HEALTH & SAFETY PROTOCOL FOR ALS SYSTEMS CERTIFIED BY CERTIFIED BY Manufactured in Angus, UK NSF/ANSI 60
Your IWS Engineer is: ...................................................... You can contact me on: ...................................................... Health & Safety Audit History Engineer Date Signature Next Review Due 2
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Contents 5. PPE GUIDELINE 6. CHLORINE DIOXIDE GENERATOR (ALS SYSTEM) 24. CHLORINE DIOXIDE GENERATOR (TA SYSTEM) 42. ADJUSTING DOSING LEVEL 44. PRIMING OF THE ALS SYSTEM 47. PRIMING OF THE TA SYSTEM 50. REPLACING & RECONNECTING IBC’S 53. XZIOX EH800 MATERIAL SAFETY DATA SHEET 62. XZIOX ACT900 ACTIVATOR MATERIAL SAFETY DATA SHEET 68. XZIOX MIX MATERIAL SAFETY DATA SHEET 4
PPE GUIDELINE Full Face Respiratory Mask Or A Face Shield Chemical Resistant Gloves Rubber or Plastic Boots - Steel Toed Protective Apron/Suit ONLY TRAINED STAFF SIGNED OFF BY IWS ARE TO ENTER THE CABINET/MAKE ALTERATIONS PLEASE REFER TO THE MATERIAL SAFETY DATA SHEET FOR FULL DETAILS 5
ALS System 6
TABLE OF CONTENTS 81 81 General Safety Guidelines 81 Symbols 92 Safety Instructions 130 CE Conformity 141 General Notes 141 Chemical Spillage 141 Bypass Line 150 Personal Protective Equipment 152 Chemical Spillage - Recommended Actions 152 Storage, Transport and Repairs 163 Water Quality 163 Introduction 174 LDPCLO2 Instrument Connections 185 Main System Components 196 Hydraulic Connections 1170 Pressure Valves 1181 Browsing the Menu System 1192 Mode Selection 2103 System Settings 2114 Calibration 2125 Priming 2125 Stats 2136 Status Messages MDCL Module 7
GENERAL SAFETY GUIDELINES General Remarks This manual includes basic information relating to the assembly, operation and maintenance of the ALS15C Chlorine Dioxide Generator. It is highly recommended that any personnel that are to use the equipment study the complete manual before installation or operation of the equipment. This manual should also be in close proximity to the equipment at all times. Symbols Throughout this manual special symbols are used to draw your attention to specific points which are labelled as follows: WARNING: This symbol is warning about risks Ignoring this information may lead to severe personal injury or material damage CAUTION: This symbol is warning about issues that may arise through incorrect operation NOTICE/ADVICE: This symbol identifies additional, important, information SAFETY INSTRUCTIONS The appropriate/correct operation of the Chlorine Dioxide Generator is described in this manual however: WARNING: Inappropriate use of this equipment affects the safety of this and other devices used in conjunction with this equipment. Installation, operation and maintenance should only be completed by trained and compotent engineers All installations should conform to those laid out in the manual and in accordance with manufacturers guidelines. Failure to do so will invalidate any warranty claims The end user/operator is responsible for ensuring that the equipment operates within local authority guidelines Before any maintenance work commences, ensure that the dosing pump heads are depressurised and flushed through with clean water Always consult MSDS sheets Always wear personal protective equipment (PPE) whilst using this equipment. 1 8
CE Conformity The ALS15C Chlorine Dioxide Generator conforms to the following standards: Pressure Equipment Directive 97/23/EC EU Machinery Directive 2006/42/EC EU EMC Directive 2004/108/EC Low voltage directive 2006/95/EC Appendix I No. 1.5.1 of machinery directive 2006/42/EC The following harmonised standards are considered: EN ISO 12100-1, EN ISO 12100-2, EN 809 EN 60206, EN 60529, EN 610000-6-1/2/3/4 The following harmonised national standards are considered: DVGW standards: Technical rules W 224 and W 624 NOTICE: A declaration of conformity is available upon request 2 9
GENERAL NOTES The pumps must only be used with: X9%ZIOX EHH8y0d0rochloric Acid X7.Z5I%OX ACSTo9d0iu0m Chlorite They should not be used in explosive atmospheres (EX) They should not be used to dose flamable liquids The should no be used to dose radioactive chemicals Keep the pump protected from sun and rain. Avoid excessive water splashes. The power to the system must be immediately isolated and the pumps disconnected during any emergency within the vicinity of the system. Always ensure that chemical usage strictly complies with the regulations concerning their use and storage. Always comply with local safety regulations. The manufacturer of this system cannot be held liable for damage to persons or property caused by incorrect installation, improper or incorrect use of the system The system must be installed so that it is accesible at all times for maintenance purposes. Do not block the enclosure opening/ The unit must also be correctly programmed on a site specific basis. Dosing must be interrupted if there is no water flow or malfunction. Repairs and maintenance of the system and all of its accessories must only be performed by qualified personnel. Strict compliance with all national and local regulations is required when using the ALS15C generator. The operator is responsible for compliance with safety-related local instructions. The generator must be installed and operated in accordance with the instructions contained within this manual. It is forbidden to use installation materials that are not approved by the manufacturer or supplier. The system can only be used with appropriate safety valves approved by the manufacturer. Failure to do so may lead to the loss of any warrranty claim. The system must never be allowed to operate with the valves closed as there is a risk to the connected flexible hosing or rigid pipework. A supplemental power supply isolation device must be installed outside of the room where the system is installed. The system should be electrically isolated before any protective covers (e.g. the controller cover) is removed. 3 10
