TUV MOLLIK-M Series Operating instructions

MOL®LIK module - Operating and Maintenance Manual Version: 10/2016
MOL Katalysatortechnik GmbH, 06217 Merseburg, Germany 1/ 22
Operating and Maintenance Manual
MOL®LIK module
Type
MOLLIK-M __ __
Read and keep this operating and maintenance manual carefully!
Warranty and guarantee claims require demonstrable compliance
with the instructions contained in this manual!

MOL®LIK module - Operating and Maintenance Manual Version: 10/2016
MOL Katalysatortechnik GmbH, 06217 Merseburg, Germany 2/ 22
Revision
4
Valid from
18.10.2016
It replaces the version of
13.06.2016
© Copyright 2015 by MOL Katalysatortechnik GmbH.
All rights reserved
The contents of this operating and maintenance manual are protected by copyright.
The use of this operating and maintenance manual or its individual contents is only allowed in relation to
their intended purpose, provided that the origin and the copyright protection are indicated appropriately.
Any commercial use (in any manner whatsoever), such as the distribution, reproduction, storage or publi-
cation, is prohibited without the written permission of MOL Katalysatortechnik GmbH.

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Table of contents
Chapter Contents Page
1GENERAL 5
1.1 Structure of the documentation 5
1.2 Information on the formal layout of this manual 5
1.3 Warranty 5
2GENERAL SAFETY INSTRUCTIONS 6
2.1 Duty of the operator to exercise due care 6
2.2 Safety information and symbols used 7
2.3 Safety measures during normal operation 7
2.4 Maintenance, repair and cleaning work 8
2.5 Dangers arising if the safety instructions are not observed 8
3PRODUCT DESCRIPTION 9
3.1 Designated use 9
3.2 Technical data 9
4TRANSPORT 11
4.1 Transport 11
4.2 Content of the shipment 11
4.3 Storage 11
5INSTALLATION 12
6COMMISSIONING 13
6.1 Checks prior to commissioning: 13
6.2 Basic settings 13
6.3 Shutting-down of the system in normal situation 14
6.4 Restart after maintenance or repair 14
7OPERATION 15
7.1 Required operating conditions 15
7.2 Operating the system 15
7.3 Faults 15
8MAINTENANCE 16
8.1 Maintenance and cleaning intervals 16
8.2 Maintenance and inspection 16
8.3 Maintenance and inspection intervals 17
9SPARE PARTS 18

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10 STANDARDS AND REGULATIONS 19
11 APPENDIX 20

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1 General
1.1 Structure of the documentation
In this documentation the user will find all important information of the specified MOL®LIK module:
Safety instructions
Instructions on commissioning, handling and maintenance
Technical data
If you would like more information or should any problems occur that are not covered by
this operating and maintenance manual, then please request the missing information directly to MOL
Katalysatortechnik GmbH.
1.2 Information on the formal layout of this manual
Listing and action steps are marked by a ““.
References are indicated by ““.
Highlighting is used to draw particular attention.
1.3 Warranty
The warranty is only accepted when
The MOL®LIK-module is used in accordance with the information contained in this
operating and maintenance manual,
The MOL®LIK-module is handled correctly,
Repairs are carried out exclusively by authorized personnel,
Only original spare parts or spare parts recommended by MOL Katalysatortechnik
GmbH are used for repairs,
No unauthorized changes are made to the MOL®LIK-module.
Excluded from warranty are the typical wear and tear parts i.e., all movable parts, seals, lamps, etc.

