only be replaced by quali- fied personnel. 5.1.1 Hydraulic connections Connection Description 5.4 Operating conditions and limits Cold water dilution G½"... -
Page 13: Dilution Water (Generated Solution)
5 | Technical data 5.5.3 Dilution water (generated solution) duced “in situ” that are authorised under Article 95 of the regulation. These precursors must be sourced from a manufacturer or supplier Description Material listed in accordance with Article 95 of the BPR. Please ask your sup- Reactor vessel plier to confirm conformity with the biocide ordinance (certificate or letter of access). -
Page 14: Dimensions
6 | Dimensions 6 Dimensions Injection nozzle All dimensions in millimetres (mm). EASYZON L (5–40) Fig. 7: Injection nozzle Mounting plate for water supply module Fig. 4: External dimensions with cover Fig. 8: Mounting plate for water supply module Fig. 5: Cover dimensions Fig. 6: Depth... -
Page 15: Installation
7 | Installation 7 Installation • The chemical tanks can be positioned so that the suction lines are <50 m. • The water supply module can be mounted within one metre of DANGER the system. Incorrect installation can impair safety! 7.3 Mounting the system on the wall Incorrect installation can expose personnel and the surrounding en- vironment to hazards. -
Page 16: Cable And Tube Entry System
7 | Installation Installation example 1 Installation example 2 Standard installation with one injection point Installation with 50-litre tank and several injection points Fig. 11: Installation examples 1 Flow meter (optional) 2 Natural ventilation 3 Withdrawal of dilution water 4 Communications device (optional) 5 Permanent water supply line 6 EASYZON L system 7 Double check valve... -
Page 17: Installing The Cables
7 | Installation 13 mm x 1 8 mm x 1 6 mm x 2 6 mm x 1 5 mm x 2 Blind Fig. 13: Cable and tube entry system 4 mm x 4 1 Entry frame 2 6-way frame inlay 3 Seal insert Fig. 14: Seal insert selection 7.5.1 Installing the cables... -
Page 18: Installing The Injection Nozzle
7 | Installation Set the pressure control valve between 0.7 and 1.0 bar when the sys- tem is dosing (→ Initial commissioning [} 26]) because this is cru- cial to the correct functioning of the system. 7.6.2 Installing the injection nozzle Fig. 16: Installing the injection nozzle 1 ½"... -
Page 19: Installing External Dosing Pumps
7 | Installation 6. Connect the pressure side of the pump to the dosing line and the injection nozzle. CAUTION O Internal dosing pump installed. System damage due to incorrect wiring! Incorrect wiring can lead to irreversible damage to the system. 7.6.4 Installing external dosing pumps u Disconnect the power supply to the EASYZON before carrying out You can connect two external dosing pumps and one internal dosing... - Page 20 7 | Installation Ter- Terminal designation minal Emergency shutoff Chlorite tank empty detector Chemical bund level switch Acid tank empty detector Batch tank start/ stop Not active Digital inputs Batch tank low Batch tank high Spare +24 V DC - acid Chemical solenoid valve control out- puts +24 V DC –...
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Page 21: Electrical Wiring Diagram
7 | Installation 7.7.2 Electrical wiring diagram Electrical wiring diagram with details of the mains connection and the signal inputs and outputs. -
Page 22: Installing The Level Switch For Suction Lances
7 | Installation 7.7.3 Installing the level switch for suction lances 7.7.5 Installing an auxiliary alarm The EASYZON L has two level switch inputs located on the control You can connect devices with a normally closed, voltage-free alarm panel (→ Design and function [} 11], items 11 and 12). These are output to the EASYZON L circuit board to stop the operation of the male 4-pin M12 connections, the configuration of which is shown in system in the event of an external alarm state (e.g. -
Page 23: Connecting To The Power Supply
7 | Installation 2. Select a cable entry insert of a suitable size from the set supplied 1. Refer to the pump manual for the correct external stop input (→ Cable and tube entry system [} 16]). and pin assignment. 3. Guide the cable from the NC contact of the switch through the 2. -
Page 24: Transportation
8 | Transportation 8 Transportation CAUTION Machine damage due to improper transport and delivery pro- cedures Improper transport and delivery procedures may result in irrevers- ible damage to the system and may affect the warranty. u Seek assistance when lifting the system to minimise the risk of damage to the system and injury to persons. -
Page 25: Storage
9 | Storage 9 Storage You have to shut down the system for a longer period of time before placing it into storage (→ Shutting down the system for a longer period of time [} 44]). Proper storage extends the service life of the system. -
Page 26: Commissioning
10 | Commissioning 10 Commissioning Pre-commissioning check Done ( ) The suction lines for chemical precursors (Ø 4 mm x 6 mm) are no longer than 50 m each. CAUTION Table 18: Pre-commissioning checks Damage to the system due to incorrect installation 10.2 Initial commissioning If you start up the system before the installation has been fully com- pleted, irreversible damage may occur to the system and the prepar-... -
Page 27: Priming The Dosing Pumps
10 | Commissioning 5. Check that all hydraulic components, hose connections, hoses, 10.2.5 Water purge set reactor, etc. remain leak-free for at least 15 minutes. Refill the You connect the water purge set to the inlet of the strainer. You use it bucket with cold water as required to maintain water suction. - Page 28 10 | Commissioning CAUTION Danger of devices switching on automatically! You must be aware that the system and the dosing pumps are two separate devices in terms of on-site chlorine dioxide preparation. u The EASYZON system operates automatically if the product tank is almost empty.
