Diox. Cloro

8/13/2019 Diox. Cloro

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Bello Zon Type CDVa for diluted chemicals

Please carefully read through these operating instructions in full. Do not discard!Damage caused by incorrect operation will invalidate the guarantee!

These operating instructions were delivered with following system:

See Fig. 2 Identification Code System in Annex (page 8) for identification

Operating InstructionsProMinent Chlorine DioxideGenerating SystemsBello Zon Type CDVa

Affix type identification

Part No. 987796 ProMinent Dosiertechnik GmbH 69123 Heidelberg Germany BA BEZ 014 12/01 GB

P r o M i n e n t


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Publishing details:Operating Instructions Bello Zon Chlorine Dioxide

Generating Systems Type CDVa ProMinent Dosiertechnik GmbH

ProMinent Dosiertechnik GmbHIm Schuhmachergewann 5-1169123 HeidelbergP.O. Box 101760 69007 [email protected]

Subject to technical modificationsPrinted in Germany

Publishing Details


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Contents

General User Information .................................................................. 41 Functional Description ................................................... 51.1 Production Process .............................................................. 51.2 System Concept ................................................................... 51.3 System Description .............................................................. 61.3.1 Reactor ................................................................................. 61.3.2 Exhaust system .................................................................... 61.3.3 Metering Pumps ................................................................... 61.3.4 Feed Monitoring ................................................................... 71.3.5 Metering Valve ...................................................................... 71.3.6 Bypass Line .......................................................................... 71.3.7 Systems without Bypass Monitoring .................................... 71.3.8 Intake Lances ....................................................................... 71.3.9 Safety Trays .......................................................................... 81.4 Control .................................................................................. 81.4.1 Functional Sequence ............................................................ 81.4.2 Display Elements of the Control ........................................... 81.4.3 Function Buttons .................................................................. 81.4.4 Identity Code, Revision Status (Version), Operating Code ... 91.5 Operating Modes.................................................................. 91.5.1 Manual Setting of Chlorine Dioxide Rate: Internal Control... 91.5.2 Flow-Dependent Chlorine Dioxide Metering ........................ 101.5.3 Measured Value-Dependent Chlorine Dioxide Metering:

Controlled Variable-Dependent ............................................ 111.5.4 Combined Activation ............................................................ 111.5.5 Remote Control Input: Contact (Pause Function) ................ 111.5.6 Remote Control Input: Analog .............................................. 121.5.7 Outputs for Signalling Facilitites: Alarm and Warning .......... 121.5.8 Analog Output ...................................................................... 122 Mounting/Installation ..................................................... 122.1 Prerequisites and Safety Notes ............................................ 122.2 Wall Mounting....................................................................... 132.3 Hydraulic Connections ......................................................... 132.3.1 Bypass Line .......................................................................... 142.3.2 Water Connection for Exhaust Systems............................... 142.3.3 Venting Line .......................................................................... 142.3.4 Intake Lances ....................................................................... 142.3.5 Intake Lines .......................................................................... 142.3.6 Checking Pipe Screw Fittings and Connections .................. 152.4 Electrical Connection ........................................................... 152.4.1 Opening the Control ............................................................. 152.4.2 Installation of Cable Connections ........................................ 152.5 Affixing Information Signs .................................................... 163 I nit ial Op erat ion (Commis sioni ng) .............................. 173.1 Information on Applicable Regulations ................................ 174 Operation ........................................................................... 174.1 Setting the Metering Rate .................................................... 174.1.1 Systems with Internal Control .............................................. 174.1.2 Systems with Flow-Dependent Metering ............................. 184.1.3 Systems with Control Variable-Dependent Metering ........... 184.2 Accuracy of Metering Rate ................................................... 194.3 Calibrating the Metering Pumps ........................................... 194.4 Setting the Feed Monitors .................................................... 204.5 Bypass Water Failure ............................................................ 204.6 Changing Component Containers........................................ 204.6.1 Bleeding ............................................................................... 214.7 Checking the Reaction - Sampling Chlorine Dioxide ........... 214.8 Determining Chlorine Dioxide Concentration ....................... 224.9 Chlorine Dioxide Metering Rate ........................................... 22


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4.10 Consequences of Incorrect Setting ...................................... 224.10.1 Incorrect Setting of Metering Pumps ................................... 224.10.2 Incorrect Setting of Feed Monitoring.................................... 234.10.3 Incorrect Setting of Bleeder Cock Valves Acid/Chlorite ....... 234.10.4 Incorrect Setting at Bypass .................................................. 234.10.5 Incorrect Setting in Control .................................................. 235 System Maintenance ...................................................... 235.1 Regular Checks .................................................................... 235.2 Maintenance Work................................................................ 245.2.1 Maintenance of Metering Pumps ......................................... 245.3 Troubleshooting .................................................................... 245.4 Shutting Down the Chloride Dioxide System ....................... 265.4.1 Shutting Down for a Short Period ........................................ 265.4.2 Shutting Down for a Prolonged Period................................. 265.4.3 Shutting Down and Frost-Proof Storage .............................. 266 Technical Data .................................................................. 276.1 Accessories .......................................................................... 276.1.1 Intake Lances ....................................................................... 276.1.2 Supplementary Kit and Spare Parts ..................................... 276.1.3 Venting Valve Reactor Room ................................................ 276.1.4 Fuses .................................................................................... 28

6.1.5 Bello Zon -Acid and Bello Zon -Chlorite ............................. 286.1.6 Safety Trays .......................................................................... 286.1.7 Set for Determining Chlorine Dioxide ................................... 286.1.8 Heating Systems for Chemical Lines ................................... 296.1.9 Metering Points .................................................................... 296.1.10 Suction Accumulator Bello Zon .......................................... 296.2 Protective Filter ..................................................................... 296.3 Temperature .......................................................................... 296.4 Bypass Pump (Stainless Steel) ............................................. 296.5 Spare Parts ........................................................................... 297 Conformity Declaration .................................................. 30

Annex

General User InformationThese operating instructions describe the technical specifications andfunctions of the Bello Zon chlorine dioxide generating systems, they providedetailed safety information and are organised in clear steps which areexplained by following examples:Device descriptions are identified by normal flowing text: The completesystems are preassembled on a plastic support bracket.

Actions/activities to be carried out are identified by bullets (bold type dots):

Reset bleeder cock valves to initial position.

Cross references are identified by arrows and bold type texts:> Detailed description as of Page 61

Safety notes are set in bold italics and identified by a warning symbol.

WARNING : Effective monitoring of the flow of bypass water is a prerequisite for reliable and safe operation of chlorine dioxide systems .

Working notes are emphasised and set in italics:

NOTE: All machines, fittings and system components must be installed such that they are easily accessible to facilitate operation and maintenance! Wherever

possible set up machine at eye level!

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General User Information


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1 Functional DescriptionBello Zon systems serve the purpose of producing and metering chlorinedioxide. 20 years of experience gained in the construction of these systemsensures a high safety standard and outstanding operational reliability.

1.1 Production Process

Hydrochloric acid-chlorite process:5 NaClO 2 + 4 HCl > 4 ClO 2 + 5 NaCl + 2 H 2OSodium chlorite + hydrochloric acid > chlorine dioxide +sodium chloride + water

1.2 System ConceptType CDV Bello Zon systems produce and simultaneously meter a 2 %chlorine dioxide solution. The chlorine dioxide is produced by combiningthe two components Bello Zon acid (9 % hydrochloric acid solution) andBello Zon chlorite (7.5 % sodium chlorite solution).The two components are mixed in the reactor thus producing a chlorinedioxide solution with a concentration of 20 g/l. Under normal operatingconditions, this chlorine dioxide solution can be safely managed in the sealedreactor of a Bello Zon system.WARNING:The sodium chlorite concentration in CDV systems should be7.5 weight % ( 0.3 %) and the hydrochloric acid concentration

9 weight % (+1 %).

If the concentration of sodium chlorite is not maintained in CDV type Bello Zon systems the quantity indicated in the display will be falsified and a risk of accident will be posed in the case of higher sodium chloriteconcentrations.

Gaseous chlorine dioxide is explosive as from a concentration of 300 mg/m 3. At a critical chlorine dioxide concentration, an aqueous chlorine dioxidesolution with a concentration of 8 g/l, for example, can be expected. For thisreason, the reactor of a Bello Zon system features a completely sealeddesign. A backpressure valve (approx. 1.5 bar prepressure) that ensures nogas phase can occur is located at the reactor outlet. Particular care must betaken during the installation to ensure that vacuum cannot occur at themetering point under all operating conditions.

