operating instructions for the "lotus air" system

operating instructions for the "lotus air" system
This manual contains important information about
safe installation and operation of the unit. Strictly
comply with this information to avoid harming people
or damaging property.
It is strictly prohibited to use this equipment with radioactive chemicals!
OPERATING INSTRUCTIONS FOR THE
"LOTUS AIR" SYSTEM
Before switching this instrument on, read this manual
in its entirety.
Keep the manual near the instrument for future
reference
DOWNLOAD ERMES COMMUNICATION SOFTWARE
www.ermes-server.com
Read carefully!
ENGLISH edition
R12-02-15
1
This manual contains important information about SAFE installation and operation of the unit.
Read and retain for future reference.
Strictly comply with this information to avoid harming people or damaging property.
The information contained in this manual may contain inaccuracies or typographical errors.
The information contained in this manual is subject to change at any time without prior notice.
Version: R3-05-13
CE STANDARDS
Low Voltage Directive
⎬
2006/95/EC
EMC Electromagnetic Compatibility Directive
⎬
European harmonised standards under the Directive
2004/108/EC
⎬
2006/42/EC
GENERAL NOTES ON SAFETY
During installation, testing and inspection it is mandatory to comply with the following management
and safety instructions.
2
Safety
This manual contains basic instructions for installation, operation and maintenance. It is therefore mandatory for the
installation technician and the equipment administrator to study the entire manual prior to installing and commissioning.
The manual must be found near the generator at all times. It is also mandatory for the operator to consider the general
rules listed in the "Safety standards" chapter as well as the specific safety instructions in the other chapters of this manual.
Warning
Some of the functions described below may require other accessories (not included in the "LOTUS
AIR" supply). Some of the features described may not be available with the "LOTUS AIR" software
release purchased. Or some functions are available but not described in this manual. In this case,
contact your dealer for more information.
Symbols
In accordance with the European guidelines concerning the characterisation of special risks, all safety instructions in this
manual are marked with the following symbols:
This symbol draws attention to the risks that may be encountered.
Failure to comply can lead to serious consequences for personal safety and damage to property.
Danger
This symbol draws attention to the problems that can be caused by incorrect equipment operation.
Attention
Additional notes
3
This symbol indicates additional important information.
PART ON THE DOSING PUMPS IN THE "LOTUS AIR" SYSTEM
The pump must only be used for dosing liquid products.
It should not be used in explosive atmospheres (EX).
It should not be used to dose flammable chemicals.
It should not be used with radioactive chemicals.
Attention
Use the pump only after installation.
Use the pump in accordance with the data and technical specifications on the label.
Do not modify or use differently from that indicated in the user manual.
Keep the pump protected from sun and rain. Avoid splashing water.
Additional notes
The power to the system must be immediately disconnected and the pump
disconnected from the electrical outlet during any emergency within the
environment where the pump is installed.
If you use particularly aggressive chemicals strictly comply with the regulations
concerning their use and storage.
Always comply with local safety regulations.
The manufacturer of the dosing pump cannot be held liable for damage to
persons or property caused by incorrect installation, improper or incorrect use
of the dosing pump!
Install the dosing pump so that it is accessible at all times for maintenance
purposes.
Do not block the dosing pump area!
The unit must be controlled by an external control system. Dosing must be
interrupted if there is no water.
Assistance and maintenance of the dosing pump and all its accessories must
always be performed by qualified personnel.
Before any installation and maintenance:
• carefully read the chemical characteristics of the product to be dosed and
refer to the Safety Data Sheet of the product;
• wear the most suitable PROTECTIVE EQUIPMENT;
• drain the connection hoses of the dosing pump;
• carefully wash the hoses that have been used with particularly aggressive
materials.
4
General safety regulations
The manual describes the proper use of the "LOTUS AIR" generator.
Improper use of the generator compromises its safety function and that of the other devices
connected to it and therefore such use is strictly forbidden.
Danger
Installation and maintenance must only be carried out by authorised technicians.
Maintenance repairs should only be carried out only by the manufacturer or by technicians
authorised by the manufacturer. Interventions or alterations to the device that are not in
accordance with the provisions of this manual, with respect to regular maintenance, shall
be considered improper and render any product warranty null and void.
The operator is responsible for compliance with safety-related local regulations.
The device must be accessible at any time for operation and maintenance.
Before activating the dosing pumps, remove the pressure from the pump heads.
Before starting maintenance, drain and thoroughly wash the tested pumps.
Pay attention to the chemical safety data sheets!
Wear protective clothing when you must handle unknown or hazardous chemicals.
Additional notes
5
For proper compliance with European regulations concerning the use of this equipment
with hazardous chemicals, refer to EU directives DIN 939 (HYDROCHLORIC ACID) and DIN
938 (SODIUM CHLORITE)
Operating safety instructions
Strict compliance with all national and local regulations is required when using the
"LOTUS AIR" generator. The operator is responsible for compliance with safety-related
local instructions.
Danger
The generator must be installed and operated in accordance with the instructions in this
manual.
It is forbidden to use installation materials that are not approved by the manufacturer or
supplier.
The generator can only be used with appropriate safety valves approved by the manufacturer.
Failure to comply with this rule leads to be loss of the right to any kind of warranty!
Before operating the system, turn off the pressure from all parts of the system.
The system must never work with the valves closed as there lies the risk of the flexible
hoses or rigid hoses bursting.
Disconnect the power supply before opening the controller container.
Pay attention to all the national regulations during installation.
Additional notes
The system must not be installed outdoors.
The system must be protected from unauthorised access.
The place where the unit is installed must be protected from direct sunlight and frost and
should be well ventilated.
Places with temperatures below 10°C must be provided with appropriate systems that
enhance the temperature.
It must be possible to transport the chemical containers to the system without any restriction.
An emergency exit is strictly required!
The system must be mounted on a vertical solid wall without stress.
The system must be mounted in such a way as not to cause vibrations.
