GRUNDFOS INSTRUCTIONS. Oxiperm. OCD-164 ( g/h) Installation and operating instructions. Other languages.

GRUNDFOS INSTRUCTIONS Oxiperm OCD-164 (30-2000 g/h) Installation and operating instructions Other languages http://net.grundfos.com/qr/i/96709679

English (GB) English (GB) Installation and operating instructions Original installation and operating instructions Contents Page 1. General safety instructions 2 1.1 Introduction 2 1.2 Purpose of this manual 2 1.3 Symbols used in this document 2 1.4 Users 3 1.5 Obligations of the operator 3 1.6 Maintenance and service personnel 3 1.7 Correct usage 3 1.8 Inappropriate usage 3 1.9 Safety and monitoring equipment 3 1.10 Chemicals 3 2. Technical data 5 2.1 General data 5 2.2 Electrical data 7 2.3 Delivery state 7 3. Fundamentals 8 3.1 Chlorine dioxide for water treatment 8 3.2 Functional sequence 8 4. Design and function 9 4.1 Design of the system 9 4.2 Components 10 4.3 Mode of operation of the system 10 5. Installation 11 5.1 Transport and storage 11 5.2 Unpacking 11 5.3 Installation location 11 5.4 Installation scheme 12 5.5 Wall mounting 14 5.6 Hydraulic connection 14 5.7 Electrical connection 15 5.8 Interfaces RS-232, -422 and -485 17 6. Operation of control electronics 18 6.1 Program structure 18 6.2 Control and display elements 19 6.3 Automatic mode 19 6.4 Manual operation 19 6.5 Logbook 19 6.6 System choice 20 6.7 Units 20 6.8 Setup 20 6.9 Local/remote 23 7. Commissioning 24 7.1 Directives 24 7.2 System choice 24 7.3 Selection of operation mode 24 7.4 Venting of the bypass line 27 7.5 Calibrating the dosing pumps 29 7.6 Adjusting the dosing controllers 30 8. Operation of the system 31 8.1 Automatic operation 31 8.2 Manual operation 33 8.3 Faults 34 8.4 Error messages of the controller 35 8.5 Fuses and LEDs of the controller 36 8.6 Possible faults when changing the tank 36 9. Maintenance 37 9.1 Maintenance of the dosing pumps 37 9.2 Maintenance of the suction lines 37 9.3 Maintenance of reactor 38 9.4 Maintenance of injector 39 10. Spare parts kits and spare parts 40 10.1 DMI dosing pumps with double-head system 40 10.2 DMI dosing pumps with single-head system 41 10.3 Dosing pumps DMX 221 41 10.4 Bypass, post mixer, and dosing controller 41 10.5 Enclosure exhaust device 42 10.6 Bypass with solenoid valve and flow limiter (standard version: solenoid valve) 43 10.7 Bypass, circulating pump 230 V - 50 Hz, 120 V - 60 Hz 44 10.8 Bypass (version solenoid valve/ball valve, batch mode) 45 10.9 Bypass for external booster pump 47 11. Accessories 48 11.1 External booster pump 48 11.2 Load unit for booster pump 50 11.3 Hose connections/hose 50 11.4 Gas sensor and gas warning device 50 12. Current setting data 51 13. Quick Guide 52 14. Disposal 52 1. General safety instructions 1.1 Introduction The OCD-164 disinfection system is a state-of-the-art solution, which complies with recognised safety regulations. Conformity with applicable standards, directives and laws has been verified. Nevertheless, certain risks which cannot be prevented by the manufacturer are associated with the use of the system. 1.2 Purpose of this manual Inform users of optimum use of the system. Warn users of possible residual risks when using the system correctly, and identify measures that should be taken to avoid damage. Caution users against obvious misuse or inappropriate use of the system, and inform them of the necessary care that must be taken when operating the system. 1.3 Symbols used in this document Caution Warning If these safety instructions are not observed, it may result in personal injury. If these safety instructions are not observed, it may result in malfunction or damage to the equipment. s or instructions that make the job easier and ensure safe operation. Information about possible residual risks can be found: on warning signs located at the installation site, and immediately before steps associated with a residual risk. 2

