Operating and installation instructions. Dosing system Granudos 10-CPR Touch XL

Transcription

1 Operating and installation instructions Dosing system Granudos 10-CPR Touch XL Operating instructions part 1: for dosing unit, without measuring and control unit Part 1, to operating instructions of the measuring and control unit, CPR Touch XL, no.: BA MR 001 Item no.: Language: EN

2 Granudos 10-CPR Touch XL, dosing unit Table of contents 1 Information regarding these instructions / general information Scope of validity Target group Symbols used Warranty Further information Safety Appropriate use Safety instructions: Handling of chemicals, risks to persons and the environment Protective measures and behavioral rules Product description - delivery scope Delivery scope / accessories Product description The function of the GRANUDOS 10-CPR, dosing unit Plastic housings with additional fittings (standard) Chlorine dosing (standard) Dissolving system (standard) Acid dosing (standard) Flocculant dosing (standard) Buffer tank with / without protective tray (optional) Control CPR Touch XL (standard) Identification of the device / name plate Technical data Transport / storage Storage of chemicals Assembly Selecting the place of installation Assembly information / installation suggestion Mechanical installation Hydraulic installation Installation of the dissolving and measuring water supply Installation of the dosing line for chlorine solution Buffer tank (optional) Installation of an overflow pipe from the rinsing tray to the collecting tray Flocculant dosing Electrical installation Commissioning Commissioning - comments Initial operation Install the hose pumps and roller carriers Prepare acid dosing for operation Prepare flocculant dosing for operation Filling the filling hopper with chlorine granulate Bleeding the motive water pump and the pipes to the GRANUDOS 10-CPR Setting the water flow in the dissolving system Adjustment of the water level in the rinsing tray Index: 00 Change date: 15/07/2016 Operating instr. no.: BA SW Granudos 10-CPR Dosiereinheit EN.docx Page 2 of 52

3 Granudos 10-CPR Touch XL, dosing unit 6 Operation / handling General Top up consumables Maintenance, service, faults Device maintenance Clean the dirt filter Exchanging the dosing screw and the dust seal Injector with flow switch Waiting and setting the floater control valve for the feed of the rinsing tray Exchanging and setting the "Chlorine empty" switch at the dosing hopper (option) Exchanging the dosing hose of the dosing pump Regular water inspection Fault removal Shutting down - Storage - Disposal General Decommissioning the GRANUDOS 10-CPR dosing device Buffer tank (optional) Documents Declaration of conformity Terminal diagrams Commissioning report Operating data sheet Maintenance protocol Spare parts list, wearing parts list, consumables Appendices Imprint All rights reserved Copyright by WDT Werner Dosiertechnik GmbH & Co KG Support: see footer Publications of any kind and translation into other languages, also of excerpts, is only permitted with the explicit approval of WDT - Werner Dosiertechnik GmbH & Co. KG. Subject to technical changes These operating instructions are based on the German original provided by the WDT Company. Responsible for the content: WDT - Werner Dosiertechnik GmbH & Co. KG Hettlinger Str. 17 D Wertingen-Geratshofen Tel.: +49 (0) / Fax: +49 (0) / info@werner-dosiertechnik.de Index: 00 Change date: 15/07/2016 Operating instr. no.: BA SW Granudos 10-CPR Dosiereinheit EN.docx Page 3 of 52

4 Granudos 10-CPR Touch XL, dosing unit 1 Information regarding these instructions / general information 1.1 Scope of validity These instructions describe the function, installation, commissioning and operation of the GRANUDOS 10-CPR dosing system with appropriate accessories. These operating instructions must be carefully read before use and must be stored near the device for immediate use. These operating instructions apply in combination with the operating instructions for the Measuring and Control Unit CPR Touch XL No.: BA MR Target group Only our authorised partners and persons who were instructed regarding the device functions and have read and understood the operating instructions may work on the system. Electrotechnical connection work may only be performed by appropriately trained specialist staff! 1.3 Symbols used The following types of safety instructions and general instructions are used in this document: DANGER! "DANGER" identifies a safety instruction that is neglected at the risk of severe or life-threatening injuries or major damage to goods! CAUTION! "CAUTION" identifies safety instructions that are neglected at the risk of injuries, damage to health or damage to goods! ATTENTION! "ATTENTION" identifies safety instructions that are neglected at the risk of damage to goods! Index: 00 Change date: 15/07/2016 Operating instr. no.: BA SW Granudos 10-CPR Dosiereinheit EN.docx Page 4 of 52

5 Granudos 10-CPR Touch XL, dosing unit CAUSTIC! "Caustic" identifies a safety instruction that is neglected during handling of chemicals at the risk of injuries or damage to goods. ESD-SENSITIVE! "ESD SENSITIVE" identifies electronic components that can be damaged by electrostatic discharge. The generally known precautions regarding ESD-sensitive devices must be adhered to when handling these devices! Hint! A "HINT" characterises information that may help to improve the operation. Mandatory sign Use face protection! Mandatory sign Use protective gloves! According DIN EN 374 Mandatory sign Use protective apron! Mandatory sign Use protective boots! Index: 00 Change date: 15/07/2016 Operating instr. no.: BA SW Granudos 10-CPR Dosiereinheit EN.docx Page 5 of 52

6 Granudos 10-CPR Touch XL, dosing unit 1.4 Warranty All devices and systems of the WDT Company are produced using the latest production methods and comprehensive quality control. Please send your warranty claims according to the general warranty conditions (see below) to WDT should there nevertheless be a reason for complaint. General warranty conditions WDT provides a warranty for 2 years from the date of commissioning, a maximum period of 27 months after delivery, assuming correct installation and commissioning with completed and signed commissioning protocol. Wearing parts such as seals, hoses, membranes, dosing screw conveyors, electrodes, roller carriers and other parts that are subject to mechanical or chemical wear are excluded. We provide a warranty for half a year on those parts. Our ERP programme requires an invoice for each delivery (also for warranty services). Customers will receive a credit note after returning the faulty part and its inspection as required. Please return goods within 14 days. Costs for consequential damage and costs resulting from handling warranty claims are excluded. Warranty claims are not valid when the damage was caused by frost, water, over-voltage or inappropriate handling. Hint! Please send a completed commissioning protocol together with the defective part to Company WDT to maintain your warranty claims. We reserve the right to settle the warranty claim when no commissioning protocol is available. ATTENTION! Modification of the device is not permitted. Warranty and product liability claims become void when this requirement is not fulfilled. 1.5 Further information Further information regarding specific topics such as layout of the dosing performance or description of the operating parameters is available from your specialist dealer or directly from: Company WDT Werner Dosiertechnik GmbH & Co KG Hettlinger Straße Wertingen - Geratshofen Tel Fax http: // Index: 00 Change date: 15/07/2016 Operating instr. no.: BA SW Granudos 10-CPR Dosiereinheit EN.docx Page 6 of 52

7 Granudos 10-CPR Touch XL, dosing unit 2 Safety 2.1 Appropriate use The GRANUDOS 10-CPR may only be used for the purposes specified in Section 3.2 of the product description! The locally applicable regulations regarding accident prevention, worker safety and drinking water protection must be adhered to. 2.2 Safety instructions: The operating instructions must be carefully read and considered before installation and use! Work on the system and changes to the settings may only be performed by instructed persons! Take note of the warning information on the device! Handling of chemicals, risks to persons and the environment In emergencies relating to the handling of chemicals, you can contact a Poison Emergency Call Centre! Emergency call number: Poison Emergency Call Munich (or any other poison centre) Telephone: Extract from the GUV-V D 5 accident prevention regulations Installation rooms for chlorination systems and storage rooms 3a (1) Chlorination systems must be installed in lockable rooms and the chemicals intended for chlorination must be installed in lockable rooms. To 3a Section1: These requirements are intended to protect the chlorination systems and chemicals against weather effects and access by unauthorised parties. (2) Rooms according to Section 1 may not be intended for permanent use by people. To 3a Section2: Index: 00 Change date: 15/07/2016 Operating instr. no.: BA SW Granudos 10-CPR Dosiereinheit EN.docx Page 7 of 52

8 Granudos 10-CPR Touch XL, dosing unit Permanent use is given when persons remain longer than 2 hours per day in a room. Repair and maintenance work on the chlorinating system are exempt Protective measures and behavioral rules CAUSTIC! PROTECTIVE EQUIPMENT! The GRANUDOS 10-CPR dosing system doses the calcium hypochlorite granulate (generally called: chlorine pellets) as well as the ph-reducer from the dosing canister. These substances react strongly on contact and produce chlorine gas when combined outside of water. It is therefore essential to perform all work with these chemicals very diligently and to wear personal protective equipment: Face protection, protective gloves, protective apron, and boots. The chlorine granulate and the sulphuric acid may not be mixed with each other or with other chemicals and substances! Store the chemicals to ensure that unauthorised persons cannot access them. The information in Section 3.5.1, Storage of chemicals must be taken in account when storing chemicals. More information is provided in the safety data sheets of the chemical substance producers! ESD-SENSITIVE! The electrical components in the control units of the systems are sensitive towards electrostatic discharge. The generally known precautions regarding ESD-sensitive devices must be adhered to when handling these devices! Disconnect the system from the power supply Discharge the personal static charge Index: 00 Change date: 15/07/2016 Operating instr. no.: BA SW Granudos 10-CPR Dosiereinheit EN.docx Page 8 of 52