Make sure free access from all sides is possible for operation and maintenance!
A valve and an attachable floor draining duct must be set up for any spilled chemicals to
be eliminated without any risk.
6
Safety regulations in case of chemical spills I
If the odour of chlorine dioxide (a penetrating odour similar to that of chlorine) can be smelt,
access is allowed only with the required personal protective equipment.
Danger
If the odour of chlorine dioxide is smelt, immediately turn off the system from a safe position,
for example with an emergency stop switch away from the system
In rare error cases, the hazardous ClO2 solution can leak. For example, install a gas detector
that disables the system in case of a leak of ClO2 and triggers an alarm that is recognised
at a distance.
When using hazardous substances, keep in mind that their latest safety data sheets provided
by the manufacturers are available. The safety data sheets indicate the measures to be
adopted. Since the risk potential of a substance can be evaluated at any time based on newly
learnt knowledge, the safety data sheet should be checked regularly and replaced if necessary.
The system administrator is responsible for the availability of the updated version of the
safety data sheet and the preparation of the risk assessment of the relative workstations.
The administrator generates hazardous substances with this system.
The administrator is obliged to adjust the operating instructions according to the system
if any recent knowledge concerning the risks of a particular hazardous substance is learnt
and must include how to avoid them or if national regulations contain different provisions
from those specified in the instruction manual supplied.
7
Safety regulations in case of chemical spills II
The following personal protective equipment is required to access the "LOTUS AIR" device
Attention
Face shield
Rubber or plastic boots
Protective gloves (ClO2 sealed model)
Protective apron
Full face respirator
The composition and the type of personal protective equipment required may vary from one
country to another and change over time.
If you come in contact with the acid: See the "Acid CE safety data sheet" of
the supplier.
Danger
If you come in contact with the chlorite: See the ''Chlorite CE safety data sheet''
of the supplier.
If you come in contact with the ClO2 solution or the ClO2 gas: immediately remove
the clothes that have come in contact with the chlorine dioxide or with the liquid solution,
wash the skin thoroughly with soap and plenty of water. Splashes in the eye must be washed
with running water for several minutes while keeping the eyelid wide open. If you have
inhaled chlorine dioxide move to a place where there is fresh air, lying down in a position of
absolute rest and protected from temperature changes. Consult a doctor immediately even if
the affects do not appear immediately. If necessary, organise rapid transport to the hospital.
Orange-yellow ClO2 gas has leaked: immediately clear the environment and disconnect
the power supply, for example, from the emergency stop switch. Use complete protective
equipment and water spray for the gas to settle.
Orange-yellow ClO2 solution has leaked: immediately clear the environment and
disconnect the power supply, for example, from the emergency stop switch. Wear protective
equipment and pour a ClO2 sodium thiosulphate solution then dilute with water and
eliminate into the drain.
An incorrect dilution or with concentrated HCl in the HCl tank and with dosing pumps
that have already pumped the concentrated chemicals to the reactor: immediately clear the
environment and disconnect the power supply, for example, from the emergency stop switch.
Alert the fire department and inform them of the risk of explosion due to concentrated ClO2.
The ClO2 gas can explode even after hours!
8
Storage, transport and repairs
Additional notes
In case of repairs, return the unit after having cleaned it and having washed the hydraulic
components. Attach the material decontamination declaration to be sent for repairs.
The unit can be damaged due to non-compliant storage or transport.
Store or transport the unit adequately packed, preferably in its original packaging.
Always follow the storage conditions when transporting or storing, even when the unit is
packed.
Although packed, always protect the unit from moisture and the action of chemicals.
9
Introduction
The chlorine dioxide generator named "LOTUS AIR" is used to produce liquid chlorine dioxide. This disinfectant kills all
bacteria, germs, viruses and fungi very rapidly and works at very low concentration.
The generator works according to the hydrochloric acid - chlorite process and uses diluted chemicals such as hydrochloric
acid (HCl 9%) and sodium chlorite (NaClO2 7.5%) in accordance with the following chemical formula:
Hydrochloric acid + Sodium chlorite = Chlorine dioxide + Sodium chlorite + Water
4 HCl + 5 NaClO2 = 4 ClO2 + 5 NaCl + 2 H2O
In the process, each chemical is pumped with a certain proportion in a reactor, which does not work pressurised, by means
of two dosing pumps.
Within the reactor, the chemicals react to the chlorine dioxide with a concentration of 2% (= 20 g/l).
Advantages
The chlorine dioxide can be pumped directly into the pressurised systems at the pressure of the pumps and similarly in the
storage tanks if there is no pressure, to distribute the disinfectant to the various points of use.
The system can work proportionally with a contact water meter, a current signal or measurement of chlorine dioxide.
10
A
B
C
11
6
A
B
C
D
E
F
8
924.00
11
5
10
7
6
9
Controllato da:
Massimo_F
4
Data:
31/05/2013
1
8
Peso Lordo:
Peso Netto:
7
4
1
8
5
9
BACK VIEW
10
6
207.00
11
7
314.00
B
C
D
E
F
6- Reaction tank
Progettato da:
Controllato Data:
Toll. Gen. Peso Lordo: Peso Netto: A
da:
±0.05
Massimo_F 20/06/2013
7- Reaction tank emptyingMassimo_F
solenoid
valve
Materiale:
8- Active carbon filter
EdizioneFoglio
Assieme_Lotus_B_Dimensionale
1/
00
4
6
3
5
2
4
1
9- Reaction
tank water
filling
solenoid valve
1
10- Storage tank
11- Drain tap
3
FRONT VIEW
Note: components position could be different
Foglio
1 1
2
207.00
390.00
314.00
“LOTUS AIR” Version
Edizione
00
A
B
C
D
“LOTUS AIR” is made of the followings components:
Materiale:
Toll. Gen.