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2 General safety instructions
2.1 Duty of the operator to exercise due care
The MOL®LIK-module has been designed and built under careful consideration of the applicable
harmonized standards and technical specifications. It reflects state-of-the-art technology and en-
sures the maximum amount of safety.
However, the safety of the device can only be achieved in practice if all necessary measures are
taken. It is the operator's duty of care to plan these measures and check their implementation.
In particular, the operator must ensure that
The MOL®LIK-module is used as intended,
The MOL®LIK-module is only operated in a faultless, functional condition and in particular that
the safety installations are regularly checked for their functionality,
The required personal protective equipment (PPE) is available for operating, maintenance and
repair personnel to wear (and its use must be ensured),
This operating and maintenance manual is always available in a legible and complete way near
the place of installation of the device,
Only qualified and authorized personnel may operate, maintain and repair the device,
The staff are regularly instructed in all relevant aspects of occupational safety and environmental
protection, and are familiar with the instructions and the safety information contained in this op-
erating and maintenance manual,
Any modifications to the device may only be made by authorized and qualified personnel.

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2.2 Safety information and symbols used
Practical safety instructions are given in this operating and maintenance manual to indicate possi-
ble risks when operating the MOL®LIK-module.
These residual risks include hazards to
People
MOL®LIK-module
The environment
The following symbols are primarily intended to draw attention to the safety instructions!
This symbol indicates that particular danger to personnel is likely.
(Danger to life and danger of injury)
This symbol indicates that particular danger to device, material and
environment is likely.
This symbol indicates information. It does not identify any safety in-
structions.
2.3 Safety measures during normal operation
The device may only be operated by trained and authorized persons.
Before commissioning the device, check for signs of visible damage and make sure that it will only
be operated in a faultless condition! Immediately report any deficiencies found to the person re-
sponsible!
Before commissioning the device, remove any material or items from the working area of the device
that are not required for operation!
Before commissioning the device, check and make sure that all safety devices are working
properly!

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In case one of the following circumstances occurs, the device has to be in-
spected by authorized maintenance staff:
The MOL®LIKmodule is not working properly, even though the operating
and maintenance instructions have been followed.
The MOL®LIK module has been damaged.
The accessories (optional) exhibit obvious signs of damage.
2.4 Maintenance, repair and cleaning work
Maintenance and repair work must only be carried out by trained personnel!
Shut down the system before performing any maintenance and repair work
on the MOL®LIK-module!
Before recommissioning after maintenance and repair works:
Make sure that the MOL®LIK-module and/or any other components
which was removed (e.g. the lighting unit) are re-installed and correctly
positioned.
Check that any screw connections are tightened properly.
After completing any maintenance or repair work and before resuming pro-
duction, make sure that
All the materials, tools and other equipment needed for the execution of
any maintenance or repair work have been removed from the working
area of the system,
Any leaking liquids have been removed.
All the system´s safety installations function properly!
Do not insert any objects into the interspaces of the MOL®LIK module, this
may damage the catalyst module.
You may be injured if you insert your fingers into the interspaces of the
MOL®LIK module.
Do not use a high pressure washer to clean the MOL®LIK module.
2.5 Dangers arising if the safety instructions are not observed
Non-observance of these safety instructions can result in danger to persons, material and environ-
ment. If these safety instructions are not observed, any claim for damages may become void.

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3 Product description
3.1 Designated use
The MOL®LIK technology is used for chemical-free water treatment and serves to keep a high
functionality and quality in the water system. The main areas of application include, for example:
Closed and open cooling water circuits in conjunction with suitable filtering technology.
Process water circuits with upstream filter technology.
It is forbidden to use the MOL®LIK technology in systems for drinking water supply. In special cases,
upon agreement with the producer MOL Katalysatortechnik GmbH, this interdiction may be waived.
Exceptions may vary from country to country.
We recommend installation by a specialist company.
Any other use or any use beyond what is specified is deemed to be not the in-
tended purpose.
The manufacturer or supplier does not accept any liability for damage resulting
from such use. The risk is borne entirely by the user/operator.
The regulations and directions provided in this operating and maintenance man-
ual and those locally applicable must be strictly complied with.
The manufacturer assumes no liability for damage caused by non-observance of
this operating and maintenance manual and the other applicable regulations and
by improper use.
3.2 Technical data
Parameter
Value
Max. operating temperature
+90°C
Ambient temperature (min. / max.)
+5°C to +40°C
Operating pressure
0 - 10 bar