After the reactor, the chlorine dioxide is substantially diluted with water in abypass line. The quantity of water required for this dilution should be setsuch that a concentration of 0.1 to 0.5 g/l is produced in the bypass line.This eliminates the risk of corrosion while this intense dilution (1:100) alsoreduces the corrosiveness of the chlorine dioxide solution containinghydrochloric acid.WARNING:

Mixing of the chemicals outside the Bello Zon reactor must be avoided under all circumstances. (Also refer to: Extract from the hazardous

substances information sheet of FIGAWA in the annex, Page 5).The metered quantity can be set manually (internal activation) or fullyautomatically (external activation).The systems are designed such that chlorine dioxide is produced only in thequantities actually required.Bello Zon systems are manufactured in compliance with the relevantguidelines applicable in Germany, i.e. DVGW working codes of practiceW 624 (chlorine dioxide in water treatment) and the accident preventionregulation Chlorination of water (GUV 8.15 or VBG 65).

NOTE (for systems installed in Germany):The system operator is obliged to read these guidelines and to use thechlorine dioxide system accordingly.

Functional Description

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1.3 System DescriptionSeries CDVa chlorine dioxide generating systems represent completelyassembled turn-key installations ready for connection.> See Fig. 1 and table with performance specifications in Annex

The following are always included in the scope of delivery of each Bello Zon system: the intake lances to suit the relevant component tank and supplementary kit with various hardware.The system configuration is defined by the identification code

CDVa XA.XXXXXDXXThe version of the bypass line and of the control can be varied dependent onthe identification code.> See Fig. 2 and Fig. 3 in Annex

1.3.1 ReactorThe reactor is installed separated from the pumps in a closed housing.

An inspection window is provided in the line above the reactor. Here thereaction can be observed in the form of a slight yellow discolouration.

The chlorine dioxide solution flows through the metering valve into thebypass. Here it is mixed into the flow of water.

1.3.2 Exhaust systemThe exhaust system ensures a regular exchange of air in the reactor housing.It consists of an injector and a solenoid valve which is switched by thecontrol system.The fresh air is fed into the reactor room either via a ventilation valve or via aline which leads to atmosphere.The ventilation valve is available as an accessory (see Section 6.1.3).

1.3.3 Metering PumpsThe metering pumps are mounted at the bottom end of the support bracket.The bleeder bottles are arranged between them. On the intake side, a hoseleads from the intake lances to the pumps. A rotary knob is provided on themetering pumps to adjust the stroke length.The stroke frequency is calculated by the control and sent by way of pulsesto the pumps. One metering stroke is carried out for each incoming pulse.The pumps therefore operate at independent frequencies. The relevantdelivery rate is determined by calibrating the capacity. These values areentered in the control. The control then calculates the relevant frequency sothat both pumps deliver the same quantity.The stroke length must no longer be varied after gauging capacity in litres.The stroke length of the pumps should be set approximately the same

( 20%).The liquid ends are made of Plexiglas. Various pumps are used dependent onthe capacity of the chlorine dioxide system.> See table of performance data in Annex

Calibration measuring cylinders are arranged over the pumps. They are usedto calibrate (gauge) the capacity of the pumps.



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1.3.4 Feed MonitoringThe task of the feed monitoring element is to ensure that both chemicals flowconstantly during system operation.If the volumetric flow of a component is reduced by more than 30%, the feedmonitoring element triggers an alarm and switches off the chlorine dioxidesystem.The operating point must be set correctly by means of vertical adjustment in

order to ensure feed monitoring functions correctly.

1.3.5 Metering ValveThe metering valve is located in the bypass line and is installed in a crosspiece fitting. The valve opens at a reactor internal pressure of approx. 1.5 bar.

1.3.6 Bypass LineThe chlorine dioxide solution produced (20 g/l) is diluted in the bypass waterline and fed to the main flow of water.The bypass line is made up in various versions depending on theidentification code: Bypass line with variable-area flowmeter and minimum contact Bypass with turbine wheel flowmeter and minimum contact Non-return valve Premixing device Bypass pump made of stainless steel or cast iron

A flow monitor is installed in the bypass line which signals when the flowdrops below a minimum flow rate and then switches off the system.The flow monitor may be a variable-area flowmeter or a turbine wheelflowmeter. The response value of the minimum contact in conjunction withthe turbine wheel flowmeter is adjustable in the control system. The currentflow in the bypass can also be monitored.The turbine flowmeter can not be used if the bypass water is to be enrichedwith chlorine dioxide (e.g. in circuit systems).

NOTE:If the bypass water is not free of solid particles, a protective filter should beconnected downstream of the turbine flowmeter.> See Section 6.2 Protective Filter

1.3.7 Systems without Bypass MonitoringIf the system does not feature bypass monitoring, the operator must ensurethe metering system is interlocked with the flow of water in which the chlorinedioxide is fed. This ensures that the system is always switched offimmediately if there is no flow of diluting water.

1.3.8 Intake Lances

The intake lances must suit the container size (length of intake lances) andthe system capacity (diameter/wall thickness of intake line).> See Section 6.1.1

They feature a two-stage level monitoring facility. If the level of thecomponents drops to the first stage, initially, the control triggers the messageAcid level low or Chlorite level low as an initial warning.This is indicated by the red alarm lamp (Fig. 4-L2) flashing.The system, however, continues to operate. In addition, the Warning relay isalso activated.



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When the level reaches the second (lower) stage, the system shuts down andthe message Acid container empty or Chlorite container empty isindicated at the control.The alarm relay is now activated.The red alarm lamp (Fig. 4-L2) now lights permanently. If connected, a hornalso signals.

1.3.9 Safety TraysSafety trays are available as accessories in two versions, i.e. with and withoutleakage warning.They are designed to take up 30 l and 200 l containers.> See Section 6.1.6

1.4 ControlThe control with the inputs and outputs, display/indicators as well as thenecessary operating elements is located on the right next to the reactorhousing. The number of inputs and outputs is defined by selection of theidentification code.> See Fig. 4 in Annex

1.4.1 Func tiona l Sequence A pulse is generated in the control and sent to the metering pump which inturn carries out one stroke. This stroke produces a signal in the feed monitorwhich is sent back to the control. If the feedback to the control fails, thesystem is shut down after eight missing pulses in series and thecorresponding error message appears in the display.

At the same time the red alarm lamp (Fig. 4-L2) flashes.The system can be restarted by pressing the Acknowledge button.

1.4.2 Display Elements of the ControlThe operating mode, chlorine dioxide capacity and flow rate, if water meterconnected, are indicated in the display.LED indicators at the top of the control unit indicate the control signals forthe pumps (Fig. 4-L5 Acid, Fig. 4-L9 Chlorite) by way of a yellow flashinglight.They light red in the case of fault.The relevant green feed monitoring LEDs (Fig. 4-L6, Fig. 4-L10) are locatednext to them.The indicators for a bypass water pump if fitted (Fig. 4-L3) and for monitoringthe flow of bypass water (Fig. 4-L4) are located at the top left.The indicator for the diluting water pump (between acid and chlorite) isprovided for use in CDK systems and therefore has no function for this series(L7 and L8).

1. 4.3 Function Buttons

Start/Stop

With this button, the system can be started or metering stopped from anyprogram level. In Standby mode, it is possible to change the setting data.

The green LED (Fig. 4, L1) lights during operation.

STARTSTOP



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Discharge

The solenoid valve of the exhaust system is opened and the air extractedfrom the reactor housing. Discharge duration: 5 min by pressing button,during normal operation: 12 sec.

Calibrate/Start-Up

A certain number of strokes is triggered at maximum frequency.Change

Changing a function/mode of operation.

Smaller

Reduces a displayed numerical value.

Back

Exits operating menu in steps, back by one setting level at a time.

Larger

Increases a displayed numerical value.

Store

Saves a displayed value or status.

Acknowledge

Acknowledgement of error messages

1.4.4 Identity Code, Revision Status (Version),Operating Code

The ordering system based on the identity code enables easy selection ofthe system variant to be ordered. The identity code must be specified in theorder. When expanding a system, the identity code of the system must also

be changed accordingly.Due to the fact that electronics and software are subject to constant updateand improvement, the version numbers are used as the means of identifica-tion. All systems which are supplied within a certain time interval have thesame hardware and software revision statuses irrespective of the identitycode. They must be quoted in the case of complaints or when extendingsystems which are already installed. They can be shown on the display bypressing the change button.To facilitate system setup on site, an operating code has been introducedwhich makes it possible to activate and deactivate the various optionsavailable in the system. This code can also be shown on the display.

1.5 Operating Modes> Refer to annex for graphic representation of operating modes.

1.5.1 Manual Sett ing of Chlorine Dioxide Rate:Internal Control

Here, the metering capacity of the system can be set manually from zero tomaximum capacity. The control varies the drive frequency of the pumpsaccordingly.In this mode of operation, the system can be used for treating water atconstant volumetric flow rates. The system can be switched on or offexternally via the remote control contact (control hardware adaptationnecessary).

R



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1.5.2 Flow-Dependent Chlorine Dioxide MeteringIn this mode, the amount of chlorine dioxide produced is controlled by meansof the signal provided by a contact water meter in the main flow of water. Thepulse interval is set during the start-up procedure (range: 0.1 - 320 litres).The table below should be used as an aid in selecting the suitable contactwater meter.

