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

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1Description of chlorine dioxide system,
chemical principle and functional mode of system
Chemical principle of system
Hydrochloric acid chlorite process:
Sodium chlorite + hydrochloric acid →chlorine dioxide + sodium chloride + water
5NaClO2+ 4HCl →4ClO2+ 5NaCl + 2H2O
The Bello Zon®CDKa systems generate a 2 % chlorine dioxide solution (20 g/l ClO2) by combining
concentrated hydrochloric acid and concentrated sodium chlorite together with water (see
ch. 1.2.10). Immediately after production, the sodium chloride is fed to the water to be treated.
The dosage can be set both manually (internal control) or automatically (external control), by
using a flow signal and/or control setting.
Function of the system:
Three metering pumps driven by a programmed microprocessor control feed the components
acid, chlorite and water by way of hoses and three-way valves to the reactor. There they mix and
react, forming a 2 % chlorine dioxide solution. The feeding of the components to the reactor is
checked by flow monitors.
The chlorine dioxide solution flows through the metering valve into the bypass. From there the
pre-diluted ClO2is fed to the metering station.
Control of the metering pumps is carried out in the order “water”- “acid”- “chlorite”; the three
pumps work independently of each other and do not have to be adjusted for equal rates of
metering.
Flow monitors register when the metering pumps start stroking and this is indicated at the control.
If the flow monitor pulses fail, this is indicated after eight successive strokes and metering is
stopped. Should high excess pressure occur during correctly functioning flow monitoring, the
metering rate decreases and the system switches to “fault”.
Changes in parameters relevant to operation such as stroke length, pressure at metering valve,
etc. necessitate re-calibrating the rate of flow of the metering pumps.
Metering can be arrested at the control. Input signals are ignored in the arrest position “Standby”,
the pumps are not driven, and it is possible to change settings.
The intake lances or intake fittings (referred to below as “intake lances”in either case) leading
from the acid and chlorite tanks are equipped with a two-stage level switch. If the level of one of
the components falls, then a float in the level switch sinks to the middle position, and the control
displays the message “acid level low”or “chlorite level low”. If the float sinks to the lowest
position, then the system shuts down, and the control displays the message “Acid Cont. EMPTY”
or “Chlorite Cont. EMPTY”. In addition, there is a hose connected between the intake lance
“acid”and the reactor housing for venting (option: CDKa xA...). In this way acid fumes are
conducted to the reactor housing and do not pollute room air.
For the water supply tank there are two one-stage level monitoring devices. The refill time is
entered into the configuration menu. The level monitoring device “FULL”serves as a safety
device. After the level monitor switch “EMPTY”activates the refilling of water, there is a five-
second span of time until the system shuts down. This is a safety factor, in case, for example,
water fails to flow or the float gets caught.
There is an optional flow rate monitor built into the bypass (turbine wheel flow meter or variable-
area flow meter). If the rate of flow sinks below a minimal level, metering is stopped until the rate
of flow again exceeds the minimum rate. In case the system delivered does not contain a bypass
monitor (see ch. 1.1.1 “Identification code”), the user must ensure that during metering a
sufficient rate of flow through the bypass is guaranteed.
Description and Function

