Page 1 ® WALLACE & TIERNAN CHLORINE DIOXIDE GENERATOR DIOX-A 250 INSTRUCTION MANUAL...
Page 2 DIOX-A 250 Note Original manual! WT.085.266.000.DE.IM.0919...
Page 3: Table Of Contents
DIOX-A 250 Contents Contents Introduction Target groups Conventions Safety Intended use General safety instructions Safety instructions specifically for the chlorine dioxide generator Standards and legal requirements Data sheets Description Versions Required accessories Optional Accessories Operating principle View Technical data DIOX-A with booster pump DIOX-A without booster pump Operating modes Installation...
Page 4 Contents DIOX-A 250 Commissioning Setup Settings list Interfaces Selecting the interface Connecting PROFINET IO-Device Connecting PROFIBUS DP Connecting MODBUS TCP Changing the IP address of the CPU Connecting Process Monitoring System (PMS) Data formats Reference list Operation Control and display unit Operating the control unit Display scheme Operation menus...
Page 5 DIOX-A 250 Contents Maintenance Maintenance/inspection plan Maintenance by the operator Maintenance by qualified personnel Maintenance and spare parts Maintenance sets overview Maintenance parts Optional accessories 10. Wiring diagrams 10.1 Wiring diagrams WAE8885 10.2 Cable inlet 11. Index...
Page 6 Contents DIOX-A 250 WT.085.266.000.DE.IM.0919...
Page 7: Introduction
DIOX-A 250 Introduction 1. Introduction Target groups This instruction manual provides information for installation, operating and maintenance personnel. It is required to operate and maintain the unit. This instruction manual is intended for the operating personnel. It contains important information which will enable the operator to run the system in a safe, reliable, trouble-free, and economical way.
Page 8: Conventions
DIOX-A 250 Introduction Conventions The different weighting assigned to the various notes in this Notes manual is indicated by means of pictogram symbols. Picto- Note Meaning gram Risk to life and limb Danger! Risk involving electric current. Warning! Switch the system OFF at the emergency stop switch.
Page 9: Safety
DIOX-A 250 Safety 2. Safety Intended use The chlorine dioxide generator DIOX-A 250 is designed for the generation and dosing of a chlorine dioxide solution for disinfecting water. The operational safety of the system can only be guaranteed so long as it is used strictly as intended. The system may only be used for the purpose defined in the order and under the operating conditions indicated in the technical specifications.
Page 10: General Safety Instructions
DIOX-A 250 Safety General safety instructions The manufacturer attaches great importance to ensuring that work on its system is always perfectly safe. Safety is our guiding principle right from the design phase. The system is therefore equipped with safety features. The safety instructions in this documentation must be observed Safety instructions unconditionally at all times.
Page 11: Safety Instructions Specifically For The Chlorine Dioxide Generator
DIOX-A 250 Safety Safety instructions specifically for the chlorine dioxide generator Note The operator is obliged to provide the user with operating instructions on the safe use of the chlorine dioxide generator. These operating instructions must include the information listed below.
Page 12 DIOX-A 250 Safety • All containers used for chemicals, suction lances and collecting basins must be clearly marked to avoid confusion. • Display notices about water chlorination in the workplace and in the immediate vicinity in accordance with the requirements of the accident prevention regulation on the chlorination of water.
Page 13 DIOX-A 250 Safety • Remove any clothing that has come into contact with the sodium chlorite solution immediately and wash thoroughly. Do not allow the solution to dry. • Aqueous solutions of chlorine dioxide are not flammable. What to do in the event of fire •...
Page 14: Standards And Legal Requirements
DIOX-A 250 Safety Standards and legal requirements Applicable in Germany. • „Chlorung von Trinkwasser“ (German accident prevention regulation on the chlorination of potable water), DGUV Information 203-086 • „Dosieranlagen für Chlordioxid“ (Chlorine dioxide feed systems) DVGW W 624, • „Chlordioxid in der Wasseraufbereitung“ (Chlorine dioxide in water purification applications) DVGW W 224, •...
Page 15: Description
• Suction lances If carboys are used: • Adaptor plugs for carboys • Collecting basins for carboys The individual components can be obtained separately or from Evoqua. The exact requirements pertaining to the accessories are described in chapter 4.
