Grundfos Vaccuperm VGA-117 User manual

Vaccuperm VGA-117
Gas dosing regulator
Installation and operating instructions
GRUNDFOS INSTRUCTIONS
Other languages
http://net.grundfos.com/qr/i/95714246

English (GB)
2
English (GB) Installation and operating instructions
Original installation and operating instructions.
CONTENTS
Page
1. Safety instructions
These installation and operating instructions contain important
information for the user of the product:
• Technical data
• Instructions for commissioning and use
• Safety instructions
If you require further information, or if problems occur that are not
described in detail in this manual, please contact Grundfos.
1.1 Symbols used in this document
This manual contains the following standardised safety
instructions about possible residual risks:
1.2 Safety advice for handling chlorine
1.2.1 Hazards of chlorine gas
• Causes whooping cough, dyspnoea and lacrimation.
• Has a slight paralysing effect to the central nervous system.
• Concentrations of more than 10 ppm chlorine gas in the
respiratory air mean an acute danger to life.
• Inhaling air with a high concentration of chlorine gas for a long
time is lethal.
1.2.2 Hazards of liquid chlorine
• Causes burns of skin.
• Causes reddening and blistering of skin.
1.2.3 Rules of conduct
• Change chlorine containers only with gas mask.
• Enter contaminated rooms only with protective suit and
compressed-air respirator.
• In case of flight wear gas mask, if possible. Observe wind
direction.
1. Safety instructions 2
1.1 Symbols used in this document 2
1.2 Safety advice for handling chlorine 2
1.3 Protective equipment 3
1.4 First aid in case of accidents 3
1.5 Handling chlorine containers 4
1.6 Chlorine rooms 5
2. Introduction 6
2.1 Correct usage 6
2.2 Inappropriate usage 6
2.3 Qualification of the users 6
2.4 Responsibilities of the operator 6
2.5 Maintenance and service personnel 6
2.6 Type key VGA-117 dosing regulator 7
2.7 Transport and storage 7
2.8 Unpacking 7
3. Technical data 8
3.1 General technical data 8
3.2 Dosing flow 8
3.3 Accessories 8
3.4 Dimensions 8
3.5 Electrical data of servomotor 9
3.6 Physical and chemical data of chlorine 10
4. Design and function 10
4.1 Description of the device 10
4.2 Functional principle 11
5. Assembly and installation 12
5.1 Selection of vacuum lines 12
5.2 Connecting the dosing regulator 13
5.3 Connecting an external controller to a servomotor with
analog control 13
5.4 Connecting an external controller to a servomotor with
reversing potentiometer 15
5.5 Installation example 16
6. Startup 16
6.1 Checking the tightness 16
6.2 Chlorine extraction 17
7. Operation 18
7.1 Switching on the chlorine gas dosing system 18
7.2 Setting the dosing flow 18
7.3 Reading the dosing flow 18
7.4 Servomotor 19
7.5 Switching off the chlorine gas dosing system 19
7.6 Changing the chlorine container while the system is
running 19
8. Maintenance 19
9. Fault finding 20
10. Disposal 20
Warning
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.
Warning
Toxic by inhalation.
Irritating to eyes, respiratory system and skin.

English (GB)
3
1.3 Protective equipment
1.3.1 Personal protective equipment
The operating authority of a chlorine gas dosing system has to
provide respiratory equipment (full-sight gas mask), personally
fitted, labelled by name, with an effective chlorine filter (B2P3)
and at least 1 spare filter per gas mask, for each operator. The
protective equipment must be stored easily accessible outside
the chlorine rooms.
• For systems with chlorine drums at least 2 protective suits with
compressed-air respirators must be available.
1.3.2 Obligations of the operating authority
• Introducing the operators to handling the protective
equipment.
• The operators must use the personal protective equipment
regularly, or carry out exercises with it at least every 6 months.
• The gas mask filters must be replaced regularly
– after the expiry of the date of durability
– at least 6 months after opening (note the opening date on
the filter)
– after contact with chlorine.
• Observe employing prohibition according to the local laws.
1.3.3 Storage of the protective equipment
• Outside the chlorine rooms
• Well visible
• Easily available at any time
• Protected from dust and moisture.
1.4 First aid in case of accidents
1.4.1 First aid after inhaling chlorine
1. Keep calm.
2. Remove injured persons from the dangerous area.
3. Helpers must pay attention to personal protection.
4. Remove contaminated clothes.
5. Calm down injured persons and keep them warm with
blankets.
6. Supply fresh air, use oxygen respirator, if possible.
– No mouth-to-mouth resuscitation!
7. Call medical aid or transport to hospital
– lying
– sitting in case of difficulty in breathing.
– State chlorine as the cause.
1.4.2 First aid after chemical burn of skin
1. Keep calm.
2. Remove contaminated clothes.
3. Rinse skin with plenty of water.
4. Bandage the wound aseptically.
5. Seek medical aid.
– State chlorine as the cause.
1.4.3 First aid after chemical burn of eyes
1. Keep calm.
2. Rinse eyes with plenty of water while the patient is lying.
– Protect healthy eye, if necessary.
– Spread eyelids widely, let the eye move to all sides.
3. Seek ophthalmologist.
– State chlorine as the cause.
1.4.4 First aid after internal chemical burn
1. Keep calm.
2. Drink water in short sips.
– If possible, take medical charcoal.
3. Seek medical aid.
– State chlorine as the cause.