The contact spacing should be selected depending on the feed rate and onthe flow rate in the main water line of the water meter.The following estimation applies for this purpose:Maximum contact spacing (MaxK) = Capacity (g/h) / feed rate (mg/l)Minimum contact spacing (MinK) = (Max.K) / 10

The contact spacing should always be between MinK and MaxK. Thisensures the maximum input frequency is not exceeded and a maximumtransmission ratio of 7 is maintained (one water meter pulse = 7 pumpstrokes of chlorite).Potential-free contact input (via optocoupler) for connection of contacts(e.g. reed ) or switching transistors ( open collector output).Maximum input frequency: 4 switching operations/secondNo Namur signal input.It is also possible to connect a water meter with an analog signal(0/4 - 20 mA) (control hardware adaptation necessary).The following table should be used to assist in selecting the analog flowmeter.

The upper limit of the measuring range is specified in the configuration menu.Standardised input (0/4-20 mA) for active (current sources) and passive(variable resistance) signal generators.Terminal assignments

Type Capacity Feed refer- IDM flow meter refer-at 5 bar ence value ence measuring range

CDV 35 46 g/h 0.3 mg/l 0-150 m 3 /h

CDV 60 66 g/h 0.3 mg/l 0-250 m 3 /h

CDV 120 130 g/h 0.3 mg/l 0-450 m 3 /h

Terminals Connection Plug-in slot Plug-in card

1(V+),2(+),3(-) Analog input Plug-in slot 1 Order No.: 725236

Flow rate Plug-in cardCurrent input B

Type Capacity Reference Maximum ReferenceRecommended water meter

at 5 bar feed rate flow rate pulse inter- Part number Pulseval interval

CDV 35 46 g/h 0.3 mg/l 153 m 3 /h 20 30.44.41 25 litres



Active signal generators (the majority flow meters) are connected to theterminals 2(+), 3(-).

A voltage of 20 V is available at terminal 1(V+). Variable resistors (1 k - 5 k )are connected to the terminals 1(V+), 2(+).



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Terminals Connection Plug-in slot Plug-in cardassignment

30 (+), 31 (-) Contact input Plug-in slot 6 Order No.: 725321

Remote control Plug-in carddigital inputthree-conductor


6(V+),7(+),8(-) Analog input Plug-in slot 3 Order No.: 725236

Flow rate Plug-in cardCurrrent input B

1.5.3 Measured Value-Dependent Chlorine DioxideMetering: Controlled Variable-Dependent

There are two different input positions available for selection: Contact input - for connection of controller with potential-free frequency

output (e.g. WS controller, DULCOMETER D1C) Analog input (0/4-20 mA) - for connection of controller with standardised

current output (e.g. DULCOMETER D1C, dialog)

Contact input

Terminal assignments 41(+), 42(-)This option is set as standard in the device.Signal frequency: 0 - 4 HzThe pulse frequency output for pump activation of the DULCOMETER D1Ccontroller can be connected to this input.

Analog input

Terminal assignments

The controlled variable signal output (0/4-20 mA) of DULCOMETER D1Ccontrollers can be connected to this input. Terminals 7(+), 8(-).

1 .5.4 Combined Activa tionIt is possible to combine flow-dependent and measured value-dependentactivation. Both signals are processed multiplicatively.

1.5.5 Remote Control Input: Contact(Pause Function)

The system can be switched on and off externally via the remote controlcontact input.For connection to: - Controller with limit contact

- Locking contactTerminal assignments

It is also possible to operate the system with basic load metering in thismode of operation.The required basic load metering rate can be set in the configuration menu.



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1.5.6 Remote Control Input: AnalogWith this function, the system capacity can be set from an external point withthe aid of an analog signal. When combined with other input signals, both areprocessed multiplicatively.

Terminal assignments

1.5.7 Outputs for Signalling Facili ties: Alarm and War ning

The control system can output signals at two different signalling devices.Operating faults can be output in the form of a warning signal via theterminals 64, 65: e.g., in the case of the level switches in the componenttanks responding to the first stage or if the bypass water does not flowcorrectly.Operating faults can be output as an alarm signal, which can implementsystem shutdown, via terminals 61, 63: e.g., if the metering monitor respondsor if the supply voltage fails.> See Fig. 15 Error messages

1.5.8 Analog OutputThis option comprises up to 3 outputs: Flow rate, controlled variable andcapacity. Terminal assignments in addition to the basic unit:


4(+), 5(-) Analog output Plug-in slot 2 Order No.: 725240Flow rate

Plug-in card,current output B

9(+), 10(-) Analog output Plug-in slot 4 Order No.: 725240Controlledvariable Plug-in card,

current output B

35(+), 36(-) Analog output Plug-in slot 8 Order No.: 725240Capacity

Plug-in card,current output B


27(+),28(E),29(-) Analog input Plug-in slot 5 Order No.: 725236

Remote control Plug-in cardcurrent input B

2 Mounting/Installation

2. 1 Prerequisites and Safety Notes> See safety and installation hints for Bello Zon systems

The installation hints stipulate that a separate room need not necessarilyhave to be provided for chlorine dioxide systems, i.e. under certainpreconditions, installation can take place in operating rooms: If the system is necessary for the process taking place there If small quantities of diluted chemicals are in the system If the system and chemicals are secured to prevent access by unauthorized persons.

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NOTE:Persons who have access to the room, in which the chlorine dioxide system is

installed, must have participated in appropriate safety instruction.The place of installation must be protected from sunlight, frost and renewingthe air must be possible.The permissible ambient temperature must be observed for drinking waterapplications. (Refer to table Capacity data, Annex, Page 7.)

It should be possible to transfer chemical containers to the system withoutobstruction.It must be possible to safely dispose of any spilt chemicals with the aid of awater connection and floor drain.Following connections are necessary: Connection of the bypass water line Water line min. 1 bar (free of solids and turbidity substances) Floor drain Electrical connection

2.2 Wall MountingThe installation kit contains anchor bolts, wall plugs, washers and nuts.> See Fig. 5 in Annex

The Bello Zon system should be mounted on a suitable wall as close aspossible to the metering point.

The mounting height should be selected such that the chemical containersstill have sufficient room under the system and the control display isconvenient to read of.

When full, the liquid level of the chemical container should always be belowthe metering pump.

> See 6.1.1 for container height of Bello Zon components

2.3 Hydraulic ConnectionsWARNING:The system must be installed such that a vacuum cannot occur at the

metering point under any circumstances, i.e. also during operationdowntimes, inspections etc. If this requirement cannot always beensured, a bleeder valve (refer to accessories, Chapter 6) or a pipe

bleeder with backpressure valve should be installed after the premixing stage in the bypass line.

In addition, the maximum permissible operating pressure for the system must not be exceeded under any operating conditions.

Particular care must be taken to ensure that metering does not take place if the water to be treated fails (no flow). This can be achieved, for instance, in that the system is controlled by a flowmeter or the systemoperates parallel to a delivery pump and is interlocked with it (via the

remote control contact input). NOTE:The entire installation should be checked for leaks at maximum operating

pressure. A protective filter should be used if there are solid particles or turbiditysubstances in the water of the bypass line, in the water line for the dischargedevice or in the measuring water line.> See Section 6.2 Protective Filter

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2.3.1 Bypass LineThe volumetric flow rate through the bypass should be 1-1.5 m 3 /h. Thebypass flow rate should be approx. 2 - 2.5 m 3 /h for metering rates greaterthan 120 g/h. A bypass pump must be used if this flow rate is not achievedby installation of a control valve in the main water line. For this purpose, aslanted seat valve (refer to Accessories, Chapter 6) should be installed tocontrol the volumetric flow in the bypass.

Nominal diameter of bypass line DN 25, material: PVCIf it is necessary to dismantle the bypass line, simply release the expandingstuds used for securing the line:Slide a knife blade between the white dome head and the grey PVC tab andcarefully lift off.Replacement studs are contained in the supplementary kit (included in scopeof delivery, see Section 6.1.3).The reactor must be flushed before carrying out maintenance. As a rule, it isnot possible to discharge the entire contents of the reactor into the processwater within a short space of time.Installation of a flushing device (refer to Accessories, Chapter 6) isrecommended for this purpose.

2.3.2 Water Connection for Exhaust System Water line nominal diameter DN 10, minimum pressure: 1 bar, run from left

to solenoid valve Arrange waste water line over constant downward slope. Do not connect to

other waste water lines before the drain. A screw fitting should be provided just before and after the system tofacilitate disassembly.

2.3.3 Venting LineIf no venting valve is installed, a venting line can be fitted from the reactorhousing, ascending and as short as possible to the outside.> See Section 6.1.3

2.3.4 Intake Lances Fix supplied labels as far as possible above the end cover on the pipe

(arrow tip first) so that the chemical names Acid and Chlorite are clearlylegible.

Fit intake lances in corresponding containers, the foot valve should hang just above the base, firmly screw on end cap.

Cut intake hoses to length, make sure that they are arranged on a constantascent to the pumps in order to counteract gasification (note permissible

intake height).> See table of performance data in Annex

NOTE:The intake hoses must be arranged such that connection free of mechanical

stresses is ensured at the liquid end.

