U 180-2 en

Change-over Device U 180-2 Operation Manual

Read this manual completely and keep it! No warranty in case of damages caused by incorrect operation. 15.710050-V1.0 1

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Imprint
Change-over Device U 180-2 Operation Manual Version 1.0 Publisher: ALLDOS Eichler GmbH Reetzstrae 85 76327 Pfinztal (Sllingen) Postfach 1210 76318 Pfinztal Tel. +49 (0) 72 40 61-0 / Fax. +49 (0) 72 40 61-177 E-Mail: alldos.de@alldos.com Internet: http://www.alldos.com 2004 by ALLDOS Eichler GmbH Subject to change. 2 V1.0

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Installation Data
NOTE Please fill in this form following commissioning. It will help you and your ALLDOS servicing partner to adjust the device during subsequent corrections.

Owner: ALLDOS customer No.: Contract No.: Order No. of device: Serial number of device: Put into service on: Location of device:

Used for:

Installation Diagram

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Contents
Imprint .............................................................................................................. 2 Installation Data ............................................................................................... 3 Installation Diagram ........................................................................................ 3 1 Of General Interest ................................................................................ 6
1.1 1.2 1.3 In General ................................................................................................... 6 Using this Paper ......................................................................................... 6 Warranty ..................................................................................................... 6

Safety Instructions ................................................................................ 7

2.1 2.2 2.3 Application of the Product ........................................................................... 7 Obligations of the Operating Authority ........................................................ 7 Averting Dangers ........................................................................................ 7

Technical Data ....................................................................................... 8

3.1 General Data .............................................................................................. 8 Change-over ............................................................................................... 8 Control Panel .............................................................................................. 8 Ambient Conditions ..................................................................................... 8 Varianten ..................................................................................................... 8 Actuator ...................................................................................................... 8 Control Panel .............................................................................................. 8 Prfmittel ..................................................................................................... 8 Language of labelling .................................................................................. 8 Dimensional Drawings ................................................................................ 9 Change-over ............................................................................................... 9 Control Panel .............................................................................................. 9 Plants Picture ............................................................................................ 10 Connection Diagram ................................................................................. 10

3.2

3.3

3.4 3.5

Installation ............................................................................................ 11
4.1 4.2 4.3 4.4 Transport and Storage .............................................................................. 11 Unpacking ................................................................................................. 11 Mounting Conditions ................................................................................. 11 Mounting (to solid wall) ............................................................................. 11

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Commissioning .................................................................................... 12
5.1 Preparations for Commissioning ............................................................... 12 Gas Connections ...................................................................................... 12 Electrical Connections .............................................................................. 12 Checks before Commissioning ................................................................. 13 Electrical Connections .............................................................................. 13 Gas Connections ...................................................................................... 13 Checking the Tightness of Pressure Gas Lines ........................................ 13 Checking the tightness with nitrogen ........................................................ 13 Leak Detecting with ammonia (Dosing media Cl2 or SO2) ........................................................... 14 Test of Functioning of the Change-over Process ...................................... 14

5.2

5.3

Operating ............................................................................................. 15
6.1 6.2 Device Description .................................................................................... 15 Function .................................................................................................... 15 Operation .................................................................................................. 16 Manual emergency operation in case of power failure .................................................................. 16 Exchange servo motor .............................................................................. 17 Possible Faults .......................................................................................... 17

6.3

Maintenance ......................................................................................... 18
7.1 7.2 Cleaning and maintenance intervals ......................................................... 18 Exchange of gaskets ................................................................................ 18 Dismantling the change-over valve ........................................................... 18 Re-assembly of the change-over unit ....................................................... 19

Spare Parts........................................................................................... 20
8.1 8.2 8.3 8.4 Change-over 180-2 ................................................................................... 20 Manual Emergency Operation Lever ........................................................ 22 Spare Parts Set ........................................................................................ 22 Spare Parts List ........................................................................................ 23

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1.1

Of General Interest
In General
This operation manual contains all information for safe operation of the described product: Technical Data Instructions for commissioning, operation and maintenance Safety Instructions If you require further information or if any problems arise which are not reflected in detail in this manual, contact ALLDOS directly for the information needed.

1.2

Using this Paper

Descriptions are written as plain text. Lists are indicated by squares (), sublists by dashes (-). Operation steps are indicated by bullets (), substeps by small bullets (). Cross-references are indicated by italic letters and an arrow (). The headings WARNING, CAUTION and NOTE have the following meaning:

WARNING

Danger of injuries and accidents!