GENERAL NOTES (Cont.) The system must not be installed outdoors The system must be protected from unathorised access or alteration. Environments where temperatures drop below 10 degrees centigrade must utilise systems to maintain the temperature above this level where the ALS15C is in use. Access to the system installation area, for the purposes of chemical transportation, must be unrestricted. An emergency exit is required. The system must be mounted on a vertical solid wall and in such as way as to not cause vibrations. CHEMICAL SPILLAGE If the odour of chlorine dioxide (a penetrating odour similar to that of chlorine) can be smelt, access to the surrounding area should be restricted to those wearing PPE. If the odour is smelt, immediately turn off the system from a safe position. In rare circumstances, the chlorine dioxide solution can leak. A chlorine dioxide detector (gas) can be installed to trigger an alarm in the event that a leak is detected. When using hazardous substances MSDS sheets should be readily available and their advice sought on the containment and control of spilled chemicals. The system administrator is responsible for the availability of the up to date MSDS and the preparation of relevant risk assessments and method statements relating to this systems use. BYPASS LINE SAFETY (IF INSTALLED) Chemicals being drawn uncontrolably into the reactor can be caused by a vacuum in the bypass line. In the event of gas and water mixing, chlorine dioxide can ‘gas out.’ In extreme cases, if the gas concentration exceeds 300 g/m3 an explosion can occur in the reactor. Take appropriate measures to ensure that the bypass line of the LDPCLO2 system does not become subect to a vacuum. Particles in the bypass water could block the flow switch. This can lead to an unacceptably high concentration of chlorine dioxide. If the bypass line is not completely full with water, a critical gas phase can form, resulting in an explosion in the bypass line. Install a pre-filter in the bypass line if required. PERSONAL PROTECTIVE EQUIPMENT The following PPE is recommended when using the ALS15C system: Face Shield Rubber or plastic boots - steel toed Protective Gloves (CLO2 compatible) Protective Apron/suit Full Face Respirator The composition and type of PPE required may vary from on country to another. Please consult MSDS, risk assessments and method statements for further information. If stil unsure, please consult a suitable qualified HSE advisor. 4 11
CHEMICAL SPILLAGE - RECOMMENDED ACTIONS FFoorr ccoonnttaacctt wwiitthh EAHC8ID00seseeeAECHID80M0 SMDSSDSShSeheetet FFoorr ccoonnttaacctt wwiitthh ACCHTL9O0R0ITseEesAeeCTC9H0L0OMRSITDES MShSeDeSt Sheet PERSONAL CONTACT WITH CHLORINE DIOXIDE SOLUTION OR GAS: Immediately remove any clothing that has come into contact with the substance, was the affected area thoroughly with soap and plenty of water. Splashes in the eye must be washed with running water for several minutes whilst keeping the eye lid open. If the gas is inhaled, move to a place with fresh air and lie the patient down ensure that they are protected from extremes of temperatures. Seek medical attention. CHLORINE DIOXIDE SOLUTION LEAK: Immediately clear the area and disconnect the power supply to the system. Wear PPE and pour a chlorine dioxide sodium thiosulphate solution then dilute with plenty of water to drain. CHLORINE DIOXIDE GAS LEAK: Immediately clear the area and disconnect the power supply to the system. Wear PPE and use a water spray to settle the gas. INCORRECT DILUTION: If the incorrect diltuion of excessive concentrated chemicals have been pumped into the reactor immediately clear the area and disconnect the power supply to the system. Alert the emergency services (Fire) and inform them of the risk of explosion by concentrated CLO2. STORAGE, TRANSPORT AND REPAIRS In case the need to return the equipment arises the system should be correctly decontaminated by the manufacturer or authorised personnel. A material decontamination declaration should be attached and returned with the system. Store or transport the unit in its original packaging to avoid damage. Always protect the equipment from mositure. WATER QUALITY Serious malfunctions of the system and corrosion can occur to the pipe work of the treated water. For the best results, the water and surrounding environment should be as follows: Temperature 10-30 Degrees Centigrade Relative Humidity 5% < 40 Degrees -- 70% at 45 degrees (non condensing) Pressure Max 8 Bar Water Quality Free of Iron, manganese and particles. Must be non corrosive 5 12