±0.05
B
12
C
D
E
1 - "LOTUS" control and management instrument
A
2- HCl dosing pump
3- Chlorine dioxide dosing pump
LOTUS-B
/
443 pump
2
7 NaClO dosing
6
8
5 1
2
5- Pressure balancing multi-function valve 12 - NPED4 probes holder
Progettato da:
Massimo_F
2
3
5
390.00
F
“LOTUS AIR” Version 2
924.00
D
3
Progettato da:
Controllato
da:
Massimo_F Massimo_F
Main components
Hydraulic connections
The hydraulic components to be installed for the pumps to work properly are:
Suction Hose with a level probe and bottom filter x 2
Delivery Hose with injection valve
Discharge hose x 3
Suction Hose.
Unscrew the suction ring nut completely on the pump body and draw the components required to assemble the hose:
tightening ring nut, Holding ring and hose holder.
Assemble as shown, making sure that the hose is fully inserted on the hose holder.
Tighten the hose on the pump body by tightening the ring nut with your hands.
Connect the other end of the hose to the bottom filter using the same procedure.
Suction Hose.
Tightening Nut
Holding ring
Hose holder
O-ring
Valve
Figure A
Delivery Hose.
Unscrew the suction ring nut completely on the pump body and draw the components required to assemble the hose:
tightening ring nut, Holding ring and hose holder.
Assemble as shown, making sure that the hose is fully inserted on the hose holder.
Tighten the hose on the pump body by tightening the ring nut with your hands.
Connect the other end of the hose to the injection valve using the same procedure.
12
Discharge hose.
Insert one end of the Discharge hose on the drain hose connection as shown in figure A (page 12).
Place the other end directly into the tank containing the product that is to be dosed. In this way, the liquid that leaked
during the priming phase will return into the tank.
Delivery hose
connection
Discharge handle
Discharge Hose
Suction Hose
connection
Self-venting pump body (chlorine dioxide dosing pump)
Discharge hose connection
Delivery hose
connection
Suction Hose connection
Note:
13
- the suction, delivery and Discharge valves are DIFFERENT.
- the delivery and Discharge hoses are of the same type.
- the Discharge hose can be slightly bent to be inserted into the tank of the product that is to be dosed.
Assembling the bottom filter with a level probe.
The level probe must be assembled using the relative kit with the supplied foot valve.
The foot valve is made to be installed at the bottom of the product container without sediment priming issues.
Connect the BNC on the level probe on the level input on the right side of the instrument. Insert the level probe with
the assembled bottom filter at the bottom of the tank of the product to be dosed.
Additional connections (with reference to page 11)
Connect the dioxide pump delivery (3) to the multi-function valve suction (5)
Connect the multi-function valve delivery to the system to dose the chlorine dioxide by injection
Connect the filling solenoid valve input (9) to a water source*
Connect the filter Discharge output (8) and the bleed of the reserve tank (10) to a drain
Danger
6
5
4
3
2
1
Connect the dosing pump suction (2 and 4) to the chemicals
*max 2bar with pressure stabiliser
D
C
C
400.00
509.00
D
B
B
A
A
14
Operating logic
The "LOTUS AIR" chlorine dioxide generator consists of the following main components: a production management tool,
4-filling level reaction tank, 2-filling level storage tank, HCl dosing pump, NaClO2 dosing pump, chlorine dioxide dosing
pump, reaction tank emptying solenoid valve and reaction tank with water filling solenoid valve. Note: during first startup
use water instead of chemicals (e.g.: priming, seal check, calibration)
Dioxide production cycle, the 7 main phases
Phase 1: Activation of the water filling solenoid valve up to the first level in the reaction
tank. Disabling the solenoid valve.
Phase 2: Activating the pump to dose the HCl up to the second level in the
reaction tank. Disabling the pump.
Phase 3: Activating the pump to dose NaClO2 up to the third level in the
reaction tank. Disabling the pump and the instrument outputs.
Phase 4: 15-minute count for the chemical reaction and consequent production of chlorine dioxide.
Phase 5: Activation of the water filling solenoid valve up to the fourth level in the reaction
tank. (dilution)
All the levels must be reached in less than 60 seconds, otherwise
an alarm is triggered. Any alarm during this phase stops the procedure
and empties the reaction tank.
Phase 6: Activating the emptying solenoid valve of the reaction tank and filling the reserve tank.
Phase 7: Disabling the emptying solenoid valve until the product decreases to the first level in the reaction tank.
Once this operation is complete, the dioxide production cycle begins again and, depending on the setting
of the set-points, the dioxide dosing pump is activated to empty the storage tank.
15
Connections to the motherboard
Before performing any operation on the terminal board of the instrument, it is mandatory to disconnect it from the mains. To
facilitate the connections to the motherboard, it has been divided into two blocks: electrical connections and I/O connections.
Danger
The terminal numbering is relative to the block on which you are working!
L 1 2 3 4 5 6
E E E E E E E
F2
LA
LB
F1
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
N N N N N N N N
7 8 9 10 11 12
24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46
]
]
I/O Connections
Electrical Connections
Electrical connections:
F1: Main fuse (6.3AT)
F2: Instrument fuse (3.15AT)
LA - LB Remove the jumper to disable the relay outputs
MAIN POWER SUPPLY (115VAC / 240VAC):
L (Phase), E (Earth), N (Neutral)
SET-POINT OUTPUTS (115VAC TO 240VAC):
(the potential free outputs are not protected with a fuse and isolation between the outputs and the power supply is 250V
MAX):
1-E-N
2-E-N
3-E-N
6-E-N
(F2 Fuse-protected) OUT HCl
(F2 Fuse-protected) OUT NaClO2
(F2 Fuse-protected) OUT H2O
(F2 Fuse-protected) Emptying solenoid valve
OUTPUT N/A:
7(N.C.), 8(C), 9(N.O.) Potential free contact
GENERAL ALARM OUTPUT:
10(N.C.), 11(C), 12(N.O.) Potential free contact
Attention: the connections must be implemented by qualified personnel
16
I/O Connections:
OUTPUTS FOR A DIGITAL SIGNAL PROPORTIONAL PUMP:
1(-) ; 2(+): ClO2 pump signal output
3(-) ; 4(+): Pump retainer 2 ext
5(-) ; 6(+): Pump retainer 3 ext
7(-) ; 8(+): Pump retainer 4 ext
9(-) ; 10(+): Pump retainer 5 ext
11(-) ; 12(+): Pump retainer 6 ext
RS485:
20: GND
21: + Signal 485 (A)
22: - Signal 485 (B)
23: n/c
OPTO ISOLATED
SIGNALS
open manifold
(-)not a shared
signal!
