Grundfos Vaccuperm VGS -145 Installation And Operating Instructions Manual

Marca: Grundfos

Modelo: Vaccuperm VGS -145

Tipo: Installation And Operating Instructions Manual

Este manual también es adecuado para

Vaccuperm VGS -141, -143, -145

Gas dosing system

Installation and operating instructions

GRUNDFOS INSTRUCTIONS

Other languages

http://net.grundfos.com/qr/i/95714262

Table of contents

Vaccuperm VGS -141, -143, -145

English (GB)

Installation and operating instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Deutsch (DE)

Montage- und Betriebsanleitung . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Español (ES)

Instrucciones de instalación y funcionamiento. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Français (FR)

Notice d'installation et de fonctionnement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

Ελληνικά (GR)

Οδηγίες εγκατάστασης και λειτουργίας . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96

Polski (PL)

Instrukcja montażu i eksploatacji . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120

Română (RO)

Instrucţiuni de instalare şi utilizare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143

Русский (RU)

Паспорт, Руководство по монтажу и эксплуатации . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166

Türkçe (TR)

Montaj ve kullanım kılavuzu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190

Declaration of conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214

Declaration of conformity EAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215

English (GB)

English (GB) Installation and operating instructions

Original installation and operating instructions

CONTENTS

Page

1. Of general interest

1.1 Structure of the documentation

The Grundfos device VGS-141 / VGS-143 / VGS-145 is a state-

of-the-art solution, which complies with recognised safety

regulations.

Conformity with applicable standards, directives and laws has

been verified.

Nevertheless, certain risks which cannot be prevented by the

manufacturer are associated with the use of the system.

Purpose of this manual:

• Inform users of optimum use.

• Warn users of possible residual risks when using correctly and

identify measures that should be taken to avoid damage.

• Caution users against obvious misuse or inappropriate use

and inform them of the necessary care that must be taken

when operating the system.

1.2 About this manual

This manual contains the following standardised safety

instructions about possible residual risks:

Information about possible residual risks is provided:

• On warning signs displayed in the installation location.

• At the start of each section in this manual.

• Directly before any operating procedures that could involve

residual risks.

1.3 User/target groups

Users are persons who are responsible for operating and

monitoring the device VGS-141 / VGS-143 / VGS-145 at the

installation location. The system may only be operated by trained

and qualified personnel. Personnel must have appropriate

technical knowledge and be familiar with the basic principles of

measuring and control technology.

1.3.1 Responsibilities of the users

The users’ responsibilities:

• Read this manual before operating the VGS-141 / VGS-143 /

VGS-145.

• Be trained by qualified personnel from Grundfos in the

operation of the system.

• Observe the recognised regulations governing safety in the

workplace and accident prevention.

• Wear appropriate protective clothing in accordance with

national regulations for the prevention of accidents when

operating the system and handling chemicals

(German GUV-V D05).

1. Of general interest

1.1 Structure of the documentation

1.2 About this manual

1.3 User/target groups

1.4 Responsibilities of the operator

1.5 Maintenance and service personnel

1.6 Correct usage

1.7 Inappropriate usage

2. Handling chlorine

2.1 Physical and chemical data

2.2 Safety advice for handling chlorine

2.3 Checking the tightness

2.4 Constructional requirements of chlorination plants

2.5 Principle function of the components

2.6 List of valid laws and regulations (in Germany)

2.7 Recommended diameter

3. Technical Data

3.1 General Data

3.2 Data of the accessory components

3.3 Dimensioned drawing

4. Installation

4.1 Transport and storage

4.2 Unpacking

4.3 Storage/Downtimes

4.4 Installation

4.5 Replacing the electrical servomotor

5. Commissioning

5.1 Preparations for commissioning

5.2 Checks before commissioning

6. Operation

6.1 Description of the system

6.2 Increasing the dosing flow manually

6.3 Reducing the dosing flow manually

6.4 Engaging the servomotor

6.5 Disengaging the servo motor

6.6 Operating the servomotor

6.7 Adjusting the Servomotor (option)

6.8 Switching on

6.9 Switching off

6.10 Possible faults

7. Maintenance

7.1 Maintaining the servomotor

8. Disposal

Warning

These complete installation and operating

instructions are also available on

www.grundfosalldos.com.

Prior to installation, read these installation and

operating instructions. Installation and operation

must comply with local regulations and accepted

codes of good practice.

Warning

If these safety instructions are not observed, it may

result in personal injury!

Caution

If these safety instructions are not observed, it may

result in malfunction or damage to the equipment!

Note

Notes or instructions that make the job easier and

ensure safe operation.

English (GB)

1.4 Responsibilities of the operator

The owner of the building or operator of the VGS-141 / VGS-143 /

VGS-145 is responsible for the following:

• Consider this manual to be part of the product and ensure that

it is kept clearly accessible in the immediate vicinity of the

system for the entire service life of the system.

• Meet the installation requirements specified by the

manufacturer (required water connections and fittings,

environmental conditions, electrical connection, protective

tube for dosing line if necessary, audible or optical warning

device for alarm messages if necessary).

• Ensure that water lines and fixings are regularly checked,

serviced and maintained.

• Obtain official approval for storing chemicals, if necessary.

• Train users in the operation of the system.

• Ensure that the regulations for the prevention of accidents are

observed in the installation location (German GUV-V D05

regulation for the prevention of accidents, "Chlorination of

Water" dated January 1997).

• Provide all users and service personnel with protective

clothing in accordance with GUV-V D05 (face mask, gloves,

protective apron).

1.5 Maintenance and service personnel

The system may only be maintained and serviced by authorised

service personnel from Grundfos.

1.6 Correct usage

The Grundfos VGS-141, VGS-143, VGS-145 may be used for

dosing chlorine (Cl

) as being described in this manual.

1.7 Inappropriate usage

Applications other than those listed in section 1.6 Correct usage

are considered not to be in accordance with the intended use and

are not permitted. The manufacturer, Grundfos, accepts no

liability for any damage resulting from incorrect use.

The system comprises state-of-the-art components and has

undergone safety-related testing.

2. Handling chlorine

2.1 Physical and chemical data

Under normal conditions of pressure and temperature, chlorine is

a yellowish green gas with a pungent odour. It exists as diatomic

molecule Cl

It is not flammable, but can under certain circumstances promote

the flammability of metals, hydrocarbons etc.

Vapour pressure curve of chlorine

Fig. 1 Vapour pressure curve of chlorine

Solubility of chlorine gas in water

Fig. 2 Solubility of chlorine gas in water

Warning

Unauthorised structural modifications to the system

may result in serious damage to equipment and

personal injury.

It is forbidden to open, modify, change the structure

of, bridge, remove, bypass or disable components,

especially safety equipment.

Atomic weight 35,457

Molecular weight Cl

70,941

Density (liquid) 1,57 g/cm

at -34,05 °C

Density (gaseous) 3,214 g/l at 0 °C, 1 bar

1 l liquid chlorine at 0 °C

corresponds to 457 l (0,457 m

)

gaseous chlorine

1 kg liquid chlorine at 0 °C

corresponds to 311 l (0,311 m

)

gaseous chlorine

Specific gravity 2,486 (specific gravity of air: 1)

Boiling point - 34,05 °C (1 bar)

Melting point - 100,98 °C

Evaporation heat 269 kJ/kg (at 0 °C)

Heat conductivity 0,527 kJ/m

h (liquid chlorine)

Degree of purity acc. to

DIN 19607

99,5 %

TLV (Threshold Limit Value) 1,5 mg/m

(0,5 Vol.-ppm)

TM04 0691 0908TM04 0692 0908

-50 -40

-30 -20

-10 0

30 40

50 60 70

Temperature (°C)

English (GB)

2.2 Safety advice for handling chlorine

2.2.1 Risks to health

Chlorine gas is toxic, more than 50 Vol.-ppm in the indoor air

mean an acute danger to life.

Hazards of chlorine gas

• Irritating to eyes, respiratory system and skin.

• Causes whooping cough.

• Causes causticization of skin and respiratory system.

• Lethal by lung edema in case of long influence or high

concentration.

• Slight paralyzing effect to the central nervous system.

Hazards of liquid chlorine

• Causes causticization of skin.

• Causes reddening and formation of bubbles.

2.2.2 Personal safety equipment

The operating authority of a chlorination plant has to provide for

the operation personnel:

For each person

Respiratory equipment (full-sight gas mask)

• with an effective chlorine filter (B2P3), colour mark: grey with a

white ring

• at least 1 spare filter per gas mask

• personally fitted (perfectly tight)

• labelled by name

Only plants with chlorine drums

• at least 2 protective suits with compressed air respirators

Storage of the safety equipment

• outside the chlorine rooms

• well visible

• easily available at any time

• protected from dust and moisture

• Introducing the operation personnel to handle the safety

equipment

• Carrying out exercises (at least half-yearly)

• Regular replacement of the gas mask filters

– after the expiry of the date of durability

– at least 6 months after opening (mark the opening date on

the filter)

– after contact with chlorine

– Observe employing prohibition according to § 14 ArbStoffV

(in Germany) resp. according to local laws!

2.2.3 Rules of conduct

• Change of chlorine containers only with gas mask.

• Entering contaminated rooms only with protective suit and

compressed air respirator.

• In case of flight wear gas mask, if possible.

Observe wind direction!

• Eating, drinking and storing food is prohibited in chlorine

rooms.

2.2.4 First aid in case of accidents

First aid after having inhalated chlorine

• Keep calm.

• Remove injured persons from the dangerous area.

– Helpers must pay attention to personal protection!

• Immediately remove contaminated clothes.

• Calm down injured persons and keep them warm with

blankets.

• Supply fresh air; use oxygen respirator (alternately with

inhalating steam), if possible.

– No mouth-to-mouth resuscitation!

• Fast and gentle transport to hospital

– lying

– sitting in case of difficulty in breathing

– state chlorine causticization as the cause.

First aid after causticization of the skin

• Keep calm.

• Remove contaminated clothes.

• Rinse skin with plenty of water

• Bandage the wound germ-freely

• Seek medical aid.

– State chlorine causticization as the cause.

First aid after causticization of the eyes

• Keep calm.

• Rinse causticized eyes with plenty of water while the person is

lying.

– Protect healthy eye, if necessary.

– Spread eyelids widely, let the eye move to all sides.

• Seek ophthalmologist.

– State chlorine causticization as the cause.

First aid after internal causticization

• Keep calm.

• Drink water in short sips.

– If possible, take medical charcoal.

• Seek medical aid.

– state chlorine causticization as the cause.

2.2.5 Transport and storage of chlorine

Basic rules for transport and storage of chlorine

• Treat containers carefully, do not throw!