INTRODUCTION The ALS15C is used to produce liquid chlorine dioxide. This disinfectant kills all bacteria, germs, viruses and fungi very rapidly and works at a low concentration. The generator works according via a reaction between hydrochloric acid and sodium chlorite. The following reaction takes place within the equipment: HydrochloricEHac8id00++SAodCiTu9m0C0h=loCrihtelo=rinCehloDriionxeidDeiox+idEeH+80S0od+iuWmaCtehrloride + Water 4 HCL + 5 NaCLO2 = 4 CLO2 + 5 NaCL + 2 H2O Each chemical is pumped proportionally into the reactor vessel by two chemical dosing pumps. Each stroke from the dosing pumps is triggered based on the incoming signal from a pulse emitting water meter. An in-line flow sensor ensures that each chemical dosing pump is functioning/stroking correctly. To ensure a consistent flow into the reactor multi-function valves are used. Each multi-function valve provides pressure sustaining and pressure relief features. Inside the reactor, the two chemicals combine and are allowed to react for a set amount of time which results in an output concentration of 2% (20g/l) of Chlorine Dioxide (CLO2). This mixture is added to the flow line and is diluted further. LDPCLO2 INSTRUMENT CONNECTIONS A Main Fuse 6A B Instrument Fuse 3.15A L(Live) E(Earth) N (Nerutal): 85-264 VAC 50/60Hz 3(Live) E(Earch) N (Neutral): 85-264 VAC 50/60 Hz Alarm relay only 6(-) - 8(+): mA input 11(-) - 10(+): Standby contact 6 11(-) - 12(+): Level contact acid 19(-) - 18(+): Level contact chlorite 19(-) - 20(+): BYPASS input 22(-) - 23(+): Pump output acid 24(-) - 25(+): Pump output chlorite 37(-) - 36(+): Water meter input 13
MAIN SYSTEM COMPONENTS The ALS15C panel consists of the following main components: AD B EE CC F G A) LDPCLO2 Controller and pump management instrument B) Reactor Reaction Chamber (8 bar maximum pressure) C) MFKT/PR Pressure Relief Valve D) MFKT/PL Pressure Sustaining Valve E) SEFL/V Flow Sensor F) VIS/R Dosing Pump - hydrochloric acid - 3 Lph @ 5 Bar G) VIS/B Dosing Pump - sodium chlorite - 3 Lph @ 5 Bar 7 14
HYDRAULIC CONNECTIONS Suction Hose Unscrew the suctionring nut complete and remove it from the pump. Remove all components required to assemble the hose holding kit. Assemble as shown below 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 suction filter / suction lance using the same procedure. Delivery Hose Unscrew the delivery ring nut completely as before. Assemble as shown below making sure that the hose is fully inserted on the hose holder. Tighten the hose on the pump body or pressure valve by tightening the ring nut with your hands Connect the other end of the hose to the pressure valve or injection fitting using the same procedure. Pump Head Connections 15 8
PRESSURE VALVES Pressure Sustaining Valve (RED KNOB) This valve type remains closed until a specific pressure is reached at the valve. This allows for the dosing pump to operate at a constant pressure and avoids chemicals being syphon through to the injection point whilst the pump is not in operation due to a negative pressure. The pressure valve can be set by: Pulling the knob until a click is heard Rotate the knob to the desired set pressure Push the knob until a click is head. Note: if the chemical tank is located above the injection point use 0.1 bar per meter plus an additional bar to the set pressure. Pressure Relief Valve (YELLOW KNOB) This valve discharges chemical through the discharge line one the pressure has exceeded the setting inputted (max 10 bar). The pressure valve can be set by: Pulling the knob until a click is heard Rotate the knob to the desired set pressure Push the knob until a click is head. NOTE: The pressure valves should only be adjusted based on site specific calculations / calibrations. We would highly recommend that only trained / authorised personnel make such adjustments 9 16
BROWSING THE MENU SYSTEM On the top right of the LDPCLO2 controller there is a wheel that is used for browsing the menu system and programming the system. The wheel can be rotated in both directions to move the cursor throug the menus and pressed to confirm/enter the selection. When exiting a menu (selecting OK or ESC) you will often be prompted to save any altered settings. Click YES to save or NO to discard. Main Menu Mode Selection - selects the working mode of the system Production - adjusts the maximum system production value Water Meter - adjusts the working mode of the water meter System Settings - input management and passwords Instrument Reset - reverts system to factory defaults International - time/date/language settings Calibration Pump Reactor Priming Exit MAIN (RUNNING) SCREEN Local Date and Time Live G/H production - mc/h read by flow meter SEFL feedback display Menu Selection 17 10
MODE SELECTION Within the main menu screen press the wheel and enter the administrator password. Select ‘mode selection’. Before configuring a working mode, please verify chlorine dioxide (grams per hour) value set within the production menu. Constant Mode This mode allows production of chlorine dioxide based on a percentage value. This value is based on the ‘grams per hour’ value set in the production menu. Below the percentage, the calculated value is displayed based on the percentage inputted. Proportional WM Mode This mode allows production of chlorine dioxide based on production mg/l and water flow read by the external pulse emitting water meter. To eidt water meter parameters, move the cursor onto OK and press enter on the wheel. Note: this menu can also be accessed through the water meter menu [mc] Total amount of cubic meters that have passed through the water meter FM Input P/L Water meter counter mode (pulses per litre, litres per pulse, 0/4-20mA) RST TOT Totaliser reset ([mc]) TIMEOUT Countdown for water metering no longer receiving pulses Proportional mA Mode This mode allows production of chlorine dioxide proportionally to a mA reading and is based on the percentage value set. For each mA field set the percentage value according to the value set in the production menu. Note: a 0% value is required The g/h values will automatically populate based on the percentage set. 11 18