GND is a shared
ground!
REACTION TANK LEVEL INPUTS:
24 (-) ; 25 (+ White) Water Level 1
(-) is a shared (GND)
26 (-) ; 27 (+ Black) HCl Level
ground !
28 (-) ; 29 (+ Brown) NaClO2 Level
YELLOW
30 (-) ; 31 (+ Light Blue) Water Level 2
STORAGE TANK LEVEL INPUTS:
32 (- Black) ; 33 (+ Light Blue) "Low" Level
45 (- Black) ; 44 (+ Brown) "High" Level
PROXIMITY SENSOR INPUT (MOD. “SEPR”):
34(+ Brown) ; 35 (Black) ; 36 (- Blue)
connect terminal 36 with terminal 32
CONTACT INPUT:
34
; 35
connect terminal 36 with terminal 32
PULSE EMITTING WATER METER (HALL EFFECT): 37(+12VDC) ; 38(INPUT) ; 39(GND)
PULSE EMITTING WATER METER (CONTACT): 38(INPUT) ; 39(GND)
TEMPERATURE PROBE INPUT (PT100)
40(green) ; 41(brown) ; 42(white) ; 43(yellow)
(remove the jumper before installing the probe)
Attention: the connections must be implemented by qualified personnel
17
Probe modules connection
At the top of the motherboard there are 4 adaptors for the installation of the probe modules and inputs.
Upon request, these modules are installed by the manufacturer. For proper installation, check the installed modules and
implement the required connections. A standard Ethernet cable (RJ45) is required for the ETHERNET version (module
with red circle).
Ch1
1
2
3
4
MDCI Ch1
Ch2
1
MDPH Ch2
2
Ch3
3
Danger
Ch4
4
1
2
MDCL Ch3
MDMA Ch4
MDRH Ch2
Digital input module
pH or ORP probe input module*
Cl probe module:
Flow sensor module (mA)
Terminal 1 : STOP (+)
Terminal 2 : HCl (+) LEVEL
Terminal 3 : NaClO2 (+) LEVEL
Terminal 4 : GND (in common)
Adaptor: supplied BNC probe
ECL2/2
ECL2/20
ECL17/10
ECL18/10
4-wire connection
Terminal 1 : red wire (+)
Terminal 2 : black wire (-)
*as specified during order
Probe connection:
Terminal 1 : brown wire (+)
Terminal 2 : white wire (-)
Terminal 3 : green wire (IN)
Terminal 4 : yellow wire (GND)
ECL4
ECL5
ECL6
ECL7
2-wire connection
Probe connection:
Terminal 3 : black wire (-)
Terminal 4 : red wire (+)
18
Browsing the menus
At the top right of the "LOTUS AIR", there is the knob to browse and programme the instrument. The knob can be rotated in both directions to move the cursor through the menus and the selection. The function is confirmed by pressing
the relative function.
NOTE: When the changes have been made press the wheel on "OK" to save and exit the sub-menu. Select "ESC" key and press the knob to exit without
saving. Access to configuration menu is enbled during reaction time or during storage tank filling only.
Probes (page 22)
Water Meter (page 25)
Mode Selection (page 26)
System Settings (page 20)
Service (page 28)
Clean (page 28)
Pump Calibration (page 29)
Priming page (page 30)
Communication (page 31)
Log Setup (page 33)
Reaction Time (page 33)
Alarms (page 28)
Main screen
Local Time
Local Date
Probe: ClO2
Water Meter Activity
Probe: temperature
Probe: pH or ORP*
Wheel for browsing
and selecting options
Reaction
Chamber
filling
discharging
Reaction Time
Additional notes
19
Storage
Tank
i.e.: 100 p/m shows output
quantity per minute.
180 blinking value means that
system is overloaded
(propotional mode only)
*The configuration and screens may differ (i.e.: ORP probe or pH Probe when ordering).;
you can download the latest version of this manual from the manufacturer's website or
by contacting Technical Support.
"LOTUS AIR" system setting
For the "LOTUS AIR" system to work properly all the settings listed below must be configured properly. It is
recommended to primarily set the DATE & TIME.
“System Settings”, “Mode Selection”
“Probes”, “Water Meter”, “mA Input”
“Clean”, “Service”
SETTINGS
Enter this menu by selecting “MENU’” from the main screen, enter the PASSCODE (default is: 0000) and select “Settings”.
Save the settings by selecting “ESC”, then confirm the changes by moving to “YES” and pressing the knob.
pH Comp* & Cl Comp
To enable the pH (based on temperature) or chlorine (based on the pH value) compensation factor, move the
cursor next to the item that is to be changed, press and turn the knob. The compensation can be enabled (YES)
or disabled (NO). pH compensation isn’t available in ORP version. *not available for ORP model
PASSCODE to access the menus of the instrument
To set a new PASSCODE to access the instrument menu, choose "PASSCODE" and enter the 4-digit number.
Move the cursor to "EXIT" and select "YES" to save. The new PASSCODE is now operational.
Language / Time / Date
To set the display language of the instrument move the cursor to "ENGLISH/EU" (default language and metric
system) and press the knob to select. Note: when using the "ENGLISH/US" option, the units of measurement
will be changed with respect to the United States. To adjust the time and/or date, move the cursor to the
desired item and press the knob to adjust the individual fields.
The pH measurement in a system highly depends on temperature.
