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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.
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Imprint
Change-over Device U 180-2
Operation Manual
Version 1.0
Publisher:
ALLDOS Eichler GmbHReetzstrae 85 76327 Pfinztal
(Sllingen)Postfach 1210 76318 PfinztalTel. +49 (0) 72 40 61-0 /
Fax. +49 (0) 72 40 61-177E-Mail: [email protected]:
http://www.alldos.com
2004 by ALLDOS Eichler GmbH
Subject to change.
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Installation Data
NOTE Please fill in this form following commissioning. It will
help you and your ALLDOS servicing partner to adjustthe 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 In General
...................................................................................................6
1.2 Using this Paper
.........................................................................................6
1.3 Warranty
.....................................................................................................6
2 Safety Instructions
................................................................................
7
2.1 Application of the Product
...........................................................................
7
2.2 Obligations of the Operating Authority
........................................................7
2.3 Averting Dangers
........................................................................................7
3 Technical Data
.......................................................................................
8
3.1 General Data
..............................................................................................8
Change-over
...............................................................................................8Control
Panel
..............................................................................................8Ambient
Conditions.....................................................................................8
3.2
Varianten.....................................................................................................8Actuator
......................................................................................................8Control
Panel
..............................................................................................8Prfmittel
.....................................................................................................
8Language of labelling
..................................................................................8
3.3 Dimensional Drawings
................................................................................9Change-over
...............................................................................................9Control
Panel
..............................................................................................9
3.4 Plants
Picture............................................................................................10
3.5 Connection Diagram
.................................................................................10
4
Installation............................................................................................
11
4.1 Transport and Storage
..............................................................................11
4.2 Unpacking
.................................................................................................11
4.3 Mounting Conditions
.................................................................................11
4.4 Mounting (to solid wall)
.............................................................................11
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5
Commissioning....................................................................................
12
5.1 Preparations for Commissioning
...............................................................12Gas
Connections
......................................................................................12Electrical
Connections
..............................................................................12
5.2 Checks before Commissioning
.................................................................13Electrical
Connections
..............................................................................13Gas
Connections
......................................................................................13
5.3 Checking the Tightness of Pressure Gas
Lines........................................13Checking the
tightness with nitrogen
........................................................13Leak
Detecting with ammonia
(Dosing media Cl2 or SO2)
...........................................................14Test
of Functioning of the Change-over Process
......................................14
6 Operating
.............................................................................................
15
6.1 Device
Description....................................................................................15Function
....................................................................................................15
6.2 Operation
..................................................................................................16
Manual emergency operationin case of power failure
..................................................................16
Exchange servo motor
..............................................................................17
6.3 Possible Faults
..........................................................................................17
7
Maintenance.........................................................................................
18
7.1 Cleaning and maintenance
intervals.........................................................18
7.2 Exchange of gaskets
................................................................................18Dismantling
the change-over valve
...........................................................18Re-assembly
of the change-over unit
.......................................................19
8 Spare
Parts...........................................................................................
20
8.1 Change-over
180-2...................................................................................20
8.2 Manual Emergency Operation Lever
........................................................228.3 Spare
Parts Set
........................................................................................22
8.4 Spare Parts List
........................................................................................23
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1 Of General Interest
1.1 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 indetail 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 lettersand an
arrow().
The headings WARNING, CAUTIONand NOTEhave the following
meaning:
!WARNING Danger of injuries and accidents!
CAUTION Danger of incorrect operation or damage to the
product!
NOTE There is an exceptional feature.
1.3 Warranty
Warranty in accordance with our general terms of sale and
delivery shall only bevalid, 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
andqualified personnel,
original spare parts are used for repairs,
only parts approved by ALLDOS are being used in the whole gas
dosingplant.
Warranty is not valid for typical wearing parts, e. g.
gaskets, o-rings, diaphragms
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2 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 betweentwo 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 noresponsibility for
damages caused by unintended use.
2.2 Obligations of the Operating
AuthorityThe 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"Functionand Safety of Chlorination Plants")
arranging regular maintenance
2.3 Averting Dangers
The Change-over Device is an additional danger point for leakage
within the gasdosing 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 authorizedpersonnel!