2.3.5 Intake Lines NOTE:Only use suitable hoses otherwise the durability of the connection cannot be

guarantied. Check the diameter of the intake line.



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Slide union nut and clamping ring over the hose, then slide end of hoseas far as it will go over the connection sleeve, slightly widen hose end ifnecessary.

> See Fig. 6 in Annex

The clamping effect is achieved by firmly tightening the nut while at thesame time pressing down the hose.

You will obtain a firm hose connection if you now briefly pull the line secured

to the liquid end and then tighten the union nut once again.

2.3.6 Checking Pipe Screw Fittings and Connections Before initial operation, all screw fittings on the system as well as the

connections should be checked for leaks and retightened if necessary.

2.4 Electrical ConnectionElectrical installation must be carried out by a trained electrician inaccordance with the documents (wiring diagram) provided.WARNING:The system must not be under voltage (live) when working on it.

NOTE: A lockable repair switch with overload and short-circuit trigger should therefore be provided on site for the system.

A flexible electrical cable 3 x 1 mm 2 should be used as the mains powersupply line. All other cables used by the customer for the alarm, contactwater meter etc. should be flexible.

2 .4.1 Opening the Contro lBefore opening the unit, particular care must be taken to ensure that powersupply to the unit is disconnected. Release the four screws in the upper section of the housing.

The housing can be opened by pressing with the index finger on the frontedge of the upper section.

The retaining hooks are unlocked by pulling forward. The entire uppersection can now be detached by pulling forward.

> See Fig. 7 in Annex

WARNING:Carefully separate the upper section and lower section from each other both sections are connected by a ribbon cable!

With the aid of both guide rails, the upper section can now be fitted in theapprox. 80 mm high slide-in unit. All connection terminals are now freelyaccessible.

2.4.2 Installation of Cable ConnectionsTo facilitate electrical connection of the terminals, closed holes are providedon the underside of the control which must be punched out in order to passthrough the connection lines. The leadthroughs must be broken out on the control corresponding to the

system configuration.> See Fig. 8 in Annex

NOTE:First connect the cables of the rear row. The leadthroughs in the rear row are

allocated to Pg 9 and Pg 11 screw fittings (Fig. 9).Special punch tools are available for breaking out the holes to ensure the pc-

board and thread are not damaged (Fig. 10 and 11).

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Slide screw fitting, thrust ring and seal from the installation kit onto thecable, screw into threaded hole and hand tighten.

NOTE:The 9 leadthroughs in the front row are for Pg 7 screw fittings.> See Fig. 10 in Annex

Fit Pg 7 screw fittings over the cable and lock in position with locknut. Run wires to the terminals corresponding to the electrical wiring diagram.

> See Fig. 19 in Annex NOTE:Various cable identification rings are fitted in order to differentiate betweenequivalent cables (e.g. power supply). (S for acid and C for chlorite.)Unused terminals must be connected to the corresponding pin strips beforeclosing the unit.

2.5 Affixing Information SignsThe two signs below must be displayed together at entrances to rooms, inwhich Bello Zon chlorine dioxide systems are installed.

The two signs below must be displayed together at entrances to rooms, in

which the component Bello Zon

-chlorite is stored or used.

The following sign must be displayed in rooms, in which sodium chlorite(component Bello Zon -chlorite) is used:

These include storage and filling rooms as well as the room, in which tanksare installed and connected to the Bello Zon systems.

Do not use containers andequipment alternatively Sodium chlorite + acid =Highly toxic chlorine dioxide gasDANGER OF FATAL INJURY!

Chlorine dioxide systems Access for authorized personsonly

Sodium chloriteNaCIO 2



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3 Initial Operation (Commissioning)

3 .1 Information on Appl icab le Regula tions As stipulated in valid accident prevention regulations in Germany, chlorinedioxide systems must not be placed into operation before they have beenchecked by an authorized inspector to ensure they are in a conditionappropriate to their intended purpose.

In addition, before restarting operation, the safety of chlorine dioxidegenerating systems must be checked by an approved inspector.In compliance with regulations applicable in Germany, this inspection mustbe repeated at least every 6-12 months.

Only specially instructed persons who can be expected to perform their workreliably are permitted to operate and maintain chlorine dioxide systems andhandle chemicals.

> See Accident Prevention Regulations GUV 8.15 and VBG 65Chlorination of Water

For this reason, commissioning is carried out by ProMinent service or byspecially trained personnel in accordance with the correspondingcommissioning instructions.

Operating and maintenance personnel of the chlorine dioxide system receiveinstructions as part of the commissioning procedure.

4 Operation

Directly after switching on with the Start-Stop button, the systemidentification code is indicated in the top line of the display. It begins withCDVa. Below this, the relevant hardware/software version is indicated on theleft and the active code on the right. The active code (= operating status ofthe system) is adapted as part of the commissioning procedure. After 30seconds, the display switches over to the normal operating status. Theoperating mode and metering rate are then displayed.

4.1 Setting the Metering Rate> Refer to Annex for graphic representation of the software menu

page 2-4

The system must be shut down in order to make entries in the control.

If the system is in operation:

Press the Start/Stop button

Standby appears in the display

Press the Store button

The message Standby parameter? appears in the display

4.1.1 Systems with Internal Control Press the Store button

The message Parameter max. metering appears in the display

Press the Store button

The message Max. metering xx g/h appears in the display

The required system capacity can now be set with the Smaller button or theLarger button.

Press Store button

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A smaller stroke length can also be set if the frequency of the meteringstrokes is not sufficient to ensure the chlorine dioxide is mixed optimally withthe main flow of water.

NOTE:Correct calibration (capacity gauging) in accordance with Section 4.3 and

readjustment of the feed monitoring system in accordance with Section 4.4 are necessary every time the stroke length is adjusted.

4.1.2 Systems with Flow-Dependent Metering

Systems controlled dependent on the flow rate are set similar to thatdescribed above. See Section 4.1.1 . In this case, however, in contrast to theabove, the feed rate is referred to the main flow of water:

Example 0.1 mg/l.

The maximum and minimum flow rates of the main water flow are entered atthe controler of the system.

The systems shuts down if the flow rate drops below the minimum set valuein the main water line.

Press Store button

Parameter feed rate ClO 2 appears in the display Press Store button

Feed rate ClO 2 xx mg/l appears in the display

The required concentration after mixing in the main flow of water can now beset with the Smaller button or the Larger button.

Press Store button

Parameter max. flow rate appears in the display

Press Store button

Max. flow rate xx m 3 /h appears in the display

The maximum flow rate at the water meter can now be set with the Smaller

button or Larger button. Press Store button

4.1.3 Systems with Control Variable-Dependent Metering

In this case, the input signal is a control variable from a controller output.

The maximum value for metering capacity (control variable 100 %) is enteredin the parameter menu.

Press Store button

Parameter max. metering appears in the display

Press Store buttonMax. metering xx g/h appears in the display

The maximum system capacity can now be set with the Smaller button orLarger button.

Press Store button

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4.2 Accuracy of Metering RateThe accuracy of the metering rate depends on following parameters:

Backpressure in bypass Intake head Stroke length and frequency of pump Pump temperature Conveyed medium: Its concentration, density, vapour pressure

The pump reaches its operating temperature after one hour of operation atmaximum frequency. A cold pump delivers more than a warm pump.

The metering accuracy at maximum stroke length and maximumbackpressure is -5 % +15 %.

The reproducibility under constant conditions and at

~ min. 60 % stroke length in CDV 35 and~ min. 50 % stroke length in CDV 60 and 120

is better than 2 %.

All data are referred to water (20 C).

4.3 Calibrating the Metering PumpsThe pumps should be at operating temperature before calibrating (gaugingcapacity). After storing the metering rate, the following message appears inthe display

Pump calibration acid tt min (depending on the size of the system).

Press Store button

The message Acid tt min. xxx ml appears in the display

On the basis of the metering rate as set above, there is a minimum volumewhich the acid pump must deliver. This value can be called up:

Press and hold Smaller button until the value indicated in the display nolonger changes.

NOTE:The value now indicated is the minimum volume which the pumps must deliver in order to ensure the required metering rate.

The stroke length must be increased if this volume is not obtained duringcalibration (capacity gauging).

Fill both calibration cylinders with water exactly up to marking. Placecalibration cylinders on even, horizontal surface to facilitate read-of. Theliquid level should be at eye level.

Remove both intake lances from the containers and place in separatebuckets of water. This removes residual chemicals on the outside andprevents the intake lances running empty.

Slowly lift the intake lances, hold vertically and carefully place in the

calibration cylinders.The symbol for the start-up button should appear at the bottom right of thedisplay. The calibration procedure can then be started.

Press Calibrate/start-up button.

The system completes a number of strokes corresponding to its size andswitches off automatically.

Remove intake lances from the measuring cylinders (lift slowly and holdvertically), read off the new values at the calibration cylinders. Calculate thedifference between 500 ml resp. 1000 ml and the new values (in ml).

Enter the measured value for the acid pump with the Larger/smallerbuttons.