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Type of system: ClO2metering rate:
1 = CDKa 150 = 150 g/h
3 = CDKa 420 = 420 g/h
4 = CDKa 750 = 750 g/h
5 = CDKa 1500 = 1500 g/h
7 = CDKa 6000 = 5900 g/h
8 = CDKa 10000 = 9800 g/h
An optional pump in the bypass is regulated to start up and stop simultaneously with the
metering. If a turbine wheel flow meter has been installed as bypass monitor, metering will also
be stopped when the bypass flow rate exceeds the average rate in the main line.
A static mixer (premixer) to improve mixing can be delivered as an accessory.
An automatic discharge device, consisting of an injector and a solenoid valve, turns on periodically
for a few seconds to extract liquids or fumes in the event of possible leakage from the reactor
housing. These are then conducted safely to waste water.
1.1 Detailed description of system
Series CDKa chlorine dioxide systems are completely assembled installations ready for
connection.
An accessory set containing diverse small parts is part of delivery for each Bello Zon®System.
1.1.1 Identification code
The system configuration is determined by the identification code used for configuring Bello Zon®
Systems
Bello Zon®chlorine dioxide generating
system for concentrated chemicals
(CDK), series a CDKa
Operating voltage:
0 = 230 V, 50/60 Hz
1 = 115 V, 50*/60 Hz
* CDKa 420, 750 and 1500 not
deliverable with 115 V, 50 Hz 3
Intake lance chemicals:
0 = no intake lances
1 = variable intake lances for 60 l
container (height 500–700 mm)
2 = flexible intake fittings up to 5 m
with two-stage level switch 4
Description and Function
1
control-variable input:
for connecting controller to flow rate
dependent metering)
0 = none
1 = contact, pulse range 0–4 Hz
2 = analog (0/4–20 mA)
and contact (reversible) 6
5
Bypass construction:
0 = without bypass monitor
1 = with turbine wheel flow meter*
2 = with variable area flow meter*
A = with installed calibration vessels
B = without installed calibration
vessels 2
Nr. 12345678910
CDKa x X x x x x x X x x
N.B.
X is place marker for a letter and
x is place marker for a number
Enter identification code here:
CDKa __________

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The hardware and software version numbers are displayed on the control panel (hardware
version before the slash, software version after the slash, e.g. 01/01.1). Version numbers should
be given in the event of complaints or when expanding a previously installed system.
An operating code simplifies the setup of the system on location. This code enables activation of
the various options available.
1.1.2 Operating code “Aktiv”
Bello Zon®systems are delivered with a factory-set “identification code”. The identification code
is a result of the composition of the system as determined by the user’s order, e.g., whether flow
rate metering or reading-dependent metering is desired. Should application needs change, control
defaults can be altered within limits, depending on the hardware. The operating code “active”
serves this purpose. Models with the identification code CDKaxAxxx11Dxx contain both control
variants for contact signals. If there is a “0”in the identification code at the corresponding
position, then this variant in the active code cannot be activated. The access code is entered to
set the operating code.
Analog outputs:
0 = none (standard setting)
1 = analog (0/4–20 mA) for recorder 9
Remote control input:
0 = none
1 = contact (pause function)
2 = analog (0/4–20 mA)
3 = contact and analog (0/4–20 mA) 10
NB:
System options are set in grey areas
Description and Function
Flow input
(for connecting water meter)
0 = none
1 = contact, pulse range 0–4 Hz
contact water meter
2 = frequency 0–10 Hz
3 = analog (0/4–20 mA)
and contact (reversible) 7
Control for bypass pumps
N = control inactive
P = control activated
1
Flow rate monitoring in bypass
N = inactive
T = turbine
O = contact input (Normally open)
C = contact input (Normally closed) 2
8
Language default:
E=English
D= German
F=French
I=Italian
S=Spanish
Nr. 12345678
AKTIV x x x x x x x x
N.B.:
x is place marker for a letter
Enter operating code here:
AKTIV _ _ _ _ _ _ _ _

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The possibilities for making settings using
the function keys of the control panel are
explained in connection with operating the
system (see ch. 5 ff.).
Control variable
N= inactive
K=contakt (0–4 Hz)
0=analog 0–20 mA
4=analog 4–20 mA 3
Flow input
N=inactive
K=contakt (0–4 Hz)
F=frequency
0=analog 0–20 mA
4=analog 4–20 mA 4
Language
E=English S = Spanish
D=German H = Hungarian
C= Czech R = Rumanian
F=French B = Portuguese
I=Italian N = Dutch
P=Polish 5
Analog output
N=inactive
0=0–20 mA
4=4–20 mA 6
Remote control input:
contact (pause function)
N=inactive
O=NO, Normally open
C=NC, Normally closed 7
8
Remote control input: analog
N=inactive
0=0–20 mA
4=4–20 mA
Description and Function