Page 16 DIOX-A 250 Description 3.2.1 Suction lances The design and length of the suction lances must match the chlorine dioxide generator and the used containers. Evoqua offers the following types of suction lances: Article No. Description W3T168018 length 475 mm W3T168019...
Page 17: Optional Accessories
W2T505585 For 10 - 20 l carboys W2T505586 For 30 l carboys W2T505587 For 60 l carboys Optional Accessories Evoqua recommends the following accessory kit: Article No. Description W3T169989 Accessory kit operating water supply incl. solenoid valve Operating principle The chlorine dioxide generator works on the basis of the acid/ chlorite process and generates chlorine dioxide as an aqueous solution.
Page 18 DIOX-A 250 Description A solution with 20 g/l (20 000 ppm) of chlorine dioxide is produced. This solution is diluted to 2 g/l (2000 ppm) directly after the reaction tank and flows to the point of application. If there is insufficient operating water available for dilution, the system switches to STOP.
Page 19: View
DIOX-A 250 Description View A ClO solution discharge to the storage tank M Ball valve NaClO with sample tap B Static mixer N Ball valve HCl with sample tap C Control with emergency main switch O Flushing ball valve D Support for suction lances P Membrane valve E Beaker Q Reaction tank...
Page 20: Technical Data
DIOX-A 250 Description Technical data DIOX-A 50 DIOX-A 100 DIOX-A 170 DIOX-A 250 Capacity ClO , approx. 50 g/h 100 g/h 170 g/h 250 g/h Operating water approx. 400 l/h 800 l/h Operating water pressure 2-10 bar (g) Counter pressure max.
Page 21: Diox-A With Booster Pump
DIOX-A 250 Description DIOX-A with booster pump (Installation example using carboys)
Page 22: Diox-A Without Booster Pump
DIOX-A 250 Description DIOX-A without booster pump (Installation example using carboys) This type of installation may be used only if the water pressure is high enough for the vent gas aspiration injector. Otherwise use a booster pump. WT.085.266.000.DE.IM.0919...
Page 23: Operating Modes
DIOX-A 250 Description Operating modes 3.9.1 Systems with proportional volume generation • The generated quantity of chlorine dioxide solution depends on the feed rate of the overall water volume which requires treatment. • An external feed rate signal must be connected for proportional volume generation.
Page 24 DIOX-A 250 Description WT.085.266.000.DE.IM.0919...
Page 25: Installation
To prevent health risks or damage to the system, follow the safety notes and warnings attached to the system and in the instruction manuals in any case. • Only Evoqua customer service or personnel specifically trained by Evoqua may install the system. Scope of supply •...
Page 26: Transport, Storage, Unpacking
DIOX-A 250 Installation Transport, storage, unpacking • During transport, protect the system against humidity, frost and damage. • When unpacking check against the parts list to ensure that all listed items have indeed been delivered. • Do not dispose of the packing materials until after the system has been successfully commissioned.
Page 27: Installation
DIOX-A 250 Installation 4.3.2 Operation water • The operating water must always be supplied in sufficient quantities and at a suitable admission pressure (see technical data) • The operating water must not contain any particles (potable water quality) • If the water pressure is too low, a booster pump is necessary •...
Page 28 DIOX-A 250 Installation (Installation example using carboys) WT.085.266.000.DE.IM.0919...
Page 29 DIOX-A 250 Installation 4.4.2 Connecting the operating water pipe Note The operating water must always be supplied in sufficient quantities and at a suitable admission pressure (2 - 10 bar (29 - 145 psi) and should not contain any particles. The water supply pipe can be installed with the optional accessory kit W3T169989: straight from below or from the side (also refer to 3.7 and 3.8).
Page 30: Risk Of Explosion
DIOX-A 250 Installation 4.4.3 Install the solution line 1 Install the solution line without stress. 2 Between the chlorine dioxide generator and the point of application install a stop valve and a sample tap (refer to chapter 3.7). 3 The maximum pressure at the point of application must not exceed 8 bar (116 psi).
Page 31 DIOX-A 250 Installation W3T160367 W3T160366 BZ-1544.019 07-FEB-11 / mb 3 Place the carboys for hydrochloric acid (HCl 9 %) and sodium chlorite solution (NaClO 7.5 %) each into the appropriate collecting basin below the generator: • diluted hydrochloric acid on the left •...