1.4 Users Users are persons who are responsible for operating and monitoring the disinfection system at the installation location. The system must only be operated by trained and qualified personnel. Personnel must have appropriate technical knowledge and be familiar with the basic principles of measurement and control technology. 1.4.1 Obligations of the users Read this manual before operating the disinfection system. Be trained by qualified personnel from Grundfos Water Treatment in the operation of the system. Observe the recognised regulations governing safety in the workplace and accident prevention. Wear appropriate protective clothing in accordance with national regulations for the prevention of accidents when operating the system and handling chemicals. Keep secret the user code for the operating software. 1.4.2 User workstation The disinfection system is electronically controlled. Users and service personnel operate the system via a display with control and display elements. See section 6.2 Control and display elements. 1.5 Obligations of the operator The owner of the building or the operator of the disinfection system is responsible for the following: Keep this manual clearly accessible in the immediate vicinity of the system. Meet the installation requirements specified by the manufacturer (required water connections and fittings, environmental conditions, electrical connection, protective tube for dosing line (if necessary), audible or optical warning device for alarm messages (if necessary)). Ensure that water lines and fixings are regularly checked, serviced and maintained. Obtain official approval for storing chemicals, if necessary. Instruct users in the operation of the system. Provide the user code for the operating software only to users who have received appropriate technical training. Ensure that the regulations for the prevention of accidents are observed in the installation location. Provide all users and service personnel with protective clothing (face mask, gloves, protective apron). 1.8 Inappropriate usage Applications other than those listed in section 1.7 Correct usage are not in accordance with the intended use and are not permitted. The manufacturer, Grundfos Water Treatment, accepts no liability for any damage resulting from incorrect use. The system comprises state-of-the-art components and has undergone safety-related testing. Warning Unauthorised structural modifications to the system may result in serious damage to the equipment and personal injury. It is forbidden to dismantle, modify, change the structure of, bridge, remove, bypass or disable components, including safety equipment. 1.9 Safety and monitoring equipment The disinfection system is fitted with the following safety and monitoring equipment: two collecting trays for the two chemical containers (accessories), alarm functions in the control system. 1.10 Chemicals 1.10.1 Chlorine dioxide concentration In the reaction tank of the disinfection system, diluted sodium chlorite and diluted hydrochloric acid are mixed to create a chlorine dioxide concentration of approximately 20 g per litre of water. The chlorine dioxide solution is diluted again, and dosed into the main line to be disinfected, according to the requirements. According to the German drinking water ordinance (TrinkwV 2001), the chlorine dioxide concentration in drinking water must not exceed a maximum of 0.4 mg per litre of water. The following safety instructions must be observed: Warning Risk of explosion when using chemicals in too high a concentration. Only use sodium chlorite in a diluted concentration of 7.5 % by weight in accordance with DIN EN 938. Only use hydrochloric acid in a diluted concentration of 9.0 % by weight in accordance with DIN EN 939. The safety data sheets from the supplier must be observed. English (GB) 1.6 Maintenance and service personnel The system may only be maintained and serviced by authorised service personnel from Grundfos Water Treatment. 1.7 Correct usage The disinfection system is used to mix a diluted chlorine dioxide solution from 7.5 % sodium chlorite and 9 % hydrochloric acid. In accordance with the conditions described in this manual, it is used to dose the chlorine dioxide solution produced continuously or non-continuously into the (drinking) water line of a building or to feed it into a swimming pool, process water, wastewater or other industrial system for water disinfection. Warning Risk of explosion and serious damage to equipment and personal injury as a result of operating faults due to confusing the chemical containers or suction lines. Do not confuse the containers. Observe the red and blue markings on chemical pumps, suction lines and chemical containers: Red = HCl, blue = NaClO 2. Warning Risk of burns when skin and clothing come into contact with sodium chlorite and hydrochloric acid. Affected skin and clothing must be washed immediately in water. Warning Risk of irritation to eyes, respiratory system and skin, if chlorine dioxide is inhaled. When changing the chemical containers, wear protective clothing in accordance with regulations for the prevention of accidents. 3

English (GB) 1.10.2 Storing chemicals Chemicals must be stored in the appropriately marked original plastic containers. Do not store chemicals near grease, flammable substances, oils, oxidising substances, acids or salts. Empty and full containers must be kept closed, and stored exclusively in areas where national regulations for the prevention of accidents apply to storage. 1.10.3 Procedure in case of an emergency The general safety regulations and regulations for the procedure in case of an emergency as specified in EN 12671 (D) apply. Actions in case of an emergency: Ventilate the installation location immediately. Wear protective clothing (safety goggles, gloves, respirator and/or self-contained breathing apparatus, protective apron). Implement initial help measures: In case of contact with the eyes, rinse immediately with plenty of water for at least 15 minutes. Consult a doctor. In case of contact with the skin, wash immediately with plenty of water. Remove all contaminated clothing. In case gas is inhaled, move the casualty to a source of fresh air. Avoid taking deep breaths. Consult a doctor (look out for a racing pulse, as vasodilating treatment may be required). Spillages: In case of contact with clothing, remove the clothing immediately and wash with plenty of water. Chemical spillages in buildings must be washed away with water. Firefighting: Aqueous solutions of chlorine dioxide are not directly flammable. Extinguish the surrounding fire with water, preferably using a fire sprinkler system to dilute the ambient gas. Inform the fire brigade of the installed production capacity and any harmful starting substances that are being stored (precursor substances) so that precautions can be taken regarding possible risks. For emergency phone numbers, please see the acceptance report. 4

2. Technical data 2.1 General data 2.1.1 Performance and consumption data System OCD-164 ClO 2 preparation capacity at 6 bar counterpressure Max. system pressure Consumption of components 50 Hz 60 Hz 1) HCl NaClO 2 Solenoid valve 2) (standard) Dilution water requirement for bypass system Bypass pump 3) internal/external In batch mode Min. 4) Max. 5) English (GB) g/h l/h bar bar l/h l/h l/h l/h l/h l/h -30 30 421 10 10 0.7 0.7 420 420 7.7 14-120 120 426 9 6 2.9 2.9 420 420 31 55-220 220 430 7 7 5.2 5.2 420 420 56 100-350 350 437 9 9 8.3 8.3 420 420 89 160-700 700 933 9 9 16.5 16.5 900 900 179 320-1000 1000 948 9 9 24 24 900 900 258 450-1500 1500 970 9 9 35 35 900 900 383 680-2000 2000 996 9 6 48 48 900 900 517 900 General concentration range for all systems: 0.5-3.3 g/l 1) With max. preparation capacity, shortened reaction time 2) With admission pressure 2 bar higher compared with the pressure at the injection unit 3) Depends on flow losses of solution line up to injection unit 4) Concentration of ClO 2 solution approx. 3.3 g/l. Inlet pressure for bypass water: 3-8 bar 5) Concentration of ClO 2 solution approx. 2 g/l. Inlet pressure for bypass water: 3-8 bar 2.1.2 Temperatures and concentrations 2.1.3 Materials Permissible concentration of NaClO 2 solution 7.5 % by weight Permissible concentration of the HCl solution 9.0 % by weight Permissible ambient temperature 5 C to 40 C Permissible process water temperature (bypass water) 2 C to 40 C Permissible component temperature (chemicals) 5 C to 40 C Storage temperature of system -5 C to 50 C Storage temperature of chemicals 5 C to 40 C Permissible relative humidity 2.1.4 Connections and weights max. 80 %, non-condensing Components Materials Supporting frame PP Screws, washers and nuts 1.4301 Reactor Post-mixer Piping Gaskets Grey PVC, 1.4571 painted RAL 6017 Grey PVC Grey PVC FPM/PTFE 164-OCD Connection for bypass (water inlet) Connection for ClO 2 solution line Motive water pressure Enclosure exhaust device optional Motive water requirements Connection, exhaust device Weight of system DN DN bar l/h DN kg -30 800 33-120 800 34-220 800 34-350 1300 57 20 20 5 20-700 1300 62-1000 1300 66-1500 1300 76-2000 1300 82 Caution The solution line must be provided with a pressure relief valve set to 10 bar. This is a safety measure for the case that a pressure of more than 10 bar occurs in the dilution water line while the chlorine solution line at the outlet side of the system is shut. 5

