Granudos 25-S4 User manual

WDT Operating Instruction GRANUDOS 25/45/100 (S41 -06/12) page 1 of 27

Series No..........................Customer..........................................Date of delivery……….……………

Operating instructions GRANUDOS 45/100-S4

Safety Devices

1. Chlorine an aci may not be mixe together

or with other chemicals

Pay attention to the safety evices on

chemical containers

2. The osing hopper must be screwe even

an firmly to the container

3. Ensure after changing a rum, that it is firmly

fixe in position an the securing systems are

use

4. In service the issolving system must be

covere with the supplie cover

5. Only instructe personnel may work with the

GRANUDOS

6. Ensure booster pump oes not run ry,

always isolate pump when backwashing.

WDT Operating Instruction GRANUDOS 25/45/100 (S41 -06/12) page 2 of 27

Commissioning Form for GRANUDOS-S4

Please see hereto § 4 ommissioning

Objekt:.................................................................date..................................

GRANUDOS-T pe:..................... ear:...................ser.no................................

Commissioning undertaken b .............................sign…….............................

Sign of operator:...........................................................................................

1. Dissolving s stem (

at switches note 6 seconds dela !)

1.1 Adjust pressure switch: see § 4.3 [ ]

1.2 Check pressure switch: close inlet ball valve– L2 burns, GR stopp [ ]

1.3 Check flow switch: close outlet ball valve - dos. off, L1 burns [ ]

1.4 Check level switch: switch body up - dos. o , L1 burns [ ]

1.5 Check level switch: switch body down - GR stopps, L2 burns [ ]

1.6 Adjust water level: – adjust washer to pressure conditions [ ]

1.7 Check function of floating valve: water low reacts smoothly [ ]

2. Dosing unit chlorine

2.1 Function heating nozzle: dosing tube warm [ ]

2.2 Function empt switch: turn drum – L4 burns [ ]

2.3 Function dosing motor: programme „test chlorine“ – chlorine dosed [ ]

2.4 check clamp bands and safet belt [ ]

2.5 introduction to drum change § 4.6 [ ]

3. Dosing unit pH-correction

3.1 Function empt switch: take suction lance out o container – L3 burns [ ]

3.2 Function dosing pump: programm “test acid” – acid is suct up [ ]

4. Control unit – after opening of the housing

4.1 check all push connectors: well pushed in [ ]

4.2 External control: auto-controller on „Manual“ – chlorine doses [ ]

4.3 External control: auto-controller on „Manual“ – acid doses [ ]

4.4 External control: check any linked switch o [ ]

5. Other jobs

5.1 Clean GRANUDOS thoroughl [ ]

5.2 Clean environement of GRANUDOS thoroughl [ ]

5.3 Operation instructions discussed and handed to the operator [ ]

No warranty without fully signed commissioning form!

WDT Operating Instruction GRANUDOS 25/45/100 (S41 -06/12) page 3 of 27

TABLE OF ONTENTS

Test certification: loose insert

Main Safety devices 1

Commissioning form 2

page

1. Notes to this manual................................................................................................................... 4

1.1 What does that manual desrcibe .................................................................................................... 4

1.2 Target group .................................................................................................................................... 4

1.3 Safekeeping of the manual .............................................................................................................. 4

1.4 Intended use .................................................................................................................................... 4

1.5 Safety notice/used symbols:............................................................................................................ 4

2. Technical Description ........................................................................................................... 6

2.1 Technical Data .................................................................................................................................. 6

2.2 The Drum Carrier ......................................................................................................................... 7

2.3 Chlorine Dosing Assembly ................................................................................................................ 7

2.4 Acid Dosing ....................................................................................................................................... 8

2.5 Dissolving System ............................................................................................................................. 8

2.6 Control System with program GR S41 .............................................................................................. 9

2.6.1 Operation elements .................................................................................................................... 9

2.6.2 Operation and Test Programmes............................................................................................. 10

2.6.3 Dosing Performance Dosing scheme ...................................................................................... 11

2.6.4 Diagnosis by LED indication ...................................................................................................... 12