• Protect containers from turning over or rolling away!

• Protect containers from direct sun rays and temperatures over

50 °C!

• Transport of containers only with valve protection nut and

protection cap.

Valid regulations

– Regulations for accident prevention "Chlorination of water"

(GUV-V D5) with process instructions

– Regulations concerning places of work (ArbStättV)

– Technical rules for gases 280, 310 und 330

Warning

R 23 Toxic by inhalation.

R 36/37/38 Irritating to eyes, respiratory system

and skin.

Caution

Further obligations of the operating authority

Warning

Handling of chlorine containers only by experienced,

practised personnel!

Warning

This rules are valid for both full and empty

containers, as empty containers still contain rests of

chlorine and therefore are under pressure.

Warning

Strictly observe local law and regulations for

handling, transport and storage of chlorine.

English (GB)

2.2.6 Pressure vessels and mountings

Chlorine is being offered in two container designs:

• Steel cylinders containing 50 kg or 65 kg, equipped with one

valve for

– the withdrawal of gaseous chlorine from the upright standing

cylinder

Variant of chlorine cylinder

Fig. 3 Variant of chlorine cylinder

• Steel drums containing 500 kg or 1000 kg, equipped with

– one valve for the withdrawal of gaseous chlorine

– one valve for the withdrawal of liquid chlorine

Fig. 4 Chlorine drum

Fig. 5 Valve position of chlorine drum

Due to safety precautions, chlorine containers are only filled up to

95 % of their capacity.

• Kind of gas, weight, owner, producing date and date of the last

testing have to be noted clearly on the container.

Chlorine containers are marked by grey colour.

• No changes or repair by the user!

• Never open container valves by force. Stuck valve spindels

can be loosened by wrapping a shred with warm water around

the valve.

– Never use an open flame!

– Never use wrench lengthening!

– Return containers with stuck valves to the manufacturer.

• Observer safety precautions and the manuals of the

manufacturer!

TM04 0693 0908

Protecting cap

Valve

Holding clip

Valve thread acc.

to DIN 477

Labelled by

stamping

Weldless chlorine

cylinder

Aluminium

label

Welded chlorine

cylinder

TM04 0694 0908TM04 0695 0908

Tyre of roller

Riser pipe (for the withdrawal of gaseous chlorine)

Protecting cap

Valves

Dip pipe (for the withdrawal of liquid chlorine)

Valve for gaseous chlorine

Colour ring

Valve for liquid chlorine

Warning

Observe safety precautions for chlorine containers

English (GB)

2.2.7 Chlorine extraction

Before the extraction

• The chlorine containers must be stored at least for 8 hours in

the container room so that the content can adapt the ambient

temperature.

• Turn chlorine drums on the support until the dip pipe and the

riser pipe are placed vertically (observe the markings on the

drum).

• Check tightness.

Connection

• Protect containers from turning over or rolling away!

• Dry the piping and the withdrawal system with dry nitrogen or

dry air.

• No foreign matter must get into the plant.

• Mount new gaskets to the connection line.

• Connect the container.

• Slowly open the container valve.

Withdrawal of gaseous chlorine

In case of higher chlorine requirement several chlorine containers

of the same temperature have to be connected with header lines.

Withdrawal of liquid chlorine

• Within chlorination plants only possible from chlorine drums.

• Application of an evaporator is necessary.

• Withdrawal of gaseous chlorine:

Observe residual pressure of ca. 2 bar.

• Withdrawal of liquid chlorine:

Observe residual pressure of ca. 4 bar.

After the extraction

• Close container valve.

• Disconnect container from the plant.

• Screw on valve protection nuts.

• Screw on protection cap.

2.3 Checking the tightness

Before commissioning check the tightness of the whole plant.

Therefor see chapter 5.2.2 Checking the tightness of the vacuum

lines, Inspections before commissioning

2.4 Constructional requirements of chlorination plants

All chlorine rooms

Fig. 6 Warning sign DIN 4844

– Warning sign according to DIN 4844 part 1 no. 4.2, to be

installed at entrances

Fig. 7 Supplementary sign

– Supplementary sign according to DIN 4844 part 1 no. 4.5, to

be installed at entrances

Fig. 8 Mandatory sign

– Mandatory sign according to DIN 4844 part 1 no. 4.3, to be

installed inside the rooms

Fig. 9 Instruction sheet for first aid

• Instruction sheet for first aid in case of chlorine gas

intoxications, to be installed inside the rooms

• Maximum temperature: 40 °C

– recommended temperature: 18-20 °C

– recommended minimal temperature: 15 °C

• Overpressure lines of dosing equipment must not end in the

open air

• Chlorine rooms must not be dedicated for the permanent stay

of people.

• Only chlorine containers and the chlorination plant may be

present in the rooms.

Warning

Chlorine containers must never have a higher

temperature than other parts of the plant. Danger of

liquefaction and possible chlorine break-out!

Caution

At 15 °C about 1 % (DIN 19607) of the content can

be withrawn per hour. In case of higher withdrawal

danger of malfunction by the formation of ice on

containers and piping!

Container size Withdrawal quantity

50 Kg 500 g/h

65 Kg 650 g/h

500 Kg 5 Kg/h

1000 Kg 10 Kg/h

Caution

Do not completely evacuate the chlorine drums.

Danger of withdrawing deposits!

Caution

Immediately close connection lines.

No moisture must get into the lines!

TM04 0699 0908TM04 0700 0908TM04 0701 0908TM04 0702 0908

Chlorination unit

Acces only for

instructed persons

asdajlk llasdf lalsdk lasdlfkl lasdkjasdlklj jlakjlkjdl alsdfkljkj asdlklk lalsdk asdajlk llasd f lalsdk lasdlfkl lasdkjasdlklj jlakjlkjdl alsdfkljkj

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sdk asdajlk llasdf lalsdk lasdlfkl lasdkjasdlklj jlakjlkjdl alsdfkljkj asdlklk lals

asdajlk llasdf lalsdk lasdlfkl lasdkjasdlklj jlakjlkjdl alsdfkljkj asdlklk lalsdk asdajlk llasd f lalsdk lasdlfkl lasdkjasdlklj jlakjlkjdl alsdfkljkj

asdajlk llasdf lalsdk lasdlfkl lasdkjasdlklj jlakjlkjdl alsdfkljkj asdlklk lalsdk

asdajlk llasdf lalsdk lasdlfkl lasdkja

asdajlk llasdf lalsdk lasdlfkl lasdkjasdlklj jlakjlkjdl alsdfkljkj asdlklk lalsdk asdajlk llasd f lalsdk lasdlfkl lasdkjasdlklj jlakjlkjdl alsdfkljkj

asdajlk llasdf lalsdk lasdlfkl lasdkjasdlklj jlakjlkjdl lalsdk

sdk asdajlk llasdf lalsdk lasdlfkl lasdkjasdlklj jlakjlkjdl alsdfkljkj asdlklk lalsdk asdajlk llasdf lalsdk lasdlfkl lasdkjasdlklj jlakjlkjdl alsdfkljkj

First aid in the case of

CHLORINE GAS POISONNING

HEALTH DANGERS

FIRST AID

English (GB)

Rooms with pressure lines (e. g. storage rooms for chlorine

containers)

• Flat, even floor

– not below ground level

– not higher than a possible loading ramp

Fig. 10 Regulations for chlorine rooms (1)

Fig. 11 Regulations for chlorine rooms (2)

• Direct exit to the open air

•Lockable

– doors must open outwards

– it must be possible to open the doors without a key from

inside the room

• No connection to other rooms

– separated gastight and fire-resistant from other rooms

• A maximum of two vent holes of max. 20 cm

each

• Water sprinkling system

– for precipitating escaping chlorine gas

– operation must be possiple by hand from outside the

chlorine rooms

– sufficiently dimensioned run-off with air trap

• Chlorine gas warning system

– with optical and acoustical alarm

– coupled to the water sprinkling system

– coupling must reactivate automatically after having switched

off (e. g. for container exchange)

• Chlorine gas must not be able to get into lower-lying rooms,

shafts, pits, canals or aspirating holes of ventilation systems.

2.5 Principle function of the components

Fig. 12 Components of a chlorinator

2.5.1 Vacuum regulator

• Reduces the gas pressure (overpressure) to subatmospheric

pressure (vacuum)

2.5.2 Measuring tube

• Displays the gas flow

2.5.3 Rate valve

• For adjustment of the required gas flow

– manually or automatically

2.5.4 Differential pressure regulator (option): VGA-117)

• Regulates the difference of the pressures before and after the

rate valve to a constant value

– Adjusted dosing flow stays constant even when the injector

vacuum varies.

2.5.5 Vacuummeter (option): VGA-117)

– Displays the injector vacuum

2.5.6 Injector

– Creates the vacuum necessary for operating the pant

– Mixes the chlorine gas with the water

TM04 0703 0908TM04 0704 0908

✓

TM04 0705 0908

Motive water

Vacuum regulator

Measuring

tube

Gas Dosing System

Differential

pressure

regulator

Vaccum

meter

Injector

Rate Valve

Chlorine gas

English (GB)

2.6 List of valid laws and regulations (in Germany)

Laws and Regulations

DVGW-Rules

BGBl. I 1975 S. 729

Verordnung über Arbeitsstätten (Arbeitsstättenverordnung - ArbStättV)

Regulations concerning places of work (ArbStättV)

BGBl I 1980 S. 173, 184

Verordnung über Druckbehälter, Druckgasbehälter und Füllanlagen (Druckbehälterverordnung - DruckbehV)

mit technischen Regeln Druckbehälter (TRB) mit technischen Regeln Druckgase (TRG)

Regulations concerning pressure containers, gas cylinders and filling systems (pressure containers -

DruckbehV) with technical rules for pressure containers (TRB) with technical rules for pressure gases (TRG)

BGBl I 1986 S. 1470

Gefahrstoffverordnung (GefStoffV)

Regulations for hazardous materials (GefStoffV)

BGBl I 1975 S. 2494

Verordnung über gefährliche Arbeitsstoffe (Arbeitsstoffverordnung - ArbStoffV)

Regulations for hazardous work materials (ArbStoffV)

GUV 0.1

Unfallverhütungsvorschrift "Allgemeine Vorschriften"

Regulations for accident prevention "General Regulations"

GUV-V D5

Unfallverhütungsvorschrift "Chlorung von Wasser"

Regulations for accident prevention "Chlorination of water"

GUV 49.1

Prüfliste zur Unfallverhütungsvorschrift "Chlorung von Wasser"

Checklist for Regulations for accident prevention "Chlorination of water"

GUV 0.3

Unfallverhütungsvorschrift "Erste Hilfe"

Regulations for accident prevention "First-Aid"