SYSTEM SETTINGS Within the main menu screen press the wheel and enter the administrator password. Select ‘System Settings.’ Use this menu to set contact working mode for each level input, bypass and standby and the admin/user passwords. L.HCL Contact type for hydrochloric acid level probe. Choose between NC or NO contact type L.NaCLO2 Contact type for sodium chlorite level probe Choose between NC or NO contact type STDBY/GAS Contact type for standby or gas detector contact. Can be changed by clicking the name. Contact type can be NC or NO Standby contact can also be disabled BYPASS Contact type for flow detection Choose beterrn NC or NO contact type Admin Passcode4 number code to access all menu systems User Passcode 4 number codt to access production menu only Dos Check Number of missed pulses required by the SEFL flow sensor before an alarm is triggered. 19 12
CALIBRATION PUMP Within the main screen press the wheel and enter the administrator password. Select ‘Calibration pump’ This function allos the calibration of the acid and chlorite dosing pumps based on stroke capacity. To calibrate, follow the below procedure: Choose which pump to calibrate by moved the cursor onto Acid or Chlorite pressing the wheel to confirm Insert the suction tubing from the respective pump into a graduated beaker Move the curose to start and press the wheel Wait until the end of 100 strokes Calculate the amount of chemical removed from the beaker Enter the measured quantity in ml into the [ml] field Repeat this process for the other pump. The instrument will calculate the cc/s that the pump is capable of. To save the calibration, select OK 13 20
PRIMING Within the main menu screen press the wheel and enter the administrator password. Select ‘PRIMING.’ This function facilitates priming of the acid and chlorite dosing pumps Ensure that all dosing hoses are properly connected Open the bleed valve for the pump required Choose which pump to prime by moving the cursor onto Acid or Chlorite pressing the wheel to confirm Move the cursor onto STK and enter the required number of strokes required (typicall 20 based on a suction lift of 1.5m) Move the cursor to start pressing the wheel to confirm All of the air inside the pump head will exit through the beeld outlet. Once product begins to exit via the bleed immediatley close the bleed valve. End the procedure by selecting EXIT which will return you to the main menu REACTOR PRIMING Within the main menu screen press the wheel and enter the administrator password. Select ‘Reactor Priming’ This function allows you to test the acid and chlorite dosing pumps whilst filling the reactor. Set seconds required based on pump capacity and reactor tank size. Press START to begin procedure and STOP when the reactor is full (liquid exiting the injection valve). If not press STOP and increase the seconds run if reactor prime isn’t achieved. 21 14
STATS This menu shows statistics for both acid and chlorite dosing pumps (litres or gallons dosed) and m/c or gallons passed through the pulse emitting water meter. To reset these valves move cursor on ‘Reset: No’, click, rotate wheen, choose Yes. Click the wheel move to exit and confirm changes. STATUS MESSAGES During normal operation the instrument may show warning messages on the main screen. See the below table for their meaning and suggestions of how to fix them: 15 22
MDCL Module Located under the mainboard cover of the LDPCLO2 are the two connectors that can be used to install modules. Modules come pre-installed and may appear different to that shown (depends on configurations). 23 16
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TABLE OF CONTENTS General Safety Guidelines 216 216 Symbols 216 227 Safety Instructions 238 249 CE Conformity 249 249 General Notes 350 350 Chemical Spillage 350 361 Bypass Line 361 372 Personal Protective Equipment 383 394 Chemical Spillage - Recommended Actions 3150 3161 Storage, Transport and Repairs 3172 3183 Water Quality 3194 4105 Introduction 4105 4116 LDPCLO2 Instrument Connections 4116 Main System Components Hydraulic Connections Pressure Valves Browsing the Menu System Mode Selection System Settings Calibration Priming Stats Status Messages SEFL Module Technical Information 25
GENERAL SAFETY GUIDELINES General Remarks This manual includes basic information relating to the assembly, operation and maintenance of the TA150 Chlorine Dioxide Generator. It is highly recommended that any personnel that are to use the equipment study the complete manual before installation or operation of the equipment. This manual should also be in close proximity to the equipment at all times. Symbols Throughout this manual special symbols are used to draw your attention to specific points which are labelled as follows: WARNING: This symbol is warning about risks Ignoring this information may lead to severe personal injury or material damage CAUTION: This symbol is warning about issues that may arise through incorrect operation NOTICE/ADVICE: This symbol identifies additional, important, information SAFETY INSTRUCTIONS The appropriate/correct operation of the Chlorine Dioxide Generator is described in this manual however: WARNING: Inappropriate use of this equipment affects the safety of this system and other devices used in conjunction with this equipment. Installation, operation and maintenance should only be completed by trained and compotent engineers All installations should conform to those laid out in the manual and in accordance with manufacturers guidelines. Failure to do so will invalidate any warranty claims The end user/operator is responsible for ensuring that the equipment operates within local authority guidelines Before any maintenance work commences, ensure that the dosing pump heads are depressurised and flushed through with clean water Always consult MSDS sheets Always wear personal protective equipment (PPE) whilst using this equipment. 1 26