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Page 29: Operation
11 | Operation 11 Operation SYSTEM FAULT 11.1 Control panel BATCH TANK FULL You operate the EASYZON L system using the universal control panel. Flashes red Fig. 20: System error example In this example, the system is in an error state. The current fault is SYSTEM HEALTHY described and the red LED flashes. -
Page 30: Menus And Navigation
11 | Operation 11.6 Menus and navigation The EASYZON L has three software menus that personnel can access depending on their level of training. 11.6.1 Display menu The display menu is for general users. A pin is not required for access. This menu displays useful values for the system operator. SYSTEM HEALTHY GENERATING CHLORITE USAGe... -
Page 31: Service Menu 1
11 | Operation 11.6.2 Service menu 1 Service menu 1 is for general users and technicians. A pin is required for access (→ Access codes [} 29]). This menu allows you to access and edit basic settings, functions and parameters. SYSTEM HEALTHY PROGRAM 1 EXIT MENU GENERATING... - Page 32 11 | Operation PROGRAM 9 ENGINEERS MENU PROGRAM 17 BATCH TANK LOW ENABLED = NO PIN? 0… PROGRAM 18 TMPR SENSOR ENABLED = NO PROGRAM 10 CHLORITE LOW PROGRAM 19 ENABLED = NO TMPR HIGH POINT = 50°C PROGRAM 11 ACID LOW ENABLED = NO PROGRAM 20...
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Page 33: Display Menu: Functions And Settings
11 | Operation 11.7 Display menu: Functions and settings ü The flow meter cable is installed (→ Installing a site flow meter [} 22]). 1. Enable the option for the site flow meter (→ program 15). 11.7.1 Chlorite usage counters 2. Enter the K-factor of the flow meter (→ program 16). Since refill: Displays the volume of chlorite used in litres since the counter was reset. -
Page 34: Menu Settings
11 | Operation 11.8 Menu settings Only authorised and suitably qualified personnel should change the settings (→ Personnel qualification [} 8]). See also: → Menus and navigation [} 30] → Factory settings [} 35] → System faults [} 42] Service menu: Setup Program Description Title PRIME SYSTEM •... -
Page 35: Factory Settings
11 | Operation Program Description Title TMPR HIGH POINT • The alarm is activated if the temperature (°C) inside the reactor reaches this set value. MODEM/MODBUS • Selects the Modem/Modbus output if a remote management platform (Modbus RTU) is used. MODBUS ADDRESSES •... -
Page 36: Control Function Sequences
11 | Operation 11.10 Control function sequences Diagram 1: Production process Diagram 2: Alarm/fault state sequence Switch on Active alarm? Active Acknowledge alarm? alarm System warning status for alarm delay time Batch tank Unit in standby full? BATCH TANK FULL System stopped –... -
Page 37: Maintenance
12 | Maintenance 12 Maintenance CAUTION Products from Lutz-Jesco GmbH are manufactured to the highest quality standards and have a long service life. However, some parts Danger of devices switching on automatically! are subject to operational wear. You must be aware that the system and the dosing pumps are two This means that regular inspections are necessary to ensure a long separate devices in terms of on-site chlorine dioxide preparation. -
Page 38: Remedial Maintenance
12 | Maintenance 12.2 Remedial maintenance 5. Rinse each transfer device safely with clean, cold water after transferring the chemical precursors. WARNING 6. Release the manual inhibit on the control panel to resume nor- mal operation. 7. Reset the volume usage values for the chemical precursor ac- Danger of release of toxic ClO gas! cordingly on the control panel (→... -
Page 39: Preparing The System For Routine Maintenance
12 | Maintenance 12.3 Preparing the system for routine maintenance 6. Replace the seal of the dilution inlet and the O-ring (E) of the hose adapter by unscrewing the main tank nut anti-clockwise Before you carry out routine maintenance, it is strongly recommen- and pulling the entire assembly out of the tank. -
Page 40: Performing Major Maintenance
12 | Maintenance 12.5 Performing major maintenance 12.6 Maintenance diagrams Front equipment WARNING Danger of toxic ClO gas release and risk of contact with a ClO solution! Harm to your health and irreversible damage to the system may oc- cur if all procedures are not followed exactly. u Never remove the reactor unit unless you have been trained to do so and are wearing the correct personal protective clothing and equipment. - Page 41 12 | Maintenance M Reactor Pump purge set Connect the pump purge set to the valve on the suction side of the dosing pump. Use it to purge the pump and dosing lines with water during maintenance and servicing work. Fig. 27: Pump purge set 1 Suction strainer 2 Hose Ø...