GUV 20.5

Merkblatt "Anleitung zur ersten Hilfe bei Unfällen"

Leaflet "Instructions for First-Aid in case of accidents"

GUV 20.6

Merkblatt "Verbandzeug für die erste Hilfe bei Unfällen"

Leaflet "Dressing material for First-Aid in case of accidents"

GUV 20.14

Atemschutzmerkblatt

Leaflet for the protection of the air

GUV 29.6

Merkblatt "Über den Umgang mit ätzenden Stoffen"

Leaflet "Handling of caustic materials"

GUV 60.3G26

Grundsatz für arbeitsmedizinische Vorsorgeuntersuchungen "Träger von Atemschutzgeräten für Arbeit und

Rettung" G 26

Principle for preventive industrial medicine checkup "Wearers of respiratory equipment for work and rescue"

G26

GUV 2.6

Unfallverhütungsvorschrift "Druckbehälter"

Regulations for accident prevention "Pressure containers"

GUV 2.10

Unfallverhütungsvorschrift "Elektrische Anlagen und Betriebsmittel"

Regulations for accident prevention "Electrical installations and resources"

GUV 9.9

Unfallverhütungsvorschrift "Gase"

Regulations for accident prevention "Gases"

ZH1/230

Merkblatt "Chlor"

Leaflet "Chlorine"

CEFIC

Unfallmerkblatt für den Straßentransport "Chlor" Klasse 2, Ziffer 3 at UN 2201

Accident leaflet for the road transport "Chlorine" Class 2, Number 3 at UN 2201

BGBl I 1985, S. 1550

Verordnung über die Beförderung gefährlicher Güter auf der Straße - Gefahrgut Vstr/GGVS - Klasse 2, Ziffer

3 at

Regulations for the transport of dangerous goods on the road - Gefahrgut Vstr/GGVS - Class 2, Number 3 at

GGVE

Gefahrgutverordnung Eisenbahn, Klasse 2, Ziffer 3 at)

Regulations for dangerous goods on trains, Class 2, Number 3 at)

RID

Internationale Verordnung für die Beförderung gefährlicher Güter mit der Eisenbahn - Klasse 2, Ziffer 3 at

International regulations for the transport of dangerous goods by train - Class 2, Number 3 at

BGBl I 1977, S. 1119

Verordnung über die Beförderung gefährlicher Güter auf dem Rhein (ADNR)

Regulations for the transport of dangerous goods on the Rhine (ADNR)

W203

Begriffe der Chlorung

Concept of chlorination

EW230

Einsatz von Betriebsmeßgeräten zur Kontrolle der Wassergüte und der Wasseraufbereitung

Use of operation measuring devices for the control of the water quality and the water treatment

W291

Desinfektion von Wasserversorgungsanlagen

Disinfection of water supply plants

EW623

Dosieranlagen für Desinfektions- bzw. Oxidationsmittel - Dosieranlagen für Chlor

Dosing units for disinfection or oxidation with chlorine

W640

Überwachungs-, Meß-, Steuer- und Regeleinrichtungen in Wasserwerken

Systems for monitoring, measurement, control and regulation in waterworks

DVGW-Merkblatt Arbeitshilfe zur Erstellung einer örtlichen Betriebsanweisung für Chlorungsanlagen unter

Verwendung von Chlorgas

DVGW leaflet Aid for the creation of a local manual für chlorination systems using chlorine gas

English (GB)

Standards

2.7 Recommended diameter

2.7.1 Between vacuum regulator and dosing regulator

Grundfos company standard calculated with pressure drop p = 12.5 mbar

The indications in this table result from pressure loss observations. They do not take into consideration the possible influence of length

and diameter of lines on the operational reliability of the system.

2.7.2 Between dosing regulator and injector

Grundfos company standard calculated with pressure drop p = 50 mbar

The indications in this table result from pressure loss observations. They do not take into consideration the possible influence of length

and diameter of lines on the operational reliability of the system.

DIN 19606

Chlorgasdosieranlagen zur Wasseraufbereitung

Chlorine gas dosing systems for water treatment

DIN 19607

Chlor zur Wasseraufbereitung

Chlorine for water treatment

DIN EN 937

Chlor zur Aufbereitung von Wasser für den menschlichen Gebrauch

Chlorine for the treatment of water for the human use

DIN 19643

Aufbereitung von Schwimm- und Badewasser

Treatment of swimming pool and bathing water

DIN 3179, Teil 1,2

Einteilung der Atemgeräte, Übersicht

Division of the respiratory equipment, overview

DIN 4102, Teil 2

Brandverhalten von Baustoffen und Bauteilen

Behaviour in fire of building materials and parts

DIN 477, Teil 1

Gasflaschenventile; Bauformen, Baumaße, Anschlüsse, Gewinde

Gas cylinder valves; forms, measurements, connections, threads

Length of the

vacuum line in [m]

Dosing quantity [g/h]

500 1000 2000 4000 10000 20000 40000 70000 120000 200000

0 DN 8 DN 8 DN 8 DN 10 DN 15 DN 20 DN 25 DN 32 DN 40 DN 40

10 DN 8 DN 8 DN 8 DN 10 DN 15 DN 20 DN 25 DN 32 DN 40 DN 50

20 DN 8 DN 8 DN 10 DN 15 DN 20 DN 25 DN 32 DN 40 DN 40 DN 50

30 DN 8 DN 8 DN 10 DN 15 DN 20 DN 25 DN 32 DN 40 DN 50 DN 65

40 DN 8 DN 8 DN 15 DN 15 DN 20 DN 25 DN 32 DN 40 DN 50 DN 65

50 DN 8 DN 10 DN 15 DN 15 DN 20 DN 25 DN 32 DN 40 DN 50 DN 65

75 DN 8 DN 10 DN 15 DN 15 DN 25 DN 32 DN 40 DN 50 DN 65 DN 65

100 DN 8 DN 10 DN 15 DN 20 DN 25 DN 32 DN 40 DN 50 DN 65 DN 80

Length of the

vacuum line in [m]

Dosing quantity [g/h]

500 1000 2000 4000 10000 20000 40000 70000 120000 200000

0 DN 8 DN 8 DN 8 DN 8 DN 15 DN 15 DN 20 DN 25 DN 32 DN 40

10 DN 8 DN 8 DN 8 DN 8 DN 15 DN 15 DN 20 DN 25 DN 32 DN 40

20 DN 8 DN 8 DN 8 DN 10 DN 15 DN 20 DN 25 DN 25 DN 40 DN 40

30 DN 8 DN 8 DN 8 DN 10 DN 15 DN 20 DN 25 DN 32 DN 40 DN 40

40 DN 8 DN 8 DN 8 DN 10 DN 15 DN 20 DN 25 DN 32 DN 40 DN 50

50 DN 8 DN 8 DN 10 DN 15 DN 15 DN 20 DN 25 DN 32 DN 40 DN 50

75 DN 8 DN 8 DN 10 DN 15 DN 20 DN 25 DN 32 DN 40 DN 40 DN 50

100 DN 8 DN 8 DN 10 DN 15 DN 20 DN 25 DN 32 DN 40 DN 50 DN 65

English (GB)

3. Technical Data

3.1 General Data

3.1.1 Dosing flow

3.2 Data of the accessory components

3.2.1 Servomotor with reversing potentiometer

Fig. 13 Servomotor with reversing potentiometer

Permissible medium Cl

Deviation of linearity ± 4 % of upper limit

Deviation of reproducibillity ± 2 % of upper limit

Control range 1:20

Connections VGS-141 (up to 10 kg/h) DN 10, for PVC-pipe DN 10 or PE-tube 10/14

Connections VGS-143 (up to 40 kg/h) DN 20, for PVC-pipe DN 20

Connections VGS-145 (up to 200 kg/h) DN 40, for PVC-pipe DN 40

Materials Polyurethan (enclosure), PVC, FEP, PTFE, FKM, Copper-nickel alloy and a special alloy

Type Dosing flow

VGS-141

10-200 g/h 0.5 - 10.5 #/day

25-500 g/h 2-26 #/day

50-1000 g/h 3-52 #/day

100-2000 g/h 5-100 #/day

200-4000 g/h 10-200 #/day

400-8000 g/h 20-420 #/day

500-10000 g/h 30-520 #/day

VGS-143

1-20 kg/h 50-1050 #/day

2-40 kg/h 100-2100 #/day

VGS-145

3.5 - 70 kg/h 200-3700 #/day

6-120 kg/h 400-6200 #/day

10-200 kg/h 500-10500 #/day

TM04 0956 4009

Item Description

SR, limit switch cam min.

SL, limit switch cam max.

2 Mains voltage input

3 Potentiometer input/output

4 Earth terminal

Mains voltage

220-240 V ± 10 %, 50/60 Hz ± 5 %,

100 % on time (standard)

110-120 V ± 10 %, 50/60 Hz ± 5 %

24 V AC ± 10 %, 50/60 Hz ± 5 %

Rated current

30 mA (at 230 V),

60 mA (at 115 V),

240 mA (at 24 V)

Limit switch - load

capacity

2 A at 250 V

Power consumption Approx. 2 VA

Control variant

Reversingpotentiometer 1 kΩ

Open/close signal

Actuating time

90 s for 270 ° at 50 Hz

75 s for 270 ° at 60 Hz

Adjustment angle Max. 270 °

Degree of protection IP65

Permissible ambient

temperature

-15 °C to 60 °C

Weight 2.6 kg

English (GB)

3.2.2 Servomotor with analogue control

Fig. 14 Servomotor with analogue control

3.2.3 Manual/automatic remote indication of the position of

the rate valve adjusting spindle

3.2.4 Vacuum meter with limit contacts

3.2.5 Vacuum sensors

TM04 0956 4009

Item Description

SR, limit switch cam min.

SL, limit switch cam max.

2 Programming buttons

3 Alarm output

4LEDs

5 DIP switch

6 Mains connection terminals

7 Analogue signal connection terminals

8 Earth terminal

Mains voltage

220-240 V ± 10 %, 50/60 Hz ± 5 %, 100 %

on time (standard)

110-120 V ± 10 %, 50/60 Hz ± 5 %

24 V AC ± 10 %, 50/60 Hz ± 5 %

Rated current

30 mA (at 230 V),

60 mA (at 115 V),

240 mA (at 24 V)

Limit switch -

load capacity

2 A at 250 V

Power consumption Approx. 2 VA

Control variant

Analogue control

Input/Output

Signal input/output

4-20 mA (standard setting)

0-20 mA (switchable)

Setpoint input

4(0) - 20 mA (DC)

Load 250 Ω

Overload protection 25 mA

Protection against reverse polarity to -

25 mA

ESD protection, input filter

Resolution: 10 bits

Actual value output

4(0) - 20 mA

Max. load 500 Ω

Resolution: 10 bits

Carrying capacity

of signal output

Output current: 4-20 mA

Minimum voltage for

open circuit 10 V

Potentiometer 1000 Ω

Actuating time

90 s for 270 ° at 50 Hz

75 s for 270 ° at 60 Hz

SET

Adjustment angle Max. 270 °

Degree of

protection

IP65

Permitted ambient

temperature

0 °C to 60 °C

Weight 2.6 kg

Loading capacity of the Reed contact

Switched power max. 10 W

Switched current max. 0.5 A

Switched voltage max. 200 V (DC)

Carry current 1.0 A

Contact resistance 150 mΩ

Breakdown voltage min. 250 V (DC)

Degree of protection IP65

Note

The switch is closed in automatic position!