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1.1.3 Construction: Description of the system and its construction
groups
Bello Zon®-CDKa systems (see fig. 1) are chlorine dioxide generating and metering systems
that work with concentrated chemicals. They are completely assembled ready for connection.
Performance ranges from 150 g/h to 10.000 g/h of chlorine dioxide.
Fig 1: Schematic drawing of chlorine dioxide systems CDKa 150–1500
Description and Function
713 15 venting sampling
60
19
4c
18
30c.3
3c
2c
30c
8
9
3b 10
30c.11c1a
50
30a.1
30a.2
14
2a
3a
30a
20
30a.3
32
4a
4b
6
flow meter
30c.2
drinking water
31a
11
11a
51
31c
11c
51
11b
1b
2b
5
33
34
20
mains power
chlorite
acid water
→→
→→
→
→→
→→
→
waste water
open drain
12

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Description and Function
Table 1:
Components of Bello Zon®Systems CDKa 150–1500
1 a metering pump acid
1 b metering pump water
1 c metering pump chlorite
2 a air bleed tap acid
2 b air bleed tap water
2 c air bleed tap chlorite
3 a flow monitor acid
3 b flow monitor water
3 c flow monitor chlorite
4 a reactor input valve acid
4 b reactor input valve water
4 c reactor input valve chlorite
5reactor
6observation window
7metering valve (1.5 bar)
8injector
9solenoid valve for discharge system
10 solenoid valve for water supply
11 water supply tank 35 l
11 a foot valve
11 b level monitoring device “FULL“
11 c level monitoring device “EMPTY“
12 venting hook-up acid
13 venting hook-up reactor housing
14 support bracket
15 reactor housing
18 distribution box
19 control
20 stop valve in bypass line
not illus. graduated cylinder (CDKa 150: 500 ml, CDKa 420: 1000 ml)
not illus. set of danger signs (see ch. 1.2.11)
not illus. supplementary set CDKa (small parts)
Table 2: Options
30 a calibrating vessel acid
30 a.1-3 ball valve acid
30 c.1-3 ball valve chlorite
30 c calibrating vessel chlorite
31 a variable intake lance acid for 60 l tank
31 c variable intake lance chlorite for 60 l tank
not illus. flexible intake fittings 5 m

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Description and Function
Table 3: Bypass construction
32 flow rate monitor with turbine wheel flow meter
33 flow rate monitor with variable area flow meter
34 back stroke valve (spring loaded, 0.06 bar)
Accessories, see table 4: or descriptions, see section 1.5 ff.
Table 4: Accessories
50 bypass pump with wall support bracket
51 safety collection tub (without leakage warning) 70 l
60 pre-mixing
not illus. safety collection tub (with leakage warning) 70 l
not illus. comparator for chlorine dioxide measurement
not illus. venting valve for reactor housing
not illus. Cabinets for systems CDKa 150 and 420 (on request)
not illus. DULCOFILT®G1" filter with 100 µm mesh
1.1.3.1 Reactor
The reactor is isolated in a closed reactor housing (15) with a discharge device. There is a
observation window (6) in the line above the reactor. The reaction can be observed here in the
form of a slight yellow discoloration.
The chlorine dioxide solution flows through the metering valve (7) into the bypass. Here it is
mixed into the bypass water flow.
1.1.3.2 Exhaust system
The exhaust system for gases and liquids from the reactor housing consists of an injector
(injector) (8) and a solenoid valve (a). The injector runs on a water line with a minimal pressure of
1 bar.
The solenoid valve is activated ca. six times an hour by way of the control so that the air in the
reactor housing is regularly renewed. Any possible leakage is thus removed safely as waste
water. Since chlorine dioxide is heavier than air, leakage collects in the lower portion of the
housing and is removed by the exhaust system.
Fresh air is fed into the reactor housing either via a venting valve or via a line leading in outdoor
air. The venting valve is available as an accessory (see ch. 1.5.5).
The tank for acid is also ventilated by way of the reactor housing. Corrosive acid fumes are thus
removed by the exhaust system.
1.1.3.3 Metering Pumps
The metering pumps for the chemicals acid (1a), water (1b) and chlorite (1c, see fig. 1) are
mounted at the bottom end of the support bracket. A hose leads from the intake lances to the
liquid end of the pumps. A rotary knob on the metering pumps can be used to adjust the stroke
length.
The stroke frequency is calculated by the control and sent by way of pulses to the pumps.
Each pump operates at its own independent stroke frequency. The respective delivery rate is
determined by gauging (calibration, see ch. 2.2.3). These rates are entered into the control. The
control then calculates the necessary frequency so that both chemical pumps deliver the same
quantity.
The water pump delivers 5.5 times as much as the chemical pumps.
The stroke lengths of the pumps must agree within a tolerance of ±20 %. The liquid ends are
made of acrylic glass. Various pumps are used depending on the capacity of the chlorine dioxide
system (see Table 6, ch. 1.2.2).
From the liquid end of the pumps PTFE-hoses lead to the three-way valves (2a–c). These can
be set in the positions “bleed”or “feed”. Next in line are the flow monitors (3a–c) and then the
reactor (5). At the entrance to the reactor are three vertically arranged ball valves (4a–c).