CAUTION NOTE

Danger of incorrect operation or damage to the product! There is an exceptional feature.

1.3

Warranty
Warranty in accordance with our general terms of sale and delivery shall only be valid, if the product is used according to the information within this paper, the product is not being opened or used improperly, maintenance and repair is implemented exclusively by authorized and qualified personnel, original spare parts are used for repairs, only parts approved by ALLDOS are being used in the whole gas dosing plant. Warranty is not valid for typical wearing parts, e. g. gaskets, o-rings, diaphragms

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Safety Instructions
!
WARNING Before commissioning, read the ALLDOS information paper Function and Safety of Chlorination Plants.

2.1

Application of the Product

The Change-over Device U 180-2 is used for switching over the gas supply between two container batteries within ALLDOS gas dosing systems for water treatment, strictly complying with the instructions of this manual.

WARNING

Other applications are not intended and are not permitted. ALLDOS Eichler GmbH accept no responsibility for damages caused by unintended use.

2.2

Obligations of the Operating Authority

The operating authority of the plant is responsible for obeying the following regulations (in Germany): - Unfallverhtungsvorschrift Chlorung von Wasser (GUV 8.15) Unfallverhtungsvorschrift Druckbehlter (GUV 2.6) Unfallverhtungsvorschrift Gase (GUV 9.9) Verordnung ber Arbeitssttten (ArbStttV) Verordnung ber gefhrliche Arbeitsstoffe (ArbStoffV) obeying local safety regulations, if necessary

instructing the operation personnel providing the stipulated safety equipment ( information paper "Function and Safety of Chlorination Plants") arranging regular maintenance

2.3

Averting Dangers
The Change-over Device is an additional danger point for leakage within the gas dosing plant.

WARNING

Danger of gas break-out in case of impure gas

penetration with re-liquefied gas irregular cleaning and maintenance unintended use

Only use clean gas Install a suitable filtering device before the vacuum regulator Arrange regular cleaning and maintenance Avoid liquefaction by a correct course of temperature temperature must not fall in the way of the line to the vacuum regulator

WARNING

Do not open the device! Cleaning and maintenance only by authorized personnel!

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3.1

Technical Data
General Data
max. capacity Measurements in mm Degree of protection Weight Supply voltage Actuating time Manual emergency operation
15 kg Cl2/h 225 x 310 x 265 (B x H x T) IP 55 8 kg 230 V / 50 Hz about 8 s with enclosed lever

Change-over

Control Panel
Power supply Degree of protection Operating contact
230 V / 50 Hz IP 65 1 potential-free change-over contact for operation indication of container 1 and 2 1 potential-free N.O. contact empty indication of container 1 und 2

Measurements in mm Weight

250 x 375 x 160 (B x H x T) about 5.5 kg

Ambient Conditions
admissible ambient temperature admissible storage temperature
0 ... +50 C -20 ... +60 C

3.2

Varianten
Index no.
S005

Actuator
Power Supply
230 V (standard version)

Control Panel
Index no.
V000

Description
with control panel 230 V, 50 Hz (standard version) without control panel

Language of labelling
Index no.
F000 F001 F002 F003

Description
German (standard version) English French Spanish

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3.3

Dimensional Drawings

Change-over

A-A 9 26 G " G "

G " 100 about 225

41

A about 265

Control Panel
177 8,5

394

370

t = 150mm

250

350

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3.4

Plants Picture
2 4 3 C 1 5

A I
1 2 3 4 5 6 I II Change-Over 180-2 Control Panel of the Change-over Vakuum Regulator Gas Dosing Device Header line for containers Injector Container Battery 1 Container Battery 2

B II
green Battery II

3.5

Connection Diagram

manual operation Battery I + II

green Battery I

pressure

valve

Battery I + II empty
pressure

"operation" message

Feeding

open valve

close

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4
4.1

Installation
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! Check the scope of delivery. Mount as soon as possible after unpacking.

4.3

Mounting Conditions
CAUTION In case of non-observance: Danger of damages!

Mounting place free of vibrations. (preferably in the chlorine container room) for the control panel:dry mounting place. (preferably not in the chlorine container room) Observe permissible ambient temperature!