9 Granudos 10-CPR Touch XL, dosing unit 3 Product description - delivery scope 3.1 Delivery scope / accessories The delivery scope includes the "GRANUDOS 10-CPR" dosing system consisting of the following components: Housing with collecting tray made of rotation-sintered PE in blue Dosing device for chlorine granulate Dosing device for acid Dosing system for flocculants Dissolving system for chlorine and acid The following options are available for the dosing system a) Adapter for larger hopper b) Adapter for various 10 kg buckets 3.2 Product description The GRANUDOS dosing system is intended for disinfecting swimming pool water with calcium hypochlorite The function of the GRANUDOS 10-CPR dosing unit The GRANUDOS 10-CPR is a device for dosing calcium hypochlorite granulate. The chemical is dissolved and fed into the pipe through an injector by a booster pump. The acid dosing required to regulate the ph of the swimming pool water is integrated and controlled by software and a relay system to ensure that chlorine and acid cannot be dosed at the same time. The GRANUDOS 10-CPR dosing device is particularly suitable for swimming pools with a water volume of m 3 The functions of the GRANUDOS 10-CPR Measure free chlorine with an open, potentiostatic measuring cell. ph-value, redox voltage and temperature Regulate chlorine dosing based on the measuring value for free chlorine or the redox voltage Dose chlorine granulate from a 5kg filling hopper or directly from the 10kg delivery bucket (optional) using a dosing screw and knocker. Dose flocculant from the delivery canister using a rotation-speed-controlled hose dosing pump Fill a small buffer tank with chlorine solution to disinfect additional small pools with dosing pumps (option) Index: 00 Change date: 15/07/2016 Operating instr. no.: BA SW Granudos 10-CPR Dosiereinheit EN.docx Page 9 of 52

10 Granudos 10-CPR Touch XL, dosing unit The functional principle of the GRANUDOS 10-CPR dosing system. Swimming pool 1 safety shutdown Heat exchanger 2 Circulation pump Balance tank Filter Central controller Measurm. + control Y ph minus Flocculation Water sampling and dosing connection: socket 3/4" Piping DN20 Granudos 10-CPR Acid Dosing system for Flocculation calcium hypochlorite Figure 1, Flow chart for GRANUDOS 10-CPR without buffer tank 1 Auxiliary pool Main pool Heat exchanger Circulation pump Balance tank Safetyshutdown Heat exchanger 2 Circulation pump Balance tank Filter Filter Measrm. + control Y Controller for level switch Control valve on the Granudos Air supply pressure min. 5bar Central conroller Flow control valve NC NO ph minus Flocculation Further pools possible A L max S S L min A Solenoid valve opens at container level minimum - Granudos doses with high dosing power untill container level maximum - about 10 minutes. During this time there is no dosing into the main pool Water sampling and dosing connection: socket 3/4" Piping DN20 Granudos 10-CPR Dosing system for ph reduction Buffertank for clorine solution Figure 2, Flow chart for GRANUDOS 10-CPR with buffer tank Acid Dosing system for calcium hypochlorite Flocculation ATTENTION! The locally valid regulations must be adhered to during installation. E.g. for Germany DIN Index: 00 Change date: 15/07/2016 Operating instr. no.: BA SW Granudos 10-CPR Dosiereinheit EN.docx Page 10 of 52

11 Granudos 10-CPR Touch XL, dosing unit Plastic housings with additional fittings (standard) The elegant housing (5) is sintered from a piece of blue PE and therefore extremely rugged. The dosing hopper (7) with a filling volume of 5, 10 or 15 kg (optionally also with adapter for 10 kg bucket) is inserted into the housing from the top and can therefore also easily be removed, e.g. for maintenance work. Dosing unit (11), dosing motor with dosing screw and heated downpipe are screwed into the dosing hopper from the bottom. The controller (1) is located on top of the housing. The dosing hopper is protected against splashing water by a transparent lid. The bottom section of the housing contains the dissolving and rinsing system (12) for the chlorine granulate Figure 3, GRANUDOS 10-CPR The GRANUDOS 10-CPR consists of: 1. CPR Touch XL controller (see separate instructions) 2. Measuring cell block 3. Suction lance for ph reducer (not visible) 4. Ball valve intake 5. Casing 6. Collecting tray with drain 7. Dosing hopper with lid 8. Holder for redox test cylinder 9. Dosing pump for ph reducer (acid) 10. Dosing pump for flocculants 11. Dosing unit for chlorine 12. Dissolving and rinsing system for chlorine granulate 13. Suction lance for flocculant (not visible) 14. Outlet to the swimming pool 15. Main switch (not visible, left on the controller housing) Index: 00 Change date: 15/07/2016 Operating instr. no.: BA SW Granudos 10-CPR Dosiereinheit EN.docx Page 11 of 52

12 Granudos 10-CPR Touch XL, dosing unit Chlorine dosing (standard) The dosing hopper shown (7) is hooked onto the plastic housing and is used for dosing chlorine granulate into the dissolving and rinsing system (12) Figure 4, Dosing hopper The chlorine dosing hopper (7) consists of: 7. Dosing hopper 22. Magnetic knocker (with clamping housing) 23. Dosing motor 24. Motor holder 25. Chlorine empty switch (optional) 26. Cleaning plug 27. Dosing screw (not visible) 28. Dosing pipe (with heating) The dosing system consists of a dosing hopper (7) with a capacity of approx. 5kg and a dosing unit that includes the dosing motor (23) with flange, the dosing screw (27), the motor holder (24) and the heated dosing pipe (28) with dosing outlet. Heating the dosing pipe prevents condensation of water vapour that might otherwise cause a blockage in the dosing system. The dosing unit is screwed into the bottom of the dosing hopper. The dosing hopper is either tightly sealed with a lid or provided with a transparent adapter ring, so that a 10kg bucket can be directly placed onto the dosing hopper, see Figure 5. The complete dosing system is removed from the housing in an upward direction for bucket changes or maintenance work on the dosing system. The dosing screw (27) transports the calcium hypochlorite granulate from the dosing hopper into the rinsing pipe (46) of the dissolving system located below. A solenoid knocker (22) has been installed to loosen up the chlorine granulate. It provides a brief tap on the dosing hopper at every dosing process to prevent the granulate from forming bridges in the dosing line. The chlorine dosing is arranged alternately with the acid and is monitored. See operating instructions measuring and control unit CPR-Touch XL, no.: BA MR 001. Index: 00 Change date: 15/07/2016 Operating instr. no.: BA SW Granudos 10-CPR Dosiereinheit EN.docx Page 12 of 52

13 Granudos 10-CPR Touch XL, dosing unit Adapter for chlorine buckets Adapters for different types of chlorine buckets are available so that the buckets can be directly placed onto the dosing hopper and no refilling is required. Adapter ring d 275 with clamps e.g. for HC or Melchlor, 10 kg Screw-on adapter ring e.g. for Olin-HTH, 10 kg Figure 5, Adapter for chlorine buckets Index: 00 Change date: 15/07/2016 Operating instr. no.: BA SW Granudos 10-CPR Dosiereinheit EN.docx Page 13 of 52

14 Granudos 10-CPR Touch XL, dosing unit Dissolving system (standard) The dissolving system is installed in a plastic housing and is used for separate dissolution of the chemicals Figure 6, Dissolving system The dissolving system consists of: 31. Outlet for supplying the measuring system 32. Pressure retention valve for supplying the measuring system 33. Pressure switch 34. Dirt filter d75mm 35. Motive water pump 36. Connection for manometer 37. Injector 38. Rinsing tray 39. Screw connection with hole disk 40. Rinsing tray flow switch 41. ph-reducer dosing valve 42. Dissolving and mixing cyclone 43. Connection for manometer 44. Rinsing tray overflow 45. Rinsing tray inlet float regulator valve 46. Rinsing pipe 47. Rinsing tray min/max level switch 48. Lid for rinsing tray with dust protection pipe (not shown) Index: 00 Change date: 15/07/2016 Operating instr. no.: BA SW Granudos 10-CPR Dosiereinheit EN.docx Page 14 of 52