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Description and Function
1.1.3.4 Calibration vessels (vacuum tanks)
In version CDKaxAxxxxxXx, optional calibration vessels can be arranged next to the pumps
(30a, 30c). These are used when calibrating the pumps and serve during normal usage as
vacuum tanks to collect gas pockets from the suction lines.
A short hose on the intake end of the pumps for acid and chlorite leads to a T between two
stop valves. The corresponding suction line is connected to the bottom of the stop valves
(30a.1, 30c.1). The calibration tanks are mounted above the stop valves (30a.2, 30c.2).
1.1.3.5 Flow monitors (ring initiators)
The task of the flow monitor (3a–c) is to ensure that both chemicals and water flow in the right
relationship during system operation.
If the volumetric flow of a component is reduced by more than 30 %, the flow monitor triggers an
alarm and switches off the system after eight missing pulses in a row.
The operating point must be set correctly by means of vertical adjustment of the sensors
(ring initiators) in order to ensure proper functioning of the flow monitors. From software version
3.13, the dosing monitors are also active during calibration and start up.
1.1.3.6 Metering valve
The metering valve (7) is located in the bypass line, installed in a four-way piece. The valve
opens at a reactor internal pressure of ca. 1.5 bar.
1.1.3.7 Bypass line
The chlorine dioxide solution produced (concentration = 20 g/l) is diluted in the bypass line and
fed to the main flow of water.
In the standard equipment of the system there are ball valves (20) but no bypass monitor. Various
options for the bypass line are available (see fig. 22, ch. 9) according to the identification code
(see also ch. 1.1.1 Identification Code and ch. 1.4.2 Bypass Monitoring):
-Bypass (33) with variable-area flow meter and minimum contact to signal a minimum of flow.
- Bypass with turbine wheel flow meter and minimum contact (see ch. 1.1.3.9).
-Non-return valve (34)
-premixing device (60).
IMPORTANT
•The turbine flow meter cannot be used if the bypass water is enriched with chlorine
dioxide (e.g. in circuit systems).
•If a turbine wheel flow meter is used and bypass water is not free of solid particles,
a protective filter should be connected before the turbine flow meter (see ch. 1.5.4).
1.1.3.8 Systems without bypass monitoring
If the system does not include bypass monitoring (33), the user must ensure that the system
will always shut down automatically and immediately when there is no flow of bypass water.
1.1.3.9 Systems with bypass monitoring
The control has an input for a bypass monitor. This ensures that no chlorine dioxide can be fed
without a flow of water in the bypass.The response value of minimal contact in conjunction with
the turbine wheel flow meter is set in the configuration menu (see ch. 5.2.4 “Bypass options”).
1.1.3.10 Component tanks, intake lances and intake fittings
The component containers for chemicals (e.g. 60 l drum) stand on the floor in front of the
system. The chemicals are fed by way of intake lances (31a, 31c). The length of the intake
lances must correspond to the size of the tanks, the diameter of the suction lines, and to the
capacity of the system (see table 20, ch. 1.5.7).
The intake lances contain a two-stage level monitoring device. If the amount of one of the
chemicals sinks to the first level, then the warning “acid level low”or “chlorite level low”lights up
on the control panel. A red LED “alarm”also lights up as warning (8, see fig. 11). The system
continues to run, and the relay “warning”is activated. In the second stage of the level monitoring,