Page 32: Electrical Installation
DIOX-A 250 Installation Electrical installation Warning! Risk of injuries due to electric current! • Only qualified electricians are allowed to perform electrical works on the system. When performing any work on the electrical system always observe the following: • this instruction manual and the included wiring diagrams. •...
Page 33: Commissioning
DIOX-A 250 Installation Commissioning Warning! Risk of explosion! Risk of injuries due to dangerous chlorine dioxide gas! • Wear respiratory protective equipment and protective clothing. • Check system for leaks before commissioning. • Never bring HCl and NaClO into contact with each other. •...
Page 34: After Commissioning
DIOX-A 250 Installation 11 Set the parameters in the setup menu (refer to chapter 4.7) 12 Press F4 „Menu”. 13 Touch „Maintenance”. 14 Touch „next” to go to the menu „Function test”. 15 Touch „Solenoid valve operating water: Test” and simultaneously adjust the water flow at the dosing ball valve (P) to the following flow: •...
Page 35: Setup
DIOX-A 250 Installation Setup The Setup menus provide settings for: • Type and name of the system • AutoSTART and maintenance interval • Lead signal (e.g. contact water meter for operating water) Note: Oval gear meter cannot be used with bypass installation. See also the settings list in chapter 4.8.
Page 36 DIOX-A 250 Installation For information touch the „i” box and refer to chapter 5. 10 Touch „next”. Menu „Setup: Lead signal” is displayed. 11 Select the type of the lead signal. Note: The setting „simulation” cannot be used. • When „Controller (contact)“ is used: Enter the number of pulses as set in the controller.
Page 37 DIOX-A 250 Installation 13 Touch „next”. „Setup: Factory settings” is displayed Attention: If you touch the OK box in the menu „Factory settings” more than 3 seconds, all settings will be reset to factory settings and must be set again. 14 To leave the menu touch „back”.
Page 38: Settings List
DIOX-A 250 Installation Settings list Display Factory setting Commissioning Change Capacity depending on the size 50/100/170/250 g/h of the unit AutoSTART Maintenance interval 365 days = 1 year PROFIBUS address RS 485 address Mode Generation factor 1.0 • AUTO Capacity: 100 % •...
Page 39: Interfaces
DIOX-A 250 Interfaces 5. Interfaces The controller provides interfaces for PROFINET IO-Device, PROFIBUS DP or MODBUS TCP. The corresponding hardware can be installed during commissioning or retrofitted later. Note Both status LEDs „ERROR” and „DIAG” on the SIMATIC S7 illuminate if the chlorine dioxide generator is not connected to a master PROFIBUS DP network.
Page 40: Connecting Profinet Io-Device
DIOX-A 250 Interfaces Connecting PROFINET IO-Device (Optional) This chapter provides software developers and assembly personnel with information on programming and installation for connection to a PROFINET system. The control of the chlorine dioxide generator, the Siemens SIMATIC S7-1200, is geared for data exchange over PROFINET IO-Device on a superordinate PROFINET network.
Page 41: Wiring Profinet
DIOX-A 250 Interfaces 5.2.2 Wiring PROFINET Note Follow the setup guidelines for PROFINET networks such as on network topology, the properties of the bus lines, line termination, max. segment lengths, max. number of stations, transmission rate, use/number of repeaters etc. For information, contact the PROFINET User Organization, the manufacturer or the manufacturer of the automation system you are using.
Page 42 DIOX-A 250 Interfaces PROFINET IO-Device A Display B CPU C Communication with IO-Master Note Both status LEDs „ERROR” and „DIAG” on the SIMATIC S7 illuminate if the chlorine dioxide generator is not connected to a master PROFIBUS DP network. In such case, the communication partner (IO-controller) is not available.
Page 43 The PROFINET IO-Controller is configured with the aid of the device master data file (GSDML file): GSDML-V2.32-#Siemens-PreConf_Basic8880-V1-20180720- 085016.xml The GSDML file can be downloaded from the web site: http://www.evoqua.com/en/brands/Wallace_and_Tiernan/Pages/ Firmware-Updates.aspx 192 (6 x 32) bytes of user data are transferred over the PROFINET to the IO-controller.
Page 44: Connecting Profibus Dp
DIOX-A 250 Interfaces Connecting PROFIBUS DP (Optional) The control of the chlorine dioxide generator, the Siemens SIMATIC S7-1200, is geared for data exchange over PROFIBUS DP on a superordinate PROFIBUS DP network. In this process, the control operates as a PROFIBUS DP slave and provides output data (see chapter 5.8 Reference list).