15 Granudos 10-CPR Touch XL, dosing unit The dissolving system splits the dissolving water from the filter cycle after the motive water pump (35) and the chemicals are dissolved separately from each other. The particle stream is ducted via the float regulator valve (45) into the rinsing tray (38). The water, together with the chemicals dosed through the rinsing pipe (46), is sucked off by the injector (37). The chlorine granulate and the ph reducer (liquid) are dosed into the water flowing through the rinsing pipe, following an alternating pattern with intermediate breaks. Approx. 50% of the chlorine granulate are dissolved in the injector; the remainder is kept in circulation in the dissolving cyclone (42) until it is fully dissolved. The chlorine granulate can be seen in the cyclone shortly after the start of dosing. Changes in the water supply of the dosing system that prevent appropriate functioning of the dissolving system are detected by the level switch (47), the flow switch (40) and the pressure switch (33).The chemical dosing or the motive water pump are in such cases switched off to prevent consequential damage. Accurate information in this regard is provided in the operating instructions for the Measuring and Control Unit CPR-Touch XL, No.: BA MR 001. The pressure switch installed on the pressure side of the motive water pump is intended to switch off the GRANUDOS in the event of a pressure drop or aspirated air, to ensure that the pump cannot run dry. An additional monitoring switch can be connected to switch off the dosing system in the event of a fault in the filter system, e.g. no flow in the clean water pipe. The flow switch (40) installed in the suction pipe of the injector (37) is very important for the operating safety of the GRANUDOS! When the suction performance of the injector (at least 150l/h) is too low, the switch body in the suction pipe, which is pushed up by the upwards flow, drops and switches off the chemical dosing. This ensures that only strongly flowing water is dosed and that the two chemicals do not mix in the accessible area. The floater regulation valve (45) also blocks this feed to the rinsing tray when the device stands still or in the event of operating faults. However, these measures do not ensure absolute separation from the circulation system. Where this is required, appropriately sealing isolation valves are to be installed in the supply and dosing line, i.e. reflux valves or self-closing pneumatic valves, depending on the pressure conditions. The pressure loss during operations due to those fittings has to be considered. In the event of a "Water max" fault, the overflow (44) will transport the chlorine-free excess water to the drain. The pressure retention valve (32) is used to supply the measuring system with constant pressure and prevents overflow of the rinsing tray when suction is not active. It is pre-set at the factory. The following safety package is installed to ensure that chlorine granulate and acid cannot mix and react with each other in the open part of the dissolving system: The dosing of the two chemicals takes place in fixed cycles with pauses between the dosing steps. The power supplies of the two dosing motors are interlocked by a relay system that ensures that the two motors can never operate at the same time! The water supply and the water flow is monitored by pressure switch (33), level switch (47) and flow switch (40). Dosing only takes place when the water flow is ensured. The dosing system is stopped and an appropriate fault message is generated when a deviation from the set target values occurs. Index: 00 Change date: 15/07/2016 Operating instr. no.: BA SW Granudos 10-CPR Dosiereinheit EN.docx Page 15 of 52

16 Granudos 10-CPR Touch XL, dosing unit ATTENTION! The use of sulphuric acid up to a concentration of 50% is generally possible. Changes in the dosing performance and/or increased corrosiveness have to be considered when a higher concentration or other acids (e.g. nitric acid, dissolved Na-bisulphate or others) are used! It is recommended to contact the manufacturer! The dissolving water supply should be separated from the filter function of the swimming pool. This can be done in 2 ways: (also see presentation under Section 4.4.1, Installation of the dissolving and measuring water supply. 1. Water sampling from the swimming pool 2. Water sampling between the circulation pump and the filter before chemical dosing. Only use this alternative in exceptional cases when Option 1 cannot be implemented! Acid dosing (standard) The acid dosing of the GRANUDOS 10-CPR is used to ensure complete dissolution of the chlorine granulate and to correct the ph value of the pool water. Each kg chlorine granulate requires the supply of approx litres of 37% sulphuric acid. A hose pump (Pos 9, Page 11) is installed as a standard for this purpose. Acid dosing is automatically regulated by the controller. However, acid dosing for filling the buffer tank must be adjusted. Chloride dosing must be adjusted during commissioning to ensure that the ph value of the chloride solution in the buffer tank is The calcium hypochlorite is then completely dissolved. The solution is clear for practical purposes and has no strong chlorine smell. The solution smells strongly of chlorine and is more corrosive when the ph value is too low. The solution is murky and forms sediments or deposits in the buffer tank and the dosing lines when the ph value is too high. The correct dosing ratio is set after measuring the ph value. Hose pumps can transport very small dosing amounts in a reliable and continuous manner, even when air or gas bubbles are included in the suction line. Rotating rollers press the dosing hose against the housing wall, squeeze out the liquid in front of the rollers and aspirate new liquid behind them. Hose pumps are extremely reliable and easy to operate. The hose pump aspirates the acid out of the acid canister through a suction lance (Pos 13, Page 11). The filling level in the acid canister is measured by a level switch for the empty message. Figure 7, Acid dosing pump Use sulphuric acid with a saturation level of 37-50% as ph-reducer. Concentrated nitric acid destroys the hose pump - dilute to below 10%. Sodium bisulphate "dry acid" solutions should not have concentrations higher than 20% (corresponds to 10% sulphuric acid). It must be considered whether this acid performance is sufficient for neutralisation. Index: 00 Change date: 15/07/2016 Operating instr. no.: BA SW Granudos 10-CPR Dosiereinheit EN.docx Page 16 of 52

17 Granudos 10-CPR Touch XL, dosing unit Hint! In special cases, e.g. when water is very hard and/or has a high ph value and/or a very high dosing performance is required, it is recommended to use nitric acid instead of sulphuric acid in order to prevent possible formation of gypsum residues due to high sulphate concentrations in the buffer tank Flocculant dosing (standard) The flocculant acts on very fine impurities in the swimming pool water, which are otherwise not retained by the filter, to make them suitable for filtering. Flocculant dosing is performed with a hose dosing pump (Pos 10, Page 11) that is identical to the one used for acid dosing, but has rotation speed control and a smaller hose diameter. The flocculant is sucked out of the flocculant canister with a suction lance (Pos 13, Page11). The filling level in the canister is measured by a level switch for the empty message. Figure 8, Flocculant dosing pump Buffer tank with / without protective tray (optional) 81. Active carbon filter 82. Collecting tray PP, not shown stop level switch, Level minimum alarm; Level minimum; Level maximum; Level maximum alarm; 84. Alarm switch in collecting tray (not shown) 85. Buffer tank 300 l PE Figure 9, Buffer tank without protective tray 1. Buffer tank filling is started at the minimum buffer tank control level. 2. Buffer tank filling is stopped at the maximum buffer tank control level; this is followed by a rinsing cycle to clean the dissolving system: First 20 seconds with acid, then another 20 seconds with plain water. Index: 00 Change date: 15/07/2016 Operating instr. no.: BA SW Granudos 10-CPR Dosiereinheit EN.docx Page 17 of 52

18 Granudos 10-CPR Touch XL, dosing unit 3. An alarm message is shown on the display at minimum alarm level. 4. An alarm message is shown on the display at maximum alarm level. Contact positions The contacts of the level switches are set as follows when the container is half filled: Level position Level minimum Level minimum alarm Level maximum Level maximum alarm Contact opened opened opened closed An active carbon filter (81) is screwed on top of the buffer tank. It is used to clean the chlorine-polluted air during filling of the buffer tank and for ventilating and bleeding Control CPR Touch XL (standard) Control (version GRANUDOS 10-CPR-Touch XL) See operating instructions measuring and control unit CPR-Touch XL, no.: BA MR Identification of the device / name plate Enter the data on the name plate of your device here. Array 1: Array 2: Serial no.: Enter the production date Index: 00 Change date: 15/07/2016 Operating instr. no.: BA SW Granudos 10-CPR Dosiereinheit EN.docx Page 18 of 52

19 Granudos 10-CPR Touch XL, dosing unit 3.4 Technical data GRANUDOS 10-CPR Buffer tank GRANUDOS-PB (optional) Dimensions and weights: Device dimensions W 75cm, D 55cm, H 145cm D 80cm, H 130cm Space requirements for the W 160cm, D 65cm, H 180cm W 90cm, D 90cm, H 180cm device (pedestal) Space requirements incl. operation and maintenance W 160cm, D 145cm, H 210cm W 90cm, D 90cm, H 210cm Empty weight/operating weight Approx.40kg / 60kg Connection data Electrical connection data 230VAC/50Hz ± 10%, 350W, I max.3,15a, two-pin earthed plug Protection class IP54 Hydraulic connection data Inlet DN 25 Outlet DN20 Overflow dissolving system DN20 Drain collecting tray DN25/32 Drain connection required Operating pressure Required inlet pressure Back pressure Water supply Operating data: max. Dosing performance GR 10-CPR Minimum DN25 max. 2.5barg min. 0.2barg 0-1.5barg (depending on the inlet pressure) From the swimming pool with motive water pump: Flow pressure at least.1.2barg In exceptional cases: Between circulation pump and filter, before chemical dosing with motive water pump Flow pressure at least.1.2barg Chlorine: with motor PLG30-12; approx. 0.5kg/h (1) with motor PLG30--35; approx. 2kg/h (1) Acid: max. approx. 1.3l/h (2) Flocculant: max. 50ml/h approx l/h Water throughput Motive water pump 0.33kW, 230V, 1.95A Medium temperature 5 C to 35 C Ambient temperature 5 C to 35 C Humidity in utility room Max: 70% Concentration of hypochloric acid Ventilation of the room Material --- Inlet DN 20 DN15 (suction lance) outlet Pressureless 5 C to 35 C 5 C to 35 C max. 0.2% max. 0.2% Casing: PE sintered Other functional parts: PVC or PE Seals: EPDM, Viton Tank: PE Connections: PVC Footnotes to technical data (1) The dosing performance for chlorine granulate is dependent on the type of granulate: A high dust component in the granulate or very coarse material > 3mm or elongated grains can strongly reduce the dosing performance. Granulate with a low dust component is required when maximum dosing performance is needed. (2) High chlorine dosing performance requires equivalent neutralisation performance using 37% or 50% sulphuric acid. Index: 00 Change date: 15/07/2016 Operating instr. no.: BA SW Granudos 10-CPR Dosiereinheit EN.docx Page 19 of 52