Measuring

range

-10 to 0 m WS rel.

Limit contact

outputs

slow-motion contacts S 21 according to DIN 16085

(E)

1st limit contact: break contact (opens when the

specified value is passed clockwise)

2nd limit contact: make contact (closes when the

specified value is passed clockwise)

Permissible

contact load

voltage

ohmic

load

inductive load in case of

alternating current (cos > 0.7)

230 V AC 45 mA 25 mA

110 V AC 90 mA 45 mA

24 V DC 200 mA -

Measuring range -1 to 0 bar rel.

Current output

4-20 mA

4 mA equals to -1 bar

20 mA equals to 0 bar

Power supply 24 V DC

Neccessary cable for

current signal

2-wire, shielded, order no. 96687719

(321-130)

Mains voltage

220-240 V ± 10 %, 50/60 Hz ± 5 %, 100 %

on time (standard)

110-120 V ± 10 %, 50/60 Hz ± 5 %

24 V AC ± 10 %, 50/60 Hz ± 5 %

English (GB)

3.2.6 Measuring transducer

3.2.7 Measurement and Control Electronics Conex

• See operation manual of measuring amplifiers and controller

Conex

DIA-2Q or controller Conex

DIS-2Q.

3.3 Dimensioned drawing

Fig. 15 Dimensional drawings of gas dosing systems VGS-141, VGS-143 and VGS-145

Measuring range

1:10

Below a dosing flow of 10 % no precise

measurement is possible. The current

signal 4 mA may probably not be

reached at a dosing flow of 0 %.

Deviation of linearity

< ± 4 % from upper limit of the

measuring range

Current output

4-20 mA

4 mA equals to 0 % dosing flow

20 mA equals to 100 % dosing flow

Power supply 24 V DC

Maximum load 600 Ω

Power consumption > 0.5 W

Degree of protection IP65

Degree of protection 0 °C to + 60 °C

TM04 0809 09086

390

450

1000

1810

760 (DN 20)

730 (DN 40)

1000

610

375

30 45

505

52,5

740

200

325

English (GB)

4. Installation

4.1 Transport and storage

• Handle with care, do not throw!

• Dry and cool storage place.

4.2 Unpacking

• Observe when unpacking:

– No humidity should get into gas-leading parts!

– No foreign matter should get into gas-leading parts!

• Mount as soon as possible after unpacking.

Only for devices without foot for floor mounting:

• Do not place the device standing on the pipe pieces!

Fig. 16 Gas dosing system without foot for floor mounting

4.3 Storage/Downtimes

• Store the servomotor in a well ventilated, dry room on a pallet

or rack (protected from moisture). Cover it with foil to protect it

from dust and dirt.

• Prevent condensation from forming (e.g. if the temperature

fluctuates).

If the servomotor is to be stored for longer than 4 months,

observe the following points too:

• Insert a layer of absorbent material underneath the drive's

cover.

Keep the gas dosing system in a dry, cool place.

4.4 Installation

General notes on installation

• Check the cable entries and dummy plugs for tightness.

• Tighten the hood screws so they are all equally tight.

• Continuously overloading and blocking the drive will damage

it.

• Spark-quenching capacitors may adversely affect the drives'

direction of rotation and result in damage.

Cable entries

• When storing, installing and commissioning the servomotor,

care must be taken to ensure that the cable entries have been

properly sealed. Only cables appropriate for the diameter of

the cable entries must be used.

Installing the hood

• When installing the hood, you must ensure that the O-rings

underneath the hood screws and the O-ring in the drive

housing are properly seated.

• The connection face of the hood must not show any signs of

damage.

• Tighten the hood screws equally.

Housing/Hood

• No additional bores may be drilled into the drive housing or the

hood.

Warning

Only for devices without foot for floor mounting: Do

not place the device standing on the pipe pieces!

TM04 0810 0908

Caution

Screw the device onto a completely flat, smooth

surface only.

Danger of warping!

Warning

It is a basic fact that certain parts will carry a

dangerous voltage whenever electrical devices are

operated. Only electricians or trained persons

instructed and supervised by a specialist electrician

may carry out work on electrical installations or

equipment and the relevant electrotechnical rules

must be observed.

Warning

When undertaking installation, commissioning and

testing work, all applicable safety and accident

prevention regulations must always be observed.

Warning

Before you start any (installation) work of any kind on

the drive, make sure that all affected machines/

installations are switched off.

Note

It is essential that you read this instruction manual

prior to carrying out installation and commissioning.

Warning

The servomotor may only be fitted by a qualified

specialist.

Note

When a gas dosing system with servomotor is

ordered, the servomotor is installed on the gas

dosing system ready for connection.

English (GB)

4.4.1 Devices without foot (wall mounting)

• Fix drilling jig to the desired place

• Mark the bore holes and bore them

• Put in dowels

• Screw the device to the wall

4.4.2 Devices with foot (floor mounting)

• Place the device at the desired place

• Mark the bore holes

• Remove the device

• Bore the holes

• Put in dowels

• Place the device at the desired place

• Screw the device to the floor

4.5 Replacing the electrical servomotor

Use the hand wheel to set the dosing flow to the 0 % position.

Insert the close-tolerance grooved pin (carrier) into the hand

wheel's servomotor shaft and use 4 nuts (spanner size 10) to

flange-mount the servomotor on the gears.

Scope of delivery of the electrical servomotor

Servomotor, washer discs and nuts

Required tools

Size 10 flat spanner

Checking the 0 % position

The servomotor is set to the 0 % position on delivery.

5. Commissioning

5.1 Preparations for commissioning

5.1.1 Electrical connections

Servomotor with analogue control (optional)

Fig. 17 Circuit diagram for a servomotor with analogue control

Servomotor with analogue control (optional), connected, for

example, to a Conex

DIA-2Q

• Connect the terminals to the corresponding terminals on the

external controller as shown in the connection diagram.

Fig. 18 Terminal connection diagram for Conex

DIA-2Q

Warning

When replacing a gas dosing system with an

electrical servomotor, you must observe the

instructions and warnings contained in Sections

5.1.1 Electrical connections, 5.2.4 Servomotor tests

and 6. Operation.

Warning

Never install a damaged drive.

Warning

Switch off mains before connecting!

Electrical connections only by qualified personnel!

Observe local rules for electrical installations!

Note

Depending on the selection of optional components:

Mains connection either directly (by the customer) or

via the clamp box.

TM04 0950 4009TM04 0951 4009

4(0) - 20 mA

max. 125 V

L1 N PE

Fault message

30 29

Conex DIA-2Q

4(0) - 20 mA

max. 125 V

English (GB)

5.1.2 Servomotor with analogue control (optional), connected, for example, to a Conex

DIS-2Q (microprocessor-based controller)

• Connect the terminals to the corresponding terminals on the external controller as shown in the connection diagram.

Fig. 19 Terminal connection diagram for Conex

DIS-2Q on a servomotor with integrated electronics

1. Unscrew the hood screws and remove the hood.

2. Establish the electrical connections in accordance with the

circuit diagram; see fig. 18.

– Connect terminals 51 and 52 and, if required, terminals 54

and 55, in accordance with the circuit diagram.

– Connect terminals 56 and 57 in accordance with

requirements; voltage 125 V max.

– Use separate, shielded lines with a minimum cross-section

of 0.5 mm

and a maximum length of 1000 m for low

voltages (setpoint/actual value signal lines).

– The screen must be connected on one side to the housing

earth (earth terminal).

• Close the hood again and tighten the hood screws.

Servomotor - with reversing potentiometer (optional)

Fig. 20 Terminal connection diagram for servomotor with

reversing potentiometer

TM04 0952 4009

15 16 17 18 19

21 22 23 24 25 26

L1 N PE

1 2 3 4 5 6 7 8 9 10 11121314

4(0) - 20 mA

max. 125 V

Item Description

L Phase

Mains voltage input

N Neutral

PE (earth)

51 Signal input (-)

52 Signal input (+)

54 Signal output (-)

55 Signal output (+)

Collective error message

Note

See Section 5.2.4 for warnings and notes relating to

electrical connection!

Warning

The internal wiring of the drive must never be

modified.

TM04 0953 4009

Item Description

1 N Neutral

2 Phase

Mains voltage input

(for direction "open/max.")

3 Phase

Mains voltage input

(for direction "close/min.")

Mains voltage output

(position "final position max.")

Mains voltage output

(position "final position min.")

PE (earth)

18 Start

19 Slider

20 End

open

min.

max.

18 19

< 50 V

start

slider

end

< 50 V

SL (max.)

SR (min.)

Motor control

feedback potentiometer

Limit switches

English (GB)

• Connect the terminals to the corresponding terminals on the external controller (Conex

DIS-2Q in the example) as shown in the

connection diagram.

Fig. 21 Terminal connection diagram for Conex

DIS-2Q on a servomotor with reversing potentiometer

Electrical connection

1. Unscrew the hood screws and remove the hood.

2. Establish the electrical connections in accordance with the

circuit diagram; see fig. 20.

– Connect terminals 18, 19 and 20 in accordance with

requirements; voltage < 50 V.

3. Determine the direction of rotation and, if necessary, correct it.

Determining the direction of rotation

The internal wiring means that the direction of rotation (looking

through the drive towards the output shaft) and limit switches are

assigned as follows:

• If the mains voltage is present at terminal 2, the output shaft

rotates anticlockwise (in the direction "open/max.").

– This direction of rotation is restricted by the upper switch

(max.). If the switch is activated, the mains voltage is

present at terminal 4.

• If the mains voltage is present at terminal 3, the output shaft

rotates clockwise (in the direction "close/min.").

– This direction of rotation is restricted by the lower switch

(min.). If the switch is activated, the mains voltage is present

at terminal 5.

• If the drive rotates in the opposite direction to the control

commands, swap over the connections of terminals 2 and 3.

Close the hood again and tighten the hood screws.