Page 45 DIOX-A 250 Interfaces 5.3.2 Wiring PROFIBUS DP Note Follow the setup guidelines for PROFINET networks such as on network topology, the properties of the bus lines, line termination, max. segment lengths, max. number of stations, transmission rate, use/number of repeaters etc. For information, contact the PROFINET User Organization, the manufacturer or the manufacturer of the automation system you are using.
Page 46 DIOX-A 250 Interfaces 6 Connect the PROFIBUS DP bus cable to interface X1: PB DP on the CM 1242-5 using the bus system's 9-pin PROFIBUS DP plug connector. A Interface B Interface socket 7 Restart the chlorine dioxide generator. 1 Enter the Service password. Setting the PROFIBUS DP address 2 Press F4, then touch „Setup”...
Page 47 DIOX-A 250 Interfaces 5.3.3 Configuring PROFIBUS DP-Master In order for the data on a automation system to be read, it must know the configuration for the data transfer. Data exchange configuration: The PROFIBUS DP master is configured with the aid of the device master data (GSD-file) of the SIMATIC CM1242-5 PROFIBUS DP slave V1.0.
Page 48: Connecting Modbus Tcp
DIOX-A 250 Interfaces Connecting MODBUS TCP This chapter provides software developers and assembly personnel with information on programming and installation for connection to a MODBUS system. The control of the chlorine dioxide generator, the Siemens SIMATIC S7-1200, is geared for data exchange over MODBUS on a superordinate MODBUS network.
Page 49: Connecting Modbus
DIOX-A 250 Interfaces 5.4.2 Connecting MODBUS Note Follow the setup guidelines for MODBUS networks such as on network topology, the properties of the bus lines, line termination, max. segment lengths, max. number of stations, transmission rate, use/number of repeaters etc. For information, contact the MODBUS User Organization, the manufacturer or the manufacturer of the automation system you are using.
Page 50 DIOX-A 250 Interfaces PROFINET IO-Device A Display B CPU C Communication with IO-Master WT.085.266.000.DE.IM.0919...
Page 51 DIOX-A 250 Interfaces 5.4.3 Configuring MODBUS client In order for the data on a automation system to be read, it must know the configuration for the data transfer. MODBUS functions for the data exchange: MODBUS Data length Function and data type Address register function (WORD)
Page 52: Changing The Ip Address Of The Cpu
DIOX-A 250 Interfaces Changing the IP address of the CPU For PROFINET and MODBUS Notes • The Ethernet interface of the CPU is used for the communication with an external automation system. • This Ethernet interface of the CPU is also used for the communication with the HMI.
Page 53 DIOX-A 250 Interfaces 5 Touch „Settings“. 6 Touch the symbol „Service and Commissioning”. 7 Swipe until „Assign IP Address” is displayed. 8 Touch „Assign IP Address” and then 9 Swipe upward until „Accessible devices in target subnet” is displayed. 10 Touch to activate. 11 Touch „>”...
Page 54 DIOX-A 250 Interfaces If the change was successful, „Station name and IP suite set- tings could be assigned!” is displayed. In case of a failure: „Station name and IP suite settings could not be assigned!” is displayed. Touch „close” to close the message. Touch to close the window.
Page 55 DIOX-A 250 Interfaces 24 Touch „>” to go to the next step 2/3. 25 Enter the new IP address of the PLC as of step 12. 26 Swipe upward until the slide switch „Override” is displayed. 27 The slide switch must be set to „ON”, swipe if necessary. 28 Touch „>”...
Page 56: Connecting Process Monitoring System (Pms)
DIOX-A 250 Interfaces Connecting Process Monitoring System (PMS) (Optional) The serial RS 485 bus interface is used for data transfer to the visualisation system Process Monitoring System (PMS). The visualisation system Process Monitoring System is used for archiving and monitoring of process data, for remote diagnosis and remote access using a standard browser with internet and E- mail capability.
Page 57 DIOX-A 250 Interfaces 5.6.2 Connecting RS 485 1 Shut-down the chlorine dioxide generator. Installing the communication board 2 Open control cabinet. 3 Carefully remove the two terminal covers of the PLC and lift the blind covers. 4 Connect the communication board CB1241 RS 485 from the top to the PLC and close the terminal covers.