20 Granudos 10-CPR Touch XL, dosing unit 3.5 Transport / storage The devices must be checked for possible transport damage immediately after receipt. ATTENTION! The systems and devices can be damaged by frost or high temperatures. Prevent exposure to frost during transport and storage! Do not store systems and devices next to objects with high heat radiation or directly exposed to sunlight. The device may only be transported and stored in its original packaging. Careful handling must be ensured Storage of chemicals DANGER! The safety data sheets of the chemical substance suppliers must be adhered to! The TRGS 515 regulations for the storage of chemical must be considered in addition. Index: 00 Change date: 15/07/2016 Operating instr. no.: BA SW Granudos 10-CPR Dosiereinheit EN.docx Page 20 of 52

21 Granudos 10-CPR Touch XL, dosing unit 4 Assembly 4.1 Selecting the place of installation The following is to be considered regarding the place of installation: 1. A freely accessible installation space should be chosen for easier operation and later maintenance work. 2. The dimensions for the floor drain and the temperature specifications for the environmental air and the medium according to the specifications in Section 3.4 Technical data are to be adhered to. The device may not be operated in the proximity of flammable fumes, dusts or gases. 3. The device may not be exposed to weather effects. It may not be installed in the open. The system must be protected against frost and direct sunlight. 4. A mains connection and a drain connection must be provided. 5. The operating room may not be used as a permanent work room (max. 2 hours per day) also see the locally valid accident prevention regulations (Germany BGR-GUV-R 108). 6. Equipment areas must be ventilated to ensure that hazardous substances cannot reach concentrations that are detrimental to health (accident prevention regulations BGR-GUV-R 108). 7. Collecting trays for the chemical canisters and the buffer tank must be provided. 8. It must comply with the accident prevention regulations and may not be accessible to unauthorised persons. A separate storage room for chemicals must be provided. 4.2 Assembly information / installation suggestion Remove transport locks Warning and information signs according to the locally valid accident prevention regulations (Germany: BGR-GUV-R 108) are to be provided at the intended positions. Index: 00 Change date: 15/07/2016 Operating instr. no.: BA SW Granudos 10-CPR Dosiereinheit EN.docx Page 21 of 52

22 Granudos 10-CPR Touch XL, dosing unit Layout suggestions: Space requirements Figure 10, Installation proposal incl. space requirements without buffer tank Dosing device GR10-CPR Buffer tank (optional) Space requirements Figure 11, Installation proposal incl. space requirements with buffer tank 4.3 Mechanical installation The dosing device is delivered in completely pre-assembled form with mounted collecting tray, controller and dirt filter. Unpack the GRANUDOS, place it on a suitable, level foundation in a utility room and align it. Proceed in a similar way with the dosing canisters, the buffer tank and the respective collecting trays as required. nsure that there is sufficient free space for operating and maintaining the device! Index: 00 Change date: 15/07/2016 Operating instr. no.: BA SW Granudos 10-CPR Dosiereinheit EN.docx Page 22 of 52

23 Granudos 10-CPR Touch XL, dosing unit Installation material Overflow connection for the rinsing tray Accessories for acid pump Feet Collecting tray including 4 feet with M6 screw thread and 4 sealing washers Spare parts bag with manometer, seals, and membranes Collecting tray overflow connection Maintenance set for dosing motor Accessories for flocculant pump Dosing lance Type 1SK (optional) 2 ball valves d25 with adhesive connector d25-3/4 Index: 00 Change date: 15/07/2016 Operating instr. no.: BA SW Granudos 10-CPR Dosiereinheit EN.docx Page 23 of 52

24 Granudos 10-CPR Touch XL, dosing unit 4.4 Hydraulic installation Integration into the water circulation: Swimming pool 1 safety shutdown Heat exchanger 2 Circulation pump Balance tank Filter Central controller Measurm. + control Y ph minus Flocculation Water sampling and dosing connection: socket 3/4" Piping DN20 Granudos 10-CPR Figure 12, Flow chart for GRANUDOS 10-CPR without buffer tank Acid Dosing system for calcium hypochlorite Flocculation 1 Auxiliary pool Main pool Heat exchanger Circulation pump Balance tank Safetyshutdown Heat exchanger 2 Circulation pump Balance tank Filter Filter Measrm. + control Y Controller for level switch Control valve on the Granudos Air supply pressure min. 5bar Central conroller Flow control valve NC NO ph minus Flocculation Further pools possible A L max S S L min A Solenoid valve opens at container level minimum - Granudos doses with high dosing power untill container level maximum - about 10 minutes. During this time there is no dosing into the main pool Water sampling and dosing connection: socket 3/4" Piping DN20 Granudos 10-CPR Dosing system for ph reduction Buffertank for clorine solution Figure 13, Flow chart for GRANUDOS 10-CPR with buffer tank Acid Dosing system for calcium hypochlorite Flocculation Index: 00 Change date: 15/07/2016 Operating instr. no.: BA SW Granudos 10-CPR Dosiereinheit EN.docx Page 24 of 52

25 Granudos 10-CPR Touch XL, dosing unit ATTENTION! The locally valid regulations must be adhered to during installation. For example, for Germany DIN Pressure conditions require special attention when connecting the GRANUDOS 10-CPR to the water circulation in order to avoid effects of the swimming pool circulation on the supply of dissolving water. The GRANUDOS was tested under the following conditions: With pre-pressure: 1.2bar possible counter-pressure: 1.4bar 0.6bar 1.1bar 0.3bar 0.9bar These pressures without a throttle valve inserted are shown on the dosing device. Pressure losses in the piping must be considered as well. Pressure losses should therefore be kept as low as possible. Hose connectors that allow measurement of pressure during operation using the manometer supplied are to be installed at the inlets and outlets of the dosing system. A stronger pump can be used in the event of a higher counter-pressure. ATTENTION! Take note that all ball valves of the measuring cell block must be closed before starting the connecting work Installation of the dissolving and measuring water supply The supply of the GRANUDOS 10-CPR with dissolving and measuring water should be separated from the filtering cycle of the swimming pool, to avoid effects of the swimming pool circulation on the supply with dissolving water. Circulation Only sufficient pool circulation can achieve satisfactory control of the auxiliary hygiene parameter free chlorine, ph value and redox voltage. The dosed chemicals must all reach all pool areas within a short time. The concentrations measured in the pool must be approximately equal, even under load. Water sampling The correct selection of the measuring water sampling points is essential for the effect of the measuring and control system. The measuring water should be as similar as possible to the pool water, so that changes in the pool water quality can be measured as quickly as possible. This is essential for fast compensation of changes in the pool water quality by dosing additional chemicals Measurement of the chlorine concentration at different points (e.g. behind the circulation pumps, mixed water, etc.) and comparison with the values of the pool water at different operating conditions is necessary to find the best possible sampling point. Index: 00 Change date: 15/07/2016 Operating instr. no.: BA SW Granudos 10-CPR Dosiereinheit EN.docx Page 25 of 52

26 Granudos 10-CPR Touch XL, dosing unit ATTENTION! No chemicals may be dosed upstream of the measuring water sampling point. This would distort the measuring results! Only measuring water samples taken directly from the swimming pool will result in satisfactory measuring and control results when the pool water flows through a drainage channel and a compensating tank (surge tank), into which fresh water may also be fed. Water sampling directly from the pool according to DIN is prescribed for new pools! Ensure that any connections already installed are not blocked. The pipes must be kept as short as possible. The piping of the supply lines made of PVC must be implemented using dimension d25-3/4. Increase the nominal width when the pipe length is more than 20m or when unfavourable pressure conditions occur. Ensure that the connecting sockets for water sampling and the dosing point are completely open (metal sockets could be clogged by corrosion). Implementation of pipe connections Pipe connections should always be installed on the sides. Leitungsanschlüsse Always orient line connectors towards the immer seitlich ausführen! sides! Luftpolster Air cushions OK OK Ablagerungen Deposits Connect the supply ball valve (Pos 4, Page 11) of the GRANUDOS 10-CPR to the water sampling point. The separation of dissolving and measuring water takes place in the dosing system. There are 2 options regarding the water sampling point: Option 1: Swimming pool water directly from the pool Water sampling at least 80cm below the upper water edge. The flow pressure at the GRANUDOS inlet must be at least 0.2bar overpressure. Installation of the GRANUDOS 10-CPR at a short distance below the sampling point. The height difference between GRANUDOS and the water surface should be at least 2m. Changes in the incline and decline of the supply line piping to the GRANUDOS 10- CPR must be avoided. This may lead to trapped air that can reach the pump during operation. Option 2: Swimming pool water from the swimming pool filter This alternative should only be used in exceptional cases, when Option 1 cannot be implemented! Index: 00 Change date: 15/07/2016 Operating instr. no.: BA SW Granudos 10-CPR Dosiereinheit EN.docx Page 26 of 52

