GRUNDFOS ALLDOS Vaccuperm VGA-117 Series User manual

Vaccuperm VGA-117
Gas dosing regulator
GRUNDFOS ALLDOS INSTRUCTIONS
Installation and operating instructions

Declaration of conformity
We, Grundfos Alldos, hereby declare under our sole responsibility that
the products Vaccuperm VGA-117-390 and -395 with electrical equip-
ment (with CE mark on nameplate), to which this declaration relates,
comply with the following EC Directives for harmonisation with the legal
requirements of the EC member states:
— Electrical equipment designed for use within certain voltage limits
(73/23/EEC).
Standard which has been used:
EN 60204-1:2006
— Electromagnetic compatibility (89/336/EEC).
Standards which have been used:
EN 61000-6-1:2007
EN 61000-6-3:2007
— Other bodies of rules applied:
DIN 19606:2006
26th January 2009
W. Schwald
Managing Director
Ulrich Stemick
Technical Director
2

3
CONTENTS
1. Of general interest - 3
1.1 Structure of the documentation - 3
1.2 About this manual - 3
1.3 User/target groups - 3
1.3.1 Responsibilities of the users - 3
1.4 Responsibilities of the operator - 3
1.5 Maintenance and service personnel - 3
1.6 Correct usage - 3
1.7 Inappropriate usage - 3
2. Handling chlorine - 4
2.1 Physical and chemical data - 4
2.2 Safety advice for handling chlorine - 4
2.2.1 Risks to health - 4
2.2.2 Personal safety equipment - 4
2.2.3 Rules of conduct - 4
2.2.4 First aid in case of accidents - 5
2.2.5 Transport and storage of chlorine - 5
2.2.6 Pressure vessels and mountings - 5
2.2.7 Chlorine extraction - 6
2.3 Checking the tightness - 6
2.3.1 Checking the chlorine solution lines and the diaphragm
non-return of the injector - 6
2.3.2 Checking the tightness of the vacuum lines - 6
2.3.3 Checking the tightness of pressure gas lines - 7
2.4 Constructional requirements of chlorination plants - 7
2.5 Principle function of the components - 8
2.5.1 Vacuum regulator - 8
2.5.2 Measuring tube - 8
2.5.3 Rate valve - 8
2.5.4 Differential pressure regulator (Option: VGA-117) - 8
2.5.5 Vacuummeter (Option: VGA-117) - 8
2.5.6 Injector - 8
2.6 List of valid laws and regulations - 9
2.7 Recommended diameter - 10
2.7.1 Between vacuum regulator and dosing regulator - 10
2.7.2 Between dosing regulator and injector - 10
3. Technical Data - 11
3.1 Type key dosing regulator vaccuperm VGA-117 - 11
3.2 General data - 11
3.2.1 Vacuum connection (from the vacuum regulator / to the
injector) - 11
3.2.2 Accessories (not including) - 11
3.2.3 Dosing Flow - 11
3.2.4 Accessories (not including) - 11
3.3 Dimensioned drawings - 11
3.3.1 Dosing unit VGA-117 - 11
3.3.2 Dosing regulator with servomotor - 12
3.4 Electrical data - 12
3.4.1 Servomotor with reversing potentiometer - 12
3.4.2 Servomotor with analogue control (4-20 mA/0-20 mA) - 13
4. Installation - 13
4.1 Transport and storage - 13
4.2 Unpacking - 13
4.3 Typical installation - 13
4.4 Mounting - 13
5. Commissioning - 14
5.1 Preparations for commissioning - 14
5.1.1 Vacuum connections - 14
5.1.2 Electrical connections dosing regulator - with servomotor - 14
5.1.3 Servomotor with analogue control (optional) - 14
5.1.4 Servomotor with analogue control (optional), connected,
for example, to a Conex® DIA-2Q - 14
5.1.5 Servomotor with analogue control (optional), connected,
for example, to a Conex® DIS-2Q (microprocessor-based
control device) - 15
5.2 Checks before commissioning - 16
5.2.1 Checking the gas solution lines and the non-return
diaphragm of the injector - 16
5.2.2 Checking the tightness with ammonia - 16
5.2.3 Checking the pressure connections (after changing gas
cylinder) - 16
5.2.4 Checking the inlet valve - 17
6. Operation - 17
6.1 Description of the device - 17
6.1.1 Dosing regulator - 17
6.1.2 Dosing regulator with servo motor - 17
6.2 Adjusting the Dosing Flow - 18
6.2.1 Increasing the dosing flow - 18
6.2.2 Decreasing the dosing flow - 18
6.3 Reading the dosing flow - 18
6.4 Change between automatic and manual adjustment of the
dosing flow - 18
6.4.1 Switching from automatic to manual adjustment of the
dosing flow (only devices with servomotor) - 18
6.4.2 Switching from manual to automatic adjustment of the
dosing flow (only devices with servomotor) - 19
6.5 Switching on - 19
6.6 Switching off - 19
6.6.1 Emergency Stop - 19
6.6.2 Switching off while the system is running - 19
6.7 Possible faults - 20
7. Maintenance - 20
8. Disposal - 20
1. Of general interest
1.1 Structure of the documentation
The Grundfos Alldos dosing regulator VGA-117 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.
Purpose of this manual:
• Inform users of optimum use.
• Warn users of possible residual risks when using correctly
and identify measures that should be taken to avoid damage.
• Caution users against obvious misuse or inappropriate use
and inform them of the necessary care that must be taken
when operating the system.
1.2 About this manual
This manual contains the following standardised safety
instructions about possible residual risks:
Information about possible residual risks is provided:
• On warning signs displayed in the installation location.
• At the start of each section in this manual.
• Directly before any operating procedures that could involve
residual risks.
Warning
These operating instructions are also available
on www.Grundfosalldos.com.
Prior to installation, read these installation and
operating instructions. Installation and operation
must comply with local regulations and accepted
codes of good practice.
Warning
If these safety instructions are not observed,
it may result in personal injury!
Caution
If these safety instructions are not observed,
it may result in malfunction or damage to the
equipment!
Note
Notes or instructions that make the job easier
and ensure safe operation.