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Press Store button

Enter the measured value for the chlorite pump with the Larger/smallerbuttons.

Press Store button

Rescrew intake lances in the containers.

If the value is 20% higher than the minimum volume shown in the displaymixing of the chlorine dioxide in the main water line can be improved by asmaller stroke length setting. The calibration procedure must then berepeated.

WARNING:The stroke length must not be less than 50 % in CDV 60 and CDV 120

systems and not less than 60 % in the CDV 35 system otherwiseeffective operability of the feed monitoring system and operational

reliability are no longer guarantied.

4.4 Setting the Feed MonitorsThe normal operating pressure should be applied in the bypass line whensetting the feed monitoring elements.

Set control to Standby.The feed monitoring elements (Fig. 1-7) are adjusted with the aid of twoknurled screws. In order to set a feed monitoring element, the upper knurledscrew must be turned upward as far as it will go.

Start pumps with Calibrate/start-up button.

The system performs 20 strokes at max. frequency in this menu position.

By turning the lower knurled screw, the feed monitoring element is slowlyshifted upward until the green LED flow monitoring Acid (Fig. 4-3) orChlorite (Fig. 4-5) just still lights during each stroke.

Now turn back the screw so that the feed monitoring element is set approx.2 mm below its switching point.

The feed monitoring element is locked in position with the upper knurledscrew.

WARNING:The feed monitoring element must be reset if the stroke length of a

pump is varied or the backpressure changes at the metering point.

4.5 Bypass Water Failure

The minimum contact on the bypass monitor is set such that the monitoringfunction responds as soon as the flow rate is too low. In this case, the redLED (Fig. 4-L3) comes on and the system shuts down. The warning relay isactivated. The system resumes operation automatically as soon as the flowrate increases once more.

4. 6 Changing Component Containers Switch off system by pressing the Start/stop button.

Place new component containers under system.

(Left side: Bello Zon -acid, right side: Bello Zon -chlorite)

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Place intake lances in corresponding containers such that they hangslightly above the bottom of the containers. Firmly tighten screw cap.

Check whether there are any air bubbles in the intake line, bleed ifnecessary. (See Section 4.6.1) .

WARNING: Particular care must be taken when refilling or replacing the component containers to ensure that under no circumstances are the containers

confused or interchanged. If sodium chlorite is poured into the hydrochloride acid tank (or vice versa), large quantities of chlorinedioxide gas are immediately produced. Chlorine dioxide is unstable and

as from a concentration of more than 10 vol.% (= 300 g/m 3 ) in the gas phase it tends to explosive decomposition. In such cases, potentially, anexplosion can occur even after a period of 15 to 30 minutes.

To avoid confusion, the component containers, safety trays, tank store, place of installation and storage should be identified with a clear colour marking (acid = red, sodium chlorite = blue). Safety can be further improved particularly in the case of the storage tanks by the use of different connections systems. The operating personnel is to be

instructed in the safe and responsible handling of chemicals.

4.6.1 Bleeding NOTE: After changing the containers, air may be trapped in the intake line. Pump intake is impaired by pressure. It is therefore necessary to bleed the systemuntil the intake line and liquid end are free of bubbles. The stroke length

should be set to 100 % during the suction procedure. Only adjust stroke length while pumps are in operation. If the manual operation stroke length is not 100 %, note the value before changing it in order to proceed.

Set ball cocks for bleeding (Fig. 14, Ill. 1+2, note symbol on control levers).

Press Calibrate/start-up button several times if necessary. The deliveredliquid is now collected in the bleeder bottles.

Operate pumps until the intake lines and liquid ends are filled free ofbubbles. Stop procedure by pressing Calibrate/start-up button.

Reset ball cocks and stroke length to normal operation (Fig. 14, Ill. 3+4).

WARNING: Do not pour together the liquids in the bleeder bottles and do not fill back into the chemical containers. Pour out contents and flush with large volumes of water.

4.7 Checking the Reaction Sampling Chlorine Dioxide

The reaction to chlorine dioxide results in slight yellow discolouration whichcan be observed at the inspection window of the reactor outlet.

Approx. 1 hour after successful conversion in the reactor (possibly longer inthe case of larger supply tanks) a sample should be taken from the mainwater line. This water sample is then examined for excess chlorine dioxide(colorimetric determination in accordance with DPD method).

Change operating parameters of the system until the excess chlorinedioxide has reached the required value.

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4.8 Determining Chlor ine Dioxide Concentra tionThe chlorine dioxide concentration can be determined easily and reliably withthe DPD method.

The DT1 photometer can be used for this purpose, order no. 1003473.3

> See chapter 6.1.7

The reagents are prepared in tablet or liquid form and specific volumes are

then added to the sample water. The water will then turn a red colour whichis evaluated in the photometer by comparing it to a control sample (samplewater without reagent).

Measurement with DPD 1 tablets comprises following substances:

Chlorine dioxide (ClO 2 ) and free chlorine (Cl 2, HOCl, OCl

).

Chlorine compound (e.g. chloramine), chlorite (ClO 2 ) and chloride (Cl ) are

not determined by this method.

> Extremely high chlorite content can cause problems (e.g. in bottlewashing machines). The measured value will increase continuously after addition of reagents. In this case the measured value readingtaken directly after the addition of the reagent is to be viewed as the

correct one.The present of manganese can also falsify measurements and indicatea deceptively high chlorine dioxide content.

4. 9 Chlorine Dioxide Metering Rate

In view of the various applications of chloride dioxide systems, a generallyapplicable statement cannot be made with regard to recommended meteringrates.

In the treatment of drinking water, the total chlorine dioxide feed rate mustnot exceed the limit value of 0.4 g/m 3.

The overall drinking water concept must therefore be adapted to the use ofchlorine dioxide.

Higher feed rates are used for industrial water treatment (e.g. in bottlecleaning machines).

4.10 Consequences o f Incorrec t Se tting4.10.1 Incorrect Setting of Metering Pumps4.10.1.1 Different stroke length of metering pumps and

feed monitoring element set accordingly andnot calibrated or incorrect values entered duringcalibration.

Consequences:

Excess feed of acid or chlorite

Excess acid simply increases the excess which already exists and is of littleconsequence. Excess chlorite, however, can impair the production processand result in the limit value being exceeded.

NOTE: Always set both metering pumps to the same stroke length. Set the metering monitoring element correctly. Do not forget the calibration (capacity gauging) procedure! Enter calibrated values in the control and store.

4.10.1.2 Setting Stroke Length when Metering Pump is notin Operation

Consequence: Stroke difficult to adjust. NOTE:Only adjust stroke length with the pump in operation.

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4.10.2 Incorrect Setting of Feed MonitoringIf the feed monitoring element is set too low, it is possible that the monitoringfunction no longer detects a reduction in the flow rate of >30 % and thesystem continues to operate.

Consequence: See 4.10.1.1

If the feed monitoring element is set too high, the system shuts down aftereight pump strokes.

4.10.3 Incorrect Setting of Bleeder Cock Valves Acid/ Chlorite

Ball cock set to bleeding during system operation.

Consequence: The feed monitoring element sends no signal since there isno flow of chemicals. System switched off.

NOTE:Observe symbol on control lever of ball cock!

4.10.4 Incorrect Settings at Bypass4.10.4.1 Ball Cock Before the Bypass Monitor or

Af ter the Metering Valv e Closed

Consequence: No flow in bypass, pressure increases.

Bypass monitor or feed monitor no longer sends signal.System shuts down.

NOTE:Check setting of ball cock and set to correct position if necessary.

4.10.4.2 Flow Rate and Limit Contact in Bypass SetIncorrectly

Consequence if flow rate is too low:

The chlorine dioxide concentration in the bypass becomes excessively highthus reducing operational reliability.

Consequence if flow rate is too high:

Operating pressure increases possibly above the maximum permissibleoperating pressure.

4.10.5 Incorrect Setting in Control

Parameter values entered incorrectly.

Consequence: See 4.10.1.1

5 System Maintenance

5.1 Regular Checks

Determine chlorine dioxide concentration in the treated water.

Compare levels of component containers, if applicable,observe initial warning Level low in display.

Check flow rate at the bypass.

Document consumption of Bello Zon Chlorite and Bello Zon Acid.

System Maintenance


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5.2 Maintenance Work NOTE:In accordance with Accident Prevention Regulations GUV 8.15 and VGB 65 19 (2), the safety of chlorine dioxide systems must be checked by an

approved inspector regularly, however, once a year at a minimum and before resuming operation.

This inspection can be carried out as part of the routine maintenance carried

out twice a year by customer service. It is therefore advisable to conclude amaintenance agreement.

> See Fig. 15 and 16 in Annex

The system is checked for leaks on completion of maintenance work.

Control lines or mains power connection lines must only be installed byservice technicians. Only the corresponding special lines must be used.

WARNING: Before starting any maintenance work (replacement of parts etc.) on thechlorine dioxide system, the system must be flushed out with water inorder to remove all traces of chemicals.

The contents must be discharged before opening the reactor. Press the Discharge button (Fig. 4) for this purpose.