27 Granudos 10-CPR Touch XL, dosing unit Water sampling between circulation pump and filter, upstream of the chemical dosing system, with 3/4"- socket. The flow pressure at the GRANUDOS inlet must be at least 0.2bar overpressure. The measuring water must be separately collected when the sample is too strongly affected on the way through the surge tank. Check the water quality! If the dosing system has to be installed above the pool level A free-flowing reflux valve must be installed in the supply line to the GRANUDOS. A spring-loaded reflux valve must be installed in the dosing pipe to the clean water supply in order to prevent the rinsing tray from being drained after switching off (also see installation drawing above - appropriate reflux valves are available). When overflow after switching off the machine or in the event of a fault is to be prevented Install a 3/4" solenoid valve in the feed line and a d25 or d32 reflux valve in the outlet line. Take note of minor pressure losses! A supply pressure more than 0.4bar is therefore required to start operations! Measuring water return flow The measuring water is automatically ducted to the rinsing unit of the dosing system and is thus returned to the water cycle Installation of the dosing line for chlorine solution Install the dosing lines and connect them to the injection point (ball valve) downstream of the heat exchanger and the outlet of the GRANUDOS. With buffer tank (optional) Also duct the dosing line to the buffer tank and install two solenoid valves and a flow control valve (see Figure 13, Page 24) Buffer tank (optional) The buffer tank is connected to the chlorine dosing line. 2 pneumatic valves are installed downstream of the branch of the chlorine dosing line according to the flow diagram. These are supplied with air and controlled by a solenoid valve. Connect the control lines of the pneumatic valves to the solenoid valve. The solenoid valve is connected to the on-site compressed air supply. The chlorine solution can be dosed from the buffer tank through on-site pumps to an auxiliary pool Installation of an overflow pipe from the rinsing tray to the collecting tray The screw the two overflow sockets into the rinsing tray and the collecting tray. Duct pipes from the overflow socket of the rinsing tray and the collecting tray of the GRANUDOS to the gully. Index: 00 Change date: 15/07/2016 Operating instr. no.: BA SW Granudos 10-CPR Dosiereinheit EN.docx Page 27 of 52

28 Granudos 10-CPR Touch XL, dosing unit Flocculant dosing The GRANUDOS 10-CPR is equipped with a flocculant pump. Screw the dosing fitting into the injection point and route the dosing line from the dosing pump to the injection point. Install the injection point as far from the filter and as close to the circulation pump as possible. Measuring water may never be sampled downstream of the injection point. Figure 14, Dosing unit The 4x1mm dosing line made of blue PE is part of the delivery scope. 4.5 Electrical installation DANGER DUE TO HIGH VOLTAGE! The electrical installation may only be performed by electricians! The power supply must be switched off and secured against switching on before performing any electrical work! ESD-SENSITIVE! The electronic components of the devices are sensitive to electrostatic discharge. The generally known precautions regarding ESD-sensitive devices must be adhered to when handling these devices! The following needs to be considered: Do not pull or insert a live connector. Discharge your body for at least 5 seconds before you touch the devices, e.g. by touching a grounded part of the system or by wearing an ESD ground strap that is connected to ground. Index: 00 Change date: 15/07/2016 Operating instr. no.: BA SW Granudos 10-CPR Dosiereinheit EN.docx Page 28 of 52

29 Granudos 10-CPR Touch XL, dosing unit Electrical connection Opening and closing the housing The display lid can be swivelled to the right or left, depending on the device type, to facilitate installation and service work. The locking axle has to be removed before swivelling. The locking axle can be recognised by the plastic slot screws on both sides. The other side is provided with two expanding rivets as rotating pivots. The device must be supplied with permanent voltage. This means the voltage supply may not be interlocked with the filter system. A digital input is available for interlocking the dosing device with the swimming pool filter system. Also see the terminal plans in the terminal boxes of the control or in Section 9.2 with regard to the electrical installation. For signals to the outside and from the outside, see terminal plans ATTENTION! The external control of the inputs must be floating. The maximum contact load of the relay contacts must be considered. The electrical supply of the dosing device must always be ensured. The external control inputs and outputs (switching off in the event of faults, disinfection dosing during backwash, etc.) must be connected to the clamp terminals on the base plate in the control housing. Index: 00 Change date: 15/07/2016 Operating instr. no.: BA SW Granudos 10-CPR Dosiereinheit EN.docx Page 29 of 52

30 Granudos 10-CPR Touch XL, dosing unit Inserting the cables The housing is provided with some screw connections from the factory. Several push-outs for metric cable screw glands are available for additional inlets. The two outer M25 screw glands are intended for inserting a pre-assembled interface cable with JR45 connector. ATTENTION! Please take note of the spatial separation of energy and signal cables when inserting further cables. Crossing of energy and signal lines is to be avoided! The housing must be appropriately closed once the work has been completed! The device is equipped with a temperature controller. This temperature controller can be used to control the pool water temperature. When pool heating is achieved by a flow heat exchanger, it must be ensured that control of the relevant heating circuit pump is only possible when the filter system is running. Please consider that pool temperature control can only be ensured when the filter running times chosen are sufficiently long. The sensor should be installed in an immersion sleeve into the swimming pool pipe upstream of the filter to get an accurate measuring result. ATTENTION! Immersion sleeves that come into contact with the swimming pool water must be corrosion-resistant. Index: 00 Change date: 15/07/2016 Operating instr. no.: BA SW Granudos 10-CPR Dosiereinheit EN.docx Page 30 of 52

31 Granudos 10-CPR Touch XL, dosing unit 5 Commissioning 5.1 Commissioning - comments ATTENTION! This chapter must also be considered when operations are resumed after an operating break. Only switch on the GRANUDOS 10-CPR when the rinsing tray has been filled. The work described here may only be performed by trained, specialised staff of a specialist company who have read and understood the operating instructions. The systems installed must be inspected for appropriate installation and tightness before commissioning. Use the commissioning protocol in Section 9.3 for the commissioning procedure. The device was delivered with specific factory settings. The setting values are provided in the operating data sheet in Section 9.4. ATTENTION! Alien objects that may have fallen into the rinsing device during the installation of the piping and electrical system may cause failure of the floater valve or the suction pipe of the flow switch. Remove alien objects! 5.2 Initial operation Ensure that the ball valves at the measuring cell block (2) are closed before starting operation Install the hose pumps and roller carriers The acid pump and the flocculant pump are installed at the face side of the GRANUDOS 10-CPR housing. 1. Pull the hose holder towards the front and out of the guide in the housing. Lock washer Hose set Hose holder Pump housing Pressure Figure 15, Hose dosing pump Suction connection Index: 00 Change date: 15/07/2016 Operating instr. no.: BA SW Granudos 10-CPR Dosiereinheit EN.docx Page 31 of 52

32 Granudos 10-CPR Touch XL, dosing unit 2. Push the blue roller carrier onto the axle. Figure 16, Insert roller carriers 3. Place the hose holder into the guides inside the housing until it clicks in. Figure 17, Insert the hose carrier 4. Turn the roller carrier anticlockwise while carefully pushing the hose into the housing until it is completely within the housing. Figure 18, Turn the roller carrier Then re-attach the safety disk and the transparent pump cover. The roller carrier installation is then completed. Proceed in reverse order to de-install the roller carrier and the hose holder. Insert the safety connector into an appropriate mains socked and switch on the device at the main switch Prepare acid dosing for operation The specifications in the safety data sheets for the respective chemicals must be adhered to, e.g. protective clothing: Personal protective clothing must be put on before starting work with chemical substances: Protective gloves, apron, face protection, boots. Index: 00 Change date: 15/07/2016 Operating instr. no.: BA SW Granudos 10-CPR Dosiereinheit EN.docx Page 32 of 52

33 Granudos 10-CPR Touch XL, dosing unit Figure 19, GRANUDOS 10 with acid and flocculant canister Connect the acid canister Poisonous fumes may be created when handling acids. Do not inhale fumes. 1. Unscrew the red screw lid with acid lance from the empty acid canister, place the suction lance into the collecting tray and immediately close the empty canister with the original screw lid. 2. Lift the empty canister out of the collecting tray. 3. Place a full acid canister into the collecting tray. 4. Unscrew the screw lid from the full acid canister and immediately insert the suction lance of the GRANUDOS 10-CPR dosing system and screw it tight. 5. Keep the original screw lid of the acid canister until the next acid change Prepare flocculant dosing for operation The specifications in the safety data sheets for the respective chemicals must be adhered to, e.g. protective clothing. Connecting the flocculant canister The flocculant may not come into contact with other chemicals! 1. Unscrew the blue screw lid with acid lance from the empty acid canister, place the suction lance into the collecting tray and immediately close the empty canister with the original screw lid. 2. Lift the empty canister out of the collecting tray. 3. Place the full flocculant canister into the collection container. 4. Remove the screw lid from the full flocculant canister, immediately insert the suction lance of the GRANUDOS 10-CPR dosing system into the canister and screw it tight. 5. Retain the original screw lid of the flocculant canister until the next flocculant change takes place. Index: 00 Change date: 15/07/2016 Operating instr. no.: BA SW Granudos 10-CPR Dosiereinheit EN.docx Page 33 of 52

34 Granudos 10-CPR Touch XL, dosing unit Filling the filling hopper with chlorine granulate PROTECTIVE CLOTHING! Personal protective clothing must be put on before the work is started: Tightly fitting protective goggles, protective gloves, apron, face protection, boots The safety data sheets for the respective chemicals must be adhered to. ATTENTION! Chlorine granulate and acid may not be mixed with each other or with other chemicals and substances! Filling without bucket adapter Remove the lid. Carefully pour the chlorine granulate along the wall into the filling hopper using a cup, so that no chlorine dust is generated (do not tip!). Only fill in the amount needed for approx. 1-2 weeks to ensure that the chlorine granulate will not react with air, form lumps or flow less easily. Thereafter, close the lid Filling with bucket adapter for 10kg bucket Place the new, full chlorine bucket in front of the device, unscrew the lid (for HTH) or pull off the lid (for HC and Melchlor). Pull the dosing hopper with the empty bucket upwards out of the GRANUDOS housing and place it on the floor next to the full bucket. Hold the empty bucket with your feet, screw the dosing hopper off the bucket and place it onto the floor. Slowly empty the remaining chlorine into the new bucket (chlorine dust) and screw the dosing hoper onto the full bucket or close the catch fasteners. Take the dosing hopper with the full bucket, slowly turn it and insert it into the housing so that the cable at the back and the centring bolt in front fit into the respective recesses. Index: 00 Change date: 15/07/2016 Operating instr. no.: BA SW Granudos 10-CPR Dosiereinheit EN.docx Page 34 of 52