Page 58: Data Formats
DIOX-A 250 Interfaces Data formats The following table contains data formats used during the transfer of process data: Data type Size Typical names Initials Value range (Bit) BOOL Bit, Bool BYTE unsigned Char, Byte WORD unsigned Integer, FFFF Word STRING (n*8) + 16 ASCII, String, Character string...
Page 59 DIOX-A 250 Interfaces STRING Example: ‚AB‘ STRING [2] BYTE 0 BYTE 1 BYTE 2 BYTE 3 max. length of string actual length of string ASCII value A ASCII value b 0 0 0 0 0 1 0 0 0 0 0 1 1 0 0 0 0 0 1 0 1 1 0 0 0 1 0...
Page 60: Reference List
DIOX-A 250 Interfaces Reference list The following reference list contains the data that were made available by the chlorine dioxide generator. „n” starting address of the master input area. „R” read access right. MODBUS Byte Length Value Format Access Description Register addr.
Page 61 DIOX-A 250 Interfaces 40075 n+148 BOOL Perform maintenance! 1 = Warning message active BOOL Carboy HCl MIN! 1 = Warning message active BOOL Carboy NaClO2 MIN! 1 = Warning message active BOOL Calibrate unit! 1 = Warning message active BOOL Failure calibration HCl pump! 1 = Warning message active BOOL...
Page 62 DIOX-A 250 Interfaces WT.085.266.000.DE.IM.0919...
Page 63: Operation
DIOX-A 250 Operation 6. Operation Warning! Risk of Explosion! Risk of injuries due to dangerous chemicals! Risk of system damage. The system produces chemicals in potentially hazardous quanti- ties. Solutions with low ClO concentrations and the ClO gas which occurs in the event of leakage constitute a health hazard and have an extremely corrosive effect on metals.
Page 64: Operating The Control Unit
DIOX-A 250 Operation Operating the control unit 6.2.1 Control operating panel A Type of system B Login-Symbol C Date and time D Message indicator E Scheme F Function keys F1-F4 G Messages incl. number of messages H Present capacity Status of the unit Function keys Switch generation on and off (refer to “Activating ClO2 generation”...
Page 65 DIOX-A 250 Operation Display the present fault message when the message indicator is displayed. Select the menu, leave a menu, return to the menu level above. Message indicator The message indicator is displayed in case of a fault. The number in the lower part of the indicator shows the number of fault messages currently pending.
Page 66 DIOX-A 250 Operation 6.2.3 Login, entering the password The programme menus are protected against unauthorised operation by passwords. • Operator password: Protects all operating functions. The operator password is 9040. • Service password: Protects the specific system settings and is only given to authorised specialised personnel.
Page 67: Display Scheme
DIOX-A 250 Operation Display scheme A Leak sensor B Dosing pump NaClO green = working white = stopped C Level in carboy: Empty, above empty, above Min D Dosing pump HCl green = working white = stopped E Solenoid valve operating water green = solenoid valve open white = solenoid valve closed F Flow meter operating water:...
Page 68: Operation Menus
DIOX-A 250 Operation Operation menus For changes in the operation menu the operator password 9040 is required. 6.4.1 Menu „Operation“ The menu „Operation“ is used for unit setup. 1 Press F4. The main menu is displayed. 2 Touch „Operation”. „Operation: Settings” is displayed. 3 Enter the settings: •...
Page 69 DIOX-A 250 Operation • Warning message: The system will continue generation, even when the lead signal falls below the value entered at „below“. A warning message will be displayed. • Delay time: Enter the delay time until the alarm function becomes active.
Page 70 DIOX-A 250 Operation Note „Daylight saving time” or „Wintertime” is set automatically. Date and time are refreshed within 10 seconds. 6.4.2 Menu „Diagnosis“ The menu „Diagnosis“ shows the status of the system: • present flows • external setpoint • calibration history •...
Page 71 DIOX-A 250 Operation 6.4.3 Menu „Language“ The menu „Language“ is used to select the system language German, English or French. 1 Press F4. 2 Touch „Language”. „Language” is displayed. 3 Select the language: • for German: touch „DE” • for English: touch „EN” •...
Page 72 DIOX-A 250 Operation 6.4.5 Menu „Info“ The menu „Info“ shows the following data: • system data • maintenance data • system name, order and serial number • software version 1 Press F4. 2 Touch „Info”. „Info: Operating data” is displayed. •...