English (GB)
4
1.5 Handling chlorine containers
Chlorine is stored in grey steel cylinders or drums in lockable
chlorine rooms. 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.
Observe the following:
• Store chlorine containers fireproof.
• Protect chlorine containers from heat and sunlight.
• Chlorine containers should not be modified or repaired by the
user.
• Keep full and empty containers closed.
1.5.1 Steel cylinders
• Contents: 50 kg or 65 kg
• Extract chlorine gas from the upright standing cylinder via the
valve.
Fig. 1 Design of cylinder
1.5.2 Chlorine drums
• Contents: 500 kg or 1000 kg
• Extraction of chlorine gas via the riser pipe valve.
• Extraction of liquid chlorine via the dip pipe valve.
Fig. 2 Design of drum
1.5.3 Basic rules
• Treat containers carefully, do not throw!
• Protect containers from turning over or rolling away, e.g. with
chains or clips.
• Protect containers from direct sunlight and temperatures over
50 °C.
• Transport containers only with valve protection nut and
protective cap.
1.5.4 Valid regulations
In Germany, the following regulations apply:
• Regulations for accident prevention "Chlorination of water"
with process instructions (GUV-V D5)
• Regulations concerning places of work (ArbStättV)
• Technical rules for pressurized gases (TRG 280, 310 and 330)
• Operation of baths (BGR 108)
• Chlorine gas dosing systems for water treatment (DIN 19606)
• Chlorine for water treatment (DIN 19607)
TM04 0693 0908
Pos. Description
1 Protective cap
2Valve
3 Holding clip for securing the cylinder
TM04 0694 2011
Pos. Description
1 Riser pipe for chlorine gas extraction
2 Valve for chlorine gas extraction
3 Valve for liquid chlorine extraction
4 Dip pipe for liquid chlorine extraction
5Tyre
6 Mark for adjustment of drum
1
2
3
Welded chlorine
cylinder
Weldless chlorine
cylinder
2
5
3
6
4
1
3
4
Warning
Handling of chlorine containers only by experienced
personnel.
Observe safety regulations for chlorine containers.
Warning
These rules apply for both full and empty containers,
as empty containers still contain rests of chlorine and
therefore are under pressure.
Warning
Local laws and regulations for handling, transport
and storage of chlorine must be observed.

English (GB)
5
1.6 Chlorine rooms
Chlorine rooms are rooms, where a chlorine gas dosing system
and/or chlorine containers are located. The chlorine in these
rooms is under pressure.
1.6.1 Regulations for chlorine rooms
According to the German regulations for accident prevention
"Chlorination of water", such rooms have to meet the following
requirements:
• They should not have connections to other rooms, and must
be separated gas-tight and fire-resistant.
• They must be at ground level, dry and air-conditioned.
The recommended room temperature is 18-20 °C. It should be
neither lower than 0 °C nor higher than 50 °C.
• Overpressure lines of dosing equipment must not end in the
open air.
• Ventilation openings leading into the open air must be limited
to 2 x 20 cm2.
• Appropriate exhaust devices with downstream absorption
systems must be installed.
• Chlorine gas must not get into lower-lying rooms, shafts, pits,
canals or aspirating holes of ventilation systems.
• Chlorine rooms must be equipped with a water sprinkling
system to precipitate the escaping chlorine gas.
– The sprinkling system must have a run-off with air trap.
– Operation must be possible manually from outside the
chlorine rooms.
• A chlorine gas warning system must be installed
– with optical and acoustical alarm device,
– with connection to the water sprinkling system,
– with a warning system that reactivates automatically after
switch-off (e.g. for container exchange).
• The floor of a chlorine room must be even, the exit not below
ground level and not higher than a possible loading ramp.
Fig. 3 Requirements of chlorine rooms
• Chlorine rooms must have a direct exit to the open air.
• Doors must be lockable, open outwards, and it must be
possible to open the doors without a key from inside the room.
• Chlorine rooms must not be dedicated for the permanent stay
of people.
• Eating, drinking, or storing food in chlorine rooms is
prohibited.
1.6.2 Labelling of chlorine rooms
In Germany, according to DIN 4844, the following warning signs
must be installed outside the entrance of a chlorine room:
Fig. 4 Warning sign and supplementary sign "Chlorination
plant: Access only for instructed persons"
Inside a chlorine room, the mandatory sign "Use the gas mask"
and the "Instruction sheet for first aid in case of chlorine gas
intoxications" must be installed.
Fig. 5 Mandatory sign (DIN 4844)
TM04 0704 0908
✓
✗✗
✓
TM04 0699 0908TM04 0701 0908