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the system shuts down, the message “acid tank empty”or “chlorite tank empty”lights up on the
control panel, the alarm-LED (8) flashes and the alarm-relay is activated. In case a horn is
connected to the system, it sounds a signal.
Dilution water is pumped from the water tank (11) by way of a suction hose with a foot valve (11a).
The suction hose is connected to an metering pump for water (1b), the second hose is connected
to a three-way valve on the water intake pump. The container for water has level monitoring
devices for each of the two conditions “full”(11b) and “empty”(11c). The solenoid valve is
activated by the lower monitoring switch to refill the dilution water. After several seconds, the
position of the float is checked; if it has not reached the upper position, then the system shuts
down because of insufficient dilution water. The upper monitor switch serves as overflow
protection. Both level monitors are connected to the same controller input and trigger the
message "Water tank!" in the event of a fault.
Instead of intake lances, flexible intake fittings, five meters in length, can be installed.
1.1.3.11 Control
The control (19) is mounted to the right of the reactor housing (see fig. 1, ch. 1.1.3). The number
of inputs and outputs varies according to the configuration of the system (ch. 1.1.1).
Control options
Part of standard equipment is an input for a contact water meter (flow meter). The rate of
intake can be controlled according to the flow of water in the main water line. When connecting
the contact water meter it should be noted that the maximum permissible frequency is 4 Hz.
An optional analog flow meter (0/4–20 mA) can be connected.
There is also the possibility of regulating the quantity of ClO2in relation to readings. The control
variable can be either a pulse signal (max. 4 Hz), or an analog current signal (0/4 - 20 mA). Control
by way of pulse signal is part of standard equipment.
There is an hardware option for locking the ClO2system per remote control (pause function).
The system can be turned on or off by way of a voltage-free contact.
A further hardware option makes it possible to check the momentary operating capacity
(ClO2g/h) and, in case in operation, to read the water flow meter as analog output signal
(analog output).
1.1.3.12 Distribution box
The distribution box (18) is mounted beneath the control and serves to power the metering
pumps; in addition, it contains an emergency shutdown switch and a mains filter.
For the electrical connections to the distribution box, see fig. 5, ch. 1.2.7.2.
Description and Function

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1.2. Technical specifications
The following chapters include the technical specifications necessary for mounting, installing and
operating the system and its essential components. Enquiries for further information should be
directed to the manufacturer.
1.2.1 Technical features of the system
The dimensions of the chlorine dioxide system are given below (fig. 2).
Fig. 2: Dimensions of Bello Zon®CDK 150–1500 System
Description and Function
600-640 hoch
600-640 height
ca350xca385
adapt to drum height
C
A
B
D
E
DN10/d16
PVC-U
M
BP
PVC-U
X
Z
Y
Netz
moins
DN10/d16
PVC-U
V
DN10/d16
PVC-U
S
G
Trinkwasser
Dillution water d12/9
Tiefe = T
deep
BP
PVC-U
F
Säure
acid
Ø360
500
Wasser
water
Chlorit
chlorite
380
430x500
Abwasser
waste water
freier Auslauf
open outlet
600-640 hoch
600-640 height
ca. 350x ca. 385
3260-2.2
CDK A B C D E F G BP W V T S Z Y X
150-420 0950 840 55 455.38 40,212 DN 25/d 32 068,324 380 050 1350 1140,ø14
750 1100 990 55 533.38 55,212 DN 32/d 40 113,322 380 050 1610 1447,ø14
1500 1300 1190 55 755.38 60,212 DN 40/d 50 108,272 430 190 1850 1422,ø 14