Page 73: Evacuation And Calibration
DIOX-A 250 Operation Evacuation and Calibration Warning! Risk of Explosion! Risk of injuries due to dangerous chemicals! • When working on the system wear protective clothing, protective gloves, googles or face protection. Have a respiratory mask ready to use. • Never bring HCl and NaClO into contact with each other.
Page 74: Risk Of Explosion
DIOX-A 250 Operation Ball valve in position „Generation“ Ball valve in position „Evacuation and Calibration” A Locking bolt B mark on the handle: C mark on the handle: The handle is protected against accidental turning: Prior to turning 1 Unscrew the locking bolt. 2 Pull the yellow locking catch on the handle, then turn the handle.
Page 75 DIOX-A 250 Operation During evacuation the metering pump pumps air from the suction lines, the metering pump, the flow meter and the ball valve into a beaker until all air bubbles have been removed. This section describes the evacuation of the HCl pump. The NaClO pump is evacuated in the same way.
Page 76 DIOX-A 250 Operation 7 When no more air bubbles appear, touch „Stopp”. 8 To restart evacuation (if necessary) touch „Start”. 9 To stop evacuation touch „Stopp”. 10 To finish evacuation touch „OK”. 11 Reset the HCl ball valve to the Generation position (refer to the mark on the handle): To confirm touch „Yes”.
Page 77 DIOX-A 250 Operation During calibration the control unit counts the number of pulses of the flow meter per 100 ml of liquid. The capacity of the metering pump is precisely controlled with this value. This section describes the calibration of the HCl flow. The NaClO flow is calibrated in the same way.
Page 78 DIOX-A 250 Operation 8 To continue calibration (if necessary) touch „Start” again. The number of pulses counted is displayed (approx. 250 pulses/100 ml) 9 When calibration is correct (exactly 100 ml) touch „OK”. If the calibration failed, continue until the process is completed and repeat calibration.
Page 79: Activating Clo2 Generation
DIOX-A 250 Operation Activating ClO generation Attention! Risk of system damage! • The reaction tank must be filled with water or solution! • For commissioning or re-starting, after dismantling the system or several days of non-operation it is essential to flush the system (refer to 6.10).
Page 80: Deactivating Clo2 Generation
DIOX-A 250 Operation If sufficient operating water is flowing (MIN limit value is exceeded), the metering pumps start automatically. „Generation AUTO” is displayed. Deactivating ClO generation Warning! Risk of injury due to dangerous chemicals! • Even after deactivating, the system still contains chlorine dioxide solution.
Page 81 DIOX-A 250 Operation • Before disconnecting system components it is essential to flush the system (refer to 6.10). 1 In case of an emergency switch off the main switch. 2 After reactivation observe the fault messages. Refer to 6.13.2...
Page 82: Auto Mode, Manual Mode
DIOX-A 250 Operation AUTO mode, MANUAL mode Functions of the modes: • generation dependent on external lead signal: AUTO mode: • Flow signal from IMF (inductive magnetic flow meter), contact water meter) or • concentration (from external controller e.g. SFC unit) •...
Page 83 DIOX-A 250 Operation 6.9.2 Setting the generation factor With the generation factor GF the generation rate in the AUTO operating mode can be set exactly as required on the basis of the water flow and the required ClO concentration. The generation factor can be set within the range 0.1 - 3.0. Factory setting is GF = 1.
Page 84: Flushing The System
DIOX-A 250 Operation 6.10 Flushing the system The system must be flushed before maintenance, repair or taking the system out of operation. Warning! Risk of injuries due to dangerous chemicals! System damage! • Wear respiratory protective equipment and protective clothing. •...
Page 85 DIOX-A 250 Operation 8 Open the flushing ball valve (C). To confirm touch „Yes”. 9 To start flushing touch „Start”. The solenoid valve opens and the (optional) booster pump starts automatically. Both metering pumps work. The metering pumps and the reaction tank are flushed. 10 Stop flushing after approx.
Page 86: Operation
DIOX-A 250 Operation 6.11 Operation A correctly installed and adjusted system requires the following measures for operation: • Replacement of the hydrochloric acid and sodium chlorite carboys • Daily inspection of the system for leaks • Verification of the correct function of the gas detector (option) in accordance with national regulations and the system operating instructions •...