CE Conformity TThhee TAALSS1ys5tCemChGloernineeraDtoiorxciodnefoGremnsertaotothrecofonlfloorwminsgtostathnedafordllso:wing standards: Pressure Equipment Directive 97/23/EC EU Machinery Directive 2006/42/EC EU EMC Directive 2004/108/EC Low voltage directive 2006/95/EC Appendix I No. 1.5.1 of machinery directive 2006/42/EC The following harmonised standards are considered: EN ISO 12100-1, EN ISO 12100-2, EN 809 EN 60206, EN 60529, EN 610000-6-1/2/3/4 The following harmonised national standards are considered: DVGW standards: Technical rules W 224 and W 624 NOTICE: A declaration of conformity is available upon request WARNING: The following European Directives should be followed: DIN EU 939 concerning Hydrochloric Acid DIN EU 938 concerning Sodium Chlorite Pressure Equipment Directive (97/23/EC) should also be followed 27 2
GENERAL NOTES The pumps must only be used with: XX97.%ZZ5IIOO%XX EAHCSHT8oy90dd00iru0omchClohrliocrAitceid They should not be used in explosive atmospheres (EX) They should not be used to dose flamable liquids The should no be used to dose radioactive chemicals Keep the system protected from sun and rain. Avoid excessive water splashes. The power to the system must be immediately isolated and the pumps disconnected during any emergency within the vicinity of the system. Always ensure that chemical usage strictly complies with the regulations concerning their use and storage. Always comply with local safety regulations. The manufacturer of this system cannot be held liable for damage to persons or property caused by incorrect installation, improper or incorrect use of the system The system must be installed so that it is accesible at all times for maintenance purposes. The unit must also be correctly programmed on a site specific basis. Dosing must be interrupted if there is no water flow or malfunction. Repairs and maintenance of the system and all of its accessories must only be performed by qualified personnel. Strict compliance with all national and local regulations is required when using the TA150 generator. The operator is responsible for compliance with safety-related local instructions. The generator must be installed and operated in accordance with the instructions contained within this manual. It is forbidden to use installation materials that are not approved by the manufacturer or supplier. The system can only be used with appropriate safety valves approved by the manufacturer. Failure to do so may lead to the loss of any warrranty claim. The system must never be allowed to operate with closed valves as there is a risk to the connected flexible hosing or rigid pipework. A supplemental power supply isolation device must be installed outside of the room where the system is installed. The system should be electrically isolated before any protective covers (e.g. the controller cover) is removed. 3 28
GENERAL NOTES (Cont.) The system must not be installed outdoors The system must be protected from unathorised access or alteration. Environments where temperatures drop below 10 degrees centigrade must utilise systems to maintain the temperature above this level where the TA150 is in use. Access to the system installation area, for the purposes of chemical transportation, must be unrestricted. An emergency exit is required. The system must be mounted on a vertical solid wall and in such as way as to not cause vibrations. CHEMICAL SPILLAGE If the odour of chlorine dioxide (a penetrating odour similar to that of chlorine) can be smelt, access to the surrounding area should be restricted to those wearing PPE. If the odour is smelt, immediately turn off the system from a safe position. In rare circumstances, the chlorine dioxide solution can leak. A chlorine dioxide detector (gas) can be installed to trigger an alarm in the event that a leak is detected. When using hazardous substances MSDS sheets should be readily available and their advice sought on the containment and control of spilled chemicals. The system administrator is responsible for the availability of the up to date MSDS and the preparation of relevant risk assessments and method statements relating to this systems use. MAIN OR BYPASS LINE SAFETY Chemicals being drawn uncontrolably into the reactor can be caused by a vacuum in the main or bypass line. In the event of gas and water mixing, chlorine dioxide can ‘gas out.’ In extreme cases, if the gas concentration exceeds 300 g/m3 an explosion can occur in the reactor. Take appropriate measures to ensure that the main or bypass line of the TA150 system does not become subect to a vacuum. Particles in the bypass water could block the flow switch. This can lead to an unacceptably high concentration of chlorine dioxide. If the bypass line is not completely full with water, a critical gas phase can form, resulting in an explosion in the bypass line. Install a pre-filter in the bypass line if required. PERSONAL PROTECTIVE EQUIPMENT The following PPE is recommended when using the TA150 system: Face Shield Rubber or plastic boots - steel toed Protective Gloves (CLO2 compatible) Protective Apron/suit Full Face Respirator The composition and type of PPE required may vary from on country to another. Please consult MSDS, risk assessments and method statements for further information. If stil unsure, please consult a suitable qualified HSE advisor. 29 4