2.6.5 Irritations not indicated by monitoring switches .................................................................... 14

2.7 Filter disinfection at back wash – high chlorination ...................................................................... 15

3. Installation ......................................................................................................................... 16

3.1 Placing of the GRANUDOS in the pool technique room ................................................................ 16

3.2 Installation to the pool circulation ................................................................................................. 16

3.3 Electrical connection ...................................................................................................................... 17

3.4 Fitting the acid pump roller/tube .................................................................................................. 17

4. Taking into operation .......................................................................................................... 18

4.1 Check of pump .............................................................................................................................. 19

4. 2 Deaeration of the water supply tubing ......................................................................................... 19

4.3 Adjusting the pressure switch ........................................................................................................ 19

4.4 Water flow/Suction performance of the venturi .......................................................................... 19

4.5 Water level in the flushing tank .................................................................................................... 20

4.6 Loading the Drum onto the Machine (25 50 kg plastic drum ret. sketch p. 3) ...................... 20

4.7 Providing of acid ............................................................................................................................. 21

4.8. Adjusting the dosing performance of GRANUDOS – continuous dosing ..................................... 21

4.9 Dosing Controlled by Auto Controller ........................................................................................... 22

5. Maintenance ....................................................................................................................... 23

6. ontrol board S41c - wiring - fuses ....................................................................................... 24

7. Spare Parts GRANUDOS 45/100-S4 ...................................................................................... 25

8 . Maintenance List GRANUDOS 10/45/100 ............................................................................. 26

9. Wiring diagram ................................................................................................................... 27

WDT Operating Instruction GRANUDOS 25/45/100 (S41 -06/12) page 4 of 27

1. Notes to this manual

1.1 What does that manual desrcibe

That manual describe installation, commissioning and operating of the machine.

1.2 Target group

Only people advised in the function are allowed to operate the machine. The mounting of the machine

may only be executed by skilled workers.

1.3 Safekeeping of the manual

All operation manuals are to be safekept for direct use nearby the machine.

1.4 Intended use

The machine is only allowed to be used in the intended purpose. There is no implied warranty for

other use than the intended one.

1.5 Safety notice used symbols:

Danger!

Under this sign any real fact is described that could lead to personal injury if

not regarded.

Attention!

Under this sign any real fact is described that could lead to material damages

if not regarded.

Note!

Under this sign any real fact is described that could lead to improvement of

your process if regarded.

Corrosive!

Under this sign any real fact is described that could lead to personal injury or

material damages if not regarded.

Attention

: any works at the electrical parts of

he machine may only be

executed by skilled workers. Electrical parts must be switched off.

If irritations at the electrical supply do occur, switch off the machine

immediately.

Fuses are only to be exchange through original ones with the same

strength.

WDT Operating Instruction GRANUDOS 25/45/100 (S41 -06/12) page 5 of 27

Waste disposal

Note:

The operator is responsable for the disposal in conformity to the national

regulations.

Mandatory sign:

Use eyes protection

Mandatory sign:

Use face protection

Mandatory sign:

Use protection gloves

WDT Operating Instruction GRANUDOS 25/45/100 (S41 -06/12) page 6 of 27

2. Technical Description

2.1 Technical Data

The GRANUDOS 45/100-S4 dosing system comprises:

main vertical support with rotating drum carrier

dosing assembly for calcium hypochlorite granules

acid dosing equipment

dissolving system

microprocessor control panel

measures:

space needed: 60 x 150 cm

height: 140 cm

weight: 50 kg

material:

main vertical support and drum carrier:

steel, powder coated

other parts: PVC, PE

GRANUDOS booster pump(if installed)

centrifugal pump: 0,3 kW, 230 VAC,

supply pressure: >0,2 bar (20 kPa)

fresh water supply. >2 bar (200 kPa)

water flow: app. 1000 l/h

Dosing performance with 2 dosing motors

see para “control system”:

chlorine: GR45 mot 35 rpm app. 2.4 * ( 0,44**) kg/h

GR100 mot 60 rpm app. 4,0 * ( 0,7 **) kg/h

acid: 3,0* ( 0,5 **) l/h

* cycle time 1 minute

** cycle time 6 minutes

Chlorine dosing performance depends on chlorine

quality and is affected by too fine or too coarse

or humid product. Acid dosing performance is given in litres

per hour. It is recommended to use sulphuric acid 37%.