4
1.3 User/target groups
Users are persons who are responsible for operating and
monitoring the dosing regulator VGA-117 at the installation
location. The system may only be operated by trained and
qualified personnel. Personnel must have appropriate technical
knowledge and be familiar with the basic principles of measuring
and control technology.
1.3.1 Responsibilities of the users
The users’ responsibilities:
• Read this manual before operating the VGA-117.
• Be trained by qualified personnel from Grundfos Alldos 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 (German
GUV-V D05).
1.4 Responsibilities of the operator
The owner of the building or operator of the VGA-117 is
responsible for the following:
• Consider this manual to be part of the product and ensure
that it is kept clearly accessible in the immediate vicinity of
the system for the entire service life of the system.
• Meet the installation requirements specified by the
manufacturer (required water connections and fittings,
environmental conditions, electrical connection, protective
pipe 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.
• Train users in the operation of the system.
• Ensure that the regulations for the prevention of accidents are
observed in the installation location (German GUV-V D05
regulation for the prevention of accidents, "Chlorination of
Water" dated January 1997).
• Provide all users and service personnel with protective
clothing in accordance with GUV-V D05 (face mask, gloves,
protective apron).
1.5 Maintenance and service personnel
The system may only be maintained and serviced by authorised
service personnel from Grundfos Alldos.
1.6 Correct usage
Grundfos Alldos VGA-117 may be used for dosing chlorine Cl2, as
being described in this manual.
1.7 Inappropriate usage
Applications other than those listed in section 1.6 Correct usage
are considered not to be in accordance with the intended use and
are not permitted. The manufacturer, Grundfos Alldos, accepts no
liability for any damage resulting from incorrect use.
The system comprises state-of-the-art components and has
undergone safety-related testing.
2. Handling chlorine
2.1 Physical and chemical data
Under normal conditions of pressure and temperature, chlorine is
a yellowish green gas with a pungent odour. It exists as diatomic
molecule Cl2.
It is not flammable, but can under certain circumstances promote
the flammability of metals, hydrocarbons etc.
Vapour pressure curve of chlorine
Fig. 1 Vapour pressure curve of chlorine
Solubility of chlorine gas in water
Fig. 2 Solubility of chlorine gas in water
Warning
Unauthorised structural modifications to the
system may result in serious damage to
equipment and personal injury.
It is forbidden to open, modify, change the
structure of, bridge, remove, bypass or disable
components, especially safety equipment.
Atomic weight 35.457
Molecular weight Cl270.941
Density (liquid) 1.57 g/cm3at -34.05 °C
Density (gaseous) 3,214 g/l at 0 °C, 1 bar
1 l liquid chlorine at 0 °C corresponds to 457 l (0.457 m3)
gaseous chlorine
1 kg liquid chlorine at 0 °C corresponds to 311 l (0.311 m3)
gaseous chlorine
Specific gravity 2.486 (specific gravity of air: 1)
Boiling point - 34.05 °C (1 bar)
Melting point - 100.98 °C
Evaporation heat 269 kJ/kg (at 0 °C)
Heat conductivity 0.527 kJ/m2h (liquid chlorine)
Degree of purity acc. to DIN
19607 99,5 %
TLV (Threshold Limit Value) 1.5 mg/m3 (0.5 Vol.-ppm)
TM04 0691 0908
TM04 0692 0908
0
2
4
6
8
10
12
14
16
18
20
-50 -40 -30 -20 -10 0 10 20 30 40 50 60 70
Temperature (°C)
020 40 60 80
10 30 50 70 90
2
4
6
8
10
12
14
0
Temperature (°C)

5
2.2 Safety advice for handling chlorine
2.2.1 Risks to health
Chlorine gas is toxic, more than 50 Vol.-ppm in the indoor air
mean an acute danger to life.
Hazards of chlorine gas
• Irritating to eyes, respiratory system and skin.
• Causes whooping cough.
• Causes causticization of skin and respiratory system.
• Lethal by lung edema in case of long influence or high
concentration.
• Slight paralyzing effect to the central nervous system.
Hazards of liquid chlorine
• Causes causticization of skin.
• Causes reddening and formation of bubbles.
2.2.2 Personal safety equipment
The operating authority of a chlorination plant has to provide for
the operation personnel:
For each person
Respiratory equipment (full-sight gas mask)
• with an effective chlorine filter (B2P3), colour mark: grey with
a white ring
• at least 1 spare filter per gas mask
• personally fitted (perfectly tight)
• labelled by name
Only plants with chlorine drums
• at least 2 protective suits with compressed air respirators
Storage of the safety equipment
• outside the chlorine rooms
• well visible
• easily available at any time
• protected from dust and moisture
• Introducing the operation personnel to handle the safety
equipment
• Carrying out exercises (at least half-yearly)
• Regular replacement of the gas mask filters
– after the expiry of the date of durability
– at least 6 months after opening (mark the opening date on
the filter)
– after contact with chlorine
– Observe employing prohibition according to § 14 ArbStoffV
(in Germany) resp. according to local laws!
2.2.3 Rules of conduct
• Change of chlorine containers only with gas mask.
• Entering contaminated rooms only with protective suit and
compressed air respirator.
• In case of flight wear gas mask, if possible. Observe wind
direction!
• Eating, drinking and storing food is prohibited in chlorine
rooms.
2.2.4 First aid in case of accidents
First aid after having inhalated chlorine
• Keep calm.
• Remove injured persons from the dangerous area.
– Helpers must pay attention to personal protection!
• Immediately remove contaminated clothes.
• Calm down injured persons and keep them warm with
blankets.
• Supply fresh air; use oxygen respirator (alternately with
inhalating steam), if possible.
– No mouth-to-mouth resuscitation!
• Fast and gentle transport to hospital
– lying
– sitting in case of difficulty in breathing
– state chlorine causticization as the cause.
First aid after causticization of the skin
• Keep calm.
• Remove contaminated clothes.
• Rinse skin with plenty of water
• Bandage the wound germ-freely
• Seek medical aid.
– State chlorine causticization as the cause.
First aid after causticization of the eyes
• Keep calm.
• Rinse causticized eyes with plenty of water while the person
is lying.
– Protect healthy eye, if necessary.
– Spread eyelids widely, let the eye move to all sides.
• Seek ophthalmologist.
– State chlorine causticization as the cause.
First aid after internal causticization
• Keep calm.
• Drink water in short sips.
– If possible, take medical charcoal.
• Seek medical aid.
– state chlorine causticization as the cause.
2.2.5 Transport and storage of chlorine
Basic rules for transport and storage of chlorine
• Treat containers carefully, do not throw!
• Protect containers from turning over or rolling away!
• Protect containers from direct sun rays and temperatures
over 50 °C!
• Transport of containers only with valve protection nut and
protection cap.
Valid regulations
– Regulations for accident prevention "Chlorination of water"
(GUV-V D5) with process instructions
– Regulations concerning places of work (ArbStättV))
– Technical rules for gases 280, 310 und 330
Warning
R 23 Toxic by inhalation.
R 36/37/38 Irritating to eyes, respiratory
system and skin.
Caution
Further obligations of the operating authority
Warning
Handling of chlorine containers only by
experienced, practised personnel!
Warning
This rules are valid for both full and empty
containers, as empty containers still contain
rests of chlorine and therefore are under
pressure.
Warning
Strictly observe local law and regulations for
handling, transport and storage of chlorine.