Vacuum meter with limit contacts (option)

• Connect the terminals of the plug with the corresponding

terminals of an external evaluation device according to the

connection chart.

Fig. 22 Connection chart vacuum of meter with limit contacts

Vacuum sensors (option)

• Connect the terminals of the plug with the corresponding

terminals of an external evaluation device according to the

connection chart.

Fig. 23 Connection chartof vacuum sensor

TM04 0954 4009

15 16 17 18 19 20 21 22 23 24 25 26

1 2 3 4 5 6 7 8 9 10 11 12 13 14

IDM

SL (max.)

SR (min.)

open

min.

max.

18 19

< 50 V

start

slider

end

< 50 V

potential-free relay outputs

Measuring amplifier

Feedback potentiometer

Note

See Section 5.2.4 for warnings and notes relating to

electrical connection!

Warning

The internal wiring of the drive must never be

modified.

TM04 0813 0908TM04 0814 0908

24 V DC

4-20 mA

English (GB)

Measuring transducer (option)

• Connect the terminals of the plug with the corresponding

terminals of an external evaluation device according to the

connection chart.

Fig. 24 Connection chart of measuring transducer

5.1.3 Measurement and Control Electronics Conex (option)

• see operation manual of measuring amplifiers and controller

Conex

DIA-2Q or controller Conex

DIS-2Q

5.1.4 Chlorine measuring cell (option)

• see operation manual of the chlorine measuring cell

5.1.5 Mounting the manual/automatic position remote

indication at the rate valve

This indication shows e.g. in the switch room, if the optional

servomotor is engaged and thus able to convert the incoming

signals.

• Loosen the cover of the adjustment knob with a big

screwdriver; take off the adjustment knob.

• Put the magnetic bridge sensor (item 5.6) into the lower cavity

of the gearbox bearing and fasten using the two recessed

head screws (item 5.7).

• Disassemble the adjustment knob by fully screwing out the

clamping nut.

• Insert the adjustment knob tongs into the washer disc (item

5.5) in a way that the tongs collar is in the washer disc.

• Apply the washer disc to the adjustment knob enclosure so

that the holding pin of the enclosure dips into the hole of the

washer disc.

• Slide the spring washer over the adjustment knob tongs and

screw the clamping nut onto the tongs.

• Put the adjustment knob onto the gearbox spindle as far as it

will go and tighten the clamping nut.

• Fit the cover of the adjustment knob again.

Fig. 25 Manual/automatic position indication

5.1.6 Gas connections

• Connect line from vacuum regulator

• Connect line to injector

Fig. 26 Gas connections of gas dosing systen VGS

5.2 Checks before commissioning

Check tightness of the total plant before start-up

5.2.1 Checking the gas solution lines and the diapgragm non-

return of the injector

• Observe the manual of the injector!

5.2.2 Checking the tightness of the vacuum lines

Vacuum lines are all lines between vacuum regulator and injector.

• Close all container valves

• Close the rate valve

• Open the shut-off valve at the injection unit

• Open motive water valve

• Switch on the booster pump

• Open the rate valve

Floater shows gas flow or vacuummeter shows more than -

9m w.c. => Leakage in vacuum line!

• Close rate valve

• Switch off booster pump

• Close motive water valve

• Close the shut-off valve at the injection unit

• Check the vacuum lines and the connection. If necessary,

• carefully re-tighten them.

• Check tightness again!

– Floater shows no gas flow, vacuummeter shows -9 m w.c. or

less => Vacuum lines are tight.

TM04 0815 0908TM04 0859 0908

24 V DC

4-20 mA

5.1

5.14

5.13

5.12

5.7

5.6

5.5

Warning

Ensure that all container valves are closed before

connecting!

Only use the intended gas lines!

TM04 0816 0908

Warning

Check the tightness not until the total plant is ready

for start-up.

Danger of chlorine break-out!

Note

More possible reasons for insufficient operating

vacuum

• injector layed out too weakly or defective

• injector obstructed

• booster pump layed out too weakly or defective

to injector

from vacuum regulator

English (GB)

5.2.3 Checking the tightness of pressure gas lines

Pressure gas lines are all lines from the gas containers to the

vacuum regulator.

• If the plant is equipped with a nitrogen rinsing device:

Check tightness roughly with nitrogen.

• Detailed checking with amonia.

Checking the tightness with nitrogen

• Close all container valves

• Open container connection valves and all shut-off valves up to

the gas dosing system

• Open the connection valve of the nitrogen cylinder

• Slowly open the valve of the nitrogen cylinder, until the lines

have a pressure of about 10 bar (read at the manometer of the

vacuum regulator).

• Apply soap water to all components under pressure

– Formation of bubbles and/or pressure drop at manometer:

Leakage in pressure lines!

Depressurize the plant!

Eliminate leakage!

Check tightness again!

No formation of bubbles, pressure at manometer does not drop

significantly within one hour: Pressure lines are tight.

Checking the tightness with ammonia

• Open all container valves and container connection valves and

quickly close them again

• Slowly pass the open ammonia bottle along pressure-gas

leading parts

• Formation of white mist: Leakage in pressure lines!

Depressurize the plant!

Eliminate leakage!

Check tightness again!

Fig. 27 Formation of white mist: Leakage in pressure lines!

– No formation of white mist: Pressure lines are tight.

Fig. 28 No formation of white mist

Fig. 29 Danger of leakages

5.2.4 Servomotor tests

5.2.5 Checking the servomotor's direction of rotation

The servomotor is controlled by an external controller. This

means that the servomotor's direction of rotation depends on the

controller's cabling and settings being correct.

Warning

Maximum nitrogen pressure 16 bar!

Danger of damages and chlorine break-out when

being exceeded!

TM04 0849 0908TM04 0697 0908

Warning

Liquid ammonia must not come in contact with parts

of the plant!

Danger of leakages by corrosion!

TM04 0698 0908

Warning

The drive may only be commissioned if the hood and

cable entries are properly closed.

Warning

Please note that the process of commissioning the

drive will cause associated fittings/levers/rodding to

move.

Warning

Check that all the emergency equipment/functions on

your installation are working correctly.

Warning

Once all adjustment work has been completed,

check that the drive and the fittings/levers, etc.

operated by it are working correctly.

Warning

Never work with a damaged drive.

Caution

When commissioning, all the installation's

components must be ready for operation.

Note

Follow the installation and operating instructions for

the components used.

Note

Observe the installation and operating instructions

for the controller and the gas dosing system.

English (GB)

6. Operation

6.1 Description of the system

Fig. 30 Functional scheme VGS-141, -143, -145

Fig. 31 Front hood to take off, with swing-out clear vision flap

TM04 0819 4917

TM04 0820 4917

Item Component Description

1 Line to the injector

2 Differential pressure regulator

It regulates the difference of the pressures before and after the rate valve to a

constant value.

• Adjusted dosing flow stays constant, even when the injector vacuum fluctuates.

• with electronic vacuum sensor (option)

3 Electronics (option)

Measuring amplifier for the chlorine concentration Conex

DIA-2Q or Conex

DIS-2Q

• amplifies the signal of the optional measuring cell

4 Clamp box (option)

5Servomotor

6 Rate valve

Adjusting the desired gas flow

• manually with the hand wheel

• automatically with an electrical servomotor (5) (option)

• servomotor can optionally be equipped with a 4 - 20 mA signal input for

proportional control (no further electronics necessary)

7 Measuring tube

Displays the gas flow

• with magnetic detection of the floater position (option)

8 Vacuummeter

Displays the injector vacuum

• with limit contacts (option)

Sensor for the operation vacuum

(option)

For measuring the vacuum at the inlet of the gas dosing system

10 Line from the vacuum regulator

11 Foot

Front hood (17) to take off, with swing-

out clear vision flap (18)

Caution

The rate valve is not a perfectly closing shut-off

valve!

English (GB)

6.2 Increasing the dosing flow manually

• Open the flap

• Turn hand wheel slowly to the right

• Close the flap

Fig. 32 Adjusting the dosing flow

6.3 Reducing the dosing flow manually

• Open the flap

• Turn hand wheel slowly to the left

• Close the flap

Fig. 33 Decreasing the dosing flow

6.4 Engaging the servomotor

• Open the flap

• Turn the hand wheel as far as it will go to the left.

• Push the hand wheel upwards, whilst slowly turning to the

right, until it locks into place.

• The servomotor is now connected to the regulating valve and

the hand wheel is blocked.

• Close the flap

Fig. 34 Automatic adjusting of the dosing flow

6.5 Disengaging the servo motor

• Open the flap

• Push the hand wheel downwards and the servomotor will

disengage.

• Now the dosing flow can be adjusted by hand

• Servomotor is disconnected from rate valve

• Close the flap

Fig. 35 Manual adjusting of the dosing flow

6.6 Operating the servomotor

6.6.1 Servomotor with reversing potentiometer

6.6.2 Servomotor with analogue control

Displays/Control elements

Status LEDs

The status LEDs indicate the operating state of the servomotor.

Fig. 36 LEDs

(from right to left)

DIP switch

The DIP switch is used to reprogram the final positions and define

the direction of rotation.

On delivery, the switches are set to the "Inverse" direction of

rotation (= normal) and "Automatic" (= operation).

Fig. 37 DIP switch

TM04 0821 0908TM04 0822 0908TM04 0823 0908TM04 0824 0908

Warning

The terminals at the limit switches are live when the

switch closes.

Note

During operation, all functions are controlled by an

external controller.

Observe the installation and operating instructions

for the controller and the gas dosing unit.

Warning

Do not touch bare wires or clamping screws!

TM04 0957 4009

Item Description

1 Red LED: Fault

2 Blue LED: Operation

Green LED:

Clockwise rotation (in the direction "close/min.")

Yellow LED: Anticlockwise rotation (in the direction

"open/max.")

TM04 0958 4009

Item Description

Switch "inv./ " Reversing the effective direction

Switch "Auto/Man"

Operation (Auto)

Programming (Man)

Man.

Inv.

Auto

On =

Inv. =

Auto =

Man. =

English (GB)

Programming buttons

The programming buttons are used to reprogram the final

positions. In closed-loop control (DIP switch set to "Auto"), none

of the programming buttons work.

Fig. 38 Programming buttons

6.6.3 Reprogramming the setpoint range, final positions and

control direction

Setpoint range

In the factory settings, the setpoint range is set to 4-20 mA.

To change from 4-20 mA to 0-20 mA:

1. Disconnect the power to the servomotor.

2. Hold the SET and R buttons down.

3. With the buttons held down, switch the mains voltage on.

To change from 0-20 mA to 4-20 mA:

1. Disconnect the power to the servomotor.

2. Hold the SET and L buttons down.

3. With the buttons held down, switch the mains voltage on.

Final positions

In the factory settings, the left (max.) final position is set to

100 % stroke at 20 mA and the right (min.) final position to

0 % stroke at 4 (0) mA.