The degree to which the latter, influences conductivity depends on
the solution used.
In the "LOTUS AIR" system it is calculated using the table at the side.
The "LOTUS AIR" system can be configured to use a fixed (25°C) or
variable temperature and compensate automatically.
20
View pH or ORP* / Cl / Temp
The instrument can only display a few items on the main screen, including the 3 main parameters: pH, chlorine
and temperature. Set YES or NO to enable or disable the display of these items.
Feeding
The distribution of the dioxide from the storage tank it’s launched by using an internal relay. Field not editable.
Reset
To restore the instrument to the factory settings, select this item and confirm with "YES". The instrument will
restart with the initial configuration values​​. Note: this operation also deletes and restores the two PASSCODEs.
Once restarted you must configure the instrument.
Standby
This function allows the stop all instrument activities (LOCK ALL) or the dosing activity only (DOSING ONLY)
when there is a change in the contact. Configurable options are: contact type NO - N.C. or disabled. Choose
LOCK ALL for the complete stop of instrument or DOSING ONLY to stop dosing activity only. The contact is
located on module MDCL-CH1 (pin 1 and GND).
CC/S
This option set CC/S value for storage pump and can be configured from 0,01 to 9,99 CC/S. Change this value
only if system is working at different values than 5bar.
RESERVE
This option set production cycles countdown starting from last low level warning (for Hcl and NaClO2 pumps).
Accetted values are within 0 (disabled) and 200.
*as specified during order
21
PROBES
Enter this menu by selecting “MENU’” from the main screen, enter the PASSCODE and select “PROBES”. Save the
settings by selecting “ESC”, then confirm the changes by moving to “YES” and pressing the knob.
Chlorine Dioxide & Select Probe
Before calibrating the chlorine probe (Ch3) verify that the selected model is the correct one. Select "SELECT
PROBE" in the "PROBES" menu. If necessary, select the item and turn the knob until you see the correct
model of the probe. Confirm by pressing the knob and moving the cursor to “ESC”, then confirm the changes
by moving to “YES” and pressing the knob.
Probe
Scale (mg/l)
ECL 2/2
2,000mg/l ClO2
ECL 2/20
20,00mg/l ClO2
ECL4,5,6,7
10,00mg/l ClO2
ECL 17/10
10,00mg/l ClO2
None (rH only)*
999mV
*setpoints are related to Redox channel and chlorine view is disabled
Select "CHLORINE DIOXIDE" in the "PROBES" menu to calibrate 2 points of the previously selected probe.
Attention
Attention: this procedure assumes that the instrument is configured properly and connected to a
working probe, otherwise the results may not be reliable.
Calibrating the first point (P1)
- move the cursor to “P1” and press the knob.
- install an “active carbon filter” in the probe-holder.
- let water flow into the probe-holder for 30 minutes.
- press the knob with the cursor on “OK”. Remove the filter.
Calibrating the first point (P2)
- move the cursor to “P2” and select it.
- use a photometer or DPD system to read the chlorine in the plant. Enter the value read in “Cal. at”.
- press the knob with the cursor on “OK”.
If an error message is displayed repeat the calibration procedure!
22
pH Probe
Before you calibrate the pH probe (Ch2) verify that you have two buffer solutions with values close
​​
to those found
in the plant (e.g. 7pH and 4pH). Select "pH PROBE" in the "PROBES" menu to calibrate 2 points of the probe.
Attention
Attention: this procedure assumes that the instrument is configured properly and connected to a
working probe, otherwise the results may not be reliable.
Calibrating the first point (P1)
Select "P1" in the "pH Calibration" menu and press the knob to enter the first point that is to be calibrated.
Prepare the buffer solution 7,00 pH and immerse the probe sensor. Wait for the value to stabilise. Enter the
value of the buffer solution in the “Cal. at” field. Press to confirm. End by moving the cursor to “OK” and
press to move on to the next step.
Attention
Warning: The value of the buffer solution may change if the ambient temperature is different from
20°C. Read the label of the buffer solution for more information. In this case the "pH Default" value
should be changed.
Calibrating the second point (P2)
Select ''P2'' in the ''pH Calibration'' menu and press the knob to enter the second point that is to be calibrated.
Prepare the buffer solution 4,00pH and immerse the probe sensor. Wait for the value to stabilise. Enter the
value of the buffer solution in the “Cal. at” field. Press to confirm.
To end the procedure, select "OK" and press the knob. The tool will prompt the saving ("Save") of the settings.
Press "YES" or "NO" to either save or not.
Attention
Warning: The value of the buffer solution may change if the ambient temperature is different from
20°C. Read the label of the buffer solution for more information. In this case the "pH Default" value
should be changed.
ORP Probe
ORP calibration procedure involves probe’s selection with one point (P1) calibration. From “Menu Calibration” choose “ORP probe”.
Attention
Note: This procedure assumes that instrument is correctly configured and a working ORP probe connected and installed on system. Measurement must be performed using plant water. Otherwise unattended results may occurr.
Calibration can be performed in two ways: the first by alignment with a buffer solution, the second by reading the residual ORP level of the pool with the DPD1, comparison with the attached graph followed by alignment of the pumps group. The choice of method is exclusively at the user’s discretion. In both cases, to establish the set-point value, a check using the DPD1 or other analysis system is necessary. The enclosed graphs provide a reference between the mV value read by the pumps group and the quantity of residual ORP expressed in mg/litre, and are l
1) Measure buffer solution temperature and verify that it is the same printed on solution’s label.
2) Remove protective cap from probe and wash probe’s tip into water. Then dry it by shaking up to the air.
3) Set “Cal. at” value to match buffer solution value then put probe’s tip into buffer solution and wait until instrument shows a stable reading value (mV field).
4)Move cursor on “OK” and press wheel ton cofirm the new calibration value. If calibration process fails the instrument will show “CALIBRATION FAILED”. Repeat procedure otherwise move on “ESC” and press wheel.