6
2.2.6 Pressure vessels and mountings
Chlorine is being offered in two container designs:
• Steel cylinders containing 50 kg or 65 kg, equipped with one
valve for
– the withdrawal of gaseous chlorine from the upright
standing cylinder
Variant of chlorine cylinder
Fig. 3 Variant of chlorine cylinder
• Steel drums containing 500 kg or 1000 kg, equipped with
– one valve for the withdrawal of gaseous chlorine
– one valve for the withdrawal of liquid chlorine
Fig. 4 Chlorine drum
Fig. 5 Valve position of chlorine drum
Due to safety precautions, chlorine containers are only filled up to
95 % of their capacity.
• Kind of gas, weight, owner, producing date and date of the
last testing have to be noted clearly on the container. Chlorine
containers are marked by grey colour.
• No changes or repair by the user!
• Never open container valves by force. Stuck valve spindels
can be loosened by wrapping a shred with warm water
around the valve.
– Never use an open flame!
– Never use wrench lengthening!
– Return containers with stuck valves to the manufacturer.
• Observer safety precautions and the manuals of the
manufacturer!
2.2.7 Chlorine extraction
Before the extraction
• The chlorine containers must be stored at least for 8 hours in
the container room so that the content can adapt the ambient
temperature.
• Turn chlorine drums on the support until the dip pipe and the
riser pipe are placed vertically (observe the markings on the
drum).
• Check tightness.
Connection
• Protect containers from turning over or rolling away!
• Dry the piping and the withdrawal system with dry nitrogen or
dry air.
• No foreign matter must get into the plant.
• Mount new gaskets to the connection line.
• Connect the container.
• Slowly open the container valve.
TM04 0693 0908
Protecting cap
Valve
Holding clip
Valve thread acc.
to DIN 477
Labelled by
stamping
Weldless chlorine
cylinder
Aluminium
label
Welded chlorine
cylinder
TM04 0694 0908
TM04 0695 0908
Warning
Observe safety precautions for chlorine
containers
Tyre of roller
Riser pipe (for the withdrawal of gaseous chlorine)
Protecting cap
Valves
dip pipe
(for the withdrawal of liquid chlorine)
Valve for gaseous chlorine
Colour ring
Valve for liquid chlorine
Warning
Chlorine containers must never have a higher
temperature than other parts of the plant. Danger
of liquefaction and possible chlorine break-out!

7
Withdrawal of gaseous chlorine
In case of higher chlorine requirement several chlorine containers
of the same temperature have to be connected with header lines.
Withdrawal of liquid chlorine
• Within chlorination plants only possible from chlorine drums.
• Application of an evaporator is necessary.
• Withdrawal of gaseous chlorine: Observe residual pressure of
ca. 2 bar.
• Withdrawal of liquid chlorine: Observe residual pressure of
ca. 4 bar.
After the extraction
• Close container valve.
• Disconnect container from the plant.
• Screw on valve protection nuts.
• Screw on protection cap.
2.3 Checking the tightness
Before commissioning check the tightness of the whole plant.
2.3.1 Checking the chlorine solution lines and the diaphragm
non-return of the injector
• Observe the manual of the injector!
2.3.2 Checking the tightness of the vacuum lines
Vacuum lines are all lines between vacuum regulator and injector.
• Close all container valves
• Close the rate valve
• Open the shut-off valve at the injection unit
• Open motive water valve
• Switch on the booster pump
• Open the rate valve
– Floater shows gas flow or vacuummeter shows more than -
9 m w. c.: Leakage in vacuum line!
• Close rate valve
• Switch off booster pump
• Close motive water valve
• Close the shut-off valve at the injection unit
• Check the vacuum lines and the connection. If necessary,
carefully re-tighten them.
• Check tightness again!
– Floater shows no gas flow, vacuummeter shows -9 m w. c.
or less: Vacuum lines are tight.
2.3.3 Checking the tightness of pressure gas lines
Pressure gas lines are all lines from the gas containers to the
vacuum regulator.
• If the plant is equipped with a nitrogen rinsing device: Check
tightness roughly with nitrogen
• Detailed checking with ammonia
Checking the tightness with nitrogen
• Close all container valves
• Open container connection valves and all shut-off valves up
to the gas dosing system
• Open the connection valve of the nitrogen cylinder
• Slowly open the valve of the nitrogen cylinder, until the lines
have a pressure of about 10 bar (read at the manometer of
the vacuum regulator).
• Apply soap water to all components under pressure
– Formation of bubbles and/or pressure drop at manometer
Leakage in pressure lines!
– Depressurize the plant!
– Eliminate leakage!
– Check tightness again!
No formation of bubbles, pressure at manometer does not drop
significantly within one hour: Pressure lines are tight.
Checking the tightness with ammonia
See chapter 5.2.2 Checking the tightness with ammonia.
Caution
At 15 °C about 1 % (DIN19607) of the content can
be withrawn per hour. In case of higher
withdrawal danger of malfunction by the
formation of ice on containers and piping!
Container size Withdrawal quantity
50 Kg 500 g/h
65 Kg 650 g/h
500 Kg 5 Kg/h
1000 Kg 10 Kg/h
Caution
Do not completely evacuate the chlorine drums.
Danger of withdrawing deposits!
Caution
Immediately close connection lines.
No moisture must get into the lines!
Warning
Do not check the tightness until the whole plant
is ready for start-up.
Danger of chlorine break-out!
Note
More possible reasons for insufficient operating
vacuum
• injector layed out too weakly or defective
• injector obstructed
• booster pump layed out too weakly or
defective
Warning
Maximum nitrogen pressure 16 bar!
Danger of damages and gas leakage when being
exceeded!