35 Granudos 10-CPR Touch XL, dosing unit Adapter ring d 275 with clamps e.g. for HC or Melchlor, 10kg Screw-on adapter ring e.g. for Olin-HTH, 10kg Figure 20, Adapter for chlorine buckets Bleeding the motive water pump and the pipes to the GRANUDOS 10-CPR The pump and the piping must be carefully bled before each start. The following must be considered during installation and commissioning to prevent the motive pump from running dry: 1. It must be manually checked whether the rotary pump can easily be turned. After removing the fan hood, the ease of movement of the shaft can be tested by turning the fan wheel with a screwdriver. The floating ring seal is clogged when the shaft cannot be easily turned. Try to loosen it by jerking it backwards and forwards. The pump must be removed and disassembled in case this is not possible. ATTENTION! Failure of the pump is inevitable when the pump is switched on while the floating ring seal is blocked. 2. Open the ball valve at the water sampling point and the dosing point as well as the supply valve at the pre-filter and wait until the rinsing tray is half full before commissioning. This ensures that water has run through the pump and that the pump is bled. Thereafter, open the stop valve upstream of the cyclone. Only thereafter, switch on the GRANUDOS 10-CPR at the main switch (15). 3. The pipes to the GRANUDOS must be carefully bled. The d75 pre-filter must be monitored for this purpose. When the water level in the filter drops significantly after the pump is switched on, switch off the GRANUDOS, open the bleeding screw on top of the filter, let water run into the filter and then switch on the machine. It might be Index: 00 Change date: 15/07/2016 Operating instr. no.: BA SW Granudos 10-CPR Dosiereinheit EN.docx Page 35 of 52

36 Granudos 10-CPR Touch XL, dosing unit necessary to repeat the process a few times until the filter remains filled; a few air bubbles in the upper area of the filter are not relevant. ATTENTION! If the pump draws air during the operation or when it is switched on without monitoring, the floating ring seal of the pump will run dry, overheat and start to leak. This may happen when the system is installed above the swimming pool level, when the supply line is emptied or when the filter system is switched off. The following installation instructions must be adhered to in such cases. 1. A free-flowing reflux valve is to be installed into the supply line to the dosing device. 2. A spring-loaded reflux valve must be installed in the dosing pipe to the clean water supply to prevent draining of the rinsing tray after switching off. Appropriate reflux valves are available. 3. Install a 3/4" solenoid valve in the feed line and a d25 or d32 reflux valve in the outlet line when overflowing is to be prevented once the system has been switched off or in the event of a fault. Take note of minor pressure losses! A supply pressure of more than 0.4bar is required for safe operation! 4. A bleeding valve that is to be connected to the bleeding connector is optionally available. The outgoing water is ducted back to the dissolving tray Setting the water flow in the dissolving system Further procedures are only possible when the system is switched on. Switch on the system at the main switch, located on the left side of the control unit. The motive water pump starts up. The pump is always in operation when the device is switched on, except when the pressure switch (33) or the level switch min (47) is triggered. The hole disk in the screw connection (39) downstream of the injector (37) adapts the suction performance of the injector to the pressure conditions. A drop of the water level in the rinsing tray (38) during the initial operation implies that a diaphragm with a smaller hole must be inserted into the screw connection. A diaphragm with a larger hole is required or the diaphragm must be removed, when the water level increases or the switch body of the flow switch (40) is not clearly pushed upwards. A 6mm diaphragm is installed ex factory; diaphragms with 5.5mm and 7mm are included in the spare parts bag attached. Index: 00 Change date: 15/07/2016 Operating instr. no.: BA SW Granudos 10-CPR Dosiereinheit EN.docx Page 36 of 52

37 Granudos 10-CPR Touch XL, dosing unit Overview of dissolving system Figure 21, Dissolving system The dissolving system consists of: 31. Outlet for supplying the measuring system 32. Pressure retention valve for supplying the measuring system 33. Pressure switch 34. d75mm dirt filter with bleeding facility 35. Motive water pump (different versions) 36. Connection for manometer 37. Injector 38. Rinsing tray 39. Screw connection with hole disk 40. Suction pipe flow switch 41. ph-reducer dosing valve 42. Dissolving and mixing cyclone 43. Connection for manometer 44. Rinsing tray overflow 45. Rinsing tray inlet float regulator valve 46. Rinsing pipe 47. Rinsing tray min/max level switch 48. Lid for rinsing tray with dust protection pipe (not shown) Setting the pressure switch The pressure switch installed (33) registers the effective pressure of the motive water pump (35). The GRANUDOS system switches off when the switching power is not reached after air was aspired or a pressure drop in the water supply. This ensures, in addition to the electrical interlock, that: Index: 00 Change date: 15/07/2016 Operating instr. no.: BA SW Granudos 10-CPR Dosiereinheit EN.docx Page 37 of 52

38 Granudos 10-CPR Touch XL, dosing unit Dosing is switched off when the motive water pump delivers too little water. The motive water pump is not exposed to cavitation risk. The dosing device must operate in automatic mode in order to set the switching point. Remove the lid from the pressure switch for this purpose, turn the adjustment button by 0.25bar to the right and wait for 6 seconds. In case the dosing system continues running, repeat the process until the dosing device stops and the "Pressure min." alarm message is shown. The GRANUDOS dosing system stops. Now turn the adjustment button to the left by 0.25bar and acknowledge the alarm message. The dosing system starts up. The dosing system will show a fault when the pressure drops by 0.25bar. The switching point is set to 1.5barg ex factory Adjustment of the water level in the rinsing tray The water level in the rinsing tray is changed by turning the floater at the floater control valve (45) in or out. Turning the floater out results in a higher level, turning it in results in a lower level. One rotation corresponds to approx. 1cm. Set the floater in the rinsing tray so that the water level is approx. in the middle of the rinsing tray. NOTICE! This competes commissioning of the dosing unit. Additional commissioning information as well as a description of the operation and settings of the control unit are provided in the Operating Instructions, Part 2, Measuring and Control Unit CPR-Touch XL No. "BA MR 001", Sections 5 and 6. Index: 00 Change date: 15/07/2016 Operating instr. no.: BA SW Granudos 10-CPR Dosiereinheit EN.docx Page 38 of 52

39 Granudos 10-CPR Touch XL, dosing unit 6 Operation / handling The nationally valid accident prevention regulations in Germany: Operation of baths BGR/GUV-R 108 must be taken into account. 6.1 General More information regarding the operation and setting of the dosing device is provided in the Operating Instructions, Part 2, Measuring and Control Unit CPR-Touch XL No. "BA MR 001", Section Top up consumables PROTECTIVE CLOTHING! Personal protective equipment must be used when handling chemicals; tightly fitting protective goggles, protective gloves, apron, face protection, boots The safety data sheets for the respective chemicals must be adhered to. Refilling acid For exchanging the acid canister see Section 5.2.2, connecting the acid canister. The specifications in the safety data sheets for the respective chemicals must be adhered to! Topping up the flocculant For exchanging the acid canister, see Section 5.2.3, connecting the flocculant canister. The specifications in the safety data sheets for the respective chemicals must be adhered to! Refilling chlorine granulate For exchanging the chlorine granulate, see Section 5.2.4, Filling the filling hopper with chlorine granulate. Index: 00 Change date: 15/07/2016 Operating instr. no.: BA SW Granudos 10-CPR Dosiereinheit EN.docx Page 39 of 52

40 Granudos 10-CPR Touch XL, dosing unit 7 Maintenance, service, faults 7.1 Device maintenance It is recommended to task a specialist company with maintenance. Hint! The maintenance work required for smooth operation is described in the maintenance protocol in Section 9.5. For opening the controller housing, see Section 4.5. DANGER DUE TO HIGH VOLTAGE! The device must be switched off and secured against re-operation before any electrical work is carried out! Clean the dirt filter Always close the inlet and outlet valves when working on water-conducting lines. A clean preliminary filter is important for appropriate operation. A dirty filter may cause cavitation at the motive water pump and thus damage the pump. Loosen the upper and lower union nut at the filter and remove the filter from the holder to clean it. Pull out the filter insert under running water. Clean the filter hood and the filter insert under running water Exchanging the dosing screw and the dust seal Exchanging the dosing screw When only the dosing screw is to be exchanged, the seal in the dust protection cap should be exchanged as well. The sealing disks made of EPDM and felt are part of the delivery scope Figure 22, Dosing motor with dosing screw 2 1 Index: 00 Change date: 15/07/2016 Operating instr. no.: BA SW Granudos 10-CPR Dosiereinheit EN.docx Page 40 of 52