English (GB)
6
2. Introduction
2.1 Correct usage
The VGA-117 dosing regulator is exclusively designed for dosing
chlorine gas into a vacuum line.
2.2 Inappropriate usage
Operational safety is only guaranteed, if the product is used
correctly. All operating methods conflicting with correct usage are
not permitted, and lead to the expiry of all liability claims.
2.3 Qualification of the users
Based on his professional training and experience, the user must
have a good knowledge of the operation of chlorine gas dosing
systems. He must be so familiar with the relevant laws and
regulations governing safety in the workplace and accident
prevention, and with the recognised standards of good practice,
that he is able to judge the safe working condition of a chlorine
gas dosing system.
The user is responsible for operation and monitoring of the
product at the installation site.
The responsibilities of the user:
• Read this manual before operating.
• Be trained by qualified Grundfos personnel in the operation of
the product.
• Observe the relevant 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.
2.4 Responsibilities of the operator
The operator of the product is responsible for the following:
• Ensure that this manual is kept clearly accessible in the
immediate vicinity of the system for the entire service life.
• Meet the installation requirements specified by the
manufacturer (environmental conditions, required water
connections and fittings, electrical connection, protective pipe
for dosing line if necessary, audible or optical warning device if
necessary).
• Ensure that water lines and armatures 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 site.
• Provide all users and service personnel with protective
clothing (e.g. face mask, gloves, protective apron) in
accordance with the national regulations.
2.5 Maintenance and service personnel
The product may only be maintained and serviced by personnel
authorised by Grundfos.
Warning
Unauthorised structural modifications to the product
may result in serious damage to equipment and
personal injury.
It is forbidden to open, modify, bridge, remove,
bypass or disable components, especially safety
equipment.

English (GB)
7
2.6 Type key VGA-117 dosing regulator
The type key serves for the identification of the product, not for configuration purposes.
2.7 Transport and storage
• Transport carefully, do not throw!
• Store in a dry and cool place.
2.8 Unpacking
Observe when unpacking:
• The delivery must be complete.
• No humidity and no foreign matters should get into
gas-leading parts.
• Mount the components of the dosing system as soon as
possible after unpacking.
Code Example VGA-117 -1000 /5 -M O , N
VGA Vaccuperm Gas Advanced
Dosing flow
500 25-500 g/h
1000 50-1,000 g/h
2000 100-2,000 g/h
4000 200-4,000 g/h
6000 300-6,000 g/h
8000 400-8,000 g/h
10000 500-10,000 g/h
Connection input and output
1PEhose8/11
2 PE hose 10/14
3 PVC pipe DN15 (d 20)
Adjustment of the dosing flow
M Manual
A Automatic, 230-240 V, 50/60 Hz
B Automatic, 110-115 V, 50/60 Hz
Control
0 Without
14-20mA
2Direct
Differential pressure regulator
Y Yes, with vacuummeter
NNo

English (GB)
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3. Technical data
3.1 General technical data
3.2 Dosing flow
3.3 Accessories
The following accessories are not included in the standard
delivery:
• Hoses of different lengths
• Holding plate for wall fixing when changing containers
• Ammonia water for tightness check.
3.4 Dimensions
Fig. 6 VGA-117 dosing regulator with and without servomotor
Accuracy ± 4 % of upper limit
Permissible medium Cl2
Setting range 1:20
Permissible vacuum
regulator VGA-111, VGA-146 (up to 4000 g/h)
Flowmeter
According to the floater principle, ball
in measuring glass, length of
measuring glass 190 mm
Weight Without servomotor: 2.6 kg
With servomotor: 4.2 kg
Vacuum line between
dosing regulator and
injector
PE hose 8/11 or 10/14
PVC tube DN 15 (d20)
50-1,000 g/h 2-50 lbs/day
100-2,000 g/h 5-100 lbs/day
200-4,000 g/h 10-210 lbs/day
300-6,000 g/h 15-310 lbs/day
400-8,000 g/h 20-420 lbs/day
500-10,000 g/h 30-520 lbs/day
TM04 841618118
575
600
145
12.5
170
107
46
80
Ø 6
12.5
375
400
105
12.5
130
46
80
12.5
Ø 6