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Module type
∅Diameter x length (mm)
Weight (kg)
MOLLIK-M 75 xxxx
∅180 x 350
2.0/2.0
MOLLIK-M 100L xxxx
∅180 x 560
2.7/2.7
MOLLIK-M 150L xxxx
∅180 x 560
3.1/3.1
MOLLIK-M 100 xxxx
∅250 x 350
3.6/3.6
MOLLIK-M 150 xxxx
∅250 x 350
3.9/3.9
MOLLIK-M 225 xxxx
∅250 x 600
4.2/4.2
MOLLIK-M 300 xxxx
∅250 x 600
4.7/4.7/4.8
MOLLIK-M 600 xxxx
∅370 x 600
10.5/10.5/10.7

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4 Transport
4.1 Transport
The MOL®LIK module has to be transported carefully, do not throw it!
The storage location must be dry and dust-free.
Adhere to the permissible ambient temperatures!
When moving the MOL®LIK module, use suitable means of transportation in order to rule out any
transport damage.
The entire shipment should be checked for completeness and transport damage immediately on arri-
val. Transport damage must be reported to the supplier immediately.
Do not drop the MOL®LIK module and the control unit (optional) supplied. To avoid damage, protect
the MOL®LIK module from impact or shocks.
4.2 Content of the shipment
MOL®LIK module(s)
Operating and maintenance manual
Optional: MOL®LIK LED control unit
4.3 Storage
Do not store and use the MOL®LIK module at temperatures over 40°C or below
5°C, which may damage the MOL®LIK module.
The MOL®LIK module can be stored for a period of several months if the storage conditions are com-
plied with.

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5 Installation
Assembly must be performed according to the MOL Katalysatortechnik
GmbH documentation and by qualified personnel in accordance with DIN,
VDE or locally valid specifications
The user must ensure that the MOL®LIK module is assembled and installed
in such a way that their safe use (and maintenance) is not affected.
The module is suitable for use in non-pressurized vessels. Appropriately, certified catalyst modules
are available for use in pressure vessels. The use of appropriate upstream filter technology has been
proven to minimize the cleaning time on the catalyst module.
The module is inserted in the fluidic stabilized (non-turbulent) area - but with a good streamflow - and
optionally secured with a safety chain.
The area above the installation site should be kept clear for installation purposes and for maintenance
works on system equipment (e.g. pipes, air ducts, etc.) or attention must be given to provide sufficient
spacing for this system equipment.
This installation site should be easily accessible.

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6 Commissioning
In order to avoid faults and damage, please read all the instructions (including the
instructions of the component suppliers) prior to commissioning of the system!
The system may only be started up for the first time by an authorized employee
or service technician from MOL Katalysatortechnik GmbH.
Before each initial commissioning, the operating staff must make sure that a safe
commissioning is possible, and that no one can be injured in the process. All
fittings and fastenings must be checked to see whether they are tightened se-
curely!
6.1 Checks prior to commissioning:
The following points must first be ensured before commissioning the system:
The minimum and maximum values for the operating pressure and operating
temperature must be complied with (Point 3.2 “Technical data”).
The following additional conditions must be met:
The MOL®LIK module has been correctly and completely installed and commissioned.
The MOL®LIK module is completely covered with water.
The MOL®LIK module is securely fixed and is placed in a location characterized by a good water
flow.
A function test has been carried out on the system with water.
The environmental conditions conform to the specifications.
The operating staff must be trained on all parts of the system and be aware of the structure, func-
tion, operation and maintenance of the system.
All devices, fixtures and fittings are ready for use and are in operating condition.
The supply of raw water is ensured, in accordance with the specification.
The quality of the raw water conforms to the specification and water analysis.
6.2 Basic settings
Before commissioning the system, the basic settings must be made and the val-
ues entered in the list of operating parameters. The basic settings will be carried
out for you by a service technician of MOL Katalysatortechnik GmbH.
These values are optimized following commissioning.