5.2.1 Maintenance of Metering PumpsCheck following points during maintenance:

Firm fit of liquid end screws

Firm fit of metering lines (delivery and intake side)

Firm fit of pressure control valve and of intake valve.

Check for moisture at leakage hole on head.

If moisture is found, this indicates a probable diaphragm breakage.

5.3 Troubleshooting5.3.1 Feed Monitoring LED (Fig. 4-L6 or L10)

does not Flash during Pump Stroke(Fault 5.3.4 Occurs after 8 Strokes)

Cause 1:

Feed monitoring element not set correctly.

> See Section 4.4

Cause 2:

Air in intake line from container to pump.

> See Section 4.6

5.3.2 Liquid Escapes from head Disc of a PumpCause: Diaphragm leaking

Remedy: Retighten socket head cap screws on liquid end.

If tightening the socket head cap screws is not successful, notify ProMinentService.

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5.3.3 Metering Pump does not Delivers althoughthe Yellow LED of the Metering Pump(Fig. 4-L9 or 4-L10) Flashes

Cause 1: Air may be trapped in the liquid end.

Remedy: Bleed system as described under Commissioning Section 4.6.1.

Cause 2: The stroke length is set to too small a value.

Remedy: Increase stroke length with adjustment.

5 .3.4 Red LED - Mete ring Pump(Fig. 4-L9 or 4-L10) Lights Up

The message in the display indicates the pump concerned or - in the case ofchemical level low - which container is empty.

Cause 1: Delivery rate has been reduced (by more than 30 %) due to an increase in the operating pressure or due to an increase in the intake head.

Remedy: Readjust feed monitoring (explained in Section 4.4 Setting Feed Monitoring).

Cause 2: Function connector on pump worked loose or cable is not connected correctly.

Remedy: Check orange cable from pump to control.

Cause 3: Ball cock in metering line set incorrectly.

Remedy: Check setting of ball cocks, note symbol on control lever.

Cause 4: Component container empty.

Remedy: Change container, bleed intake lines.

5.3.5 Red LED of Bypass Pump (Fig. 4-L3) Lights UpCause 1: Ball cock (Fig. 1-12) set incorrectly.

Remedy: Check setting of ball cocks in bypass.

Cause 2: Cable not connected correctly.

Remedy: Check cable from bypass monitor to control.

Cause 3: Bypass pump no longer delivers

Remedy: Check bypass pump.

Cause 4: Float or turbine wheel is blocked.

Remedy: Remove deposits.

Cause 5: Limit contact defective.

Remedy: Check limit contact and replace if necessary.

5.3.6 Metering Pump is not Primed Despite FullStroke Movement and Bleeding

Cause: Crystalline deposit on ball seat due to valves drying out.

Remedy: Briefly lift up intake hose, thoroughly flush through pump, if not successful, remove and clean valves.

System Maintenance


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5.3.7 Metering Pump was in Operation for aProlonged Period of Time and Suddenly noLonger Delivers

Bleed metering line, check level in container, if not successfulCause: Pump diaphragm probably defective.

Remedy: Notify service.

5.3.8 Metering Pump does not Move, Indicator Lamp(Fig. 4-L5 or 4-L9) does not Light

Check power supply, if power applied:Cause: Fuse defective.

Remedy: Have fuse checked by service and replaced if necessary. NOTE:Only use the specified fuse ratings (see Section 6.1.4)If the fault cannot be rectified by changing the fuse, notify ProMinent Service.

5.4 Shutt ing Down the Chloride Diox ide Sys tem5.4.1 Shutting Down for a Short PeriodIf the chlorine dioxide system is to be shut down only for a short period,switching off the system via the Start/Stop button will be sufficient. Thepower supply for system control and chlorine dioxide measurement shouldnot be disconnected.

5.4.2 Shutting Down for a Prolonged PeriodChlorine dioxide is an unstable compound that disintegrates over time.Therefore, if the system is to be shut down for a prolonged period (severaldays), it is advisable to flush out the reactor with water. The installation of aflushing device in the bypass line is recommended for this purpose (refer to

Accessories, Chapter 6.1.3). Switch off system by pressing the STOP button. Open the configuration menu in the control display. Set the start-up time parameter to min. 30 minutes in the Start menu. Remove the intake lances from the chemical containers and place

separately in a bucket filled with water. Press Start button and set the stroke length of both metering pumps

to 100%. Allow system to operate until the pump heads, reactor and lines up to the

metering valve are completely filled with water (this ensures no chlorinedioxide can flow out of the reactor during disassembly).

Disconnect system from power supply.

5.4.3 Shutting Down and Frost-Proof StorageIf the chlorine dioxide system is to be prepared for winter, it will be necessaryto completely discharge the reactor and bypass line. After flushing with water,the system can be discharged by opening the back pressure valve on thereactor outlet/bypass and by removing the inlet valves on the underside ofthe reactor. Switch on the discharge system by pressing the Discharge push button

before disassembling the reactor inlet valves.

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30 litre 200 litre 500 litre Flexible intake line

Intake lance PN 790650 791563 791612 792195

Container height 420 mm 940 mm 970 mm variabel

6 Technical Data

6.1 Accessories

6.1.1 Intake Lances As necessary accessories, the intake lances are included in the scope ofdelivery of a Bello Zon chlorine dioxide generating system. They are adaptedto the various container heights and to the intake hose diameter used in thecorresponding size of system.When ordering the system, the relevant intake lances are selected dependingon the container sizes used by the operator.Table: Intake lances for various container sizes

NOTE:To ensure trouble-free operation, only ProMinent intake lances with two-

stage float switches should be used.

6.1.2 Supplementary Kit and Spare PartsThe supplementary kit is included in the scope of delivery of a Bello Zonsystem. It consists of the parts which are necessary for installation at thecustomer. Cable screw fittings Pg 7, Pg 9 and Pg 11 including sealing rings, thrust

rings and lock nuts Dummy discs, plugs and lock nuts for stamped out and no longer required

leadthroughs in the control so that the specified type of enclosure isretained.

Wall plugs, anchor bolts and washers for mounting the system on a wall. Expanding studs in two sizes (as replacement) Clamping length 7, mm for securing metering lines, tab thickness 1 mm Clamping length 8 mm, for securing bypass line and cable duct, tab

thickness 3 mmSupplementary kit Part No. 791388> See Fig. 16 Spare Parts Sets in Annex.

6.1.3 Valves and Flushing DeviceBleeder valve for reactor chamber (can be used instead of a bleeder line that

is routed to the outside), Part No. 791801.Bleeder valve for bypass line (to prevent the breakthrough of chemicals inlong bypass lines or vacuum), Part No. 1001260.

Slanted seat valve, DN 25 (for adjusting the bypass flow rate with bypasspump installed), Part No. 1001877.

Flushing device (for installation in bypass line for discharging reactor beforemaintenance), Part No. 1000525, see Fig. 13.

Technical Data


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6.1.4 FusesControl:

A 5x20 mm fine-wire fuse must be used to provide fuse protection.

Mains voltage 200-240 V: 0.2 A super slow-blow PN: 712057

Mains voltage 100-120 V: 0.4 A slow-blow PN: 712021

The fuse is located in a fuse holder with bayonet catch in the terminal box ofthe control.Metering pump:

Fine-wire fuse 6.3 x 32 mmfor 230 V: 0.25 A slow-blowfor 115 V: 0.5 A slow-blow

6.1.5 Bello Zon -Acid and Bello Zon -ChloriteBello Zon -acid 30 l PN: 950130

200 l PN: 950131500 l PN: 950132

Bello Zon -chlorite 30 l PN: 950135200 l PN: 950136500 l PN: 950137

6.1.6 Safety TraysSafety trays with leak monitor

Leakage in the safety tray is monitored by means of a level switch.

Order number: 40 l PN: 791728

250 l PN: 791729

Scope of delivery: 2 trays plus pc-board

Terminal assignments in addition to basic unit:

Safety trays without leak monitor

Order number: 40 l PN: 791726

250 l PN: 791727Scope of delivery: 1 tray

6.1.7 Set for Determining Chlorine Dioxide

Photometer DT 1 PN: 1003473


47(+)(br), Leakage Plug-in 9 Order No.: 72527548(-)(w) monitoring acid

49(+)(br), Leakage Plug-in card48(-)(w) monitoring digital input

chlorite Bello Zon

Technical Data


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6.1.8 Heating Systems for Chemical Lines(For the case that the ambient temperature about the chlorine dioxide systemor the chemicals is below 10 C)Intake hose diameter 6/4 mm Part No. 1001636Intake hose diameter 8/5 mm Part No. 1001637Intake hose diameter 12/9 mm Part No. 1001638Intake hose diameter 19/16 mm Part No. 1001639

6.1.9 Metering PointsMetering tube, DN 25, PVC(can be used up to pipe diameter DN 80) Part No. 1001823Immersion tube, DN 25, PVC(can be used up to pipe diameter DN 100) Part No. 1001822

6.1.10 Suction Accumulator Bello Zon

Used for CDVa 35 to CDVa 120Suction accumulator CDVa Acid Part No. 1001820Suction accumulator CDVa Chlorite Part No. 1001821> See Fig. 12 in Annex

6.2 Protective FilterDULCOFILT protective filter G 1 Part No. 911056Nominal flow rate at delta p = 0.2 bar: 4 m 3 /hReplacement strainer element Part No. 143076Pore size 100 m

6.3 TemperaturePermissible ambient temperature: +10 to +40 CPermissible treatment water temperature: + 2 to +40 CPermissible component temperature (chemicals): +10 to +40 C

6.4 Bypass Pump (Stainless Steel)Motor dataRated voltage: 220 - 240 VRated current: 2.2 A Motor: 540 WSpeed: 2880 rpmElectrical protection: Integrated overload protection

6.5 Spare Parts> See Bello Zon parts list, Part No. 987902

Technical Data


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EC Declaration of Conformity

We, ProMinent Dosiertechnik GmbH

Im Schuhmachergewann 5-11D-69123 Heidelberg

hereby declare that, on the basis of its functional concept and design and in the version brought intocirculation by us, the product specified in the following complies with the relevant, fundamental safetyand health stipulations laid down by EC regulations.