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3 Technical Data
3.1 General Data
Change-over
max. capacity 15 kg Cl2/h
Measurements in mm 225 x 310 x 265 (B x H x T)
Degree of protection IP 55
Weight 8 kg
Supply voltage 230 V / 50 Hz
Actuating time about 8 s
Manual emergency operation with enclosed lever
Control Panel
Power supply 230 V / 50 HzDegree of protection IP 65
Operating contact 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 250 x 375 x 160 (B x H x T)
Weight about 5.5 kg
Ambient Conditions
admissible ambient temperature 0 ... +50 C
admissible storage temperature -20 ... +60 C
3.2 Varianten
Actuator
Index no. Power Supply
S005 230 V (standard version)
Control Panel
Index no. Description
V000 with control panel 230 V, 50 Hz (standard version)
without control panel
Language of labelling
Index no. Description
F000 German (standard version)
F001 English
F002 French
F003 Spanish
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3.3 Dimensional Drawings
Change-over
Control Panel
t = 150mm
250
177 8,5
394
370
350
A - A
G
"2
6
9
G "
100
about 225
G
"
41A
A
about 265
about312
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3.4 Plants Picture
1 Change-Over 180-22 Control Panel of the Change-over
3 Vakuum Regulator
4 Gas Dosing Device
5 Header line for containers
6 Injector
I Container Battery 1
II Container Battery 2
3.5 Connection Diagram
Feeding
pressure
pressure valve
valve
open close
Battery I + II
empty
"operation"
message
green
Battery IIgreen
Battery I
manual operation
Battery I + II
2 134
5
A B
C
6I II
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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!
Check the scope of delivery.
Mount as soon as possible after unpacking.
4.3 Mounting ConditionsCAUTION 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 twodowels 10 mm.
Insert the dowels.
Fix the mounting plate with two washers with two hexagonal
screws 8x80 tothe 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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5 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 CommissioningGas Connections
CAUTION Danger of operation failures! Observe permissible line
cross-sections!
Lay and connect the connection lines of both extraction points
(bottles, tanks orheader lines) and the vacuum regulator. Please
make sure that the lines have nobuckles 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 fromcorrosion and
moisture.
CAUTION Before connecting the mains cable: Check that the power
supply specified on the ratingplate corresponds to the local
supply. An incorrectsupply 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 supplycables 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
Electrical Connections
Check the electric 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 PressureGas 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
tightnessroughly 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 gasdosing system
Slowly open the valve of the nitrogen cylinder, until the lines
have a pressureof about 10 bar (read at the manometer of the vacuum
regulator), closevalve again.
!WARNING Maximum nitrogen pressure 16 bar!
Danger of damages and gas leakage when beingexceeded!
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
dropsignificantly within one hour: Pressure lines are tight.
Close all container connection valves.
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Leak Detecting with ammonia(Dosing media Cl
2or SO
2)
Leaks are localized by passing the open bottle of ammonia near
to the junctionpoints and by squeezing slightly ammonia out of the
bottle. If there is a leak wheregas escapes, white vapour is
generated. Even the slightest leakages discoveredhave to be
repaired immediately.
! WARNING Liquid ammonia must not come in contact with parts
ofthe 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 checkthe tightness of the stuffing box.
open slowly the connecting valves of the containers until the
contactpressure 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 thecontact 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 checkthe tightness of the stuffing box.
open slowly the connecting valves of the containers until the
contactpressure 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 thecontact 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 andthe left battery.
Press the test key
- until the LED indicating operation of the right battery lights
up.
close all the container valves of the right battery.
- Depending on the dosing capacity, the contact pressure gauge
dropsnow more or less fast.
When the pressure falls below the adjusted value, the
change-over deviceactivates automatically the left battery. The
corresponding LED lights up andthe contact pressure gauge indicates
the pressure of full receptacles.
The empty container battery is indicated optically, i.e. the LED
for the emptyside extinguishes, while the LED for the battery which
is now in operationlights up.
!
WARNING The container valves and the connecting valves of
the
containers have to be closed when exchanging theempty
containers.
The valves are to open again, after having connectedthe new,
full rcontainer
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6 Operating
6.1 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. Asthe exact point of time when the connected
container battery will be empty cannotbe determined in advance, the
continuous chlorine gas dosing is endangered.
The automatic ALLDOS change-over device guarantees a continuous
dosingprocess, as the changing over from the empty receptacles to
the ones in reserve iseffected automatically. The change-over
process is indicated optically at the controlunit.
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. Thechange-over device works on the principle
of a three-way motor valve, that isactuated 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 withthe 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.
The change-over is connected to
- two container batteries at the input side
- a vacuum regulator at the output side.