drum carrier

2 2 clamp bands

3 belts for fasten drum

4 dosing hoper

5 locker for safety belt

6 dissolving system

7 controlsystem

8 type label (not seen)

9 locker for drum carrier

10 acid pump

11 dust protection tube

12 acid carboy lance

13 acid container with tub

WDT Operating Instruction GRANUDOS 25/45/100 (S41 -06/12) page 7 of 27

2.2 The Drum Carrier

The rotating drum carrier assembly (6) is fixed to the main vertical support (10). The drum

(1) with chlorine is fixed on the carrier assembly (6) by band clamps ( ) and a retaining belt.

The dosing hopper (3) is fixed on the drum in place of the drum lid. The carrier with the drum is

then turned through 180° to the dosing position, the chemical is dosed into the dissolving

system (5) where it is fully dissolved and conveyed by a venturi to the buffer tank.

2.3 Chlorine Dosing Assembly

10 dosing hopper 16 hopper cover

11 dosing motor 17 knocker

12 dosing screw 18 seal washer

13 motor mounting 19 dosing hopper screw ring

14 dosing nozzle heated

15 drum empty switch with adjusting screw and ED

The dosing screw (1 ) meters the chlorine through the heated dosing nozzle (14) to the dissolving

system. If the drum empty switch (15) is indicating, app 1 kg chlorine is left in the hopper. The knocker

(17) gives a hit to the hopper wall at each dosing motor run cycle so supporting flowing of the granules.

Dosing performance is adjusted by the switch 4 at front fascia, see para "Start up operation".

14 18

17 10

WDT Operating Instruction GRANUDOS 25/45/100 (S41 -06/12) page 8 of 27

2.4 Acid Dosing

The acid required for pH control is metered by the peristaltic pump to

the

flushing water via the dosing injector. As the pH-control is vital for

the correct function of the chlorine/ORP-control, chlorine dosing is

stopped if the level switch at the supply carboy lance indicates container

empty. Besides this primary effect of controlling the pH-value, the dosing

of the acid at this point ensures an always clean dissolving system and

tubing, blockage of the injection valve is avoided.

As acid use one on base of sulphuric acid (37 – 50 %), please do not

use concentrated hydrochloric acid for this job as that penetrates the

peristaltic hose and will destroy the pump head. Diluted hydrochloric acid

may be not strong enough for the neutralisation job. Please note that using

dry acid (sodium bisulphate) 0% (= maximum concentration) is equivalent

to a only 10% sulphuric acid.

Maximum dosing performance is app. 3 l/h and is set as for chlorine.

The dosing cycle set for chlorine is valid for acid too.

2.5 Dissolving System

20 pressure switch 28 allocation rinsing water

21 floating valve 29 level control switch

22 flushing tank 30 union bush with washer nozzle

23 flushing tube 31 outlet ball valve d25

24 flow monitoring 32 supply connection d25 with filter

25 venturi nozzle 33 fitting to connect pressure gauge

26 circulation pump 34 overflow tube

27 cyclone mixing/dissolving chamber

The dissolving water is normally supplied from before or from behind the filter. There must be a

sufficient suppl pressure to avoid dr running and/or cavitation on the booster pump, at

20 21 22 23

34 33

WDT Operating Instruction GRANUDOS 25/45/100 (S41 -06/12) page 9 of 27

least 0.2 bar. The pump pressure is controlled by the pressure switch ( 0) fitted on top of the pump. At

a pressure below the set switch pressure by sucking air or at pressure drops the machine stopps, lamp 1

& will burn. At works 1,5 bar is set.