8
2.4 Constructional requirements of chlorination plants
All chlorine rooms
Fig. 6 Warning sign DIN 4844
– Warning sign according to DIN 4844 part 1 no. 4.2, to be
installed at entrances
Fig. 7 Supplementary sign
– Supplementary sign according to DIN 4844 part 1 no. 4.5,
to be installed at entrances
Fig. 8 Mandatory sign
– Mandatory sign according to DIN 4844 part 1 no. 4.3, to be
installed inside the rooms
Fig. 9 Instruction sheet for first aid
• Instruction sheet for first aid in case of chlorine gas
intoxications, to be installed inside the rooms
• Maximum temperature: 50 °C
– recommended temperature: 18 - 20 °C
– recommended minimal temperature: 15 °C
• Overpressure lines of dosing equipment must not end in the
open air
• Chlorine rooms must not be dedicated for the permanent stay
of people.
• Only chlorine containers and the chlorination plant may be
present in the rooms.
Rooms with pressure lines (e. g. storage rooms for chlorine
containers)
• Flat, even floor
– not below ground level
– not higher than a possible loading ramp
Fig. 10 Regulations for chlorine rooms (1)
Fig. 11 Regulations for chlorine rooms (2)
• Direct exit to the open air
• Lockable
– doors must open outwards
– it must be possible to open the doors without a key from
inside the room
• No connection to other rooms
– separated gastight and fire-resistant from other rooms
• A maximum of two vent holes of max. 20 cm2each
• Water sprinkling system
– for precipitating escaping chlorine gas
– operation must be possiple by hand from outside the
chlorine rooms
– sufficiently dimensioned run-off with air trap
• Chlorine gas warning system
– with optical and acoustical alarm
– coupled to the water sprinkling system
– coupling must reactivate automatically after having
switched off (e. g. for container exchange)
• Chlorine gas must not be able to get into lower-lying rooms,
shafts, pits, canals or aspirating holes of ventilation systems.
TM04 0699 0908
TM04 0700 0908
TM04 0701 0908
TM04 0702 0908
Chlorination unit
Acces only for
instructed persons
asdajlk llasdf lalsdk lasdlfkl lasdkjasdlklj jlakjlkjdl alsdfkljkj asdlklk lalsdk asdajlk llasdf lalsdk lasdlfkl lasdkjasdlklj jlakjlkjdl als dfkljkj
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k asdajlk llasdf lalsdk lasdlfkl lasdkjasdlklj jlakjlkjdl alsdfkljkj asdlklk lalsdk asdajlk llasdf lalsdk lasdlfkl lasdkjasdlklj jlakjlkjdl alsdfkljkj
sdk asdajlk llasdf lalsdk lasdlfkl lasdkjasdlklj jlakjlkjdl alsdfk ljkj asdlklk lals
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asdajlk llasdf lalsdk lasdlfkl lasdkjasdlklj jlakjlkjdl alsdfkljkj asdlklk lalsdk
asdajlk llasdf lalsdk lasdlfkl lasdkja
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asdajlk llasdf lalsdk lasdlfkl lasdkjasdlklj jlakjlkjdl lalsdk
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First aid in the case of
CHLORINE GAS POISONNING
HEALTH DANGERS
FIRST AID
TM04 0703 0908
TM04 0704 0908
✓

9
2.5 Principle function of the components
Fig. 12 Components of a chlorinator
2.5.1 Vacuum regulator
• Reduces the gas pressure (overpressure) to subatmospheric
pressure (vacuum)
2.5.2 Measuring tube
• Displays the gas flow
2.5.3 Rate valve
• For adjustment of the required gas flow
– manually or automatically
2.5.4 Differential pressure regulator (Option: VGA-117)
• Regulates the difference of the pressures before and after the
rate valve to a constant value
– Adjusted dosing flow stays constant even when the injector
vacuum varies.
2.5.5 Vacuummeter (Option: VGA-117)
– Displays the injector vacuum
2.5.6 Injector
– Creates the vacuum necessary for operating the pant
– Mixes the chlorine gas with the water
TM04 0705 0908
Motive water
Vacuum regulator
Measuring
tube
Gas Dosing System
Differential
pressure
regulator
Vaccum
meter
Injector
Rate Valve
Chlorine gas