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Temperature Probe
To calibrate the temperature probe select “Calibration Temp” from the “Probe” menu. In order to complete this
task, it is necessary to use a professional thermometer to take the temperature of the plant.
Warning: this procedure can be completed only if the instrument is correctly installed and the
temperature probe is in good condition. Otherwise you could get unreliable results.
Take the temperature of the plant using a thermometer and enter it in the “Calib at.” field. Then press the knob
and move the cursor on “OK”. Confirm by pressing the knob again. End by moving the cursor to “EXIT” and
pressing the knob. Then turn the knob to select “YES” if you want to save the changes or “NO” to exit, restoring
the previous values. Then press the knob again to enforce your choice.
Temperature Alarm
Use this function to set a temperature value above which the instrument stops all activities, activates the main
alarm output and generates a warning message. To set the temperature value proceed as follows:
- press on the knob
- set the value by turning the knob
- press the knob and move the cursor on "ESC". Then press the knob again to confirm ("YES") and save the
setting.
ECL probe selection
pH probe calibration menu
ORP probe calibration menu
Temperature calibration menu
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WATER METER
This menu allows you to set the operation mode of a pulse emitting water meter connected to the "LOTUS AIR" system.
Enter this menu by selecting “MENU’” from the main screen, enter the PASSCODE and select “WATER METER”. Save the
settings by selecting “ESC”, then confirm the changes by moving to “YES” and pressing the knob.
Mode
This function allows you to set the display mode and to calculate the reading scale of the pulse emitting water
meter connected to the "LOTUS AIR" system. The possible configurations are:
IMP/LTR (calculation based on number of pulses set in VALUE for each litre)
LTR/IMP (calculation based on number of litres set in VALUE for each pulse)
mA (calculation based on RESOLUTION and MAXFLOW)
Value
Setting the operation mode on “IMP/LTR” or “LTR/IMP” defines the number of pulses or litres necessary to
complete a single unit for each pulse or litre.
Max.Flow (cbm/h) & Resolution
Set these values if you use the mA calculation method. Max Flow defines the maximum value of the flow in
cbm/h (cubic meters per hour) to achieve compared with the highest resolution mode of 20mA.
Resolution determines the operation of the pulses based on the incoming signals received in 0/20mA or
else 4/20mA. It is recommended to perform the calibration of this incoming signal, after having chosen the
configuration type (see page 28)
TIMEOUT
If no more pulses are received from water meter during seconds set (e.g.: 20s, max 99s) then "LOTUS AIR"
system will end the dosage .
25
WORKING MODE
This menu allows you to set the operation mode of the system. Enter this menu by selecting “MENU’” from the main screen,
enter the PASSCODE and select “WORKING MODE”. Save the settings by selecting “ESC”, then confirm the changes by
moving to “YES” and pressing the knob.
PROPORTIONAL (WM)
This function allows you to set the operation mode proportional to the PUMP output based on the flow detected
by the pulse emitting water meter.
The PUMP CL output (based on 180 strokes per minute) is referred to as "P1" on the main board of the instrument.
T
Example: Set PUMP CL [%] at 100 with flow at 10 m³/h.
The chlorine pump will dose to its full capacity (180 strokes per minute) for flux values ​​greater than or equal
to 20m³/h.
The chlorine pump will dose at 50% of its capacity (90 strokes per minute) for values of flow reading of 5m³/h.
The activity of the chlorine pump will be proportional to flux values ​​lower than that set.
PROP.(WM) + READING (CL)
This function allows you to set the operation mode proportional to the PUMP output based on the flow detected
by the pulse emitting water meter and the value read by the chlorine probe.
The PUMP CL output (based on 180 strokes per minute) is referred to as "P1" on the main board of the instrument.
Example: Set PUMP CL [%] to 100 @ 10m3/h; 1mg/l to 180p/m; 0.80 to 0p/m
When the values ​​of the flow will be greater than or equal to 10mc/h, the pump will be active in proportion to the
reading values ​​of the chlorine probe. For example at 0.9mg/l and at 10mc/h, the pump will dose at 90 strokes per
minute (out of 180). For flux values ​​less than or equal to 10mc/h, the pump will also be dependent on the input
flow. For example, at 0.95mg/l and at 5mc/h, the pump will be active with 67,5 strokes per minute (out of 180).
75% of 180 strokes per minute are determined by the value of chlorine read and 50% from the input flow,
then the percentage of strokes produced by the pump will be determined by (75 * 50) /100 = 37,5%. 37,5%
of 180 strokes is 67,5 cpm
PROPORTIONAL (mA)
This function allows you to set the operation mode proportional to the PUMP output based on current received
from mA input.
The PUMP CL output (based on 180 strokes per minute) is referred to as “P1” on the main board of the instrument.
T
Example: set PUMP CL to 180p/m @ 20mA and 0p/m @ 0mA
The chlorine pump will dose to its full capacity (180 strokes per minute) for ma reading values ​​greater than
or equal to 20mA. The chlorine pump will dose at 50% of its capacity (90 strokes per minute) for ma reading
values of 10mA. The activity of the chlorine pump will be proportional to mA values lower
​​
than that set.
Note: one of mA value must be set to 0 otherwise the insturment will change it automatically.
26
CONSTANT
This mode allows you to set the constant operation mode for the PUMP [pulses per minute].
The PUMP CL output (based on 180 strokes per minute) is referred to as ''P1'' on the main board of the instrument.
Example: Set PUMP CL [P/m] to 180 The chlorine pump, when active, will dose to the maximum of its
capacity (180 strokes per minute).
READING (Cl)
This mode allows you to set the operation mode proportional to the values ​​read from the chlorine probe.
The PUMP CL output (based on 180 strokes per minute) is referred to as ''P1'' on the main board of the instrument.
Example: Set PUMP CL [%] to 1,00mg / l to 180 strokes per minute and 0,80mg / l for 0 strokes
per minute
The chlorine pump will dose to its full capacity (180 strokes per minute) for reading values greater
​​
than or
equal to 1,00mg/l.