41 Granudos 10-CPR Touch XL, dosing unit Tools for exchanging the dosing screw or the dosing motor: a) 8mm spanner to loosen the dosing motor b) Measuring device (multimeter) for voltage measurement c) Small blade or small screw driver to clean the headless screw d) 2.5mm Allen screw for the headless screw of the dosing screw Removal of the dosing motor and the dosing screw PROTECTIVE CLOTHING! Put on personal protective equipment before starting the work. a) Remove the lid from the dosing hopper. b) Lift the dosing hopper with dosing motor and dosing screw upwards and remove it. Fill all of the chlorine granulate in the dosing hopper into a bucket and close it. c) Opening the terminal box at the dosing hopper. d) Remove the protective caps from the M5x20 fastening screws (8) and undo the screws (9) with an SW 8 spanner. e) Pull the motor with the dosing screw out of the holder - while holding a flat collection container under the Figure 23, Dosing hopper motor holder to ensure that no chlorine granulate is dispersed. Immediately clean the motor holder on the inside and remove dispersed chlorine granules. f) Clean the screw Observe whether the chlorine granulate is strongly compacted inside the screw or whether it drops off easily when the screw is pulled out. Compacted granulate indicates that the granulate is either wet or that its dust content is too high. The dosing screw may also be worn so that the granulate is no longer appropriately transported Maintenance of the dosing motor a) Disconnect the motor cable at the terminal box on the hopper and pull the cable out of the bushing b) Use a small screwdriver, knife or similar to scrape out the sealing putty from the threaded hole of the fastening screw (3) at the PVC flange of the dosing screw. c) Loosen the fastening screw with the SW 2.5 Allen key and pull the dosing screw off the shaft. d) Pull the dust cap off the dosing motor and remove the old sealing disks e) Grease the felt disk on both sides with silicone grease f) Fill the bearing recess of the dosing motor with silicone grease g) First slide the EPDM (rubber) sealing disk and then the greased felt disk onto the shaft and then firmly slide on the dust cap h) Take the old O-ring out of the groove of the dust cap, insert a new O-ring and apply approx. 2 layers of Teflon tape i) Grease the face sides of the dosing motor / PVC dust cap and the dosing screw with silicon grease j) Slide the dosing screw onto the shaft, so that the fastening screw sits on the flattened part of the motor shaft k) Press the dosing screw against the motor and tighten the threaded pin. Index: 00 Change date: 15/07/2016 Operating instr. no.: BA SW Granudos 10-CPR Dosiereinheit EN.docx Page 41 of 52

42 Granudos 10-CPR Touch XL, dosing unit ATTENTION! Do not tighten too strongly, as the PVC thread may otherwise be stripped. Figure 24, Dosing motor l) Thoroughly seal the threaded hole using sealing material. m) Insert the cable into the screw gland, applying silicon grease to the cable end as required and connect the cable: white to white, brown to brown. n) Check the function of the dosing motor. o) Slide the dosing motor into the - cleaned - motor mount, evenly fasten it with new M5x20 screws and press on the protective flaps. ATTENTION! When no sealing material is used, the screw will strongly corrode within a short time and can then no longer be loosened. It will only be possible to exchange both parts together in case the dosing screw or the motor must later be exchanged again! Exchanging only the dosing motor a) Completely unscrew the threaded pin and insert a new threaded pin. b) Clean the front side of the adapter of the old dosing screw and grease it with silicone grease c) Open the terminal box on the dosing hopper, loosen the dosing motor cables (brownwhite), insert a new motor cable and fasten it (brown on brown, white on white). d) Slide the dosing screw onto the motor shaft so that the threaded pin rests on the flat part of the motor shaft, press the screw firmly against the motor and tighten the threaded pin. e) Slide the motor with screw back onto the cleaned holder, fasten the flange - not too tightly - and press the protective caps onto the screw heads. f) Place a new O-ring onto the screw guidance pipe, wrap it with Teflon tape (approx. 3 layers), grease and slide the dosing unit into the holder Index: 00 Change date: 15/07/2016 Operating instr. no.: BA SW Granudos 10-CPR Dosiereinheit EN.docx Page 42 of 52

43 Granudos 10-CPR Touch XL, dosing unit Exchanging only the dosing screw a) Pull the dust cap off the dosing motor, remove the old set of seals from the dust cap, properly clean the dosing motor shaft, apply fresh silicon grease to the ball bearing, press the sealing washer 19/4x0.5 EPDM (11, Figure 22) onto the shaft. Thoroughly grease the felt disk (12, Figure 22) and slide it on, slide the dust cap on top of it, detach the old Teflon tape and put on new tape in approx. 3 layers. b) Grease the front of the adapter of the new dosing screw with silicone grease c) Slide the dosing screw onto the motor shaft so that the threaded pin rests on the flat part of the motor shaft, press the screw firmly against the motor and tighten the threaded pin. d) Slide the motor with screw back onto the cleaned (!) holder, fasten the flange - not too tightly - and press the protective caps onto the screw heads Injector with flow switch Flow switch overview Flow switch with LED 82. Union nut for flow switch 83. Viton hose to rinsing tray 84. Sealing ring for switching body 85. Switching body (in suction pipe) 86. Suction pipe 87. Union nut injector inlet 88. Injector 89. Injector nozzle with integrated flow diaphragm 90. Union nut and injector outlet Figure 25, Flow switch Exchanging the diaphragm Loosen the union nuts ( ) and take out the injector (88). The nozzle is sealed with an O-ring at the end of the internal thread of the injector nozzle (89). Lift the disk with a small screw driver and insert another one or do not install a diaphragm as required Change the sealing ring (84) for the switch body Loosen the union nut (82) and remove the flow switch (81). Unscrew the suction pipe (86) from the injector (88). Turn the suction pipe and shake the switch body (85) out of the suction pipe. Remove the sealing ring (84) and carefully clean the switch body. Install a new sealing ring. Assemble in reverse order. Index: 00 Change date: 15/07/2016 Operating instr. no.: BA SW Granudos 10-CPR Dosiereinheit EN.docx Page 43 of 52

44 Granudos 10-CPR Touch XL, dosing unit Maintain and setting the floater control valve for the feed of the rinsing tray Figure 26, Complete floater control valve and floater valve tappet Overview of floater valve, complete x 1mm rinsing water hose connector /8 nut with seal 103. Union nut for floater assembly 104. Water level adjustment screw ml floater 106. Floater valve body Overview of floater valve tappet 108. Membrane piston 109. Sealing membrane 110. Valve cone with O-ring seal Exchanging the sealing membrane Loosen the union nut (103) and remove the upper part of the floater valve. Take out the inner membrane valve assembly ( ), pull the valve cone from the membrane piston (108) and install a new sealing membrane (109) in the valve cone. Also exchange the O- ring on the valve cone (110). Assemble in reverse order. Set the water level in the rinsing tray: See Section Index: 00 Change date: 15/07/2016 Operating instr. no.: BA SW Granudos 10-CPR Dosiereinheit EN.docx Page 44 of 52

45 Granudos 10-CPR Touch XL, dosing unit Exchanging and setting the "Chlorine empty" switch at the dosing hopper (option) The display at the controller lights up, although there is chlorine granulate in the hopper. The dosing hopper shown (7) is hooked onto the plastic housing and is used for dosing chlorine granulate into the dissolving and rinsing system (11) Figure 27, Dosing hopper The chlorine hopper (7) consists of: 7. Dosing hopper 22. Magnetic knocker (with clamping housing) 23. Dosing motor 24. Motor holder 25. Empty switch (option) 26. Cleaning plug 27. Dosing screw (not visible) 28. Dosing pipe with heating The empty switch (25) is accessible once the housing front lid has been removed. The adjustment screw with switch LED can be seen on the narrow side on top of the GRANUDOS 10-CPR. This LED should not light up when the dosing hopper is empty, the display must show "Chlorine empty". When the switch LED is on, turn the adjustment screw to the left until the LED goes off. The fault indicator at the controller responds with a delay of 6 seconds. A new switch must be installed when the switch does not respond to the adjustment potentiometer or when the adjustment screw is destroyed. Adjusting the switch Turn the adjustment screw to the right until the switch LED lights up, then carefully turn it back until the switch LED goes off, then continue turning it approx. by a further 10. The fault indicator on the display lights up. After filling the dosing hopper past the switching level, the fault indicator on the display goes off. Index: 00 Change date: 15/07/2016 Operating instr. no.: BA SW Granudos 10-CPR Dosiereinheit EN.docx Page 45 of 52

46 Granudos 10-CPR Touch XL, dosing unit Exchanging the "Empty" switch: 1. The switch is inserted into a holder. 2. Open the terminal box, detach the 3 switch wires and pull out the cable. 3. Press out the old switch. 4. Slide the new switch into the holder. 5. Insert the cable into the terminal box and attach according to the terminal plan. 6. Close the terminal box and fill the screw heads with grease to prevent corrosion. 7. Adjusting the switch - see above Exchanging the dosing hose of the dosing pump Further steps, see Section 5.2.1, Install the hose pumps and roller carriers 7.2 Regular water inspection Also see Operating Instructions Measuring and Control Unit CPR-Touch XL, No.: BA MR 001, Section Fault removal Hint! The faults are indicated on the display in the IN and OUT list by the appropriate symbol. Also see Operating Instructions Measuring and Control Unit CPR- Touch XL, No.: BA MR 001, Section 7.3. The rinsing tray should not overflow when the GRANUDOS is switched off. If this happens, one of the following elements is leaking: Floater valve Exchange membrane Switch body in the suction pipe Replace seal Pressure retention valve in the measuring water pipe upstream of the motive water pump adjust the valve, exchange the membrane as required Index: 00 Change date: 15/07/2016 Operating instr. no.: BA SW Granudos 10-CPR Dosiereinheit EN.docx Page 46 of 52