10
2.6 List of valid laws and regulations
Laws and Regulations
DVGW-Rules
BGBl. I 1975 S. 729 Verordnung über Arbeitsstätten (Arbeitsstättenverordnung - ArbStättV)
Regulations concerning places of work (ArbStättV)
BGBl I 1980 S. 173,
184
Verordnung über Druckbehälter, Druckgasbehälter und Füllanlagen (Druckbehälterverordnung - DruckbehV) mit
technischen Regeln Druckbehälter (TRB) mit technischen Regeln Druckgase (TRG)
Regulations concerning pressure containers, gas cylinders and filling systems (pressure containers - DruckbehV)
with technical rules for pressure containers (TRB) with technical rules for pressure gases (TRG)
BGBl I 1986 S. 1470 Gefahrstoffverordnung (GefStoffV)
Regulations for hazardous materials (GefStoffV)
BGBl I 1975 S. 2494 Verordnung über gefährliche Arbeitsstoffe (Arbeitsstoffverordnung - ArbStoffV)
Regulations for hazardous work materials (ArbStoffV)
GUV 0.1 Unfallverhütungsvorschrift "Allgemeine Vorschriften"
Regulations for accident prevention "General Regulations"
GUV-V D5 Unfallverhütungsvorschrift "Chlorung von Wasser"
Regulations for accident prevention "Chlorination of water"
GUV 49.1 Prüfliste zur Unfallverhütungsvorschrift "Chlorung von Wasser"
Checklist for Regulations for accident prevention "Chlorination of water"
GUV 0.3 Unfallverhütungsvorschrift "Erste Hilfe"
Regulations for accident prevention "First-Aid"
GUV 20.5 Merkblatt "Anleitung zur ersten Hilfe bei Unfällen"
Leaflet "Instructions for First-Aid in case of accidents"
GUV 20.6 Merkblatt "Verbandzeug für die erste Hilfe bei Unfällen"
Leaflet "Dressing material for First-Aid in case of accidents"
GUV 20.14 Atemschutzmerkblatt
Leaflet for the protection of the air
GUV 29.6 Merkblatt "Über den Umgang mit ätzenden Stoffen"
Leaflet "Handling of caustic materials"
GUV 60.3G26
Grundsatz für arbeitsmedizinische Vorsorgeuntersuchungen "Träger von Atemschutzgeräten für Arbeit und
Rettung" G 26
Principle for preventive industrial medicine checkup "Wearers of respiratory equipment for work and rescue" G 26
GUV 2.6 Unfallverhütungsvorschrift "Druckbehälter"
Regulations for accident prevention "Pressure containers"
GUV 2.10 Unfallverhütungsvorschrift "Elektrische Anlagen und Betriebsmittel"
Regulations for accident prevention "Electrical installations and resources"
GUV 9.9 Unfallverhütungsvorschrift "Gase"
Regulations for accident prevention "Gases"
ZH1/230 Merkblatt "Chlor"
Leaflet "Chlorine"
CEFIC Unfallmerkblatt für den Straßentransport "Chlor" Klasse 2, Ziffer 3 at UN 2201
Accident leaflet for the road transport "Chlorine" Class 2, Number 3 at UN 2201
BGBl I 1985, S. 1550 Verordnung über die Beförderung gefährlicher Güter auf der Straße - Gefahrgut Vstr/GGVS - Klasse 2, Ziffer 3 at
Regulations for the transport of dangerous goods on the road - Gefahrgut Vstr/GGVS - Class 2, Number 3 at
GGVE Gefahrgutverordnung Eisenbahn, Klasse 2, Ziffer 3 at)
Regulations for dangerous goods on trains, Class 2, Number 3 at)
RID Internationale Verordnung für die Beförderung gefährlicher Güter mit der Eisenbahn - Klasse 2, Ziffer 3 at
International regulations for the transport of dangerous goods by train - Class 2, Number 3 at
BGBl I 1977, S. 1119 Verordnung über die Beförderung gefährlicher Güter auf dem Rhein (ADNR)
Regulations for the transport of dangerous goods on the Rhine (ADNR)
W203 Begriffe der Chlorung
Concept of chlorination
W645-1 Überwachungs-, Mess-, Steuer- und Regeleinrichtungen in Wasserversorgungsanalagen
Devices for monitoring, measuring, control and regulation in water supply plants
W291 Desinfektion von Wasserversorgungsanlagen
Disinfection of water supply plants
W623 Dosieranlagen für Desinfektions- bzw. Oxidationsmittel - Dosieranlagen für Chlor
Dosing units for disinfection or oxidation with chlorine
W640 Überwachungs-, Meß-, Steuer- und Regeleinrichtungen in Wasserwerken
Systems for monitoring, measurement, control and regulation in waterworks
DVGW-Merkblatt Arbeitshilfe zur Erstellung einer örtlichen Betriebsanweisung für Chlorungsanlagen unter
Verwendung von Chlorgas
DVGW leaflet Aid for the creation of a local manual für chlorination systems using chlorine gas

11
Standards
2.7 Recommended diameter
2.7.1 Between vacuum regulator and dosing regulator
Grundfos Alldos company standard calculated with pressure drop p=12.5 mbar
The indications in this table result from pressure loss observations. They do not take into consideration the possible influence of length
and diameter of lines on the operational reliability of the system.
2.7.2 Between dosing regulator and injector
Grundfos Alldos company standard calculated with pressure drop p=50 mbar
The indications in this table result from pressure loss observations. They do not take into consideration the possible influence of length
and diameter of lines on the operational reliability of the system.
DIN 19606 Chlorgasdosieranlagen zur Wasseraufbereitung
Chlorine gas dosing systems for water treatment
DIN 19607 Chlor zur Wasseraufbereitung
Chlorine for water treatment
DIN EN 937 Chlor zur Aufbereitung von Wasser für den menschlichen Gebrauch
Chlorine for the treatment of water for the human use
DIN 19643 Aufbereitung von Schwimm- und Badewasser
Treatment of swimming pool and bathing water
DIN 3179, Teil 1,2 Einteilung der Atemgeräte, Übersicht
Division of the respiratory equipment, overview
DIN 4102, Teil 2 Brandverhalten von Baustoffen und Bauteilen
Behaviour in fire of building materials and parts
DIN 477, Teil 1 Gasflaschenventile; Bauformen, Baumaße, Anschlüsse, Gewinde
Gas cylinder valves; forms, measurements, connections, threads
Length of the vacuum line in (m) Dosing quantity (g/h)
500 1000 2000 4000 6000 8000 10000
0 DN 8 DN 8 DN 8 DN 10 DN 10 DN 10 DN 15
10 DN 8 DN 8 DN 8 DN 10 DN 10 DN 15 DN 15
20 DN 8 DN 8 DN 10 DN 15 DN 15 DN 15 DN 20
30 DN 8 DN 8 DN 10 DN 15 DN 15 DN 20 DN 20
40 DN 8 DN 8 DN 15 DN 15 DN 15 DN 20 DN 20
50 DN 8 DN 10 DN 15 DN 15 DN 15 DN 20 DN 20
75 DN 8 DN 10 DN 15 DN 15 DN 20 DN 20 DN 25
100 DN 8 DN 10 DN 15 DN 20 DN 20 DN 25 DN 25
Length of the vacuum line in (m) Dosing quantity (g/h)
500 1000 2000 4000 6000 8000 10000
0 DN 8 DN 8 DN 8 DN 8 DN 10 DN 10 DN 15
10 DN 8 DN 8 DN 8 DN 8 DN 10 DN 10 DN 15
20 DN 8 DN 8 DN 8 DN 10 DN 10 DN 15 DN 15
30 DN 8 DN 8 DN 8 DN 10 DN 10 DN 15 DN 15
40 DN 8 DN 8 DN 8 DN 10 DN 15 DN 15 DN 15
50 DN 8 DN 8 DN 10 DN 15 DN 15 DN 15 DN 15
75 DN 8 DN 8 DN 10 DN 15 DN 15 DN 15 DN 20
100 DN 8 DN 8 DN 10 DN 15 DN 15 DN 15 DN 20