The chlorine pump will dose at 50% of its capacity (90 strokes per minute) for reading values of the chlorine
of 0,9mg/l.
The activity of the chlorine pump will be proportional to the values of
​​ chlorine between the two set points set.
27
Alarms
Probe flow alarm (contact) can be enabled to stop a dosing procedure using a N.O. contact mode (normally open)
or N.C. contact mode (normally closed) when status on blocks changes. Rotate wheel to choose between: “DISABLE”,
“REVERSE” (N.O. contact) or “DIRECT” (N.C. contact).
Furthermore “Flow contact” can starts after a specified time when contact status changes. To set it move wheel on “Time:00
min”, click it and rotate to choose time (from 0 to 99 minutes). Confirm selection by clicking wheel.
Min / Max Range can be set to stop or continuing to dose if reading probe value aren’t within selected range after a
settable amount of time. Parameters to set are:
Mode: stop, dose, disabled.
Time: after this amount of time the selected mode is enabled
Max / Min: mV reading value from probe (refer to select probe for correct value) within the selected mode isn’t operative.
To end procedure move cursor on “OK” and press wheel to proceed to “Save” request screen. Move wheel on “YES” to
save or “NO” to discard changes.
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Pump Calibration
This function allows the calibration of the “chlorine dioxide” dosing pump based on strokes capability. To calibrate,
proceed as follows:
1. Set strokes of the metering pump according to its capability (eg 100)
2. Lay the tube of pump’s discharge within a graduated Becker
3. Move curson on Mode, press wheel, select Start, then press the knob.
4. Wait until the end of the 100 strokes
5. Measure the product in the Becker
6. Enter measured quantity in ml (ml field). The instrument calculates the cc/s that the pump is able to produce.
7. Move cursor on OK and press the wheel to save settings.
In the event of an emergency procedure can be interrupted moving cursor on Mode and selecting STOP.
29
Service & Clean
Enter this menu by selecting “MENU’” from the main screen, enter the PASSCODE and select “SERVICE” or “CLEAN”.
Save the settings by selecting “ESC”, then confirm the changes by moving to “YES” and pressing the knob.
Service
From this menu it is possible to view the functions of the inputs relative to:
pH or ORP Probe (as specified when ordering)
Cl2 Probe
Temperature Probe
Pulse emitting water meter (W.M.Hz)
Clean
From this menu you can start the cleaning process of the reaction tank by filling it and emptying it with water.
1. Select this menu to start the procedure
2. The solenoid valve (9) to load water to the reaction tank "EV H2 O2: ON” is active
3. The systems displays the message "PLEASE OPEN DRAIN". Open drain tap (11).
4. When the reaction tank is full, the water loading solenoid valve (9) stops "EV H2O2 : OFF”
5. The solenoid valve (7) of the reaction tank and the instrument displays "EV BLEED: ON”
4. Open the drain tap (11) on the storage tank (10) to drain the water
5. The procedure ends and the instrument displays "EV BLEED: OFF”
Priming
Enter into this menu to manually enable or disable pumps and outputs. This function can be used for initial pumps priming.
At the end of the procedure it is recommended to empty both the tanks: storage and reaction.
Note: if the storage tank isn’t completely empty, the EV for chlorine dioxide discharging will not turn on.
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Rotate knob, highlight output (Relay) or pump (Out) and press knob to change its own status.
COMMUNICATION (TCP/IP & GPRS)
This instrument can be controlled and programed remotely using the system called ERMES and a standard web browser
(i.e.: Google Chrome or Safari). In order to use this service an internet connection is required (lan or wan) and user must
configure the instrument to obtain a valid IP address (through a valid DHCP service or manually). If this instrument is
installed within an office network please contact your system-administrator to obtain required parameters and eventually
unlock TCP/IP port 2020.
Things to do before setup.
1. Ensure that on instrument MAC ADDRESS (see SERVICE menu) the TCP/IP port 2020 is unlocked. Check it with your system-administrator.
2. Connect to your ERMES account or create a new one at: www.ermes-server.com
Network
administrstor
required
3. Within ERMES account add the new instrument using the 6 digits code located into SERVICE menu. (choose LAN DEVICE or MODEM code based on connection type choosen prior to buy the instrument)
Parameters to be configured in the communication menu (TCP/IP)
In order to communicate via LAN cable to ERMES server the following parameters must be set:
Basic Network
skills required
If configuration requires the presence of a ROUTER with automatic IP address assignment from TCP/IP menu select IP MODE and set it to DYNAMIC.
If local LAN needs to provide static IP address then from TCP/IP menu select STATIC IP MODE
and enter the following parameters:
IP address: enter the unit unique available IP address using syntax xxx.xxx.xxx.xxx
SUBNET (netmask): range of belonging to the host within a subnet IP. For example: 255.255.255.0
GATEWAY: The IP address of the device that routes packets. For example: 192.168.1.1
DNS: IP address of the device that resolves the names of network nodes.
It is usually the same as the GATEWAY. It can bel also a public DNS address (e.g.: 8.8.8.8)
Parameters to be configured in the communication menu (GPRS)
In order to communicate via GPRS modem to ERMES server insert SIM into modem’s slot the slot.
A data plan subscription is suggestes to reduce SIM costs. From GPRS menu set the following parameters:
Ermes SERVER: select YES to activate the traffic data with Ermes server or select NO to use the GPRS modem only for SMA and/or EMAIL alerts messages.
APN: ask SIM mobile company what is the name of the access point designated
APN Username & Password: ask SIM mobile company both these parameters
PIN: Enter the assigned 4 digits code to automatically unlock the SIM
31
COMMUNICATION (MESSAGES Setup - RS485)
This instrument can send emails and / or sms when a system failure or warning happens. If instrument is configured to
operate through the LAN only email messages can be send. Otherwise if instruments has a mobile modem both SMS and
emails messages can be send.