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Page 42: Troubleshooting
13 | Troubleshooting 13 Troubleshooting 13.1 System faults Alarm type Possible cause Measures Solution Chemical underfeed The reagent flow meter detects an • Check for broken wires on the solen- • Replace cable or plug/wire (acid/chlorite) insufficient number of pulses. oid valve/flow meter •... - Page 43 13 | Troubleshooting Alarm type Possible cause Measures Solution • Check for broken wires • Replace switch/cable Auxiliary alarm The auxiliary alarm contact is open. • Check why the auxiliary unit has • Reset alarm if safe to do so gone into alarm state •...
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Page 44: Shutdown And Disposal
14 | Shutdown and disposal 14 Shutdown and disposal 5. Connect the open hose ends of the water purge set for the chemical precursor to each in-line strainer and place the foot valve in a bucket of clean, cold water. DANGER 6. -
Page 45: Disposal Of Old Equipment
14 | Shutdown and disposal 3. Carefully remove the suction lances for the chemical precursors from their drums/tanks. Ensure that the lance remains vertical. 4. Place each suction lance in its own plastic bucket of clean, cold water. 5. Make sure that all drums/tanks are tightly closed after removing the suction lances. -
Page 46: Spare Parts
Use and frequency of spare parts → Maintenance intervals [} 37] 15.1 Maintenance sets Part Description Model 43737 Maintenance set small (annual) 43738 EASYZON L 5 43739 EASYZON L 10 Large maintenance set (every 3 years) 43740 EASYZON L 20 43741 EASYZON L 40 Table 27: Maintenance sets... -
Page 47: Recommended Spare Parts
15 | Spare parts 15.2 Recommended spare parts 43748 43750 43749 43751 Part Description Components 43742 In-line strainer for chemical precursor 4 x filter screen (PVC) 43743 Double non-return valve (5/8") for pump suction 1 x DN8 DCV assembly (PVC/FPM/ ceramic) 43744 Tube coupling set (6/12 mm) -
Page 48: Reactor Assemblies
15 | Spare parts 15.3 Reactor assemblies 43773 43772 43771 43770 Part Description Components 43770 5 g/h reactor assembly and upper screw connections and Ø 8 mm chem- 1 x 5 g/h reactor (PVC) ical feed lines 3 x tube fittings (PVDF/FPM) 2 x feed line (PTFE) 43771 10 g/h reactor assembly and upper tube fittings and Ø... -
Page 49: Eu Declaration Of Conformity
(NL) EU-overeenstemmingsverklaring Ondergetekende Lutz-Jesco GmbH, bevestigt, dat het volgende genoemde apparaat in de door ons in de handel gebrachte uitvoering voldoet aan de eis van, en in overeenstemming is met de EU-richtlijnen, de EU-veiligheidsstandaard en de voor het product specifieke standaard. Bij een niet met ons afgestemde verandering aan het apparaat verliest deze verklaring haar geldigheid. -
Page 50: Decontamination Declaration
17 | Decontamination declaration 17 Decontamination declaration Due to legal regulations for the protection of our employees and operating facilities, we need the completed and signed declaration of decon- tamination in order to process your return. 1. Copy this page and complete it for each device separately! 2. -
Page 51: Warranty Claim
18 | Warranty claim 18 Warranty claim If the device breaks down within the period of warranty, please return it in a cleaned condition with the fully completed warranty claim. 1. Copy this page and fill in all fields. 2. Pack the device together with the completed warranty claim. 3. -
Page 52: Confirmation Of Training Instruction
19 | Confirmation of training instruction 19 Confirmation of training instruction You can use the following form as a copy template to record confirmation of training instructions. Confirmation of training instruction Topic of the training: Date: Training instructor: Training instructor s signature: Name First name Signature... - Page 53 Notes...
- Page 56 Lutz-Jesco GmbH Am Bostelberge 19 30900 Wedemark Germany Tel.: (+49 51 30) 58 02-0 Fax: (+49 51 30) 58 02 68 E-Mail: info@lutz-jesco.com www.lutz-jesco.com...
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