12
3. Technical Data
3.1 Type key dosing regulator vaccuperm VGA-117
Example: Dosing regulator Type key VGA-117-1000/1-M0X
3.2 General data
3.2.1 Vacuum connection
(from the vacuum regulator / to the injector)
3.2.2 Accessories (not including)
3.2.3 Dosing Flow
3.2.4 Accessories (not including)
3.3 Dimensioned drawings
3.3.1 Dosing unit VGA-117
Fig. 13 Dimensional drawing dosing unit VGA-117
Code Example VGA-117 -1000 /5 -M O , N
Vaccuperm Gas Advanced = VGA
Dosing flow
500 25-500 g/h
1000 50-1000 g/h
2000 100-2000 g/h
4000 200-4000 g/h
6000 300-6000 g/h
8000 400-8000 g/h
10000 500-10000 g/h
Connection input and output
1 PE hose 8/11
2 PE hose 10/14
3 PVC pipe DN15 (d 20)
Adjustment
M Manual
A Automatic, 230-240V/50-60Hz
B Automatic, 110-115V/50-60Hz
Control
0 Without
1 4-20 mA
2Direct
Differential pressure regulator
Y Yes, with vaccummeter
NNo
Accuracy ± 4 % of upper limit
Control range 1 : 20
Permissible medium Cl2
Permissible vacuum
regulator VGA-111, VGA-146: up to 4000g/h
Flow meter according to the floater principle, length
of the measuring tube 190 mm
Weight without servomotor: 2.6 kg
with servomotor: 4.2 kg
PE hose 8/11 or 10/14
PE hose 8/11 or 10/14
PVC pipe DN15 (d20)
Installation material: Hoses of different lengths
Holding plate for wall fixing at change of container
Test medium for leak search
50 - 1000 g/h 2 - 50 lbs/day
100 - 2000 g/h 5 - 100 lbs/day
200 - 4000 g/h 10 - 210 lbs/day
300 - 6000 g/h 15 - 310 lbs/day
400 - 8000 g/h 20 - 420 lbs/day
500 - 10000 g/h 30 - 520 lbs/day
Installation material: Hoses of different lengths
Holding plate for wall fixing at change of container
Test medium for leak search
TM04 0787 0908
375
400
105
12.5
130
46
80
Ø6
12.5

13
3.3.2 Dosing regulator with servomotor
Fig. 14 Dimensional drawing dosing regulator VGA-117 with
servomotor
3.4 Electrical data
3.4.1 Servomotor with reversing potentiometer
Fig. 15 Servomotor with reversing potentiometer
TM04 0788 0908
TM04 0956 4009
575
600
145
12.5
170
107
46
80
Ø6
12.5
2
1,
3
4
SL
SR
1,
Item Description
1SR, limit switch cam min.
SL, limit switch cam max.
2Supply voltage input
3Potentiometer input/output
4Earth terminal
Mains voltage
220 - 240 V ±10%, 50/60 Hz
±5 %, 100 % on time (standard)
110 - 120 V ±10 %, 50/60 Hz
±5 %
24 V AC ±10 %, 50/60 Hz ±5 %
Rated current
30 mA (at 230 V),
60 mA (at 115 V),
240 mA (at 24 V)
Limit switch - load capacity 2 A at 250 V
Power consumption Approx. 2 VA
Control variant Reversingpotentiometer 1 kΩ
Open/close signal
Actuating time 90 s for 270° at 50 Hz
75 s for 270° at 60 Hz
Adjustment angle Max. 270°
Degree of protection IP 65
Permitted ambient
temperature -15 to 60

14
3.4.2 Servomotor with analogue control (4-20 mA/0-20 mA)
Fig. 16 Servomotor with analogue control
4. Installation
4.1 Transport and storage
• Handle with care, do not throw!
• Dry and cool storage place.
4.2 Unpacking
• Observe when unpacking:
– No humidity should get into gas-leading parts!
– No foreign matter should get into gas-leading parts!
• Mount as soon as possible after unpacking.
4.3 Typical installation
Fig. 17 Dosing and vacuum regulator
4.4 Mounting
• Mount the dosing unit to the wall.
TM04 0956 4009
Item Description
1SR, limit switch cam min.
SL, limit switch cam max.
2 Programming buttons
3 Alarm output
4LEDs
5 DIP switch
6 Mains connection terminals
7 Analogue signal connection terminals
8 Earth terminal
Mains voltage
220 - 240 V ±10 %, 50/60 Hz ±5 %, 100 %
on time (standard)
110 - 120 V ±10 %, 50/60 Hz ±5 %
24 V AC ±10 %, 50/60 Hz ±5 %
Rated current
30 mA (at 230 V),
60 mA (at 115 V),
240 mA (at 24 V)
Limit switch - load
capacity 2 A at 250 V
Power
consumption Approx. 2 VA
Control variant Analogue control
Input/Output
Signal input/output 4 - 20 mA (standard setting)
0 - 20 mA (switchable)
Setpoint input
4 (0) - 20 mA (DC)
Load 250 Ω
Overload protection 25 mA
Protection against reverse polarity to -25 mA
ESD protection, input filter
Resolution: 10 bits
Actual value output
4 (0) - 20 mA
Max. load 500 Ω
Resolution: 10 bits
Carrying capacity
of signal output
Output current: 4 -20 mA
Minimum voltage for
open circuit 10 V
Potentiometer 1000 Ω
235
4
6
7
8
1
2
LR
SET
on
1,
SR
SL
1,
Actuating time 90 s for 270° at 50 Hz
75 s for 270° at 60 Hz
Adjustment angle Max. 270°
Degree of
protection IP 65
Permitted ambient
temperature 0 to 60
TM04 0790 0908
Item Description
1 Vacuum regulator for wall mounting
2 Dosing regulator
3 Injector
5 Remote display for container empty indication
6 Adsorption device
8 Gas warning device
11 Gas sensor
12 Gas drum
13 Heater strip
Warning
Observe the information, see chapter 2. Handling
chlorine
Mains voltage
220 - 240 V ±10 %, 50/60 Hz ±5 %, 100 %
on time (standard)
110 - 120 V ±10 %, 50/60 Hz ±5 %
24 V AC ±10 %, 50/60 Hz ±5 %
GASDETECT
64
1
3
7
5
8
9
2