The change-over is controlled by the control panel and the
contactmanometers.
- If one container resp. one container battery gets empty, the
control panelactivates the servomotor.
Status message for the container batteries:
- For each container battery there is one signal lamp:
green lamp: for "operation"
- For remote display of the "operation" state of container I und
II there isone 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
containerbattery 1 or 2.
lamplamp
pushbutton key
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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 operationin case of power failure
In case of power failure or other electric problems the
change-over device can beoperated 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 hasto be closed at first
and then the one of the full batterycan be opened.
NOTE 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 ofthe lever
points to the left. (The right battery is closed.)
Lift off the cover of the servomotor (4 screws), eventuaelly
pinch offconnecting cables. Dismantle servomotor (3 screws (
32)).
Insert the journal of the supplied hand lever (14) in the fork
(8) and fasten thelever 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 correctingdisplacement
is only about 1 mm.
Close the valves of the empty battery.
Unscrew the fastening screw and adjust the lever so that the
lower endpoints 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 inoperation.
Open slowly both receptacle batteries.
start up the chlorine gas dosing unit.
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6.3 Possible Faults
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 "Ma-nual emergency operation in case of power failure",
and have it repaired orreplace it by a new one.
Insert the lever and operate it accordingly.
observe "Manual emergency operation in case of power
failure"
27
13
14
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7 Maintenance
7.1 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).
!WARNING Switch off the entire system before starting the
cleaning and maintenance work!
7.2 Exchange of gaskets
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 valveDismantling the change-over
valveDismantling the change-over valveDismantling the change-over
valveDismantling 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),
removethe 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 theenclosure (1). Leave the nut (18) and connection nipple
(17) at theconnection 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, thatno
water and no humidity penetrate the measuringmuff of the contact
manometer (15).Danger of corrosion when installing humid parts!
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Re-assembly of the change-over unitRe-assembly of the
change-over unitRe-assembly of the change-over unitRe-assembly of
the change-over unitRe-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) andfasten 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 re-
starting, check the tightness!Danger of gas escape!
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34
32
8
35
16
39
11
2
4
9
20
5
50
19
1
41
48
8 Spare Parts
8.1 Change-over 180-2
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B - B
C - C
47.3/ 4/ 5
28
30
47.51
22
25
44
10
26
C
C
15
3
21
43
7
6
17
18
A - A
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27
1314
8.2 Manual Emergency Operation Lever
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
metI .ontraP noitpircseD krameR
1 003-2052.21 erusolcne -
2 003-3052.21 revoc -
3 004-4052.21 etalp -4 004-1806.21 etalp -
5 004-8052.21 tfahs -
6 004-9052.21 hcnarbnoitcennoc -
7 004-0152.21 elzzon -
8 004-1152.21 krof -
9 004-2152.21 xobgniffuts -
01 004-3152.21 gnihsubecnatsid -
11 004-2806.21 gnihsubcirtnecce -
31 815.05 rehsaw -
41 004-3352.21 revel -
51 0252.21 retemonamtcatnoc rab61-0
61 103-00201.54 rotomovres zH05/V032
71 004-4225.21 elppinnoitcennoc "4/1G
81 014-3225.21 tun 6/8
91 004-9425.21 hsub EFTP
02 225.05 rehsaw -
12 1452.21 tinugnisolc -
22 221.05 wercsdaeheseehc 21x5M
52 598.05 wercsdaeheseehc 61x5M62 785.05 wercsdaeheseehc
53x5M
72 512.05 nogaxehwercs 02x5M
82 8631.05 wercsdaeheseehc 02x4M
03 6711.05 wercssseldaeh 01x4M
23 419.05 wercsdaeheseehc 04x6M
43 471.45 gnirgnilaes -
53 004-2201.84 lebalevisehda -
93 4651.05 wercssseldaeh 6x5M
14 140.45 teksagtalf 2x62x5,12
34 401.25 gnir-o 5,1x21notiV
44 161.45 teksagtalf 2x45x54
54 5.721-073 tinulortnoc zH05/V032
74 004-7652.21 2-081Useirossecca -
1.74 1.330.84 lewod -
2.74 1151.05 wercs -
3.74 1.130.84 lewod -
4.74 5031.05 wercs -
5.74 915.05 rehsaw -
15.74 371.45 teksagtalf -84 004-1652.21 lebalevisehda -
05 381.25 gnir-o 5,1x7notiV
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