4.4

Mounting (to solid wall)

Change-over Mark the bore holes through the mounting plate and bore the holes for two dowels 10 mm. Insert the dowels. Fix the mounting plate with two washers with two hexagonal screws 8x80 to the wall. Control panel Mark the bore holes and bore the holes for four dowels 8 mm. Insert the dowels. Place the control panel. Screw in the 4 included screws 8x60.

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Commissioning
The change-over device U 180-2 is always installed into a gas dosing plant. Therefore the other components determine the expiration of the commissioning.

5.1

Preparations for Commissioning

Gas Connections
CAUTION Danger of operation failures! Observe permissible line cross-sections!

Lay and connect the connection lines of both extraction points (bottles, tanks or header lines) and the vacuum regulator. Please make sure that the lines have no buckles and the sealing surfaces are clean. Connect line A of the container battery 1. Connect line B of the container battery 2. Connect line C to the Change-over Device.

Electrical Connections

WARNING

Switch off the power supply before connecting the mains cable and relay contacts! The local safety regulations must be observed! Protect the cable connections and plugs from corrosion and moisture.

CAUTION

Before connecting the mains cable: Check that the power supply specified on the rating plate corresponds to the local supply. An incorrect supply voltage may destroy the device! To guarantee electromagnetic compatibility (EMC): The input and current output cables must be screened. Connect screen at one end to PE. Refer to connection diagram! Route the input, current output and power supply cables in separate ducts. Charge the potential-free connections of the operation and empty indication with max. 250 V / 2A.

Following the connection diagram page 10: Connect the servomotor to the control panel. Connect the contact manometer to the control panel. Connect the control panel to the mains. If necessary, connect the lines for remote indication, max. charge 2 A.

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5.2

Checks before Commissioning

Check the electric connections.

Electrical Connections

NOTE

The switch contact of the contact pressure gauge is adjusted in the works to 1 bar and should not be altered.

Gas Connections
Check tightness of the total plant before start-up. observe chapter 5.3 Checking the Tightness of Pressure Gas Lines observe manual of the gas dosing system!

WARNING

Check the tightness not until the total plant is ready for start-up. Danger of gas leakage!

5.3

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 (all dosing media). Detailed checking: with ammonia (dosing media Cl2 and SO2)

Checking the tightness with nitrogen

Close all container valves Open container connection valves and all shut-off valves up to the gas dosing system 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), close valve again.

WARNING

Maximum nitrogen pressure 16 bar! Danger of damages and gas leakage when being exceeded!

Apply soap water to all sealing components. 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.

Close all container connection valves.

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Leak Detecting with ammonia (Dosing media Cl2 or SO2)

Leaks are localized by passing the open bottle of ammonia near to the junction points and by squeezing slightly ammonia out of the bottle. If there is a leak where gas escapes, white vapour is generated. Even the slightest leakages discovered have to be repaired immediately.

WARNING

Liquid ammonia must not come in contact with parts of the plant! Danger of leakages by corrosion!

Start up the chlorine gas dosing unit in the following sequence: Have ready a bottle with ammonia to test the tightness of the lines. left battery Press the test key, if neccessary until the LED indicating operation of the left battery lights up. open the container valve of the left battery by 2 or 3 revolutions and check the tightness of the stuffing box. open slowly the connecting valves of the containers until the contact pressure gauge indicates 2 bar and then close the two valves again. examine all connections and stuffing boxes up to the vacuum regulator. start up the dosing device according to the operating manual until the contact pressure gauge indicates 0 bar. right battery Press the test key until the LED indicating operation of the right battery lights up. open the container valve of the right battery by 2 or 3 revolutions and check the tightness of the stuffing box. open slowly the connecting valves of the containers until the contact pressure gauge indicates 2 bar and then close the two valves again. examine all connections and stuffing boxes up to the vacuum regulator. start up the dosing device according to the operating manual until the contact pressure gauge indicates 0 bar.

Test of Functioning of the Change-over Process

Start up the dosing device. Open all container valves and container connecting valves of the right and the left battery. Press the test key until the LED indicating operation of the right battery lights up. Depending on the dosing capacity, the contact pressure gauge drops now more or less fast. close all the container valves of the right battery.

When the pressure falls below the adjusted value, the change-over device activates automatically the left battery. The corresponding LED lights up and the contact pressure gauge indicates the pressure of full receptacles. The empty container battery is indicated optically, i.e. the LED for the empty side extinguishes, while the LED for the battery which is now in operation lights up.