Page 87 DIOX-A 250 Operation • Under no circumstances should residual solutions remaining in the containers be decanted, but should be disposed of in accordance with local regulations! Attention! System Damage! Dirt in the HCl or NaClO lines causes failure of the oval gear meters.
Page 88: Emptying The System
DIOX-A 250 Operation 6.12 Emptying the system Warning! Risk of injuries due to dangerous chemicals! • Even after flushing the system can contain dangerous chemicals in minor quantities. • Only authorized and qualified personnel may empty the system (refer to chapter 7.3.2.). WT.085.266.000.DE.IM.0919...
Page 89: Messages And Fault Messages
DIOX-A 250 Operation 6.13 Messages and fault messages 6.13.1 Messages Example: Messages are displayed on the lower display line. Several messages are displayed alternately. The number of active messages is indicated. Reaction of the Message text Cause Remedy system Calibrate unit! During commissioning Calibrate the HCl and NaClO...
Page 90: Fault Messages
DIOX-A 250 Operation 6.13.2 Fault messages Warning! Risk of injuries due to dangerous chemicals and electric current! Observe before troubleshooting: • When working on the system wear protective clothing, protective gloves, googles or face protection. Have a respiratory mask ready to use. •...
Page 91: Plain Text Display
DIOX-A 250 Operation Plain text display Reaction Cause Remedy HCl-carboy empty Generation stops. HCl carboy empty Replace HCl carboy. Level probe defective, wire Check switch. breakage Empty signal of the pump Check pump. defective NaClO - carboy Generation stops. NaClO carboy empty Replace NaClO carboy.
Page 92 DIOX-A 250 Operation Plain text display Reaction Cause Remedy Calibration HCl Calibration stopped. Calibration takes too long Calibrate the HCl metering monitoring time pump, stop in good time when 100 ml is reached. Calibration NaClO Calibration stopped. Calibration takes too long Calibrate the NaClO monitoring time metering pump, stop in good...
Page 93: Maintenance
To prevent health risks or damage to the system, follow the safety notes and warnings attached to the system and in the instruction manuals in any case. • Only Evoqua customer service or personnel specifically trained by Evoqua may maintain the system.
Page 94: Maintenance/Inspection Plan
(„service maintenance), emptying and repairing the system must be performed by the customer service or by personnel especially trained by Evoqua. The following maintenance work must be done by the operator: 1 Check the system daily for functionality and leaks.
Page 95: Maintenance By Qualified Personnel
Evoqua. 7.3.1 Service maintenance Regular system maintenance, at least annually by the Evoqua customer service, is part of the servicing contract and guarantee conditions. Every 12 months the message „Effect maintenance“ is displayed until the maintenance has been executed and confirmed.
Page 96: Maintenance Menu
DIOX-A 250 Maintenance 7.3.4 Maintenance menu The maintenance menu is used • to delete the message buffer • to confirm startup and maintenance • for function test of the booster pump and solenoid valve. 1 Touch the lock symbol 2 Enter the service password (required). The lock symbol is displayed in blue.
Page 97: Maintenance And Spare Parts
All service maintenance and repair work must be performed by the customer service or personnel specifically trained by Evoqua. Due to mechanical wear, the service life of the maintenance parts listed in the tables must be expected to be shorter than the system’s service life.
Page 98 DIOX-A 250 Maintenance and spare parts Usage of maintenance sets After After After After After After 1 year 2 years 3 years 4 years 5 years 6 years WT.085.266.000.DE.IM.0919...
Page 99: Maintenance Parts
DIOX-A 250 Maintenance and spare parts Maintenance parts 8.2.1 Maintenance sets, annual W3T169965, W3T169966, W3T169967 a The ball valve DN20/d15 is used since version 10/2016. Retrofitting is possible with W3T384426 b During assembly pay attention to the flow direction of the individual components.
Page 100 DIOX-A 250 Maintenance and spare parts Item Article No. Description Quantity W3T168401 O-Ring W3T172835 O-Ring W3T169925 Non return valve W3T167548 Non-return valve W3T172725 O-Ring W2T504821 Sealing kit type 546 W3T169086 O-Ring W3T171985 O-Ring W3T185826 Service kit series B for DIOX-A 50/100 or W3T185828 Service kit series B for DIOX-A 170 or W3T161025...