To reprogram the left final position:

1. Set the Man/Auto DIP switch to "Man".

2. Use the L/R buttons to approach the required left final

position.

3. Press the SET button (blue LED flashes) and then press the L

button within 3 seconds.

– The newly set left (max.) final position at 20 mA has now

been programmed.

To reprogram the right final position:

1. Set the Man/Auto DIP switch to "Man".

2. Use the L/R buttons to approach the required right final

position.

3. Press the SET button (blue LED flashes) and then press the R

button within 3 seconds.

– The newly set right (min.) final position at 4 (0) mA has now

been programmed.

Effective control direction

In the factory settings (or after the final positions have been

programmed), the left final position is set to 100 % stroke (or the

newly programmed max. final position) at 20 mA and the right

final position to 0 % stroke (or the newly programmed min. final

position) at 4 (0) mA.

To reverse the effective control direction to 0 (4) mA at the left

final position and 20 mA at the right final position:

1. Set the DIP switch to the "inv" (inverse) position.

To reset the effective control direction to 20 mA at the left final

position and 0 (4) mA at the right final position:

1. Set the DIP switch to the direction opposite to "inv"

(not inverse).

Completing programming work

1. To complete programming work, set the Man/Auto DIP switch

to "Auto".

2. Close the hood again and tighten the hood screws.

6.6.4 Error message

• Error message output: Connection terminals 56, 57

• Maximum permissible load: 125 V

• Red LED lights up if a contact is open.

The error message contact opens in the following instances:

• If there is a setpoint violation:

set

< 4 mA (only in mode 4-20 mA)

• If the "Man/Auto" switch is set to the "Man" position

(controller in programming mode).

• If there is no operating voltage.

6.6.5 Closed-loop control

6.7 Adjusting the Servomotor (option)

In case of repairs or exchange, it may be possible to readjust the

servomotor.

TM04 0959 4009

Item Description

Button "L"

Left: Servomotor moves in the direction "open/

max.".

Button "SET" Program final position

Button "R"

Right: Servomotor moves in the direction

"close/min.".

LRSet

Note

During closed-loop control, all functions are

controlled by an external controller.

Observe the installation and operating instructions

for the controller and the dosing system.

Note

If no mA input signal is present (depending on the

setpoint range that has been set, this will be 4 mA or

0 mA), the servomotor moves to the min. final

position (0 % or programmed min. final position).

Note

The servomotor is already adjusted by works if

ordered together with the system.

Warning

The servomotor may only be adjusted by qualified

personnel, as the mains power has to be switched

on.

Danger!

Do not touch bare wires or clamp screws!

English (GB)

6.7.1 Servomotor with reversing potentiometer

Fig. 39 Servomotor with reversing potentiometer

• Take off the cover of the servomotor.

• With the connected controller, move the servomotor to 0 %

dosing flow (as indicated at the measuring tube). The gear

rack at the rate valve must jut out for at least 1 mm.

Fig. 40 Setting the limit switches

• Set this position on the controller as the zero point. Set the

upper limit switch (SR, see fig. 39) to the equivalent

servomotor position.

• Set the controller to 10 %.

• Check the dosing flow indicated at the measuring tube. If it is

not 10 %:

• Adjust the zero point again. Possibly the floater reaches the

end stop at a dosing flow of more than 0 %.

• With the connected controller, move the servomotor to 100 %

dosing flow (as indicated at the measuring tube).

• The gear rack at the rate valve must jut out for maximum

31 mm.

• Set the lower limit switch (SL, see fig. 39) to the equivalent

servomotor position.

• Remount the cover of the servomotor.

6.7.2 Servomotor with analogue control

Fig. 41 Servomotor with analogue control

• Take off the cover of the servomotor.

• Connect the 4-20 mA current sensor to terminals 51 and 52

and set it to 4 mA.

• Use programming buttons R and SET to set the servomotor to

0 % dosing flow (as indicated by the measuring tube).

• The gear rack at the rate valve must jut out for at least 1 mm.

• Set the lower limit switch (SR) to a value slightly below 0 %.

• Set the current source to 5.6 mA (this corresponds to 10 %).

This and the following step cannot be done without a current

source.

• Check the dosing flow indicated by the measuring tube.

If this is not 10 %:

Reset the zero point. The floater may reach the end stop if the

dosing flow exceeds 0 %.

TM04 0956 4009

Item Description

SR, limit switch cam min.

SL, limit switch cam max.

2 Mains voltage input

3 Potentiometer input/output

4 Earth terminal

TM04 0826 0908

Caution

In case of undershoot: The rate valve may get

damaged!

min.

(ST1)

max.

(ST2)

+0,5

31 mm

+0,5

1 mm

Caution

In case of exceeding: The rate valve may get

damaged!

TM04 0956 4009

Item Description

SR, limit switch cam min.

SL, limit switch cam max.

2 Programming buttons

3 Alarm output

4LEDs

5 DIP switch

6 Mains connection terminals

7 Analogue signal connection terminals

8 Earth terminal

Note

For exact adjustment, a current source 4-20 mA is

necessary

Caution

In case of undershoot: The rate valve may get

damaged!

SET

English (GB)

• Set the current sensor to 20 mA. Use programming buttons L

and SET to set the servomotor to 100 % dosing flow

(as indicated by the measuring tube). The toothed rack on the

regulating valve must not protrude by more than 31 mm.

Fig. 42 Rate valve with gear rack

• Set the upper limit switch (SL) to a value slightly above 100 %.

• Remount the cover of the servomotor.

6.7.3 Manual operation of the servomotor

Fig. 43 Servomotor with analogue control

If necessary, the servomotor can also be operated manually.

• Remove the hood from the servomotor.

• Move the switch (item 5, 2) to 'Man'.

• Use programming buttons L or R (item 2) to move the

servomotor to the required position manually.

• Replace the hood on the servomotor.

Switch (item 5, 2) must be reset to 'Auto' for automatic mode.

6.8 Switching on

• Close the rate valve.

• Open the shut-off valve at the injection unit.

• Open the motive water valves.

• Switch on booster pump.

• Open valve of the gas container.

• Slowly open the rate valve until the desired gas flow is

displayed by the measuring tube.

6.9 Switching off

6.9.1 Emergency

• Put on safety equipment!

• Immediately close all container valves.

• Let the plant run until all parts are evacuated from the dosing

medium.

• Switch off the plant as described in the following.

6.9.2 Short-term stop (up to 6 hours)

• Close the rate valve.

• Switch off the booster pump.

• Close the motive water valves.

• Close the shut-off valve at the injection unit.

6.9.3 Long-term stop (while the plant is still running)

• Close all container valves.

• Let the plant run until the measuring tube shows no more gas

flow.

• Close the rate valve.

• Switch off booster pump.

• Close the motive water valves.

• Close the shut-off valve at the injection unit.

TM04 0827 0908

Caution

In case of exceeding: The rate valve may get

damaged!

TM04 0960 4009

Item Description

2 Programming buttons

4LEDs

5 DIP switch

Warning

Danger!

Do not touch bare wires or clamp screws!

31 mm

+0,5

1 mm

+0,5

min.

(ST1)

max.

(ST2)

Ymax

100% = 20 mA

Ymin

0% = 4 mA

SET

Warning

Immediately leave the room in case of gas break-out

and put on safety equipment!

Then start counter-measures!

Warning

Repairs of components of the system only by

authorized personnel!

English (GB)

6.10 Possible faults

7. Maintenance

Rates for cleaning and maintenance

• at least every 12 months

• in case of malfunction

7.1 Maintaining the servomotor

8. Disposal

This product or parts of it must be disposed of in an

environmentally sound way:

1. Use the public or private waste collection service.

2. If this is not possible, contact the nearest Grundfos company

or service workshop.

Fault Cause Correction

Despite constant operating

conditions the vacuum varies

Spring in differential pressure regulator is soiled Call the service

Spring in differential pressure regulator is

damaged

Call the service

Despite constant operating

conditions the dosing flow varies

Diaphragm in differential pressure regulator is

soiled

Call the service

Diaphragm in differential pressure regulator is

damaged

Call the service

Leakage at the rate valve Bar gasket in the rate valve damaged Call the service

Floater of the measuring tube is

not caught

Measuring tube is soiled Clean the measuring tube

Desired dosing flow is not

reached

Insufficient injector vacuum

Check injector, observe the manual of the

injector

Servomotor (option) does not reach the 100 %-

position

Call the service

Leakage in vacuum line between differential

pressure regulator and injector

Eliminate leakage (see "checking the tightness")

Vacuum line between differential pressure

regulator and injector too long

Observe table "Recommended diameter" in

chapter 2.7

Vacuum line between vacuum regulator and gas

dosing system too long

Admission pressure at the vacuum regulator too

low

If necessary, open gas supply or clean filter

(observe manual of the vacuum regulator)

Regulating channel of the adjusting plunger soiled Call the service

Despite correctly displayed gas

flow the desired gas solution

concentration cannot be reached

Leakage in vacuum line between vacuum

regulator and gas dosing system

Eliminate leakage (see "checking the tightness")

Servomotor does not run Servomotor is switched to manual operation Switch servomotor to automatic operation

Servomotor does not reach the

whole range desired

Servomotor resp. electronics adjusted wrongly Call the service

Servomotor runs in wrong

direction

Servomotor resp. electronics adjusted wrongly Call the service

The adjusting spindle falls from

the "automatic" position into the

"manual" position unintentionally

The spring-loaded thrust pad has been displaced

and therefore cannot deliver enough preload to

the holding groove of the adjusting spindle.

Adjust the thrust pad.

The spring-loaded thrust pad is damaged.

Exchange the spring-loaded thrust pad

(96690346 or 50.1340); gently press on the ball.

The adjusting spindle must be able to move up

and down.

Warning

Do not open the components of the device!

Cleaning, maintenance and repair only by authorized

personnel!

Warning

Switch off the whole plant before doing cleaning and

maintenance work!

Danger of gas break-out!

Warning

Check the tightness before restarting!

Danger of gas break-out!

Note

The servomotor features permanent lubrication and

is maintenance-free.

Warning

The entire installation should be switched off before

any repair work is carried out.

Disconnect the mains voltage before opening the

housing!

Deutsch (DE)

Deutsch (DE) Montage- und Betriebsanleitung

Übersetzung des englischen Originaldokuments

INHALTSVERZEICHNIS

Seite

1. Allgemeines

1.1 Aufbau der Dokumentation

Das Gerät VGS-141 / VGS-143 / VGS-145 von Grundfos ent-

spricht dem neusten Stand der Technik und erfüllt die einschlägi-

gen Sicherheitsvorschriften.