47 Granudos 10-CPR Touch XL, dosing unit 8 Shutting down - Storage - Disposal 8.1 General The systems must be completely drained or protected against frost when they are shut down and there is a risk of frost! Disposal of old part and operating materials De-installed, contaminated parts must first thoroughly be cleaned and then disposed of according to the regulations valid at the place of operation or recycled. The instructions on the packaging of operating materials must be complied with. In cased of doubt obtain information from the authority responsible for disposal at your location. The parts/substances must be disposed of as special waste when this is not possible. 8.2 Decommissioning the GRANUDOS 10-CPR dosing device 1. Remove the suction lances from the dosing canisters and put them into a bucket with clean water. 2. Thoroughly remove the calcium hypochloride residues in the device and let the system run for an additional 10 minutes for rinsing and cleaning purposes. 3. Stop dosing by using the button. 4. The dosing hopper must be emptied and thoroughly cleaned. 5. Remove the dosing motor with dosing screw from the dosing hopper, thoroughly clean the dosing motor with dosing screw and store the dosing screw in a dry place as required no chlorine granules may remain in the vicinity! 6. Remove the roller carrier from the hose dosing pumps to release the dosing hoses. 7. Thoroughly clean all parts of the GRANUDOS 10-CPR. 8. All water-conducting parts are to be drained when there is a risk of frost, in particular the suction pipe and the pump may not be forgotten. 9. Switch off the GRANUDOS 10-CPR at the main switch. Also see Section 8.3 ATTENTION! The instructions in the "Commissioning chapter must be adhered to and the steps in the commissioning protocol must be performed when re-operating the device. 8.3 Buffer tank (optional) Empty and clean the buffer tank. The bottom sediments of the buffer tank must be sucked out. Possible resilient deposits can be dissolved with diluted nitric acid. Index: 00 Change date: 15/07/2016 Operating instr. no.: BA SW Granudos 10-CPR Dosiereinheit EN.docx Page 47 of 52

48 Granudos 10-CPR Touch XL, dosing unit 9 Documents 9.1 Declaration of conformity Index: 00 Change date: 15/07/2016 Operating instr. no.: BA SW Granudos 10-CPR Dosiereinheit EN.docx Page 48 of 52

49 Granudos 10-CPR Touch XL, dosing unit 9.2 Terminal diagrams The terminal plans for the standard version of the device are included in the Operating Instructions of the Measuring and Control Unit CPR-Touch XL, No.: BA MR 001 in Section 9.2. The special circuit plans configured for the optimal configuration of the GRANUDOS 10-CPR Touch XL dosing system are located in the terminal box of the device. 9.3 Commissioning report The commissioning protocol is included in the documents attached. 9.4 Operating data sheet The operating data sheet can be found in the Operating Instructions Part 2, Measuring and Control Unit CPR- Touch XL, No.: BA MR 001 in Section Maintenance protocol The maintenance protocol is included in the documents attached. Index: 00 Change date: 15/07/2016 Operating instr. no.: BA SW Granudos 10-CPR Dosiereinheit EN.docx Page 49 of 52

50 Granudos 10-CPR Touch XL, dosing unit 9.6 Spare parts list, wearing parts list, consumables Spare parts list Description Item no. Chlorine dosing Dosing hopper 5 kg with lid Lid for dosing hopper GR Dosing motor PLG with Maintenance set Motor holder GR 10 PLG-d Dosing screw GR10 d6/d19 with Maintenance set (1) Dosing pipe heated GR10 cable 0.5m Magnetic knocker GR 10 with complete terminal box Acid dosing Acid pump GR10 Sa complete Geared motor acid pump Sa Pump housing Sa, blue Roller carrier Sa blue (1) Hose set 3.2 x 1.6 N Sa (1) Suction set GR red (1) Dosing valve acid GR (1) Maintenance set for acid valve 3/8 KF+KFa (2) Additional for flocculation Hose set Sa 0.8 x 1.6 Ph 2x (1) Suction set NF d GR10T blue Dosing fitting 1SK-S-4x Dosing lance 1SK-S-4x1 365mm Valve rubber 4.2 x 1.6 x 20mm 2pcs (1) Filter Filter housing d75 GR Top part of d75 filter with d25 ball valve O-Ring filter d (2) Control Control board NT GRD 7 V3, power supply unit Control board IO GRD 7 V Control GR45-CPRT Display Measuring amplifier CPRT PR CL complete Main switch GR 2xE/A 16A IP Fuse holder FPG1 5x20 IP Floater valve Floater valve d25 GR10 complete Membrane for floater valve (2) Floater 0.25 l for floater valve Level switch 3/8" 1.85 m Pump Motive water pump Lo 1HM04 GR/PAK Floating ring seal Lo-A (1) Pressure switch M10 1-3bar GR Suction pipe Suction pipe GR ½ S14-US Flow switch18x1 GR10Top 2.1m Switch body GR ind.½ -US Sealing ring switch body Vi 14/ (2) Hose for suction pipe 10x2x180 Vi (2) Injector Injector 1/2" GR complete Diaphragm set for injector Injector diffuser nozzle ½ Injector mixing nozzle with ½ connector Cyclone Dissolving cyclone GR 10/ Maintenance set Seals, fuses maintenance protocol Footnotes to spare parts list: (1) Wearing parts (2) In maintenance set, Item no , included parts Index: 00 Change date: 15/07/2016 Operating instr. no.: BA SW Granudos 10-CPR Dosiereinheit EN.docx Page 50 of 52

51 Granudos 10-CPR Touch XL, dosing unit Consumables The safety data sheets of the chemical producers must be adhered to! Index: 00 Change date: 15/07/2016 Operating instr. no.: BA SW Granudos 10-CPR Dosiereinheit EN.docx Page 51 of 52

52 Granudos 10-CPR Touch XL, dosing unit 10 Appendices Own notes Index: 00 Change date: 15/07/2016 Operating instr. no.: BA SW Granudos 10-CPR Dosiereinheit EN.docx Page 52 of 52

53 Commissioning protocol IP 21 Granudos 10-CPR Touch XL This protocol is to be completed by the commissioning technician! All warranty claims expire when no completed and signed commissioning protocol is available! Object:... Date:.. City, Street, Street number: Device type:... Year of construction:... Serial no.:... Activity Completed Comment 1 Dissolving system and measuring cell block (consider 6 seconds switching delay!) 1.1 Close the ball valve at the measuring cell feed (upstream of pre-filter) 1.2 Install the roller carriers of the hose pumps 1.3 Connect dosing canisters and fill in chlorine granulate 1.4 Bleed the operating water pump 1.5 Adjust the water flow in the dissolving system 1.6 Set the water level in the rinsing tray 1.7 Check pressure switch: Ball valve intake closed, GR stopped, fault display 1.8 Adjust the pressure switch (33) 1.9 Check flow switch: Valve outlet closed, dosing stopped, fault indication 1.10 Check the level switch: Switching body high - dosing stopped, fault indication 1.11 Check the level switch: Switching body low - GR stopped, fault indication 1.12 Check the floater function: The flow responds gently 2 Chlorine dosing technology 2.1 Check the heating: Dosing pipe warm? 2.2 Check the empty switch: Pull the empty switch out of the holder 2.3 Check the dosing motor: Chlorine starting test program 3 ph-reducer dosing system 3.1 Check the empty switch: Pull the suction lance out of the canister, display 3.2 Check the dosing pump: Acid starting test program 4 Flocculant dosing system 4.1 Check the empty switch: Pull the suction lance out of the canister, display 4.2 Check the dosing pump: Flocculant starting test program, suction on 5 Control - after opening the controller 5.1 Connectors firmly latched 6 Buffer tank (optional) 6.1 Check function of the control and alarm switches in the tank: Display 6.2 Check prevention of dosing pump reflux (on site) 6.3 Check the reflux prevention in filling system Z:\org-wdt\02 Qualitätsmanagement\ISO 9001\MS - Originale - Formuale, Prüfbericht etc\wdt Inbetriebnahmeprotokoll IP\WDT IP 21 GR 10-CPR Touch XL EN FO 00.doc Page 1 of 2

54 Commissioning protocol IP 21 Granudos 10-CPR Touch XL 7 Measuring cell block (see Operating Instructions, Part 2, Measuring and Control Unit No.: MR 001 ) 7.1 Fill in cleaning beads 7.2 Insert electrodes 7.3 Open the ball valve at the measuring cell feed, set the measuring cell flow 7.4 Adjust control parameters (as required) 8 Other 8.1 Clean the GRANUDOS system 8.2 Discuss the operating instructions and hand them over Other comments: Commissioning and instruction performed:... Persons instructed: Signature of commissioner:... Countersigned by operator:... Z:\org-wdt\02 Qualitätsmanagement\ISO 9001\MS - Originale - Formuale, Prüfbericht etc\wdt Inbetriebnahmeprotokoll IP\WDT IP 21 GR 10-CPR Touch XL EN FO 00.doc Page 2 of 2

55 Maintenance protocol WP 27 Granudos 10 CPR-Touch XL This protocol must be completed by the maintenance technician! We reserve the right to determine the warranty conditions when no completed and signed maintenance protocol is available. Object:... