ProMinent Bello Zon CDKa 150 User manual

Part. No. 987848 ProMinent Dosiertechnik GmbH ·69123 Heidelberg ·Germany BA BEZ 021 08/06 GB
Operating Instructions
Bello Zon®Type CDKa
for Concentrated Chemicals
ProMinent
®
Please read through these operating instructions in full before use. Do not discard!
Damage caused by incorrect operation will invalidate the guarantee.
The manufacturer is not liable for any damage caused by failure to follow operating instructions.
Please enter identity code of the device here.
CDKa ___ ___ ___ ___ ___ ___ ___ ___ ___ ___

ProMinent®
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Publishing details:
Operating Instructions Bello Zon®Type CDKa
for Concentrated Chemicals
© ProMinent Dosiertechnik GmbH, 2002
Address:
ProMinent Dosiertechnik GmbH
Im Schuhmachergewann 5-11
69123 Heidelberg
Phone: [phone]
Fax: [phone]
[email protected]
www.prominent.com
Subject to technical alterations.
Publishing details:

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page
General Instruction for Use ......................................................................................................... 6
Important General Information
AInstructions for regulation use ......................................................................................... 7
BObligations of the user .................................................................................................... 7
CInstructions for introducing operators to chlorine dioxide system .................................. 7
D Information on general safety .......................................................................................... 8
E Emissions ........................................................................................................................ 10
FTerms and abbreviations used......................................................................................... 10
1 Description of chlorine dioxide system,
chemical principle and functional mode of system.................................................... 11
1.1 Detailed description of system ........................................................................................ 12
1.1.1 Identification code ................................................................................................ 12
1.1.2 Operating code “Aktiv”........................................................................................ 13
1.1.3 Construction: Description of the system and its construction groups................. 15
1.2 Technical specifications ................................................................................................... 20
1.2.1 Technical features of the system .......................................................................... 20
1.2.2 Performance data ................................................................................................. 22
1.2.3 Reactor specifications .......................................................................................... 23
1.2.4 Weight .................................................................................................................. 23
1.2.5 Temperature ......................................................................................................... 24
1.2.6 Climate and environment ..................................................................................... 24
1.2.7 Specifications of electrical components .............................................................. 24
1.2.8 Shock and moisture protection (IP) ...................................................................... 28
1.2.9 Supplementary kit ................................................................................................ 28
1.2.10 Chemical components ......................................................................................... 28
1.2.11 Warning signs ....................................................................................................... 28
1.3 Operating elements and indicators, tap positions ........................................................... 29
1.3.1 Electrical operating elements and indicators ....................................................... 29
1.3.2 Ball valve .............................................................................................................. 30
1.4 Safety measures ..............................................................................................................32
1.4.1 Flow monitors ....................................................................................................... 32
1.4.2 Bypass monitor .................................................................................................... 32
1.4.3 Level switch .......................................................................................................... 33
1.4.4 Exhaust ............................................................................................................... 33
Table of Contents

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Table of Contents
1.5 Chlorine dioxide system accessories .............................................................................. 33
1.5.1 Bypass pump with wall bracket ........................................................................... 33
1.5.2 Safety trays 70 l .................................................................................................... 33
1.5.3 Premixing (static mixer) ........................................................................................ 34
1.5.4 Protective filter ..................................................................................................... 34
1.5.5 Ventilation valves .................................................................................................. 34
1.5.6 Set for determining chlorine dioxide .................................................................... 34
1.5.7 Intake lances, intake fitings .................................................................................. 35
1.5.8 Spare part sets ..................................................................................................... 35
1.5.9 Part number table for spare parts and spare parts set ........................................ 35
1.6 Heating systems for chemical lines ................................................................................. 36
1.7 Metering systems ............................................................................................................ 36
1.8 Spare parts lists ............................................................................................................... 36
2Commissioning .............................................................................................................. 37
2.1 Information on current regulations .................................................................................. 37
2.2 Initial operation of the system type CDKaxAxxxxxXxx (with calibration vessels) ........... 37
2.2.1 Airing and starting ................................................................................................ 37
2.2.2 Leak test ............................................................................................................... 37
2.2.3 Setting flow monitors ........................................................................................... 38
2.2.4 Setting parameters and calibration ...................................................................... 38
2.2.5 Safety checks ....................................................................................................... 39
2.3 Commissioning system type CDKaxBxxxxxXxx (w/o calibrating vessels) ...................... 40
3Shutting down chlorine dioxide system ...................................................................... 40
3.1 Placing out of operation for a short period of time.......................................................... 40
3.2 Placing out of operation for a longer period of time ........................................................ 40
3.3 Placing out of operation and frost-proof storage ............................................................ 41
4Replacing acid and chlorite component tanks ........................................................... 41
5Operation of chlorine dioxide system .......................................................................... 42
5.1 Setting ball valves ............................................................................................................ 42
5.2 Setting the metering rate ................................................................................................. 42
5.2.1 Menu sequence “internal control”........................................................................ 42
5.2.2 Menu sequence “flow dependent metering”....................................................... 43
5.2.3 Menu sequence “control variable dependent metering”...................................... 44
5.2.4 Menu sequence “bypass options”....................................................................... 45
5.3 Accuracy of metering rate ............................................................................................... 45
5.4 Determining chlorine dioxide concentration .................................................................... 46
5.5 Chlorine dioxide metering rate ........................................................................................ 46

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Table of Contents
6Operating errors, help, troubleshooting ...................................................................... 46
6.1 Consequences of operating errors .................................................................................. 46
6.1.1 Incorrect setting of metering pumps .................................................................... 46
6.1.2 Incorrect setting of flow monitor (ring initiators)................................................... 46
6.1.3 Incorrect setting of air bleed taps (acid, chlorite and water) ................................ 47
6.1.4 Incorrect use of control ........................................................................................ 47
6.2 Malfunctions .................................................................................................................... 47
6.2.1 Malfunctioning of metering pumps ...................................................................... 47
6.2.2 Error messages at control .................................................................................... 47
7Inspection and maintenance ........................................................................................ 49
7.1 Safety requirements, safety information .......................................................................... 49
7.2 Maintenance of overall system ........................................................................................ 49
7.2.1 Maintenance and service for the Bello Zon®Reactor;
removing and detoxifying reactor content ........................................................... 49
7.2.2 Maintenance of metering pumps ......................................................................... 50
7.3 Maintenance intervals, lifetime of system ....................................................................... 50
8Mounting and dismantling chlorine dioxide systems ................................................. 51
8.1 Mechanical and hydraulic installation of system ............................................................. 51
8.1.1 Hydraulic connections .......................................................................................... 51
8.1.2 Metering pump intake lances or intake fittings for acid and chlorite ................... 52
8.1.3 Dilution water tank and water metering pump ..................................................... 53
8.1.4 Reactor space venting ......................................................................................... 53
8.2 Electrical installation of the system ................................................................................. 53
8.2.1 Control ................................................................................................................. 53
8.2.2 Connections at distributor box ............................................................................. 54
8.3 Dismantling the chlorine dioxide system ......................................................................... 54
8.4 Disposal of used parts ..................................................................................................... 54
9List of Illustrations ......................................................................................................... 55
EC Declaration of Conformity .................................................................................................. 56

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General instructions for use
Please read through these instructions for use carefully. They will enable you to make the best
possible use of this operating instructions manual.
The following sections are highlighted in the text:
-Enumerated points
•Instructions
Working instructions:
IMPORTANT
Guidelines are intended to make your work easier.
and safety instructions:
DANGER
Describes a potentially dangerous situation.
Non-observance can lead to personal injury or damage to property.
CAUTION
Describes a potentially dangerous situation. If not avoided, could cause slight or
minor injury or damage to property.
NOTICE
Describes a potentially dangerous situation.
Non-observance can lead to damage to property.
General instructions for use

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Important General Information
AInstructions for regulation use
A.a. Regulation Use
Chlorine Dioxide systems are made only for the disinfection of water and may not be used for
any other purpose.
IMPORTANT
Chlorine dioxide (ClO2) is an extraordinarily reactive gas that cannot be stored because
of its instability. It should only be produced as needed in special enclosures at the
place of use.
The amount of chlorine dioxide necessary depends on the particular need. For drink-
ing water a concentration of 0.1–0.2 mg/l is sufficient. For industrial use (e.g. rinse
water) higher concentrations are often used.
The Drinking Water Ordinance in the version of 5 December 1990 provides for doses
of up to 0.4 mg/l, whereby detectable amounts of up to 0.2 mg/l of chlorine dioxide
and chlorite are allowed as by-products of the reaction.
A.b Non-regulation use
CAUTION
Under no circumstances should chlorine dioxide systems be used for the
treatment of gaseous substances.
BObligations of the user
This operating manual should be available to all supervisors and operating personnel and kept
readily accessible near the chorine dioxide system.
The user must ensure that chlorine dioxide systems are only used and operated by specially
trained, expert persons. It is recommended to have operators confirm that they have been
trained and introduced to the system.
The user must ensure that only authorised persons have access to the system and chemicals
needed for its use.
The manufacturer should be notified immediately in the event of technical problems that could
effect the health of persons having contact with water treated by the system.
After installation of the system by trained personnel, the system must be tested and approved for
use by an expert authorised by ProMinent.
CInstructions for introducing operators to chlorine
dioxide system
AIt is mandatory that all chapters of this operating manual, especially those describing the
chlorine dioxide system and their commissioning be carefully read.
An expert from ProMinent must give operators a detailed introduction as part of the commissioning
of the system.
This manual will provide enough information to answer almost all questions arising from
malfunctioning. Questions necessitating more detailed information should be addressed to the
manufacturer of the system.