Die Konformität mit geltenden Normen, Richtlinien und Gesetzen

wurde bestätigt. Trotzdem können bei der Anwendung der Anlage

Gefahren auftreten, auf die der Hersteller keinen Einfluss hat.

Zweck dieser Anleitung:

• Einweisung des Anwenders in die optimale Nutzung.

• Warnung des Anwenders vor möglichen Restrisiken trotz

korrekten Gebrauchs und Identifikation von Maßnahmen,

die zur Vermeidung von Schäden zu ergreifen sind.

• Ermahnung des Anwenders, das System nicht zweckfremd

oder unsachgemäß einzusetzen, und Hinweise zu erforderli-

chen Vorsichtsmaßnahmen beim Betrieb des Systems.

1.2 Über diese Anleitung

Diese Anleitung enthält folgende standardisierte Sicherheitsan-

weisungen bezüglich möglicher Restrisiken:

Informationen über mögliche Restrisiken

finden Sie an folgenden Stellen:

• Auf Warnschildern am Installationsort

• Zu Beginn jedes Abschnitts in dieser Anleitung

• Direkt vor Handlungsschritten, die Restgefahren mit sich

bringen können.

1.3 Anwender/Zielgruppen

Anwender sind Personen, die für den Betrieb und die Überwa-

chung des VGS-141 / VGS-143 / VGS-145 am Installationsort

verantwortlich sind. Das System darf nur von geschultem und

qualifiziertem Personal betrieben werden. Das Personal muss

über entsprechendes technisches Fachwissen verfügen und mit

den grundlegenden Prinzipien der Mess- und Regeltechnik ver-

traut sein.

1.3.1 Verantwortlichkeiten der Anwender

Die Verantwortung der Anwender umfasst folgende Aspekte:

• Vor dem Betrieb des VGS-141 / VGS-143 / VGS-145 diese

Anleitung lesen.

• Von qualifizierten Mitarbeitern von Grundfos in den Betrieb

des Systems einweisen lassen.

• Die am Arbeitsplatz geltenden Sicherheits- und Unfall-

verhütungsvorschriften beachten.

• Beim Betrieb des Systems und beim Umgang mit Chemikalien

angemessene Schutzkleidung gemäß den nationalen Vor-

schriften zur Unfallverhütung (Deutsche GUV-V D05) tragen.

1. Allgemeines

1.1 Aufbau der Dokumentation

1.2 Über diese Anleitung

1.3 Anwender/Zielgruppen

1.4 Verantwortlichkeiten des Betreibers

1.5 Wartungs- und Servicepersonal

1.6 Bestimmungsgemäße Verwendung

1.7 Unsachgemäße Verwendung

2. Umgang mit Chlor

2.1 Physikalische und chemische Daten

2.2 Sicherheitshinweise für den Umgang mit Chlor

2.3 Dichtheitsprüfung

2.4 Bautechnische Anforderungen an Chloranlagen

2.5 Funktionsprinzip der Komponenten

2.6 Liste der geltenden Gesetze und Vorschriften (in

Deutschland)

2.7 Empfohlener Querschnitt

3. Technische Daten

3.1 Allgemeine Daten

3.2 Daten der Zubehörkomponenten

3.3 Maßzeichnung

4. Installation

4.1 Transport und Lagerung

4.2 Auspacken

4.3 Lagerung / Stillstandzeiten

4.4 Montage

4.5 Elektrischem Stellantrieb austauschen

5. Inbetriebnahme

5.1 Elektrische Anschlüsse

5.2 Prüfungen vor Inbetriebnahme

6. Bedienung

6.1 Beschreibung des Systems

6.2 Dosierleistung manuell erhöhen

6.3 Dosierleistung manuell reduzieren

6.4 Stellantrieb einrücken

6.5 Stellantrieb ausrücken

6.6 Bedienung des Stellantriebs

6.7 Einstellen des Stellantriebs (Option)

6.8 Einschalten

6.9 Ausschalten

6.10 Mögliche Störungen

7. Wartung

7.1 Instandhaltung Stellantrieb

8. Entsorgung

Warnung

Diese vollständige Montage- und Betriebsanleitung

ist auch verfügbar auf der Website

www.grundfosalldos.com.

Vor der Installation ist diese Montage- und Betriebs-

anleitung zu lesen. Die Installation und der Betrieb

müssen nach den örtlichen Vorschriften und den

Regeln der Technik erfolgen.

Warnung

Wenn diese Sicherheitshinweise nicht beachtet wer-

den, kann dies Personenschäden zur Folge haben!

Achtung

Wenn diese Sicherheitshinweise nicht beachtet wer-

den, kann dies zu Fehlfunktionen und Sachbeschädi-

gung führen!

Hinweis

Hinweise oder Anweisungen, die die Arbeit erleich-

tern und die sichere Bedienung gewährleisten.

Deutsch (DE)

1.4 Verantwortlichkeiten des Betreibers

Der Gebäudeeigentümer oder Betreiber des VGS-141 /

VGS-143 / VGS-145 unterliegt folgenden Verantwortlichkeiten:

• Diese Anleitung ist als Bestandteil des Produkts zu betrachten

und über die gesamte Nutzungsdauer des Systems hinweg

stets gut sichtbar in unmittelbarer Nähe des Systems

aufzubewahren.

• Die Installationsanforderungen des Herstellers müssen befolgt

werden (erforderliche Wasseranschlüsse und -armaturen,

Umgebungsbedingungen, elektrischer Anschluss, ggf. Schutz-

rohr für die Dosierleitung, ggf. akustische oder optische

Alarmvorrichtung).

• Sicherstellen, dass die Wasserleitungen und -armaturen regel-

mäßig überprüft und gewartet werden.

• Ggf. ist eine offizielle Genehmigung zur Lagerung von

Chemikalien einzuholen.

• Dafür sorgen, dass Anwender in den Betrieb des Systems ein-

gewiesen werden.

• Sicherstellen, dass die Unfallverhütungsvorschriften am

Installationsort eingehalten werden (Deutsche GUV-V D05

Unfallverhütungsvorschrift "Chlorung von Wasser",

Januar 1997).

• Alle Benutzer sowie das Wartungspersonal mit Schutzkleidung

gemäß GUV-V D05 ausstatten (Gesichtsmaske, Handschutz,

Schutzschürze).

1.5 Wartungs- und Servicepersonal

Das System darf nur durch autorisiertes Servicepersonal von

Grundfos gewartet werden.

1.6 Bestimmungsgemäße Verwendung

Das System VGS-141, VGS-143, VGS-145 von Grundfos dient

zur Dosierung von Chlor (Cl

) gemäß der Beschreibung in dieser

Anleitung.

1.7 Unsachgemäße Verwendung

Anwendungen, die nicht unter Abschnitt

1.6 Bestimmungsgemäße Verwendung aufgelistet sind, gelten als

nicht bestimmungsgemäß und sind daher unzulässig.

Der Hersteller Grundfos haftet nicht für Schäden, die aus einer

unsachgemäßen Verwendung resultieren.

Das System besteht aus Komponenten, die dem neusten Stand

der Technik entsprechen, und wurde einschlägigen Sicherheits-

prüfungen unterzogen.

2. Umgang mit Chlor

2.1 Physikalische und chemische Daten

Unter normalen Druck- und Temperaturbedingungen ist Chlor ein

gelblich-grünes Gas mit einem beißenden Geruch. Es liegt als

diatomares Cl

-Molekül vor.

Chlor ist nicht brennbar, kann aber die Entflammbarkeit von

Metallen, Kohlenwasserstoffen usw. fördern.

Dampfdruckkurve von Chlor

Abb. 1 Dampfdruckkurve von Chlor

Löslichkeit von Chlorgas in Wasser

Abb. 2 Löslichkeit von Chlorgas in Wasser

Warnung

Eigenmächtige bauliche Veränderungen an der

Anlage können zu erheblichen Sach- und Personen-

schäden führen.

Es ist verboten, Komponenten, insbesondere Sicher-

heitseinrichtungen, zu öffnen, zu modifizieren, bau-

lich zu verändern, zu überbrücken, zu demontieren,

zu umgehen oder außer Funktion zu setzen.

Atomgewicht 35,457

Molekulargewicht Cl

70,941

Dichte (flüssig) 1,57 g/cm

bei -34,05 °C

Dichte (gasförmig) 3,214 g/l bei 0 °C, 1 bar

1 l flüssiges Chlor bei 0 °C

entspricht 457 l (0,457 m

)

gasförmigen Chlors

1 kg flüssiges Chlor bei 0 °C

entspricht 311 l (0,311 m

)

gasförmigen Chlors

Spezifische Dichte

2,486 (spezifische

Dichte von Luft: 1)

Siedepunkt - 34,05 °C (1 bar)

Schmelzpunkt - 100,98 °C

Verdampfungswärme 269 kJ/kg (bei 0 °C)

Wärmeleitfähigkeit 0,527 kJ/m

h (flüssiges Chlor)

Reinheitsgrad gemäß

DIN 19607

99,5 %

MAK 1,5 mg/m

(0,5 Vol.-ppm)

TM04 0691 0908TM04 0692 0908

-50 -40

-30 -20

-10 0

30 40

50 60 70

Temperatur (°C)

Deutsch (DE)

2.2 Sicherheitshinweise für den Umgang mit Chlor

2.2.1 Gesundheitsrisiken

Chlorgas ist giftig. Konzentrationen von über 50 Vol.-ppm in der

Luft stellen in Innenbereichen eine akute Lebensgefahr dar.

Gefahren von Chlorgas

• Reizt die Augen, Atmungsorgane und die Haut.

• Löst Keuchhusten aus.

• Verursacht Verätzungen der Haut und der Atmungsorgane.

• Führt bei Langzeitexposition oder hohen Konzentrationen zum

Tod durch Lungenödem.

• Leichte Lähmung des zentralen Nervensystems.

Gefahren flüssigen Chlors

• Verursacht Verätzungen der Haut.

• Führt zu Rötung und Blasenbildung der Haut.