WARNING

The container valves and the connecting valves of the containers have to be closed when exchanging the empty containers. The valves are to open again, after having connected the new, full rcontainer

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6.1

Operating
Device Description
More and more chlorine gas dosing plants are equipped with a parallel installed second receptacle battery in addition to the already connected container battery. As the exact point of time when the connected container battery will be empty cannot be determined in advance, the continuous chlorine gas dosing is endangered. The automatic ALLDOS change-over device guarantees a continuous dosing process, as the changing over from the empty receptacles to the ones in reserve is effected automatically. The change-over process is indicated optically at the control unit.

Function
The change-over device is connected at the input side to two gas supply units (container or container battery) and at the output side to a vacuum regulator. The change-over device works on the principle of a three-way motor valve, that is actuated by an electrical control panel. The contact pressure gauge installed at the output side triggers the change- over process when a supply unit is empty. In case of current supply failures, the changing over can be executed manually with the provided hand lever after having removed the servomotor. The Vacuum Change-over U 186-120 consists of 3-way ball valve electric servomotor control panel contact manometer. two container batteries at the input side a vacuum regulator at the output side.

The change-over is connected to

The change-over is controlled by the control panel and the contact manometers. lamp lamp

If one container resp. one container battery gets empty, the control panel activates the servomotor.

Status message for the container batteries: - For each container battery there is one signal lamp:
pushbutton key

green lamp: for "operation" For remote display of the "operation" state of container I und II there is one potential-free change-over contact, and for remote display of the "empty" state of container I und II there is one potential-free N.O. contact.

By means of key switch it can be manually changed between container battery 1 or 2.

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6.2

Operation
Switching on and off, selecting manual and automatic operation Automatic operation No operation is necessary. Manual operation Press key switch S12. The green lamp of the corresponding container battery lights up.

Manual emergency operation in case of power failure

In case of power failure or other electric problems the change-over device can be operated manually by means of the enclosed lever (14).

NOTE

In order to avoid transfusion when changing over manually, the valve of the empty container battery has to be closed at first and then the one of the full battery can be opened. The right battery is connected, when the lower end of the lever points to the right. (The left battery is closed.) The left battery is connected, when the lower end of the lever points to the left. (The right battery is closed.)

NOTE

Lift off the cover of the servomotor (4 screws), eventuaelly pinch off connecting cables. Dismantle servomotor (3 screws ( 32)). Insert the journal of the supplied hand lever (14) in the fork (8) and fasten the lever by means of the washer (13) and hexagonal screw (27). Place the lower end of the lever pointing to the empty battery the empty battery is connected. Arrest the lever by tightening the hexagonal screw (27).

NOTE

Do not resort to force. It is sufficient to press slightly the lever to close a container battery. The correcting displacement is only about 1 mm.

Close the valves of the empty battery. Unscrew the fastening screw and adjust the lever so that the lower end points to the full container battery. the full container battery is connected. Arrest the lever. After Elimination of Power Failure Stop chlorine gas dosing unit. Close both container batteries.

NOTE

Unintended transfusion of chlorine gas occurs, if not both batteries are closed.

Take the lever off and install the servomotor. Adjust the servo motor manually to the container battery which has been in operation. Open slowly both receptacle batteries. start up the chlorine gas dosing unit.

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27 13 14

Exchange servo motor

Deenergize the control unit. Mark and pinch off the cable at the servo motor. Dismount the servo motor following the instructions in the paragraph "Manual emergency operation in case of power failure", and have it repaired or replace it by a new one. Insert the lever and operate it accordingly. observe "Manual emergency operation in case of power failure"

6.3

Possible Faults
Fault Cause Both containers are empty.

Remedy Replace containers by full ones. Close container valve, take dosing equipment out of operation, in order not to aspirate damp air into the The line from the gas container to the change-over device. Carefully remove Lack of chlorine container connection valve and line, change-over device is clogged. identifiable at the dosing clean and dr y them. For installation equipment. and restar ting operation, proceed as If plant-laterally installed: already described. indication lamp for Close all valves, keep the dosing unit "containers I and II in operation until the contact empty" lights up. manometer indicates 0 bar. Remove Valve in the change over device is par ts, rinse well with hot water and clogged dr y. Re-inser t the par ts. For restar ting operation, proceed as already described. Indication lamp of the container in operation Glow-lamp does not work. Replace glow-lamp. does not work. Power failure Switch manually. Ser vomotor does not Replace ser vomotor, switch manually work. in the meantime.
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7.1

Maintenance
Cleaning and maintenance intervals
in case of soiling in case of disturbances at the latest after one operational year Exchange gaskets every two years (spare parts set 553-180).