2.1.5 Dimensions English (GB) TM04 8193 4510 Fig. 1 Dimensioning of the system with drillholes OCD-164 A A1 B C E F G H K L M C1 C2-30 700 740 650 40 800 760 230 148 148 410 9 DN 20 DN 20-120 700 740 650 40 800 760 230 148 148 410 9 DN 20 DN 20-220 700 800 650 40 800 760 230 148 148 410 9 DN 20 DN 20-350 760 800 650 70 1010 970 268 135 181 470 11 DN 20 DN 20-700 760 800 650 70 1010 970 268 135 181 470 11 DN 20 DN 20-1000 760 800 650 70 1010 970 268 135 181 470 11 DN 20 DN 20-1500 760 800 650 70 1300 1260 268 135 181 470 11 DN 20 DN 20-2000 760 800 650 70 1300 1260 268 135 181 470 11 DN 20 DN 20 6

2.2 Electrical data Max. permissible load of potential-free output contacts Analog input Analog output Contact input Max. permissible mains impedance with 90 Watt bypass Max. permissible mains impedance with 340 Watt bypass 250 V, 6 A, max. 550 VA 0/4-20 ma, load: 50 Ω 0/4-20 ma, load: max. 500 Ω max. 50 contacts/second 0.168 + j 0.168) Ω, (testing according to EN 61000-3-11) 0.059 + j 0.059) Ω, (testing according to EN 61000-3-11) English (GB) 2.2.1 Power consumption OCD-164 Power consumption [VA] -30 to -220 300-350 to -2000 650 2.2.2 IP codes Component Electronics, dosing pumps, solenoid valve, flowmeter Bypass pump Dosing controller IP code IP65 IP44 IP67 2.3 Delivery state The compact chlorine dioxide system comprises: The preparation system, completely assembled and wired up, on a PP supporting frame, including dosing pumps and suction lines. Dosing controller for flow monitoring of hydrochloric acid and sodium chlorite. Tank-level monitor and empty indication for hydrochloric acid and sodium chlorite. Chlorine dioxide reactor. Bypass system with flowmeter and solenoid valve, or optionally circulating pump and flowmeter, solenoid valve, dosing ball valve and flowmeter. Static mixer. Control electronics, directly mounted on the supporting frame, and wired up. Optional exhaust device: Injector with solenoid valve, electrically connected to the control electronics, supporting frame with side parts. 7

English (GB) 3. Fundamentals 3.1 Chlorine dioxide for water treatment Properties of chlorine dioxide Strong and fast oxidation and disinfection agent. Applications in the treatment of drinking, service, cooling, and waste water. Chemically unstable compound Can explosively decompose into chlorine and oxygen when heated. Must be generated on site as required, since storage in cylinders is not possible. Advantages of chlorine dioxide compared to chlorine Largely good to very good bactericidal, virucidal and sporicidal effects in the complete ph range of drinking water (ph 6.5-9). The disinfecting effect of chlorine decreases with increasing ph value. No or reduced forming of trihalogen methanes. No generation of chloramines with ammonium or amino compounds. Highly reduced potential for generation of organic halogen compounds of high molecular weight. Good stability in water. Long bactericidal and bacteriostatic protection in the water network. 3.1.1 Preparation of chlorine dioxide The chlorine dioxide preparation system was specially developed for the continuous or discontinuous preparation of a chlorine dioxide solution for water disinfection. The chlorine dioxide is generated according to the hydrochloric acid/sodium chlorite procedure in line with the following stoichiometric equation: 5 NaClO 2 + 4 HCl <=> 4 ClO 2 + 5 NaCl + 2 H 2 O Sodium chlorite + Hydrochloric acid <=> Chlorine dioxide + Sodium chlorite + Water 3.2 Functional sequence Three components are required to generate a chlorine dioxide solution: Hydrochloric acid (HCl) Sodium chlorite (NaClO 2 ) Dilution water (bypass). The added quantities of these components are defined by the process, and must not be changed. The flows of the individual components are therefore monitored by flowmeters and flow controllers. Hydrochloric acid (9 % solution) and sodium chlorite (7.5 % solution) are dosed into the reactor with a volume ratio 1:1. There they react together, and generate an uncritical chlorine dioxide concentration of 20 g/l. Following the reactor, the chlorine dioxide solution is diluted by the bypass water into a solution ready for use. Fig. 2 Bypass water ClO 2 solution NaClO 2 Reactor HCl Preparation of chlorine dioxide solution TM04 8194 4510 Warning The system must only be operated using a 9 % hydrochloric acid solution and a 7.5 % sodium chlorite solution. Commercially available solutions such as 24.5 % sodium chlorite or 32 % hydrochloric acid would generate an explosive concentration, and must therefore never be used undiluted in the system. This system uses a 7.5 % NaClO 2 solution and a 9 % HCl solution in a volume ratio 1:1 for chemical reaction. The reaction time is approx. 10 minutes. This application uses a multiple stoichiometric excess of hydrochloric acid for the following reasons: A non-critical chlorine dioxide concentration of 20 g ClO 2 /l is generated in the reactor. Warning Gaseous chlorine dioxide is explosive above a concentration of 300 g/m 3. A good yield of chlorine dioxide is achieved with excess acid of 250-300 %. A further increase in the excess acid only results in a small improvement in the efficiency. Excess acid shifts the equilibrium of the disproportionation reaction between hydrochloric acid and sodium chlorite to the right, resulting in an optimum yield. 8