Page 101 DIOX-A 250 Maintenance and spare parts 8.2.2 Maintenance sets, biennial W3T371573, W3T371574, W3T371575 Item Article No. Description Quantity W3T169965 Maintenance set, annual for DIOX-A 50/100 or W3T169966 Maintenance set, annual for DIOX-A 170 or W3T169967 Maintenance set, annual for DIOX-A 250 W3T163752 Hose connectors W3T162641...
Page 102 DIOX-A 250 Maintenance and spare parts 8.2.3 Maintenance sets, every 4 years W3T371576, W3T371577, W3T371578 Item Article No. Description Quantity W3T371573 Maintenance set, biennial for DIOX-A 50/100 or W3T371574 Maintenance set, biennial for DIOX-A 170 or W3T371575 Maintenance set, biennial for DIOX-A 250 W2T505983 Ball valve, type 546 W3T171902...
Page 103: Optional Accessories
DIOX-A 250 Optional accessories 9. Optional accessories Accessories W3T169989 Item Article No. Description Qty. W3T172372 Solenoid valve W3T165734 Union W2T505692 Adaptor bush W2T504863 Adaptor nipple W2T507536 Elbow W3T165668 Pipe clamp W3T171871 Screw W3T168162 Protective cap W2T506629 Pipe 135 mm...
Page 104 DIOX-A 250 Optional accessories Item Article No. Description Qty. W2T506629 Pipe 100 mm W2T506629 Pipe W3T169363 Valve plug WT.085.266.000.DE.IM.0919...
Page 105: 10.Wiring Diagrams
DIOX-A 250 Wiring diagrams 10.Wiring diagrams 10.1 Wiring diagrams WAE8885 terminal 230V 230V 230V 50Hz 50Hz 50Hz W001 W002 W004 W006 W003 W005 W007 L N PE L N PE 4 3 2 1 4 3 2 1 4 3 2 1 4 3 2 1 Dosing pump HCl Dosing pump NaClO2...
Page 106 DIOX-A 250 Wiring diagrams terminal W018 W019 W020 W021 W022 W023 W012 W025 W024 W013 Note Motorstarter LF24-S L1 L2 L3 T1 T2 T3 minmin maxmax L1 L2 L3 Tank *) Booster pump only model Batch CB 1241 RS485 not model Batch X20: RS485 optional model Attention !
Page 107: Cable Inlet
DIOX-A 250 Wiring diagrams 10.2 Cable inlet W009 NaClO flow (OGM) W007 Status output NaClO pump W006 Status output HCl pump W008 HCl flow W005 Pulses NaClO pump W004 Pulses HCl pump W017 Leakage sensor W010 Operating water flow (OGM) W011 Operating water Min W022 E-Valve Operating water W014 Release generation...
Page 108 DIOX-A 250 Wiring diagrams WT.085.266.000.DE.IM.0919...
Page 109: 11.Index
DIOX-A 250 Index 11.Index Accessories 103 Hazardous substances 11 Accessory kit 17 AUTO mode 82 Info menu 72 Input unit 63 Beaker 75 Installation 27 Booster pump 27 Interfaces 39 Calibration 76 Language menu 71 Capacity 20 Level monitoring 18 Carboys 21 Log in 66 Chemical equation 17...
Page 110 DIOX-A 250 Index Replacing the carboys 86 target groups 7 Technical data 20 Transport 26 Transport carboys 30 Safety 10 Safety Data Sheets 14 Service password 66 Setup 35 Versions 15 Sodium thiosulphate 13 Voltage failure 86 Spare parts 97 Starting chemicals 17 Storage 26 Suction lances 30...
Page 111 ® Wallace & Tiernan Products worldwide Australia Canada China +61 1300 661 809 +1 905 944 2800 +86 21 5118 3777 info.au@evoqua.com wtoe.can@evoqua.com sales.cn@evoqua.com France Germany Singapore +33 1 41 15 92 20 +49 8221 9040 +65 6559 2600 wtfra@evoqua.com wtger@evoqua.com...
Page 112 All information presented herein is believed reliable and in accordance with accepted engineering practices. Evoqua makes no warranties as to the completeness of this information. Users are responsible for evaluating individual product suitability for specific applications. Evoqua assumes no liability whatsoever for any special, indirect or consequential damages arising from the sale, resale or misuse of its products.

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Evoqua WALLACE & TIERNAN DIOX-A 100 Instruction Manual

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