CHEMICAL SPILLAGE - RECOMMENDED ACTIONS FFoorrccoonnttaaccttwwitithhEAHC8I0D0sseeee AEHCI8D00MMSDSDSSSShheeeett FFoorrccoonnttaaccttwwitithhACCHTL9O00RIsTeEe sAeCeT9C0H0LOMRSIDTSESMheSeDtS Sheet PERSONAL CONTACT WITH CHLORINE DIOXIDE SOLUTION OR GAS: Immediately remove any clothing that has come into contact with the substance, was the affected area thoroughly with soap and plenty of water. Splashes in the eye must be washed with running water for several minutes whilst keeping the eye lid open. If the gas is inhaled, move to a place with fresh air and lie the patient down ensure that they are protected from extremes of temperatures. Seek medical attention. CHLORINE DIOXIDE SOLUTION LEAK: Immediately clear the area and disconnect the power supply to the system. Wear PPE and pour a chlorine dioxide sodium thiosulphate solution then dilute with plenty of water to drain. CHLORINE DIOXIDE GAS LEAK: Immediately clear the area and disconnect the power supply to the system. Wear PPE and use a water spray to settle the gas. INCORRECT DILUTION: If the incorrect diltuion of excessive concentrated chemicals have been pumped into the reactor immediately clear the area and disconnect the power supply to the system. Alert the emergency services (Fire) and inform them of the risk of explosion by concentrated CLO2. STORAGE, TRANSPORT AND REPAIRS In case the need to return the equipment arises the system should be correctly decontaminated by the manufacturer or authorised personnel. A material decontamination declaration should be attached and returned with the system. Store or transport the unit in its original packaging to avoid damage. Always protect the equipment from mositure. WATER QUALITY Serious malfunctions of the system and corrosion can occur to the pipe work of the treated water. For the best results, the water and surrounding environment should be as follows: Air Temperature 10-30 Degrees Centigrade Relative Humidity 5% < 40 Degrees -- 70% at 45 degrees (non condensing) Pressure Max 10 Bar Water Quality Free of Iron, manganese and particles. Must be non corrosive pH Always higher than pH6.5 and should be controlled Carbonate/Alkalinity If cabonate hardness is lower than 1.1 dH or alkalinity is lower than 0.4 mMol/l dosing of suitable chemicals for increasing the pH should be used 5 30
INTRODUCTION The TA150 is used to produce liquid chlorine dioxide. This disinfectant kills all bacteria, germs, viruses and fungi very rapidly and works at a low concentration. The generator works according via a reaction between hydrochloric acid and sodium chlorite. The following reaction takes place within the equipment: HydrochloriEcHa8c0id0++SAoCdTiu9m00C=hloCrhitleor=inCehDloiroinxeidDeio+xEidHe8+00So+dWiumateCrhloride + Water 4 HCL + 5 NaCLO2 = 4 CLO2 + 5 NaCL + 2 H2O Each chemical is pumped proportionally into the reactor vessel by two chemical dosing pumps. An in-line flow sensor ensures that each chemical dosing pump is functioning/stroking correctly. Inside the reactor, the two chemicals combine and are allowed to react for a set amount of time which results in an output concentration of 2% (20g/l) of Chlorine Dioxide (CLO2). This mixture is added to the main or bypass line and is diluted further. LDPCLO2 INSTRUMENT CONNECTIONS A Main Fuse 6A 6 B Instrument Fuse 3.15A L(Live) E(Earth) N (Nerutal): 85-264 VAC 50/60Hz 3(Live) E(Earch) N (Neutral): 85-264 VAC 50/60 Hz Alarm relay only 6(-) - 8(+): mA input 11(-) - 10(+): Standby contact 11(-) - 12(+): Level contact acid 19(-) - 18(+): Level contact chlorite 19(-) - 20(+): BYPASS input 22(-) - 23(+): Pump output acid 24(-) - 25(+): Pump output chlorite 37(-) - 36(+): Water meter input 31
MAIN SYSTEM COMPONENTS The TA150 panel consists of the following main components: A) LDPCLO2 Controller and pump management instrument B) Reactor Reaction Chamber (10 bar maximum pressure) C) MFKT/PR Pressure Relief Valve D) MFKT/PL Pressure Sustaining Valve E) SEFL/V Flow Sensor F) AMSMF/R Dosing Pump - hydrochloric acid G) AMSMF/B Dosing Pump - sodium chlorite 7 32
HYDRAULIC CONNECTIONS Dosing Pump Suction Hose Unscrew the suction ring nut completely and remove it from the pump. Remove all components required to assemble the hose holding kit. Assemble as shown below 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 suction filter / suction lance using the same procedure. Reactor Delivery Hose Unscrew the delivery ring nut completely from the pressure sustaining valve. Assemble as shown above making sure that the hose is fully inserted on the hose holder. Tighten the hose on the pressure loading valve by tightening the ring nut with your hands Connect the other end of the hose to the injection fitting using the same procedure. Dosing Pump/Relief Valve Discharge (Bleed) Hose Insert one end of the discharge (bleed) hose onto the tee connector within the enclosure. Place the other end directly into the tank of the product being dosed as this allows any fluid that is discharged during the pump priming process or fluid passed by the pressure relief valve to drain safely whilst maintaining containment. 33 8