P A 4. Design and function 4.1 Design of the system English (GB) TM04 8196 4510 Fig. 4 Reactor with components, assembled on the back of the supporting frame Pos. Description 1 Dosing system for hydrochloric acid (HCl) 1.1 Dosing pump for hydrochloric acid 1.2 Suction line with pre-empty and empty signal for HCl (red) 1.3 Dosing controller for HCl flow monitoring 2 Dosing system for sodium chlorite (NaClO 2 ) 2.1 Dosing pump NaClO 2 Fig. 3 Complete system with components, assembled on a supporting frame TM04 8195 4510 2.2 Suction line with pre-empty and empty signal for NaClO 2 (blue) 2.3 Dosing controller for NaClO 2 flow monitoring 3 Bypass water feed pipe 3.1 Solenoid valve (optional circulating pump) 3.2 Impeller counter (flowmeter for bypass water) 3.3 Non-return valve 3.4 Flow limiter 4 Reactor 4.1 Reactor housing 4.2 Reactor valves 5 Post-mixer 6 Connection for ClO 2 solution line to the injection unit 7 Connection for bypass water 8 Controller with display 9 Injector for exhaust device (option) 9

English (GB) 4.2 Components 4.2.1 Suction lines The suction lines must be matched to the tank size and the system performance (diameter of suction line). They have a dual level-control unit. If the level of the components (HCl/NaClO 2 ) drops to the first stage ("Min" contact/pre-empty signal), the alarm "HCl- MIN" or "NaClO 2 MIN" is output. This is indicated by flashing of a LED on the controller display. The system remains in operation, the relay "pre-empty signal NaClO 2 /HCl" is activated. The system is switched off when the second stage is reached ("Min"-"Min"contact/empty signal), and the alarm "HCl empty signal" or "NaClO 2 empty signal" is displayed, the "Alarm" is activated and the alarm LED lights up red permanently. If a buzzer is connected to the potential-free output relay, an audible signal is output. 4.2.2 Dosing pumps The dosing pumps are mounted at the supporting frame. They operate according to the pulse/pause procedure. The stroke length is adjusted with a rotary knob. The stroke length is preset, but may have to be corrected following gauging of the pumps since the local pressure conditions depend on the application. The dosing pumps for the systems OCD-164-30 to OCD-164-220 are delivered with an integral gauging system. Gauging of the dosing pumps for the systems OCD-164-350 to OCD-164-2000 is carried out using calibration cylinders on the suction side. Refer to the table 2.1.1 Performance and consumption data for the dosing rate to be set for the pumps. The dosing rates of the pumps should be set approximately the same (± 10-15 %) to guarantee uniform consumption of the chemicals. The stroke length must not be adjusted any further following gauging. 4.2.3 Dosing controller The dosing controllers guarantee that both chemicals flow into the system during operation. If the volume flow of one of the chemicals drops by more than 25-30 %, the dosing controller outputs an alarm and switches off the system. The working point must be correctly set to guarantee safe functioning of the dosing controller, see section 7. Commissioning. A correctly set working point is indicated by the flashing LEDs on the controller flowchart, see section 6.2 Control and display elements. 4.2.4 Reactor The reactor is installed at the rear of the supporting frame. The non-return valves on the reactor inlet and outlet must be selected depending on the system pressure. Standard valves are suitable for a system pressure of less than 3 bar. 4.2.5 Bypass The bypass water line dilutes the chlorine dioxide solution generated in the reactor (approx. 20 g/l) and routes it to the main water flow. Several versions of the bypass line are available: Bypass with solenoid valve and flow limiter Bypass with circulation pump Bypass with solenoid valve and dosing ball valve (batch mode) Bypass for external booster pump (and load unit), see section 10.9 Bypass for external booster pump. The water in the bypass is monitored by a flowmeter. The flowmeter switches the system off, if the bypass water falls below a minimum flow; the LED on the flowchart flashes. The LED lights up permanently, if the water flow is above the minimum quantity, see section 6.2 Control and display elements. Fit a particle filter upstream, if the bypass water is not free of solids. 4.2.6 Post-mixer The chlorine dioxide solution is mixed with the bypass water in the post-mixer (standard). 4.2.7 Options Power Supply 230 V, 50/60 Hz 115 V, 50/60 Hz. Bypass Bypass with pump 230 V, 50/60 Hz Bypass with pump 115 V, 60 Hz Bypass with solenoid valve 230 V, 50/60 Hz and flow limiter (standard) Bypass with solenoid valve 115 V, 50/60 Hz and flow limiter Bypass for external booster pump, see section 10.9 Bypass for external booster pump. Suction lines Suction line 1.3 m for 30/60-litre tank (standard) Suction line 2.5 m for 30/60-litre tank Suction line 2.5 m for 200-litre tank. Exhaust device Exhaust device, DN 20, 230 V 50/60 Hz (standard) Exhaust device, DN 20, 115 V 50/60 Hz Without exhaust device. Reactor non-return valves System pressure less than 3 bar (standard) System pressure more than 3 bar. Bus systems Profibus DP module Ethernet TCP/IP module. Interface RS-232 interface RS-422 and RS-485 interface. 4.3 Mode of operation of the system Positions in brackets, see fig. 4. When the system is started in normal mode, the solenoid valve (3.1) opens. Dilution water flows to the post-mixer (5), the flow is controlled via the impeller counter (3.2). The two dosing pumps simultaneously pass 9 % hydrochloric acid and 7.5 % sodium chlorite solution with a ratio of 1:1 into the reactor (4). The flow quantities of the chemicals are monitored by the dosing controllers (1.3 and 2.3). The reaction between sodium chlorite and hydrochloric acid results in a chlorine dioxide solution with a concentration of 20 g/l in the reactor (4). The dwell time in the reactor is approx. 10 minutes. In the subsequent mixer, this solution is diluted down to a concentration of max. 3.3 g ClO 2 /l, depending on the system size and performance setting, and passed on to the injection unit. The system is switched off immediately, if one of the dosing controllers or the impeller counters detects a low flow. Warning Chlorine dioxide is a toxic gas, hydrochloric acid and sodium chlorite are highly corrosive chemicals which must be handled properly. Installation and operating personnel must therefore be acquainted with the regulations concerning the handling of chlorine dioxide, hydrochloric acid and sodium chlorite. In Germany, the accident prevention regulations UVV are applicable. 10