15
5. Commissioning
5.1 Preparations for commissioning
5.1.1 Vacuum connections
Fig. 18 Vacuum connections, standard
Fig. 19 Vacuum connections, none standard, with optional
accessories
• Connect the vacuum line from the vacuum regulator (1).
• Connect the vacuum line to the injector (2).
5.1.2 Electrical connections dosing regulator - with
servomotor
• Establish the electrical connections according to the following
terminal diaprams.
5.1.3 Servomotor with analogue control (optional)
Fig. 20 Circuit diagram for a servomotor with analogue control
5.1.4 Servomotor with analogue control (optional),
connected, for example, to a Conex®DIA-2Q
• Connect the terminals to the corresponding terminals on the
external control device as shown in the connection diagram.
Fig. 21 Terminal connection diagram for Conex®DIA-2Q
TM04 0793 0908
TM04 0854 3708
Warning
Before connecting, ensure that the valves of all
gas containers are closed.
Only use the intended line types!
Item Description
1 Vacuum line from the vacuum regulator
2 Vacuum line to the injector
Caution
Only tighten the union nuts of the vacuum
connections by hand. Do not use any tools!
Danger of damages!
Maximum length of the vacuum line, see chapter
2.7 Recommended diameter
1
2
Standard
optional:
servomotor
12
differential pressure
regulator
servomotor
vacuummeter
Warning
Disconnect from mains before removing the
cover!
Observe local safety precautions!
Protect cable connections and plugs against
corrosion and moisture.
Close unused screwings with suitable caps!
Caution
Before connecting the mains cable:
Check if the mains voltage indicated on the type
plate corresponds to the local mains voltage.
Wrong voltage can lead to damages of the
product!
Caution
To ensure electromagnetic compatibility (EMC):
Signal lines must be shielded.
The shield must be connected to PE or ground on
the side of the counterpart.
Signal lines and mains lines must be guided in
different cable channels.
Note
Depends on the optional components selected:
Direct mains connection (by customer) or via the
terminal box.
TM04_0950_4009TM04 0951 4009
4(0) - 20 mA
max. 125 V
56 57
55
54
52
51
-
++
LN
L1 N PE
-
Fault message
30 29 Conex DIA-2Q
4(0) - 20 mA
max. 125 V
56 57
55
54
52
51
-
++
LN
L1 NPE
-

16
5.1.5 Servomotor with analogue control (optional), connected, for example, to a Conex®DIS-2Q (microprocessor-based control
device)
• Connect the terminals to the corresponding terminals on the external control device as shown in the connection diagram.
Fig. 22 Terminal connection diagram for Conex®DIS-2Q on a servomotor with analogue control
1. Unscrew the hood screws and remove the hood.
2. Establish the electrical connections in accordance with the
circuit diagram; see Fig. Terminal connection diagram for
Conex® DIA-2Q.
– Connect terminals 51 and 52 and, if required, terminals 54
and 55, in accordance with the circuit diagram.
– Connect terminals 56 and 57 in accordance with
requirements; voltage 125 V max.
– Use separate, shielded lines with a minimum cross-section
of 0.5 mm2and a maximum length of 1000 m for low
voltages (setpoint/actual value signal lines).
– The screen must be connected on one side to the housing
earth (earth terminal).
• Close the hood again and tighten the hood screws.
Servomotor - with reversing potentiometer (optional)
Fig. 23 Terminal connection diagram for servomotor with
potentiometer
TM04 0952 4009
15 16 17 18 19 20 21 22 23 24 25 26
L1 N PE
1 2 3 4 5 6 7 8 9 10 111213 14
4(0) - 20 mA
max. 125 V
56 57
55
54
52
51
++
LN
PE
Item Description
L Phase Mains voltage
input
N Neutral
PE (earth)
51 Signal input (-)
52 Signal input (+)
54 Signal output (-)
55 Signal output (+)
56 Collective error message
57
Note
See Section 5.2.4 for warnings and notes relating
to electrical connection!
Warning
The internal wiring of the drive must never be
modified.
TM04_0953_4009
Item Description
1 N Neutral
2Phase
Mains voltage input
(for direction "open/max.")
3Phase
Mains voltage input
(for direction "close/min.")
4Mains voltage output
(position "final position max.")
5Mains voltage output
(position "final position min.")
PE (earth)
18 Start
19 Slider
20 End
N
open
min.
PE
max.
close
N
234518 19 20
< 50 V
start
slider
end
< 50 V
1
SL (max.) SR (min.)
Motor control Reversing potentiometer
Limit switches

17
• Connect the terminals to the corresponding terminals on the external control device (Conex®DIS-2Q in the example) as shown in the
connection diagram.
Fig. 24 Terminal connection diagram for Conex®DIS-2Q on a servomotor with potentiometer
Electrical connection
1. Unscrew the hood screws and remove the hood.
2. Establish the electrical connections in accordance with the
circuit diagram; see Fig. Terminal connection diagram for
servomotor with potentiometer.
– Connect terminals 18, 19 and 20 in accordance with
requirements; voltage < 50 V.
3. Determine the direction of rotation and, if necessary, correct it.
Determining the direction of rotation
The internal wiring means that the direction of rotation (looking
through the drive towards the output shaft) and limit switches are
assigned as follows:
• If the mains voltage is present at terminal 2, the output shaft
rotates anticlockwise (in the direction "open/max.").
– This direction of rotation is restricted by the upper switch
(max.). If the switch is activated, the mains voltage is
present at terminal 4.
• If the mains voltage is present at terminal 3, the output shaft
rotates clockwise (in the direction "close/min.").
– This direction of rotation is restricted by the lower switch
(min.). If the switch is activated, the mains voltage is present
at terminal 5.
• If the drive rotates in the opposite direction to the control
commands, swap over the connections of terminals 2 and 3.
Close the hood again and tighten the hood screws.
5.2 Checks before commissioning
Check tightness of the total plant before start-up.
5.2.1 Checking the gas solution lines and the non-return
diaphragm of the injector
• Observe the manual of the injector!
5.2.2 Checking the tightness with ammonia
nia
Fig. 25 No liquid ammonia
TM04 0954 4009
15 16 17 18 19 20 21 22 23 24 25 26
L1
PE
1 2 3 4 5 6 7 8 9 10 11 12 13 14
IDM
SL (max.) SR (min.)
open
min.
max.
close
N
2345
18 19 20
< 50 V
start
slider
end
< 50 V
1
NPE
Floating relay outputs
Measuring amplifier
Reversing potentiometer
Note
See Section 5.2.4 for warnings and notes relating
to electrical connection!
Warning
The internal wiring of the drive must never be
modified.
Warning
Check the tightness not until the total plant is
ready for start-up.
Danger of gas leakage!
Warning
Liquid ammonia must not come in contact with
parts of the plant!
Danger of leakages by corrosion!
TM04 0709 0908