Pump Head Connections PRESSURE VALVES Pressure Sustaining Valve (YELLOW KNOB) This valve type remains closed until a specific pressure is reached at the valve. This allows for the dosing pump to operate at a constant pressure and avoids chemicals being syphon through to the injection point whilst the pump is not in operation due to a negative pressure. The pressure valve can be set by: Pulling the knob until a click is heard Rotate the knob to the desired set pressure Push the knob until a click is head. Note: if the chemical tank is located above the injection point use at least 0.1 bar per meter plus an additional bar to the set pressure. Pressure Relief Valve (RED KNOB) This valve discharges chemical through the discharge line one the pressure has exceeded the setting inputted. The pressure valve can be set by: Pulling the knob until a click is heard Rotate the knob to the desired set pressure Push the knob until a click is head NOTE: The pressure valves should only be adjusted based on site specific calculations / calibrations. We would highly recommend that only trained / authorised personnel make such adjustments 9 34
BROWSING THE MENU SYSTEM On the top right of the LDPCLO2 controller there is a wheel that is used for browsing the menu system and programming the system. The wheel can be rotated in both directions to move the cursor throug the menus and pressed to confirm/enter the selection. When exiting a menu (selecting OK or ESC) you will often be prompted to save any altered settings. Click YES to save or NO to discard. Main Menu Mode Selection - selects the working mode of the system Production - adjusts the maximum system production value Water Meter - adjusts the working mode of the water meter System Settings - input management and passwords Instrument Reset - reverts system to factory defaults International - time/date/language settings Calibration Pump - dedicated menu for calibrating pumps Reactor Priming - allows priming of reactor Exit MAIN (RUNNING) SCREEN Local Date and Time Live G/H production - live mc/h of flow meter SEFL feedback display Menu Selection Default Passwords 0916 ADMINISTRATOR 0000 STANDARD USER 35 10
MODE SELECTION Within the main menu screen press the wheel and enter the administrator password (0916). Select ‘mode selection.’ Before configuring a working mode, please verify chlorine dioxide (grams per hour) value set within the production menu. Constant Mode This mode allows production of chlorine dioxide based on a percentage value. This value is based on the ‘grams per hour’ value set in the production menu. Below the percentage, the calculated value is displayed based on the percentage inputted. Proportional WM Mode This mode allows production of chlorine dioxide based on production mg/l and water flow read by the external pulse emitting water meter. To eidt water meter parameters, move the cursor onto OK and press enter on the wheel. Note: this menu can also be accessed through the water meter menu [mc] Total amount of cubic meters that have passed through the water meter FM Input P/L Water meter counter mode (pulses per litre, litres per pulse, 0/4-20mA) RST TOT Totaliser reset ([mc]) TIMEOUT Countdown for water metering no longer receiving pulses Proportional mA Mode This mode allows production of chlorine dioxide proportionally to a mA reading and is based on the percentage value set. For each mA field set the percentage value according to the value set in the production menu. Note: a 0% value is required The g/h values will automatically populate based on the percentage set. 11 36
SYSTEM SETTINGS Within the main menu screen press the wheel and enter the administrator password. Select ‘System Settings.’ Use this menu to set contact working mode for each level input, bypass and standby and the admin/user passwords. L.HCL Contact type for hydrochloric acid level probe. Choose between NC or NO contact type L.NaCLO2 Contact type for sodium chlorite level probe Choose between NC or NO contact type STDBY/GAS Contact type for standby or gas detector contact. Can be changed by clicking the name. Contact type can be NC or NO Standby contact can also be disabled BYPASS Contact type for flow detection Choose beterrn NC or NO contact type Admin Passcode4 number code to access all menu systems User Passcode 4 number codt to access production menu only Dos Check Number of missed pulses required by the SEFL flow sensor before an alarm is triggered. 37 12
CALIBRATION PUMP Within the main screen press the wheel and enter the administrator password. Select ‘Calibration pump.’ This function allos the calibration of the acid and chlorite dosing pumps based on stroke capacity. To calibrate, follow the below procedure: Insert the suction tubing from the respective pump into a graduated beaker of water or disconnect pump suction hose and connect a calibration column filled with water Follow instructions in priming menu to remove any air Choose which pump to calibrate by moving the cursor onto Acid or Chlorite pressing the wheel to confirm Move the cursor to start and press the wheel Wait until the end of 100 strokes Calculate the amount of chemical removed from the beaker Enter the measured quantity in ml into the [ml] field Repeat this process for the other pump. The instrument will calculate the cc/s that the pump is capable of. To save the calibration, select OK 13 38