A set of warning signs for the chlorine dioxide system in accordance with the specifications is available under Order No 96727022 (515-662). Please find further general information for operation of a chlorine dioxide system in: Accident prevention regulations "Chlorination of water" (VGB 65 or GUV 8.15) Directive on dangerous working materials DIN 938 "Sodium chlorite solution for water treatment; technical conditions of delivery" DIN 939 "Hydrochloric acid for water treatment" "Chlorine dioxide for water treatment" DVGW directive, worksheet W 224 (German) 4.3.1 How the system operates in batch mode In batch mode, a defined ClO 2 solution is added to a holding tank (batch container), and transported to the injection units by means of dosing pumps. The ClO 2 concentration can be adjusted within a range of 0.5 to 3.3 g/l. 5. Installation 5.1 Transport and storage Warning Only transport the system, when it's empty, observe the weight. Only use suitable lifting and transport equipment. Transport system carefully. Dry, cool storage location. Protect from direct sunlight. 5.2 Unpacking The system is tested at the factory and ready for connection. Check for damage, do not install or connect a damaged system! When unpacking, look for loosely packed components. Install as soon a spossible following unpacking. Retain packaging material, of dispose of according to local regulations. English (GB) Bypass water NaClO 2 Fig. 5 Reactor ClO 2 solution HCl ClO 2 Preparation of chlorine dioxide solution For a concentration between 2 and 3.3 g/l, the quantity of bypass water is set via a dosing ball valve. In the case of concentrations below 2 g/l, the required quantity of bypass water for a 2 g/l solution is set. The desired concentration inside the solution container is then achieved by regulating the two dosing pumps. The limits for the bypass water quantity are -50 % and +20 % of the target value. If the target value is undershot (up to -50 %), the system will automatically regulate the dosing flow of the chemical pumps for the current water quantity. This is achieved by means of a pulse-pause control on the dosing pumps. When the water quantity target value is undershot, the overall performance of the system is reduced by up to -50 %. This control makes it possible to compensate pressure fluctuations in the bypass pipe. Warning Protection units should be provided in addition, such as separate collecting trays for the hydrochloric acid and sodium chlorite tanks. Protective clothing for operators has to be provided. Furthermore, the specified warning signs, danger information and first aid information must be positioned at the specified points. TM04 8197 4510 5.3 Installation location The applicable local or country-specific regulations must be observed when selecting and designing the installation location for the chlorine dioxide system. In Germany, the accident prevention regulations UVV are applicable. The installation location for the system must fulfil the following requirements: The permissible ambient temperature of +5 to +40 C must be guaranteed. The installation location must be vibration-free and isolated fireproof from other rooms. Caution Reference to the dangers when using the chlorine dioxide system and to the relevant precautionary measures must be provided using appropriate signs at access points to the system rooms and to the associated chemical storage rooms. 11

5.4 Installation scheme English (GB) Select or set a contact water meter in such a way that, at max. installation output, the control pulses are not < 5 pulses/sec. Calculation of the contacts see section 7.3.3 Contact input. The control for the system can process a max. rate of 50 pulses/sec. If a value greater than 50 pulses/sec. is calculated, use a different contact water meter. If the pressure at the injection unit is < 1 bar, a pressure loading valve must be installed. A pressure loading valve may not be used in installations with an internal centrifugal pump, as this pump only generates an increase in pressure of approx. 5 mwc. For the dosing pumps DMI with Plus3 system, ensure that the container is always underneath the dosing pump, and the suction line is positioned in a downwards direction, so that the chemicals can easily flow back via the return pipe into the container. Recommended L = min. 200 mm, see fig. 6. TM04 8199 4510 Fig. 7 System with solenoid valve, installation scheme L Pos. Description Fig. 6 Installation scheme with suction line length 5.4.1 System with solenoid valve The systemis delivered as a standard with a solenoid valve in the dilution water line. In this version, the supply of dilution water and the addition of chlorine dioxide solution are not carried out in the same water circuit. Requirements 10 bar > water pressure > 1 bar. The counterpressure at the connection of the solution line should be at least 0.5 bar less than the inlet pressure of the dilution water. Caution With the chlorine dioxide solution line shut off (at the outlet) and an input pressure of more than 10 bar in the dilution water line (at the inlet), there is a danger that the system will be damaged. The solution line must therefore be provided with an excess pressure valve set to 10 bar. TM04 8198 4510 1 Supporting frame 2 Electronics 3 Connection for dilution water 4 Connection for solution line to the injection unit 5 Suction line for HCl dosing pump 6 Suction line for NaClO 2 dosing pump 7 Main water pipe (supplied by the customer) Isolating valve for the injection unit (supplied by the 8 customer) 9 Sample extraction (supplied by the customer) 10 Non-return valve (supplied by the customer) 11 Isolating valve for dilution water extraction (supplied by the customer) 12 Supporting frame exhaust device, with solenoid valve (option) 13 Solution tank with level control (option) 14 External booster pump (option) 15 Load unit for the external booster pump 16 17 Pressure loading valve (supplied by the customer), if the system pressure is < 1 bar Inductive flowmeter (4-20 ma) or contact water meter for proportional control of the system (observe the contacts from the contact water meter). 12