The supply water is divided in the allocation rinsing water ( 8) at the discharge of the booster pump

( 6), one way leading to the flushing tank ( ), the other branch directed to the venturi nozzle ( 5),

where the water is sucked together with the dosed chemicals out of the flushing tank. The supply water

flow is controlled by means of a floating valve ( 1) and a flow switch ( 4), the latter being installed in

the suction tube of the venturi. To mix the chemicals and to ensure the complete dissolving of the

chlorine granules a cyclone mixing chamber ( 7) is fitted after the venturi.. To ensure that chlorine and

acid do not come into contact with each other in the open tank part of the dissolving assembly a

sophisticated control system is installed:

- metering of the two chemicals is regulated with pauses between the metering intervals

(para .6.3, page 11 “

Dosing Performance Dosing scheme

”).

- power supply for chlorine and acid dosing motors are connected by a relay system so that

only one or none of them can get power ( 4VDC) and dose chemical.

- flow switch ( 4) , level switch ( 9), pressure switch ( 0) supervising water supply and flow

conditions. If any non-compliance with the given limits occurs, the GRANUDOS will be

switched off.

2.6 Control System with program GR S41

The microprocessor based control of the GRANUDOS has three functions:

Contains the circuit self check and dosing and test programmes

Function control and interruption display (1 green + 4 red LED). If any

interruption is displayed, the GRANUDOS dosing is switched off.

All faults activate the fault remote control.

2.6.1 Operation elements

operation elements on front plate

- mains switch

- main fuse 3,15 Aslow

- 1 programme switch for test- and

Operation programmes

- 2 knobs to adjust the wanted dosing

performance for chlorine and acid

- 1 ED green to monitor operation

- 4 ED red to monitor irritations

operation elements inside on control plate:

2 fuses 500 mAslow,

Code switch to select programme alteratives

The control system is enclosed within a dust

proof and splash proof housing (IP 65). External switches and fault remote indication are to be connected

at the back of the control panel.

WDT Operating Instruction GRANUDOS 25/45/100 (S41 -06/12) page 10 of 27

2.6.2 Operation and Test Programmes

Leistungssteller für Chlor und Säure:

By turning the programme switch there is a retention time of seconds with flashes of the green lamp

At the performance knobs for chlorine and acid the dosing performance that is selected by the code

switches on the control plate is reduced to the wanted one.

Auto:

Dosing control by external auto-controller free chlorine and pH-

value. Dosing always within the dosing cycle advance or at the next

cycle. The cycle is to be set on 1 minute with code switch S1 on

“on”, or on 6 minutes with code switch S on “off”. Dosing of

chlorine and acid is independent.

Auto monitor.: as „Auto“ but with dynamic time monitoring: :

When controlling the GRANUDOS dosing by an external auto-

controller the dosing performance must be set high enough to

ensure the dosing times (= dosing performance) of acid and

chlorine shall not exceed 50% of total time, the actual values are

near to the set points of free chlorine and pH. If the controller

output time exceeds 50% , there must be any interruption in the

system:

- dosing performance set too low

- interruption at the dosing motor or dosing screw

- interruption at the auto control system: hanging relay,

faulty electrode etc.

The GRANUDOS controller S4 adds up all demanded dosing

time (input time) that exceeds50% of total time and stops dosing

if 60 minutes excess time is reached: Indication by flashing of the

red lamp 3 (acid) or 4 (chlorine).

Hand

Continuous dosing as set. Dosing cycle as set on code switch S

”on”1 minute, “off” 6 minutes..

With the longer cycle time you get a lower dosing performance

Test chlorine:

Test chlorine dosing for 6 minutes continuously, then stop, the green lamp flashes

Can be used to test the real dosing performance.

Test acid:

Test acid dosing for 6 minutes continuously, then stop, the green lamp flashes.

Can be used to test the real dosing performance

Test knocker

Test for knocker function: the knocker hits 4 times all seconds then stop, the green lamp flashes

Dos-off

Dosing switched off, the booster pump continues. Used for maintenance.

Off:

Switch off of all functions. Used if the machine is taken out of operation for a longer period.

Used also for a restart of the machine after switch off by the fault “level low – pump pressure”

Dosing can be switched off by an additional external switch e.g. a flow or pressure switch

in the measuring water tubing or in the circulation to prevent dosing if there is an

interruption.

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