Any modification to the product not approved by us will invalidate this declaration.

Product description: Chlorine dioxide generator

Product type: CDV ...

Serial number: see type identification plate overleaf and on device

Relevant EC regulations: EC - machine regulation (89/392/EEC) subsequently 93/44/EEC

EC - low voltage regulation (73/23/EEC) EC - EMV - regulation 89/336/EEC

subsequently 92/31/EEC

Harmonised standards used, EN 292-1, EN 292-2;in particlar: EN 60335-1 A6, EN 60335-2-41, EN 61010-1

EN 50081-1/2, EN 50082-1/2, EN 60801-2, EN 55011

EN 60555-2, EN 60555-3

National standards and other DIN VDE 0700 T1 DIN VDE 0110

technical specifications used, DIN VDE 0700 T41 DIN VDE 0106 in particular: DIN VDE 0700 T500

DVGW - compilation of rules, job sheet W224

Date/manufacturers signature: 19.07.1996

The undersigned: Mister Manfred Hholt, factory manager

Conformity Declaration


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Contents Page

Graphical representation of software menus 2-4

Properties of chlorine dioxide and information on the handlingof aqueous solutions 5

Performance data 6

Fig. 1 Design of a Bello Zon system CDVa 7

Fig. 2 Identification code system 8

Fig. 3 Operating code Bello Zon 9

Fig. 4 Control 10

Fig. 5 Wall mounting of support bracket 11

Fig. 6 Mounting of intake hose 11

Fig. 7 Bello Zon control inputs and outputs 12

Fig. 8 Arrangement of Pg screw fittings 13

Fig. 9 Installation of Pg 7 screw fittings 13

Fig. 10 Installation of Pg 9 screw fittings 13Fig. 11 Suction accumulator Bello Zon CDVa acid/chlorite 14

Fig. 12 Flushing device d32/d20 Bello Zon 14

Fig. 13 Setting of ball cocks 15

Fig. 14 Error messages in control and corresponding output signals 16

Fig. 15 Part No. - Overview of spare parts sets 17

Fig. 16 Measurements Bello Zon chlorine dioxide system CDVa 35-120 18

Fig. 17 Measurements Bello Zon chlorine dioxide system CDVa 220-600 19

Fig. 18 Measurements Bello Zon chlorine dioxide system CDVa 2000 20

Fig. 19 Electrical wiring diagramm 21

Annex


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Operating Mode: Internal ActivationThe system capacity is constant and is set in the parameter menu.

StartupOperating code: AKTIV xx NN DxxxSet the other features based on the existing options.If necessary, vary intake interval and intake duration.

Parameter settingSet the required capacity as the maximum metering rate. Gauge pump capacity in litres.Find the minimum limit value in the "Acid tt min." menu point using the "less than" button.Place the moist intake lances in the measuring cylinder filled with water. Press the "start" button and gauge the pumpcapacity in litres.The gauged value must be greater than the displayed minimum value. Enter gauged values of the pumps.

OperationThe current and maximum set capacity values are displayed.These values are not equal in systems with analog remote control.In systems with a turbine flow meter in the bypass, the bypass flow rate is also indicated.

Gauge pumpcapacity in litresChlorite tt min.

Gauge pumpcapacity in litres

Acid tt min.

Max. metering

xxx ,x g/h

ClO2 = 52.7 g/h

Internal control Metering OFF

Metering OFF

Parameter ?

Parameter

max. metering

CDVa xAxxxxxDxx

H01S01 xx NN Dxxx

Acid tt min.

xxx ,x ml

maxClO 2 = 52 7 g/h

Internal control

Chlorite tt min.

xxx ,x ml

Metering OFF

Configuration ?

Configuration

xxxx Feed.Code AKTIV XX NNDXXX

Metering

during pause

Pause metering

xx %

Start ?

Start

ttt minutes

Intake

Intake duration ?

Intake duration

xx seconds

52.7 current value

7 6 set value

Intake

Intake interval ?

Intake interval*

xxx minutes

Start

STARTSTOP


OPERATION PARAMETER SETTING

STARTUP

*For remote contactpause option only

2

*

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Operating Mode: Flow-Dependent ActivationThe system capacity is proportional to the measured flow rate.StartupOperating code: activecode (4) = K, F, 0 or 4;Set the other features based on the existing options.If activecode (4) = K Enter pulse duration of water meterIf activecode (4) = F Enter pulse value (frequency) of the flow meter

If activecode (4) = 0, 4 Enter flow rate at 20 mA (maximum measured flow rate)Flow rate at 0 (4) mA is assumed to be 0.If necessary vary intake interval and intake duration.Parameter settingSet the required feed rate (compensate for wear)Find the maximum limit value in the "max. flow rate" menu point with the "greater than" button. This corresponds to themaximum capacity of the system. In the case that the real maximum flow rate is far below this value, the real valueshould be entered. The maximum system capacity is calculated internally from the feed value and the maximum flowrate, thus deriving the minimum pump capacity value.Set minimum flow rate - this must be 0 for analog flow meter (0 - 20 mA).Gauge pump capacity in l itres:Find the minimum limit value in the "acid tt min." menu point with the "less than" button.Place the moist intake lances in the measuring cylinder filled with water. Press "start" button and gauge pump capacityin litres. The gauged value must be greater than the displayed minimum value. Enter gauged values of the pumps. Themaximum flow rate value is recalculated internally from these values.OperationThe flow rate, current system capacity and the set feed value are displayed. If the flow rate exceeds the maximum value,the system capacity remains constant and the feed value drops. Metering cuts out if the flow rate drops below theminimum value.The bypass flow rate is also indicated for systems with a turbine flow meter in the bypass.

3




Acid tt min.

Max. flow rate

xxx m 3 /h

Metering

during pause

Pause metering

xx %

Min. flow rate

xx ,x m 3 /h

Q = 47 m 3 /h

ClO2 = 52.7 g/h Metering OFF

Metering OFF

Parameter ?

Parameter

Feed rate ClO 2

Feed rate ClO 2

xxx mg/l

CDVa xAxxxx X Dxx

H01S01 xxN X Dxxx

Acid tt Min.

xxx ,x ml

Feed = 0 61 mg/l

External Control

Chlorite tt Min.

xxx ,x ml

Metering OFF

Configuration ?

Configuration

xxxx Feed.Code AKTIV XXX K DXXX

Flow signal

water meter ?

Water meter

xxx .x Liter

Flow signal

Analog ?

Q at 20 mA

xxx .x m 3 /h

52.7 current value

0 61 set value

Flow signalFrequency ?

Frequency xxx pulse./l

Start

STARTSTOP

Guage pumpcapacityin litres


STARTUP

Parameter

max. flow rate

Parameter

min. flow rate

AKTIV XXXFDXXX

AKTIV XXX0DXXX

Intake

Intake interval ?

Intake interval*

xxx minutes

Intake

Intake duration ?

Intake duration

xx seconds

Start ?

Start

tt minutes

or

or

*

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Acid tt min.

Operating Mode: Controlled Variable-Dependent ActivationThe system capacity is proportional to the value of the controlled variable signal.

StartupOperating code: Activecode (3) = K, 0 or 4;Set the other features based on the existing options.If active code (3) = K Enter pulse value of controlled variable.If necessary vary intake interval and intake duration.

Parameter settingSet required maximum capacity (in g/h).The minimum pump capacity value is calculated internally from the maximum system capacity.Gauging pump capacity in litres:Find the minimum limit value in the "acid tt min." menu point with the "less than" button.Place the moist intake lances in the measuring cylinder filled with water. Press "start" button and gauge pump capacity inlitres. The gauged value must be greater than the displayed minimum value. Enter gauged values of the pumps.

OperationThe current capacity and the maximum capacity are displayed.The bypass flow rate is also indicated for systems with a turbine flow meter in the bypass.