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6.3 Shutting-down of the system in normal situation
The system must be shut down for maintenance or repair work.
6.4 Restart after maintenance or repair
Before each initial start-up, the operating staff must make sure that a safe start-
up is possible, and that no one can be injured in the process.
All fittings and fastenings must be checked to see whether they are tightened
securely!
(Point 6.1 “Checks prior to commissioning”)

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7 Operation
7.1 Required operating conditions
The water flow and thus the treatment rate of the system depend on the raw water quality and the
capacity of the system. In any case, the specifications for the operating pressure and operating tem-
perature must be adhered to.
The maximum values for the operating pressure and the operating temperature
must not be exceeded.
Maximum operating pressure: 0 - 10 bar
Maximum operating temperature: 90 °C
7.2 Operating the system
The operation of the system must comply with the operating instructions and maintenance manual
from MOL Katalysatortechnik, as well as the documentation of the component suppliers. The system
must be regularly checked and maintained (Point 8 “Maintenance”).
The system must be only operated by trained and authorized personnel. Com-
prehensive knowledge of the system and all its individual components, as well as
knowledge of operation and maintenance are essential.
If an unauthorized modification to the system is carried out without consultation
with MOL Katalysatortechnik GmbH, this is performed at the operator’s own risk.
The prescribed and required water quality must be ensured solelyby the operator
of the system. The use of pre-treated water is only possible if the water quality
requirements have been met.
7.3 Faults
Possible faults, their causes and their remedies: See point 8.3.

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8 Maintenance
Use only original spare parts!
Always stop the water flow before parts are loosened or removed!
Switch off the system if electrical components or assemblies are touched or
removed!
8.1 Maintenance and cleaning intervals
We recommend to sign a maintenance contract with MOL Katalysatortechnik GmbH
and have the system checked annually by the customer service.
8.2 Maintenance and inspection
Operating the system with damaged parts may endanger the operating personnel
and cause further damage to the system.
Replace damaged parts immediately!
We recommend to write an operation log, where all relevant data are entered
at specified intervals.

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8.3 Maintenance and inspection intervals
Parameter
Recommended
Interval
Target value/target condition
Check of the equipment
Daily
Check of the water level
The MOL®LIK module must be com-
pletely covered by water.
Control the circulating water for de-
tached deposits.
Weekly
Detached deposits must be removed
from the circulating water
If necessary, partially replace
the water.
Check of the MOL®LIK module for pos-
sible deposits.
Weekly
Such deposits can reduce the
MOL®LIK-effect.
If necessary, remove these
deposits with a soft brush
Functional check by an authorized ser-
vice technician.
Annually
In case errors or faults occur, the operator of the system must notify MOL
Katalysatortechnik GmbH. The operator is obliged to take every necessary
step to prevent any damage or the shutdown of the system.

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9 Spare parts
Order spare parts and operating equipment directly from MOL Katalysatortechnik:
MOL Katalysatortechnik GmbH
Leunastraße 6
06258 Schkopau
Germany
Tel.: [phone] / 72 30 97
[email protected]

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10 Standards and regulations
The following standards and regulations have been applied in developing and producing the device
and when drawing up the operating and maintenance manual. The country-specific standards can
differ in detail. Compliance with applicable country-specific standards is up to the user.
Table: Standards
DIN 19643
Wasseraufbereitung von Schwimmbeckenwasser
DIN EN 292, Teil 1 + 2
Sicherheit von Maschinen –Grundbegriffe, allgemeine Gestaltungsleitsätze
DIN EN 60204, Teil 1
Sicherheit von Maschinen –Elektrische Ausrüstung von Maschinen
Teil 1: Allgemeine Anforderungen
DIN ISO 6394
Geräuschmessung an Maschinen
Table: Regulations
Trinkwasserverordnung
VBG 125
Sicherheitskennzeichnung am Arbeitsplatz

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11 Appendix