2.2.2 Persönliche Schutzausrüstung

Der Betreiber einer Chlorungsanlage muss folgende Ausrüstung

für das Bedienpersonal bereitstellen:

Für jeden einzelnen Bediener

Atemschutzausrüstung (Vollsicht-Gasmaske)

• mit effektivem Chlorfilter (B2P3), farbliche Kennzeichnung:

grau mit weißem Ring

• mindestens 1 Ersatzfilter pro Gasmaske

• passgenau (vollständig abdichtend)

• mit Namensetikett

Nur Anlagen mit Chlorfässern

• mindestens 2 Schutzanzüge mit Pressluftatmern

Lagerung der Sicherheitsausrüstung

• außerhalb der Chlorräume

• gut sichtbar

• jederzeit griffbereit verfügbar

• vor Staub und Feuchtigkeit geschützt

• Einweisung des Bedienpersonals in die Handhabung der

Sicherheitsausrüstung

• Durchführung von Übungen (mindestens alle 6 Monate)

• Regelmäßiger Austausch der Gasmaskenfilter

– nach Ablauf des Haltbarkeitsdatums

– spätestens 6 Monate nach dem Öffnen

(das Öffnungsdatum auf dem Filter notieren)

– nach einem Kontakt mit Chlor

– Die Beschäftigungsverbote gemäß § 14 ArbStoffV

(Deutschland) bzw. gemäß der vor Ort geltenden

gesetzlichen Vorschriften beachten!

2.2.3 Verhaltensregeln

• Chlorbehälter nur mit angelegter Gasmaske wechseln.

• Kontaminierte Räume nur mit Schutzanzug und Pressluftatmer

betreten.

• Bei Flucht wenn möglich Gasmaske anlegen.

Windrichtung beachten!

• Das Essen, Trinken und Aufbewahren von Lebensmitteln in

Chlorräumen ist untersagt.

2.2.4 Erste Hilfe bei Unfällen

Erste Hilfe nach dem Einatmen von Chlor

• Ruhe bewahren.

• Verletzte Personen aus dem Gefahrenbereich bringen.

– Helfer müssen auf den eigenen Schutz achten!

• Kontaminierte Kleidung sofort entfernen.

• Verletzte Personen beruhigen und mit Decken warm halten.

• Für frische Luft sorgen; sofern möglich, Sauerstoffgeräte

(im Wechsel mit Dampfeinatmung) verwenden.

– Keine Wiederbelebung durch Mund-zu-Mund-Beatmung!

• Schneller, sanfter Transport in ein Hospital

– liegend

– sitzend, falls Atembeschwerden vorliegen

– Verätzung durch Chlor als Ursache angeben.

Erste Hilfe nach einer Verätzung der Haut

• Ruhe bewahren.

• Kontaminierte Kleidung entfernen.

• Mit reichlich Wasser abspülen.

• Die Wunde keimfrei verbinden.

• Ärztliche Hilfe aufsuchen.

– Verätzung durch Chlor als Ursache angeben.

Erste Hilfe nach einer Verätzung der Augen

• Ruhe bewahren.

• Die verätzten Augen mit reichlich Wasser ausspülen, während

der Patient liegt.

– Ggf. das nicht betroffene Auge abdecken.

– Die Augenlider weit öffnen; die Augen müssen sich zu allen

Seiten bewegen.

• Einen Augenarzt aufsuchen.

– Verätzung durch Chlor als Ursache angeben.

Erste Hilfe nach einer Verätzung der inneren Organe

• Ruhe bewahren.

• Wasser in kleinen Schlucken trinken.

– Sofern verfügbar, medizinische Kohle einnehmen.

• Ärztliche Hilfe aufsuchen.

– Verätzung durch Chlor als Ursache angeben.

2.2.5 Transport und Lagerung von Chlor

Grundregeln für den Transport und die Lagerung von Chlor

• Behälter vorsichtig handhaben, nicht werfen!

• Behälter vor Umfallen oder Wegrollen schützen!

• Behälter vor direkter Sonneneinstrahlung und Temperaturen

über 50 °C schützen!

• Behälter dürfen nur mit Ventilschutzmutter und Schutzkappe

transportiert werden.

Geltende Vorschriften

– Vorschriften zur Unfallverhütung "Chlorung von Wasser"

(GUV-V D5) mit Verfahrensanweisungen

– Verordnung über Arbeitsstätten (ArbStättV))

– Technische Regeln für Gase 280, 310 und 330

Warnung

R 23 Giftig beim Einatmen.

R 36/37/38Reizt die Augen, Atmungsorgane und die

Haut.

Achtung

Weitere Verpflichtungen des Betreibers

Warnung

Chlorbehälter dürfen nur von erfahrenem, geübten

Personal gehandhabt werden!

Warnung

Diese Regeln gelten sowohl für volle als auch für

leere Behälter, da auch leere Behälter noch Chlor-

reste enthalten und daher unter Druck stehen.

Warnung

Die lokalen Gesetze und Vorschriften zu Handha-

bung, Transport und Lagerung von Chlor sind strikt

zu befolgen.

Deutsch (DE)

2.2.6 Druckbehälter und Befestigungen

Chlor wird in zwei Behälterarten gelagert:

• Stahlflaschen mit 50 kg oder 65 kg Inhalt, mit einem Ventil zur

– Entnahme von Chlorgas aus der aufrecht stehenden

Flasche.

Variante einer Chlorflasche

Abb. 3 Variante einer Chlorflasche

• Stahlfässer mit 500 kg oder 1000 kg Inhalt, mit

– einem Ventil zur Entnahme von Chlorgas

– einem Ventil zur Entnahme von flüssigem Chlor

Abb. 4 Chlorfass

Abb. 5 Ventilposition des Chlorfasses

Aus Sicherheitsgründen werden Chlorflaschen

nur auf 95 % ihrer Kapazität gefüllt.

• Gastyp, Gewicht, Eigentümer, Produktionsdatum und Datum

der letzten Überprüfung müssen deutlich lesbar auf dem

Behälter angegeben sein. Chlorbehälter sind grau markiert.

• Keine anwenderseitigen Änderungen oder Reparaturen!

• Behälterventile niemals mit Gewalt öffnen. Klemmende

Ventilspindeln können gelöst werden, indem ein in warmem

Wasser getränkter Lappen um das Ventil gewickelt wird.

– Niemals eine offene Flamme verwenden!

– Niemals eine Verlängerung für Schraubenschlüssel

verwenden!

– Behälter mit klemmenden Ventilen an den Hersteller zurück-

senden.

• Die Sicherheitsvorkehrungen und die Anleitungen des

Herstellers beachten!

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Schutzkappe

Ventil

Halteschelle

Ventilgewinde

gemäß DIN 477

Eingravierte

Kennzeichnung

nahtlose Chlor-

gasflasche

Alumini-

umschild

Geschweißte

Chlorgasflasche

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Rollreifen

Steigleitung (zur Entnahme von Chlorgas)

Schutz-

kappe

Ventile

Tauchleitung

(zur Entnahme von flüssigem Chlor)

Ventil für Chlorgas

Farbring

Ventil für flüssiges Chlor

Warnung

Die Sicherheitsvorkehrungen für Chlorbehälter

beachten.

Deutsch (DE)

2.2.7 Chlorentnahme

Vor der Entnahme

• Die Chlorbehälter müssen mindestens 8 Stunden im Lager-

raum verbleiben, damit der Inhalt sich an die Umgebungs-

temperatur anpassen kann.

• Chlorfässer auf der Abstützung drehen, bis Tauch- und Steig-

leitung vertikal ausgerichtet sind (die Markierungen auf dem

Fass beachten).

• Die Dichtheit prüfen.

Anschluss

• Behälter vor Umfallen oder Wegrollen schützen!

• Die Leitungen und das Entnahmesystem mit trockenem Stick-

stoff oder trockener Luft trocknen.

• Es dürfen keine Fremdkörper in die Anlage gelangen.

• Die Anschlussleitung mit neuen Dichtungen versehen.

• Den Behälter anschließen.

• Langsam das Behälterventil öffnen.

Entnahme von Chlorgas

Bei einem höheren Chlorbedarf müssen mehrere Behälter mit

derselben Temperatur über Sammelleitungen angeschlossen

werden.

Entnahme von flüssigem Chlor

• In Chlorungsanlagen ist eine Entnahme flüssigen Chlors nur

aus Chlorfässern möglich.

• Dabei muss ein Verdampfer verwendet werden.

• Entnahme von Chlorgas: Einen Restdruck von ca. 2 bar

belassen.

• Entnahme von flüssigem Chlor: Einen Restdruck von ca. 4 bar

belassen.

Nach der Entnahme

• Das Behälterventil schließen.

• Den Behälter von der Anlage trennen.

• Die Ventilschutzmuttern anschrauben.

• Die Schutzkappe aufschrauben.

2.3 Dichtheitsprüfung

Vor der Inbetriebnahme die gesamte Anlage auf Dichtheit über-

prüfen. Siehe hierzu Abschnitt 5.2.2 Dichtheitsprüfung der Vaku-

umleitungen.

2.4 Bautechnische Anforderungen an Chloranlagen

Alle Chlorräume

Abb. 6 Warnschild gemäß DIN 4844

– Warnschild gemäß DIN 4844, Teil 1, Nr. 4.2, an allen

Eingängen anzubringen.

Abb. 7 Zusatzschild

– Zusatzschild gemäß DIN 4844, Teil 1, Nr. 4.5, an allen

Eingängen anzubringen.

Abb. 8 Gebotsschild

– Gebotsschild gemäß DIN 4844, Teil 1, Nr. 4.3, in den

Räumen anzubringen.

Abb. 9 Anweisungsblatt für Erste Hilfe

• Anweisungsblatt für Erste Hilfe bei Chlorgasvergiftung

- in den Räumen auszuhängen

• Höchsttemperatur: 40 °C

– Empfohlene Temperatur: 18-20 °C

– Empfohlene Mindesttemperatur: 15 °C

• Überdruckleitungen von Dosiergeräten dürfen nicht in die

Umgebungsluft entleert werden.

• Chlorräume sind nicht als ständiger Aufenthaltsort für

Personen ausgelegt.

• In diesen Räumen dürfen sich nur Chlorbehälter und die

Chlorungsanlage befinden.

Warnung

Chlorbehälter dürfen niemals eine höhere Tempera-

tur aufweisen als andere Teile der Anlage. Ansons-

ten besteht die Gefahr der Verflüssigung und Freiset-

zung von Chlor!

Achtung

Bei 15 °C kann ca. 1 % (DIN 19607) des Inhalts pro

Stunde entnommen werden. Bei einer schnelleren

Entnahme besteht die Gefahr einer Funktionsstörung

infolge von Eisbildung an Behältern und Rohrleitun-

gen!

Behältergröße Entnahmemenge

50 kg 500 g/h

65 kg 650 g/h

500 kg 5 kg/h

1000 kg 10 kg/h

Achtung

Die Chlorfässer nicht vollständig entleeren. Gefahr

einer Entnahme von Ablagerungen!

Achtung

Unverzüglich die Anschlussleitungen schließen.

Es darf keine Feuchtigkeit in die Leitungen gelangen!

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Chlorungsanlage

Zugang nur für

ausgebildetes Personal