5.4.2 System with internal bypass pump As an option, the system can be delivered with an internal bypass pump instead of the solenoid valve. This version is required for treating closed water circuits, i.e. the sampling of dilution water and the addition of chlorine dioxide solution are present in the same water circuit. The bypass pump is only designed for compensation of the internal friction losses of the system, and for counteracting the pressure losses of approx. 0.1 bar in the solution line to the injection unit. The solution line to the injector should therefore be kept as short as possible. The geodetic difference in height between the connection of the solution line and the injection unit must not exceed 1 m. English (GB) Fig. 9 System with booster pump, installation scheme TM04 8201 4510 5.4.4 System with solenoid valve/ball valve (batch tank) TM04 8200 4510 As a further option, the dilution water line can also be selected with a solenoid valve and dosing ball valve. This version is required if batch mode is present, i. e. a certain concentration of ClO 2 is prepared in a tank. Dosing of the ClO 2 solution to the injection unit is carried out using dosing pumps. The concentration of the ClO 2 solution in the tank can be adjusted from 2 to 3.3 g/l. The set pressure must be adjusted to the local conditions during startup. The pressure retention valve must be set such that siphoning does not take place through emptying of the solution line when the system is switched off. Fig. 8 System with bypass pump, installation scheme 5.4.3 System with external booster pump and load unit An external booster pump can be connected to the dilution water line as a further option. This version is required, if sampling of the dilution water and addition of the chlorine dioxide solution are not in the same water circuit, and the system pressure at the injector is higher than the pressure of the dilution water supply line. In this version, a load unit is required in addition, and is controlled directly by the system electronics, see fig. 42. If the pressure set on the loading valve is too high, it may occur that the required quantity of bypass water cannot be correctly set. If the bypass water is not free from solids, a dirt filter should be installed upstream. Booster pump and load unit must be selected separately (see section 11. Accessories). TM04 8202 4510 Fig. 10 System with solenoid valve and ball valve 13

English (GB) 5.5 Wall mounting The mounting material includes screws, wall plugs, washers and nuts. Mount the supporting frame on the wall using the enclosed mounting material. Select the mounting height such that the containers with chemicals can be located underneath, and that the controller display is easy to read. Drilling scheme see section 2.1.5 Dimensions. The liquid level of the containers when full with chemicals should always be below the dosing pumps. Caution The system must be freely accessible on the left and right for maintenance work (approx. 50-60 cm space). The mounting material also contains a M6x20 countersunk screw for fixing a gas sensor, see section 11. Accessories, underneath the reactor. 5.6 Hydraulic connection Warning Before hydraulic connection, disconnect the system from the mains. It must be possible to insert the suction lines (items 5 and 6) for hydrochloric acid and sodium chlorite into the tanks without tension. Install the suction hose, return hose and the two empty alarm cables of the suction line in the tank such that the bottom end of the suction line is approx. 1 cm above the base of the tank. 5.6.1 Bypass In the case of the version with solenoid valve, provide the dilution water supply line with an isolating valve, and route the remaining part of the line up to the inlet connection in PVC tube, and connect. In the case of the version with internal bypass pump, route the dilution water line in a PVC tube as directly as possible from the main water line up to the inlet connection. Provide a sampling shut-off valve on the main water line. Warning If the sampling line and the solution line are connected to the same water circuit, a non-return valve must be fitted in the main line between the dilution water sampling point and the injector in order to prevent circulation of the solution with dangerous building up of chlorine dioxide. Route chlorine dioxide solution line to the injection unit in PVC tube. An isolating valve should also be fitted in this line directly upstream of the injection unit. 5.6.2 Safety exhaust device (option) 1. Mount the safety exhaust device underneath the system cabinet. 2. Cut the supplied PE hose to length, and connect to the diaphragm check valve of the suction injector and to the associated screwed gland of the supporting frame (in the centre of the base). 3. Route the injector motive water line in PVC tube of DN 20, and connect to the solenoid valve. Route the disposal line in PVC tube of DN 20, and connect to the outlet connection of the suction injector. 4. Insert the plug of the control voltage cable into the solenoid valve socket and tighten the plug screw. Fig. 11 Safety exhaust device, installation scheme Pos. Description 1 Disposal pipe (waste water/untreated water) DN 20 2 Suction injector 3 Solenoid valve 4 Pressure reducer 5 Water supply line 6 Booster pump Connection - version A This connection option is used if the pressure in the water line is > 4 bar, and there is an adequate total quantity of water (bypass water and motive water for the suction injector). If the pressure is > 5 bar, there should be a pressure reducer (4) installed, so that the pressure upstream of the suction injection is between 4 and 5 bar. Connection - version B This connection option is used if the pressure in the water line is > 4 bar, i.e. the prescribed pressure upstream of the suction injection must be generated via a booster pump (6). If there is an adequate volume of water in the supply line (5) (sufficient water for the bypass and suction injector), the booster pump (6) can be connected to the water supply line (5). The water supply to the booster pump (6) can be conducted via a separate water supply line at any time. TM04 8203 4510 Caution The motive water of the suction injector must be free from sand and suspended matter. It is therefore recommendable to install a dirt trap upstream of the solenoid valve. 14