PRIMING Within the main menu screen press the wheel and enter the administrator password. Select ‘PRIMING.’ This function facilitates priming of the acid and chlorite dosing pumps Ensure that all dosing hoses are properly connected Open the discharge valve for the pump required Choose which pump to prime by moving the cursor onto Acid or Chlorite pressing the wheel to confirm Move the cursor onto STK and enter the required number of strokes required (typically 20 based on a suction lift of 1.5m) Move the cursor to start pressing the wheel to confirm All of the air inside the pump head will exit through the beeld outlet. Once product begins to exit via the discharge hose immediatley close the discharge valve. End the procedure by selecting EXIT which will return you to the main menu REACTOR PRIMING Within the main menu screen press the wheel and enter the administrator password. Select ‘Reactor Priming’ This function allows you to test the acid and chlorite dosing pumps whilst filling the reactor. Set seconds required based on pump capacity and reactor tank size. Press START to begin procedure and STOP when the reactor is full (liquid at the injection valve). If not press STOP and increase the seconds run if reactor prime isn’t achieved. 39 14
STATS This menu shows statistics for both acid and chlorite dosing pumps (litres or gallons dosed) and m/c or gallons passed through the pulse emitting water meter. To reset these valves move cursor on ‘Reset: No’, click, rotate wheen, choose Yes. Click the wheel move to exit and confirm changes. STATUS MESSAGES During normal operation the instrument may show warning messages on the main screen. See the below table for their meaning and suggestions of how to fix them: Message Shown Explanation / What to do STANDBY Start/stop contact status has changed GAS DETECT* Contact status has changed LEVEL ACID or LEVEL CHLORITE* Level contact staus has changed - usually means low chemical SEFL ACID or SEFL CHLORITE* Flow sensor hasn’t received any signals from the pump (see DOS CHECK in settings menu) BYPASS* Contact status has changed OVERFLOW Pumps are working at their maximum capacity, check production (PROPORTIONAL MODE only) VSUPPLY OUT OF RANGE* Power supply exceeded working range. 185 to 275V permissible * This alarm condition must be fixed in order to return to a normal working mode! 15 40
SEFL Module Located under the mainboard cover of the LDPCLO2 are the two connectors that can be used to connect the SEFL flow sensors. 1 SEFL Acid 2 SEFL Chlorite 3 n/a 4 Common Ground Technical Information Power Supply: 100-240VAC 60/60Hz Power Rating: 32W Installation Class: I Environmental Relativ Humidity 5% t < 40 Degrees, 70% at 50 Dgrees (non condensing) Ambiant Temperature: 10-30 Degrees Chemical Temperature: 0-50 Degrees Reactor Chamber max pressure: 10 Bar Pollution Level: 2 Portection Degree:IP65 41 16
Adjusting Dosing Level Whilst on the main menu screen select menu and click the wheel to enter. Enter passcode 0000 Move cursor on to dosing rate. Click and adjust to required amount. This should not be adjusted by a great amount, if adjusted by any more than 0.50ppm at a time please contact your IWS engineer or account manager 42
Press OK once you have entered dosing rate. If you are happy you have followed the above steps correctly click yes on to save. If you feel you have made a mistake press no to saving and repeat the above process again You will now be returned to the main operating screen 43
Priming Of The ALS System • Within the main menu screen press the wheel and select ‘PRIMING.’ Then enter the password 0000 • This function facilitates priming of the acid and chlorite dosing pumps • Ensure that all dosing hoses are properly connected • Open the bleed valve for the pump required 44
Choose which pump to prime by moving the cursor onto Acid or Chlorite pressing the wheel to confirm Move the cursor onto STK and enter the required number of strokes required (typical 250 based on a suction lift of 1.5m) 45
Move the cursor to START pressing the wheel to confirm All of the air inside the pump head will exit through the bleed outlet. Once product begins to exit via the bleed immediately close the bleed valve. End the procedure by selecting EXIT which will return you to the main menu 46
Priming Of The TA System • Within the main menu screen press the wheel and select ‘PRIMING.’ Then enter the password 0000 • This function facilitates priming of the acid and chlorite dosing pumps • Ensure that all dosing hoses are properly connected • Open the bleed valve for the pump required 47
Choose which pump to prime by moving the cursor onto Acid or Chlorite pressing the wheel to confirm Move the cursor onto STK and enter the required number of strokes required (typical 250 based on a suction lift of 1.5m) 48
Move the cursor to START pressing the wheel to confirm All of the air inside the pump head will exit through the bleed outlet. Once product begins to exit via the bleed immediately close the bleed valve. End the procedure by selecting EXIT which will return you to the main menu 49
Replacing & Reconnecting IBC’s PPE Required – Face Shield Rubber or plastic boots – steel toed Protective Gloves (CLO2 compatible) Protective Apron/suit Full Face Respirator The composition and type of PPE required may vary from on country to another. Please consult MSDS, risk assessments and method statements for further informa- tion. If still unsure, please consult a suitable qualified HSE advisor. Removal • Have 2 buckets filled with water in a reachable distance on the ground from the IBC • Make sure all required PPE is being worn properly • Using steps or an appropriate method climb to the same level as the top of the IBC • Unscrew lid on IBC and carefully remove footvalve and place it into bucket of water 50
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