MESSAGES Setup
Within this menu is possible to setup up to three SMS (SMS1, SMS2, SMS3) recipients and two email (email 1, email 2)
addresses. Editing MSG ALARM and MSG WARNING ALARM is possible to setup which type of error must be notified
(see below table).
MSG warning
MSG alarm
MAXIMUM TIME REACHED
PROBE FLOW ALARM
HCl LEVEL
CHLORINE DIOXIDE IN STORAGE NO LONGER USABLE
NaClO2 LEVEL
SYSTEM NOT READY
ST.Tank Full
SYSTEM NOT READY
RS485 Setup
This instrument can be connected in a network of instruments via RS485 (max 32) to take advantage of a single modem
or LAN connection for remote programming (through ERMES server) or local (ask your provider).
Make the cable connections as described in RS485 terminal blocks (page 17) and then in the RS485 menu, set the RS485
unique ID NAME for each instrument.
CHECK if entered in ID NAME has been properly accepted by clicking on ID CHECK, if an error message is reported by
the instrument modify it.
32
COMMUNICATION (LOG & LOGBOOK)
This function, when enabled, allows to record and send to ERMES server all instrument activities (date, time, temperature,
levels, alarms, totalizers, outputs status) for a set period (EVERY) and starting from a certain time (TIME) .
Note: SET TIME AND DATE PRIOR TO ENABLE THE LOG. If not fed after 30 days the instrument will lose current date
and time.
TIME: log starting time (format 23h 59min)
EVERY: frequency of recording (format 23h 59min)
E.g.: To set the instrument to begin logging events starting from 16:00 every hour set TOME to 16h: 00 and EVERY of 1h: 00m
Note: To view on instrument’s display the archived logs select LOGBOOK
REACTION TIME TEST
This feature allows to perform a test of the permanence of liquid inside the reaction tank (1 to 20 minutes) for the specified
duration and for a single production cycle. Can be used to verify the correct functioning of the system.
33
MODBUS
Modbus is a serial communications protocol originally published by Modicon (now Schneider Electric) in 1979 for
use with its programmable logic controllers (PLCs). Simple and robust, it has since become a de facto standard
communication protocol, and it is now a commonly available means of connecting industrial electronic devices.
From main menu select COMMUNICATION then MODBUS to access the options. Set the communication speed
according to the PLC system available. Set the ID assigning an UNIQUE address to avoid conflicts.
To access the module MODBUS open the
instrument only after power is switched off!
Never make connections with the instrument
powered!
WARNING
1 2 3
1: GND
2: A-RS485 (+)
3: B-RS485 (-)
34
STATUS MESSAGES
On main screen, the instrument displays the status of the dosing activities and bioxide chlorine dioxide production. See
table below to better understand and solve any problems.
Shown Message
EXPLANATION / What to do
STORAGE TANK FULL
Product ready and storage tank full. Chlorine dioxide is ready to
be used.
MAXIMUM TIME REACHED
Use chlorine dioxide as soon as possibile for better results.
PROBE FLOW ALARM
Check plant’s flow and probes.
CHLORINE DIOXIDE IN STORAGE NO LONGER
USABLE
Chlorine dioxide life expired. Discharge storage tank.
WAITING FOR FLOW BACK
Instrument is waiting for flow back
CHECKING FOR FLOW RELIABILITY
Instrument noticed that the flow is back and it’s testing reliability
during set time
CHECK EV
Check reaction tank emptying solenoid valve
(7) for anomalies
In the event of a anomaly (e.g.: temporary loss of power and return to activity) the instrument will enter into a “SAFE
MODE” or “ALARM MODE”. Please use the below procedure to return to normal working mode:
- check alarm type and fix it (e.g: low level in tank, re-fill it)
- open drain tap (11) and wait for about one minute
- move cursor over RESTART and press WHEEL
- when instrument shows “PLEAS OPEN DRAIN” open drain tap (11)
- wait until instrument shows “PLEASE CLOSE DRAIN” then close drain tap (11)
- restore is complete when all 6 “D” letters (level down) are shown in upper right part of the display.
35
ERMES
The web-based application ERMES allows plants remote control: with it is possibile to read, analize and modify
instruments parameters from PCs, smartphones or tablets.
PLUS
•
•
•
•
•
It reduces plant intervention and inspections.
It reports on the current status of the network’s devices and connections (probes, outputs, alarms, setpoints)
It instantly gives notification of alarms by sms or email
It generates an up to date report of all plant instruments
It can display the instruments activity log as line graphs and charts and it can download it to your pc in excel or
pdf format
HOW TO USE WEB ERMES
Enter the website www.ermes-server.com and, after registration, set plants.
EMEC instruments with ETHERNET or GSM/GPRS Configuration will be immediatly connected and available for remote
control. Furthermore, with ERMES you can receive alarm messages via email, with different report option on instrument
status. If instrument has been bought with the GSM/GPRS option it’s possible to receive SMS reports on any mobile
phone.
Read “COMMUNICATION” chapters to better understand how to configure the instrument.
36
Index
Safetypage 3
Introductionpage 10
Hydraulic connectionspage 12
Electrical connectionspage 16
Main screenpage 19
System Settingspage 20
Probes page 22
Water Meter page 25
Mode Selection page 26
Alarmspage 28
Pump Calibrationpage 29
Service page 30
Clean page 30
Priming / Manual Outputs operation
page 30
Communication (TCP/IP & GPRS)
page 31
Communication (Messages Setup & RS485)
page 32
Communication (Log & Logbook) / Reaction Time Test
page 33
MODBUSpage 34
Status messagespage 35
ERMESpage 36
Information on this manual may contain technical inaccuracies or typographical errors.
The information contained may be changed at any time without prior notification or obligation.
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All materials used in the construction of the instrument and for this manual can be recycled and therefore supporting the invaluable environmental resources of our planet. Do not dispose of harmful materials in the environment!
Check with the competent authority on the recycling programs for your area!
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