5.7 Electrical connection A direct connection of the system to the power supply is made using the terminals 1 (L1), 2 (N) and 3 (PE). Depending on the Warning version, the power supply can be 230 V (AC) or 115 V (AC). The electrical connection must only be carried out by Connection to an incorrect power supply may destroy qualified personnel. Caution the system. Observe the local safety regulations! Switch off the power supply before connecting the mains cable. 5.7.1 Terminal connection diagram Make the electrical connection according to the enclosed connection diagram. English (GB) TM04 8204 4510 Fig. 12 Terminal connection diagram 5.7.2 Power supply L N PE Description L N PE Description 1 2 3 Power input 16 17 18 ------------------------------------------- 4 5 6 Power output 19 20 21 7 8 9 ------------------- 22 23 24 Solenoid valve/pump/bypass water 10 11 12 HCl dosing pump 25 26 27 13 14 15 NaClO 2 dosing pump 28 29 30 5.7.3 Potential-free outputs Solenoid valve: enclosure exhaust device Solenoid valve: exhaust device for batch tank Root NO Description Function 31 33 Fault 31/33 open in case of fault 32 34 Pre-empty signal HCl/NaClO 2 32/34 open in case of pre-empty signal 37 39 Automatic 37/39 closed in case of "system active" 38 40 Tank run dry 38/40 open in case of dry run 5.7.4 Inputs +8 V +8 V GND IN Description 59 (brown) 60 61 (blue) Dosing controller NaClO 2 63 (brown) 64 62 (blue) Dosing controller HCl 65 66 67 ------------------------------ 69 (brown) 70 (white) 68 (green) Bypass water impeller counter 15

English (GB) 5.7.5 Inputs +12 V +12 V GND IN Description Function NC 43 ------- 44 Batch tank ClO 2 overflow Contact open in case of overflow ClO 2 level above contact NO contact 45 ------- 46 Batch tank ClO 2 max. Contact closed in case of "Max" ClO 2 level above contact NO contact 47 ------- 48 Batch tank ClO 2 min. Contact open in case of "Min" ClO 2 level below contact NO contact 49 ------- 50 Batch tank ClO 2 dry run Contact open in case of dry run ClO 2 level below contact 51 (brown) ------- 52 (white) Pre-empty signal NaClO 2 Contact open in case of pre-empty signal NC NaClO 2 level below contact ------- ------- 53 (green) Empty signal NaClO 2 Contact open in case of empty signal NC NaClO 2 level below contact NC ------- ------- 54 (green) Empty signal HCl Contact open in case of empty signal HCl level below contact NC 55 (brown) ------- 56 (white) Pre-empty signal HCl Contact open in case of pre-empty signal HCl level below contact 57 ------- 58 ----------------------------------- 71 (white) 72 (brown) 73 (green) Hall sensor NaClO 2 pump 75 (white) 76 (brown) 74 (green) Hall sensor HCl pump ----------------------------------------- 77 (white) 78 (brown) 79 (green) ----------------------------------- - 81 80 83-84 Contact input water meter 85-86 Remote on/off Contact open: "Remote off" 87-88 Fault gas warning device Contact open: fault 89-90 Contact main water min. Contact open: min. contact main water 5.7.6 Analog signals Shield IN/OUT Description 95 93 IN + Analog IN 96 97 OUT + Analog OUT 16

5.7.7 Profibus/Ethernet (option) The controller can be optionally equipped with Profibus or Ethernet. Profibus-DP module The Profibus-DP connection is made via a 6-pin plug. 5.8 Interfaces RS-232, -422 and -485 The controller can optionally be equipped with interfaces. 5.8.1 Connection of RS-232 interface English (GB) TM04 8205 4510 TM04 8206 4510 Fig. 13 Profibus connection diagram Plug Signal Description 0 RTS (CNTR-P/RTS) Control signal for repeater 1 PGND Shield/protective earth 2 RxD/TxD-N Received data/transmitted data Negative 3 RxD/TxD-P Received data/transmitted data Positive 4 DP GND Ground to DP 5 V 5 DP 5 V CNTR-N 5 V supply for terminating resistors Control signal for repeater Fig. 14 Connection diagram of RS-232 interface 5.8.2 Connection of RS-422 and -485 interfaces Ethernet TCP/IP Ethernet 10 Base-T/100 Base-TX (10/100 MBit/s). Transport protocol TCP or UDP connection. The connection is made using an RJ 45 plug of category 5. TM04 8207 4510 Fig. 15 Connection diagram of RS-422 and-485 interfaces 17

English (GB) 6. Operation of control electronics 6.1 Program structure Automatic Main menu Manual operation Logbook System choice Setup Service mode Type 1, Type 2, etc. System type Language Venting Batch mode Operation mode Min. contact water Startup mode Current input Units System choice Test mode Contact input Current output Manual control Code function Target value external Reset function Date/time Exhaust enclosure Program version Bypass MIN time Auto start TM04 8208 4510 Fig. 16 Program structure 18