18
5.2.3 Checking the pressure connections (after changing gas
cylinder)
• Open the cylinder valve and quickly close it again.
• Slowly pass the open ammonia bottle along gas-leading
parts.
– Slightly press the bottle in a pumping manner, allowing the
ammonia mist to rise up.
– Formation of white mist: Leakage at the pressure
connection!
• Depressurize the plant!
• Eliminate leakage!
• Check tightness again
Formation of white mist --> pressure connection is not tight
Fig. 26 Ammonia + chlorine gas --> formation of white mist
No formation of white mist --> pressure connection is tight
Fig. 27 No chlorine gas --> no formation of white mist
5.2.4 Checking the inlet valve
• Remove the union nut at the overpressure connection and
take off the overpressure line.
• Close the rate valve.
• Open the cylinder valve.
• Slowly pass the open ammonia bottle along the overpressure
connection.
– Slightly press the bottle in a pumping manner, allowing the
ammonia mist to rise up.
– Formation of white mist: The inlet valve is not tight!
• Depressurize the plant!
• Check the inlet valve and repair it!
• Check tightness again
Formation of white mist --> the inlet valve is not tight!
Fig. 28 Ammonia + chlorine gas --> formation of white mist
No formation of white mist --> the inlet valve is tight!
Fig. 29 No chlorine gas --> no formation of white mist
6. Operation
6.1 Description of the device
6.1.1 Dosing regulator
Fig. 30 Schema dosing regulator VGA-117
TM04 0710 0908
TM04 0711 0908
TM04 0712 0908
!
!
✓
VGB-103
TM04 0713 0908
TM04 0794 0908
Item Description
1Connection for the vacuum line from the vacuum
regulator
2 Connection for the vacuum line to the injector
3Rate valve:
for manual adjustment of the desired gas flow.
4 Measuring tube: It displays the actual gas flow
Caution
The rate valve is not a perfectly closing shut-off
valve!
VGB-103
✓
1
2
3
4

19
6.1.2 Dosing regulator with servo motor
Fig. 31 Schema dosing unit VGA-117 with servomotor
6.2 Adjusting the Dosing Flow
6.2.1 Increasing the dosing flow
• Turn the adjustment knob of the rate valve slowly to the right.
Fig. 32 Increasing the dosing flow
6.2.2 Decreasing the dosing flow
• Turn the adjustment knob of the rate valve slowly to the left.
Fig. 33 Decreasing the dosing flow
6.3 Reading the dosing flow
• Read the dosing flow at the upper edge of the ball.
Fig. 34 Reading the dosing flow
6.4 Change between automatic and manual
adjustment of the dosing flow
Automatic adjustment of the dosing flow
6.4.1 Switching from automatic to manual adjustment of the
dosing flow (only devices with servomotor)
• Switch off automatic control.
• Push the coupling (1) upwards.
• Move the retention pin (2) through the coupling, until it cannot
move down any longer.
– Now the dosing flow can be adjusted by hand.
• The servomotor is disconnected from the rate valve.
Fig. 35 Disconnect to servomotor
TM04 0795 0908
Item Description
1Connection for the vacuum line from the vacuum
regulator
2 Connection for the vacuum line to the injector
3, 5 Rate valve with servomotor:
For automatic adjustment of the desired gas flow
4 Measuring tube: It displays the actual gas flow
Caution
The rate valve is not a perfectly closing shut-off
valve!
Caution
Do not screw out the adjustment knob. Do not
continue turning the knob when maximum dosing
flow is reached.
TM04 0797 0908
1
2
3
4
5
TM04 0798 0908
Note
The scale of the measuring tube is adjusted to a
gas temperature of 20 °C. In case of extremely
different temperatures the dosing flow may differ
from the value being displayed.
TM04 0717 0908
Note
In case of automatic adjustment of the dosing
flow, no adjustment can be made at the dosing
unit. All adjustment has to be made at the control
device.
Observe the manual of the control device!
TM04 0752 0908
g/h
lbs/day
12

20
6.4.2 Switching from manual to automatic adjustment of the
dosing flow (only devices with servomotor)
• Move back the retention pin (2).
– Now the coupling (1) falls down.
• Turn the adjustment knob (3), until the coupling snaps in.
– Now the servomotor is connected to the rate valve.
Fig. 36 Conect to servomotor
6.5 Switching on
• Close the rate valve.
• Open the shut-off valve at the injection unit.
• Open the motive water valves.
• Switch on the motive water of the injector.
• Open the valve of the gas cylinder.
• Slowly open the rate valve until the ball in the measuring tube
shows the desired gas flow.
6.6 Switching off
6.6.1 Emergency Stop
In case of gas break-out
• Immediately leave the room!
• Start counter-measures according to local safety precautions.
In case of small leakages
• Put on safety equipment!
• Immediately close the cylinder valve.
• Let the system run until all parts are evacuated.
• Switch off the system as described in the following
6.6.2 Switching off while the system is running
• Close the cylinder valve.
• Let the system run until the measuring tube shows no more
gas flow.
• Close the rate valve.
• Switch off the motive water of the injector.
• Close the motive water valves.
• Close the shut-off valve at the injection unit.
TM04 0753 0908
Warning
Immediately leave the room in case of gas break-
out and put on safety equipment!
Then start counter-measures!
Warning
Repairs of coponents of the system only by
authorized personnel!
3
2