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Important General Information
DInformation on general safety
NOTICE
This operating manual is to be made available to all operating personnel and kept
readily accessible near the chorine dioxide system (see ch. B).
D.a Relevant guidelines and regulations
Bello Zon®-Systems are manufactured in compliance with DVGW Guidelines W 224 (chlorine
dioxide in treatment of water) and with the accident prevention regulations “Chlorination of
Water”GUV 8.15 and VGB 65.
NOTICE
-When installing and using chlorine dioxide systems, the following regulations
and ordinances must be observed and the systems operated in accordance
thereof:
a) Accident prevention regulation “Chlorination of Water”GUV 8.15 and VGB 65
(in the version of 1 Sep. 79)
-§12 (1–5) prescribes personal protective gear that the user must provide.
b) Ordinance on dangerous working materials (Arb-StoffV), in the version of
11 Feb. 1982 BGBI/p. 145.
D.b Requirements for starting components in the production of chlorine dioxide in
Bello Zon®CDKa Systems
For process safety reasons, use only chemical components of prescribed concentrations and
with a tolerable level of recycled material (for details, see ch. 1.2.10).
NOTICE
•After finishing treatment of water for drinking purposes there may not be any
impurities left in concentrations dangerous to human health. In this respect
see “Act governing contact with food and public sale thereof (Food Act)”.
•Production using concentrations of starting chemicals exceeding those
specified is permissible only with the expressed consent of the manufacturer.
D.c Additional information on safety
NOTICE
•All rooms used in connection with chemicals must be locked when not in use.
Any such room may not be used as lounge. It must be adequately ventila-ted
and protected against frost. No one should come in contact with concentrated
chemicals. Protective clothing (goggles and protective gloves) must be
provided for working with chemicals (see section D.a.a (“Note”)).
•Rooms containing chlorine dioxide systems must be separated by fire walls
from all other rooms.
NOTICE
ACCIDENTS WITH CHEMICALS:
In case of contact with chemicals used in chlorine dioxide systems, observe
safety instructions in the chemical brochures when taking action.
CAUTION
There is danger of caustic injury (burning) in contacting the chemicals
hydrochloric
- acid HCl 30–33% and
- sodium chlorite NaClO224,5 %.
Flush immediately with large amounts of water and call medical doctor.

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Important General Information
DANGER
The intake lance “acid”belongs to the acid tank and the intake lance “chlorite”
belongs to the chlorite tank.
The intake lances and storage tanks for concentrated sodium chlorite and
hydrochloric acid must be clearly identified and under no circumstances
exchanged.
Never place both intake lances together or successively in the same bucket.
Exchanging the two intake lances when they contain chemical residues will
cause gaseous chlorine dioxide to form (poisonous, caustic, strongly oxidizing).
For all Bello Zon®systems in which the reactor cannot be flushed in mounted
position:
•Before maintenance flush the reactor thoroughly with water. Empty reactor
only outdoors or at least in an extremely well-ventilated room, e.g. in a
laboratory beneath a fume hood or in front of open window.
•When emptying, wear protective gear such as gloves and goggles
(see ch. D.a.a); observe all local regulations.
The system must be installed so that a vacuum cannot occur in the bypass line
under any circumstances (including operational standstills). If this cannot be
insured, an anti-vacuum device must be installed.
CAUTION
•It must be ensured that any chemicals spilt will be safely disposed of, e.g. by
hosing the chemicals into a floor drain.
•Suitable precautions (e.g., installing an anti-vacuum device) must be taken to
avoid any vacuum at the point of metering.
•In the event that water to be treated should fail to flow, it must be ensured that
the metering of chlorine dioxide solution will be automatically stop.
•The maximum allowable pressure for the system (see ch. 1.2.2) is not to
be exceeded under any operational conditions.
•Disconnect all electric power when mounting system.
NOTICE
•The complete system, including pipes, must be free of leaks at maximum
operating pressure (see ch. 1.2.2)
•Mount signs informing of danger according to GUV 8.15 Annex 2 and 3
(see also ch. 1.2.11)
IMPORTANT
•Deliveries to Israel:
Only fluorine-free chemicals may be used there.
•When water to be treated is enriched with ClO2, the turbine wheel flow meter may
not be used as bypass monitor (see ch. 1.4.2).
•The system may be operated only within the conditions specified herein
(see ch. 1.2.5).
•
The reactor of the Bello Zon
®
CDKa systems is subject to the Ordinance on
Pressurised Containers and is marked accordingly.
The user must see to it that regulations applying are met.
D.d Warning signs
NOTICE
Five warning signs (see fig. 6–10, ch. 1.2.11) must be hung up during installation.

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Important General Information
EEmissions
During normal usage there are no emissions from chlorine dioxide systems Bello Zon
®
Type CDKa.
For further information on possible emission dangers, see Ch. D “Information on general safety”.
FTerms and abbreviations used
bl blue
br brown
ca. approx.
CDK chlorine dioxide system for concentrated chemicals
Ch. chapter
ClO2chlorine dioxide
fig. figure
gb yellow
gn green
hhour
HCl hydrochloric acid
Hz Hertz (cycles per second)
kg kilogram
llitre
LED light emitting diode
max. maximum
mA milliampere
mg milligram
min. minute
ml millilitre
NaClO2sodium chlorite
sec. second
sw black
Tab. table
VVolt
w/o without
ws white