6.2 Control and display elements 3 15 14 13 12 The selection possibilities shown on the display are identified by the numbers 1, 2, and 3, e. g.: Main menu 1 Automatic 2 Manual operation 3 Logbook English (GB) 1 4 11 10 Menu selection is made using the keys [F1], [F2], [F3], e. g. the function key [F1] is used to select the menu item list under "1", etc. 2 Fig. 17 Controller Pos. 1 2 3 4 Description LED for dosing controller NaClO 2 LED flashes: dosing controller set correctly LED for NaClO 2 tank LED off: correct level LED flashes: pre-empty alarm active LED on: empty alarm active LED for bypass water LED on: bypass water is correct LED flashes: bypass water outside tolerance LED for dosing controller HCl LED flashes: dosing controller set correctly LED for HCl tank LED off: correct level 5 LED flashes: pre-empty alarm LED on: empty alarm 6 Arrow keys for moving in the menus 7 8 Function keys [F1], [F2], and [F3]: select menu items [F4]: [Reset] key [Enter] key Confirm inputs 9 [Escape] key Cancel or switch over to submenu 10 Display, 4-line 11 Master switch with [Emergency stop] function 12 13 14 15 16 17 18 5 16 17 LED for alarms LED on or flashing: present alarm LED display of operation mode "automatic/manual" LED flashes: automatic control LED for remote on/off mode LED flashes: remote on/off by min. contact for main water LED on: remote on/off by external contact 18 LED for service mode LED flashes: system in [Service] menu LED for alarms on the display LED on or flashing: present alarm LED for connection of display to PLC LED on: connection correct LED display LED on: display in operation 6 7 8 9 TM04 8209 4510 Example Press the [F1] key to switch to the menu "Automatic". Press the [F2] key to switch to the submenu "Manual operation". Press the [F3] key to select the menu "Logbook". Press the [Escape] key to return to the main menu (9). Press the [Enter] key to confirm an input (8). 6.3 Automatic mode In this operation mode the capacity of the system can be controlled automatically by incoming signals such as contact input, current input or Bus control. In "Manual control" mode there is no "Automatic" operation. "Automatic" operation is activated in the main menu using the [F1] key, and indicated by flashing on the display. 6.4 Manual operation This operation mode facilitates the manual input of the dosing capacity by the display in the modes current input, contact input, manual control, or Bus control. In order to operate the system in "Automatic" mode, it is first necessary to select the system type and the operation mode, see section 6.6.2 Operation modes. In order to operate the system in "Manual" mode, it is first necessary to select the system type and the operation mode. "Manual" operation is activated in the main menu using the [F2] key, and indicated by flashing on the display. 6.5 Logbook In the "Logbook" menu, all activated and acknowledged alarm messages are recorded. The operating hours can also be called in this menu. In the main menu, switch to the "Logbook" submenu using the [F3] key (Logbook). Logbook 1 active alarms 2 event list 3 operating hours Use the [F1] key to display the alarm messages (if present). Use the [F2] key to call all events. The alarm messages can be deleted, if necessary. Switching to page 2 is possible using the [ARROW RIGHT] key, the buffer can be deleted using the [F1] key. Switching to page 1 is possible using the [ARROW LEFT] key. Use the [F3] key to display the operating hours. Scroll in the respective menu using the [UP] and [DOWN] arrow keys. 19

English (GB) 6.6 System choice Define the system size and the operation mode in the "System choice" menu. The input can be cancelled at any time using the [Escape] key. The activated system type or the activated mode is displayed flashing on the display. 6.6.1 System type Scroll in the main menu using the [ARROW RIGHT] key on page 2. Use the [F1] key to switch to the "System choice" menu. In the "System choice" menu, switch to the "System type" menu using the [F1] key. Select the system size using the [F1], [F2] or [F3] keys, scroll if necessary using the [ARROW RIGHT] or [ARROW LEFT] key. After selection of the system type, the following message is displayed: System type 164-XXXXD activated Use the [Enter] or [Escape] key to return to the "System choice" menu. The system is preset in the factory. The selected type of system is displayed flashing in the "System choice" menu. Check this setting for correctness prior to starting up, or select a new system type. 6.6.2 Operation modes 5 different operation modes can be selected: Batch mode The performance of the system (100 %) is controlled by the use of a buffer tank. Current input The system performance (2.5-100 %) is controlled via an external current input signal, e. g. 4-20 ma. Contact input The system performance (2.5-100 %) is controlled via an external contact input signal, e. g. from a contact water meter. Set the contact water meter in such a way that, at max. performance the control contacts are not < 1 contact/sec. If, in exceptional cases, this value is < 1, min. 0.25 contacts/sec., the bypass "Min" time must be increased. The controller can process a maximum of 47 contacts/sec. If a value greater than 47 contacts/sec. is calculated, use a different contact water meter. Target value external The system performance (2.5-100 %) is controlled via a Bus system (can only be selected, if a bus system has been selected in the "Basic settings > Bus" menu). The mode is factory-set, i.e. the selected mode is displayed flashing in the "Operation mode" menu. Check that this mode is correct before commissioning; if necessary, select a new mode. 6.7 Units Either metric or US units of measurement can be selected on the system: Metric units Bypass water [m 3 /h] System capacity [g/h] Contact water meter [contacts/litre] The entry of the parameters for current input and contact input is described in the Section on "Commissioning". US units Bypass water [gal/h] System capacity [lb/day] 6.8 Setup In the main menu, switch to the "Basic setting" menu using the [F2] key (scroll if necessary). 6.8.1 Language In the "Basic setting" menu, switch to the "Language" menu using the [F1] key. Select language using [ARROW RIGHT] or [ARROW LEFT] key. Confirm using [Enter]. Use the [Enter] or [Escape] key to return to the "Basic setting" menu. 6.8.2 Min. contact water The min. contact in the main water line (on site) switches the system to standby, if the set minimum main water flow is fallen below. In the "Basic setting" menu, select the "Min. contact water" menu using the [F2] key. Activate or deactivate the function using the [F1] or [F2] key. Min. contact main water activated Contact water meter [contacts/gal] Use the [Enter] or [Escape] key to return to the "Basic setting" menu. The selected function is displayed flashing in the "Min. contact water" menu. 6.8.3 Current output In the "Basic setting" menu, select the "Current output" menu using the [F3] key. Example Default quantity of ClO 2 0.3 ppm Main water quantity 30 m 3 /h Contact water meter 1 contact/litre Max. system capacity 0.3 ppm x 30 m 3 /h = 9 g/h Contacts from water meter 1 contact/litre x 30 m 3 /h x 1000/3600 = 8.33 contact/sec. Manual control The system performance (0-100 %) is controlled by manual input. When "Manual control" is selected, the installation can only be started in "Manual mode". If the installation is started in "Automatic mode", an alarm message is displayed, and the system stops. Current output ClO 2 capacity 0 % = XX ma 100 % = YY ma Press the [F1] key to select the variable input fields. Switching between the values (0 %; XX ma; 100 %; YY ma) is also carried out using the [F1] key. Enter individual values using the [UP] and [DOWN] keys (modify numerical values) and the [ARROW LEFT] and [ARROW RIGHT] keys (change input position). Confirm the set values using the [Enter] key. The selected current output is activated by pressing the [Enter] key again. Current output XX - YY ma activated Use the [Enter] or [Escape] key to return to the "Basic setting" menu. 20