English (GB)
9
3.5 Electrical data of servomotor
3.5.1 Servomotor with reversing potentiometer
Fig. 7 Servomotor with reversing potentiometer
3.5.2 Servomotor with analog control (4-20 mA/0-20 mA)
Fig. 8 Servomotor with analog control
TM04 0956 4009
Pos. Description
1SR, limit switch cam min.
SL, limit switch cam max.
2 Supply voltage input
3 Potentiometer input/output
4 Earth terminal
Mains voltage
220-240 V ± 10 %, 50/60 Hz ± 5 %,
100 % ED (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)
Load capacity of limit
switch 2 A at 250 V
Power consumption Approx. 2 VA
Control variant Reversing potentiometer 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 °
Protection class IP65
Permissible ambient
temperature -15 °C to 60 °C
2
1,
3
4
SL
SR
1,
TM04 0956 4009
Pos. 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 Analog signal connection terminals
8 Earth terminal
Mains voltage
220-240 V ± 10 %, 50/60 Hz ± 5 %,
100 % ED (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)
Load capacity of limit
switch 2 A at 250 V
Power consumption Approx. 2 VA
Control variant Analog control
Input/output
Signal input, signal
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 bit
Actual value output
4 (0)-20 mA
Load max. 500 Ω
Resolution: 10 bit
Carrying capacity of
signal output
Output current: 4-20 mA
Minimum voltage for open circuit 10 V
Potentiometer 1000 Ω
Actuating time 90 s for 270 ° at 50 Hz
75 s for 270 ° at 60 Hz
Adjustment angle Max. 270 °
Protection class IP65
Permissible ambient
temperature 0 °C to 60 °C
235
4
6
7
8
1
2
LR
SET
on
1,
SR
SL
1,

English (GB)
10
3.6 Physical and chemical data of chlorine
Under normal conditions of pressure and temperature, chlorine is
a yellowish green gas with a pungent odour, which exists as Cl2
molecule.
It is not flammable, but can promote the flammability of metals,
hydrocarbons, etc.
Fig. 9 Vapour pressure curve of chlorine
Fig. 10 Solubility of chlorine gas in water
4. Design and function
4.1 Description of the device
Fig. 11 Dosing regulator without and with servomotor
Atomic weight 35.457 u
Molecular weight Cl270.941 u
Density (liquid) 1.57 g/cm3at -34.05 °C
Density (gas) 3.214 g/l at 0 °C, 1 bar
1 litre of liquid chlorine at 0 °C is equivalent to 457 litres
(0.457 m3) of chlorine gas
1 kg of liquid chlorine at 0 °C is equivalent to 311 litres
(0.311 m3) of chlorine gas
Specific gravity 2.486
(specific gravity of air: 1)
Boiling point -34.05 °C (1 bar)
Melting point -101.5 °C
Evaporation heat 269 kJ/kg (at 0 °C)
Heat conductivity 0.527 kJ/m2h
(liquid chlorine)
Degree of purity according to
DIN 19607 99.5 %
TLV (Threshold Limit Value) 1.5 mg/m3(0.5 ppmv)
TM04 0691 0908TM04 0692 0908
Temperature [°C]
0
4
8
12
16
20
-50 -30 -10 010 30 50 70
Pressure [bar]
10 30 50 70 90
2
6
14
0
10
Temperature [°C]
Solution [g/l]
TM04 8414 1811
Pos. Description
1 Servomotor (option)
2 Adjustment knob for setting the dosing flow
3 Connection for the vacuum line (to the injector)
4 Measuring glass for indication of the dosing flow
5Connection for the vacuum line (from the vacuum
regulator)
Caution
The rate valve is not a perfectly closing shut-off
valve. Do not try to stop the chlorine gas dosing
system by closing the rate valve!
Switching off the chlorine gas dosing system, see
section 7.5.3 Switching off while the system is
running.
1
5
3
2
4