Max. metering

xxx .x g/h

ClO2 = 52.7 g/h

max. ClO 2 76 g/h Metering OFF

Metering OFF

Parameter ?

Parameter

max. metering

CDVa xAxxx 1xDxx

H01S01 xT K NDxx

Acid tt min.

xxx .x ml

max.ClO 2 = 76 g/h

External control

Chlorite tt min.

xxx .x ml

Metering OFF

Configuration ?

Configuration

xxxx Feed.Code AKTIV XX X XDXXX

Metering

during pause

Pause metering

xx %

Start ?

Start

tt minutes

Intake

Intake duration ?

Intake duration

xx seconds

52.7 current value

7 6 set value

Intake

Intake interval ?

Intake interval*

xxx minutes

Start

STARTSTOP



STARTUP

Controlled vatiable

max. contact ?

Max. contact

xxx pulse/min

4

*

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Properties of chorine dioxide and guidelines for working with aqueous solutions(Extract from the safety data sheet for chlorine dioxide by FIGAWA, April 1998)

1. Physical and Chemical Properties of Gas-form Chlorine DioxideColour: Orange-yellowOdour: PungentBoiling point: 11 C

Stability:Gas-form chlorine dioxide decomposes explosively at concentrations above 300 g/m 3 (= 10 % by volume) into chlorine andoxygen.

Dilution reduces the explosive tendency; at concentrations below 10 % by volume in gases with which chlorine dioxide does notreact (e.g. air, nitrogen, carbon dioxide) there is no longer any danger of explosion.

A critical chlorine dioxide concentration is for instance an aqueous chlorine dioxide solution with a concentration of more than8 g/l chlorine dioxide (at a temperature of 20 C) within the gas room.

A significant to explosive reaction will also result with oxidising materials.

2. Characteristics of the Aqueous Solutions of Chlorine DioxideThe gas phase which forms over the aqueous solution of chlorine dioxide is decisive.

Stability:Outside a gas room aqueous chlorine dioxide solutions from a concentration of around 30 g/l are explosive, i.e. they candecompose explosively without external influences such as heat, spark, dirt or rust.

Chlorine dioxide is stable for several days in a dilute aqueous solution if the solution is pure and is kept dark and/or if thetemperature of the solution is below 25 C and its pH value is less than 7.

3. Measures in the Event of Spillage, Leakage, Gas Leak and FireHose the gas with a water jet.

Leaked solution should be doused with sodium thiosulphate and then diluted with plenty of water and rinsed into the drainagesystem. Chlorine dioxide is not inherently flammable but has fire-stimulating properties. Decomposes explosively at temperaturesabove 100 C. Chill a tank of water and hose leaked chlorine dioxide gas with a water jet. There are no fire extinguisherconstraints in the event of fires in the vicinity.

4. Health and Safety

4.2 MAK value (MAK = max. admissible concentration in the workplace) and odourthreshold

MAK value: 0.1 ppm (ml/m 3 ) and/or 0.3 mg/m 3

Odour threshold: chlorine dioxide gas is perceptible by odour from concentrations of around 15 mg/m 3.

4.2 Health Hazards A chlorine dioxide gas concentration above 45 mg ClO 2 /m

3 causes respiratory difficulties and leads to irritation of the mucousglands and headaches.

Respiratory protection: gas mask, filter B/grey

In general chlorine dioxide causes severe irritation in the region of the mucous glands of eyes and respiratory organs. Dependingon the concentration and duration of the effect this can lead to danger of suffocation, coughing attacks occasional vomiting,conjunctivitis and severe headaches. In serious cases it can cause lung oedema with breathlessness, oxygen shortage andcirculation failure. In the event of short periods of exposure to high concentrations there is a threat of glottal cramp and/orreflexive breathing or heart stoppage. Harmful to nerves (e.g. eye muscle failure).

4.3 First AidClothing which has come into contact with chlorine dioxide or its aqueous solution should be removed immediately. Wash skinthoroughly with soap and plenty of water.

If solution has splashed into the eyes, rinse under running water with the eyes wide open.

After inhalation of chlorine dioxide provide fresh air, absolute rest, lay patient horizontally, maintain body heat.Inform a doctor immediately even if complaints do not appear straight away. If necessary, remove to hospital quickly andcarefully.

5

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Performance data

Annex

System

Metering

Max. operating

Operating

Max. stroke

Metering rate

Metering

Max. intake head

Max.

Type

Chlorinedioxide*

pressure

temperature

frequency

per component*

pumpType

meteringpump**

currentinput***

g/h

mg/Hub

bar

C

Stroke/h

l/h

ml/stroke

m wc

230 V

115 V

CDV35

46

6.4

10

10-40

7200

1.15

0.16

G/4-1601

1.65

1.8A

3.5A

CDV60

66

9.1

8

10-40

7200

1.65

0.23

G/4-1201

2.35

1.8A

3.5A

CDV120

130

18

8

15-40

7200

3.25

0.45

G/4-1002

0.93

1.8A

3.5A

CDV220

225

37.5

10

10-40

6000

5.625

0.9375

G/5-1605

1.3

6.9A

12.2A

CDV400

400

66.6

10

10-40

6000

10

1.66

G/4-1310

1.9

6.9A

12.2A

CDV600

600

130

8

15-40

4620

15

3.2

Vario12017

7

1.7A

3.4A

CDV2000

2000

456

7

15-40

4380

50

11.4

Sica12050

7

3.4A

6.8A

*=Themeteringratesarerefferedtoameanoperatingpressureof5barandanoperatingtemperatureof20

Canddeterminedwiththepumpatoperating

temperature(min.3hoursatmax.frequency)

**=Intakeheadwith clean, moistvalves. Intakeheadat100 % stroke.

***=Forsystemswithoutbypasspump.


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Fig. 1: Installation example of a Bello Zon chlorine dioxide generating system CDVa

7

S ur e W as s er C hl or itChloriteWater AcidBypass

Bypass

Bello Zon

START

STOP

ST ART

STOP

l /h

25

40

60

80

16

815

14

18 19

6

7

179

1211

13

6

1

3

12

2

5

20

23

24

2122

4

25

10

Bello Zon Bello Zon

Sure Acide

ChloritChlorite

230 V, 50/60 Hz

1 water meter (contact, analogue)2 main water pipe3 bypass pipe 1-2 m 3 /h4 bypass pump5 water monitoring pipe6 solenoid dosing pump7 flow sensor8 reactor

9 reactor housing10 dosing valve (pressure sensitive)11 mixer12 stop valve13 ventilation valve14 suction device15 bypass monitor16 non-return-valve

17 control with production level display18 Bello Zon acids in safety vessel19 Bello Zon chlorite in safety vessel20 D1C - chlorine dioxide meter21 chlorine dioxide probe22 water readings monitor23 interlocking contact24 rinsing connector25 holding tank (reaction time 10-15 min.)

Bello Zon Chlorine Dioxide Plantwith Flow-Dependant Control

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System type:

1A = CDV 35 = 46 g/h2A = CDV 60 = 66 g/h3A = CDV 120 = 130 g/h4A = CDV 220 = 225 g/h5A = CDV 400 = 400 g/h6A = CDV 600 = 600 g/h8A = CDV 2000 = 2000 g/h

8

Annex

Default language:

D = GermanE = EnglishF = FrenchI = ItalienS = Spanish

Fig. 2: Identification code system Bello Zon CDVa 35-2000

The hatched options are not included in the standard control.The mixer is supplied separately for CDVa 220 to 2000.

Operating voltage:

0 = 230 V 50/60 Hz1 = 115 V 50/60 Hz

Series

Please note here the Identcode from the front page:

CDVa

Version

0 1 2 3 4 5 6 7 8 9

Bypass version:

0 = without bypass andwithout premixer

1 = without bypass,with premixer

2 = with bypass, with premixer

3 = with bypass,without premixer4 = with bypass,

with premixerwith bypass pump made ofstainless steel

5 = with bypass,without premixerwith bypass pump made ofstainless steel

6 = with bypass,with premixerwith bypass pump made ofcast iron

7 = with bypass,without premixerwith bypass pump made ofcast iron

Control variable input:

0 = None1 = Contact (max. 4 sec.)2 = Analog (0/4-20 mA)

+ contact, reversible

Flow input:

0 = None1 = Contact (max. 4 sec.)

(water meter)

2 = Frequency3 = Analog (0/4-20 mA) (Analog

flowmeter + reversible contact)

Remote controlinput:

0 = None1 = Contact2 = Analog

(0/4 - 20 mA)

3 = Contact and Analog

Analog outputs:

0 = None1 = Analog

(0/4-20 mA for recorder)

Bypass monitoring:

0 = None1 = Turbine flowmeter2 = Variable-area

flowmeter

3 = Variable-areaflowmeter and PVCsolenoid valve


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Analog output

N Inactive0 0-20 mA 4 4-20 mA

Fig. 3: Operating code Bello Zon CDVa

0 1 2 3 4 5 6 7 8

A K T I V N N N N D N N N

Bypass pump

Documents

Diox. Cloro