!
7.2 Exchange of gaskets

WARNING

Switch off the entire system before starting the cleaning and maintenance work!

Block the gas supply from both groups. Operate the entire system gas-free and switch it off. Unscrew the servomotor. Release all three pressure gas connections. Release the holding screw, remove the plug of the contact manometer (15). Remove the change-over device.

Dismantling the change-over valve

Dismantle the plate (4). Remove 3 screws (26) and distance bushings (10). Release the headless screw (30) and the cheese head screw (28), remove the fork (8) from the shaft (5). Unscrew the stuffing box (9). Remove the screws (25) and lift the cover (2). Take the washer (20), the bush (19) and the O-ring (50) out of the cover. Remove the shaft (5) with the closing unit (21), the bush (19) and the O-ring (50) from the enclosure. Remove the closing unit (21) from the lateral bolt of the shaft (5). Unscrew the three connection branches (6) with flat gaskets (41) from the enclosure (1). Leave the nut (18) and connection nipple (17) at the connection branch (6). Screw the nozzles (7) with O-rings (43) out of the connection branch (6). Clean all parts thoroughly in warm water (approx. 40 C) and dry them well.

CAUTION

When cleaning the enclosure (1) please observe, that no water and no humidity penetrate the measuring muff of the contact manometer (15). Danger of corrosion when installing humid parts!

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Re-assembly of the change-over unit

CAUTION Install only dry parts. Danger of corrosion when installing humid parts!

Replace old gaskets by new ones from the spare parts set 553-180. Re-assemble all valve parts in reversed order. Fix the change-over valve at the wall. Re-establish the pressure gas connections using new flat gaskets (47.51). Put on the plug for the contact manometer (15) and screw it in tight. Slide the servomotor (16) with the eccentric bushing (11) in the fork (8) and fasten it with screws (32) and sealing rings (34) at the plate (4). Put the cover on the servomotor and screw it together with the flat gasket.

WARNING

Re-start as described in Commissioning. Before restarting, check the tightness! Danger of gas escape!

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8.1

Spare Parts
Change-over 180-2

20

34 5 32 50 19 1 41 48 8 35 16 39 11 2 4

20

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15

A-A

3 21 43

7 6 17 18

28 30 47.3/ 4/ 5 47.51
C

B-B
C

22 C-C 25 44 10 26

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8.2

Manual Emergency Operation Lever

27 13 14

8.3

Spare Parts Set

Part no.: 553-180 contains: bush (19), washer (20), closing unit (21), flat gasket (41, 44, 47.51), o-rings (43, 50)

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8.4

Spare Parts List

Item 1 2 3 4 5 6 7 8 9 10 11 13 14 15 16 17 18 19 20 21 22 25 26 27 28 30 32 34 35 39 41 43 44 45 47 47.1 47.2 47.3 47.4 47.5 47.51 48 50

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Part no. 12.2502-300 12.2503-300 12.2504-400 12.6081-400 12.2508-400 12.2509-400 12.2510-400 12.2511-400 12.2512-400 12.2513-400 12.6082-400 50.518 12.2533-400 12.2520 45.10200-301 12.5224-400 12.5223-410 12.5249-400 50.522 12.2541 50.122 50.895 50.587 50.215 50.1368 50.1176 50.914 54.174 48.1022-400 50.1564 54.041 52.104 54.161 370-127.5 12.2567-400 48.033.1 50.1511 48.031.1 50.1305 50.519 54.173 12.2561-400 52.183

Description enclosure cover plate plate shaft connection branch nozzle fork stuffing box distance bushing eccentric bushing washer lever contact manometer servomotor connection nipple nut bush washer closing unit cheese head screw cheese head screw cheese head screw screw hexagon cheese head screw headless screw cheese head screw sealing ring adhesive label headless screw flat gasket o-ring flat gasket control unit accessories U 180-2 dowel screw dowel screw washer flat gasket adhesive label o-ring

Remark 0-16 bar 230 V / 50 Hz G1/4" 8/6 PTFE M 5 x 12 M 5 x 16 M 5 x 35 M 5 x 20 M 4 x 20 M 4 x 10 M 6 x 40 M 5x6 21,5 x 26 x 2 Viton 12 x 1,5 45 x 54 x 2 230 V / 50 Hz Viton 7 x 1,5
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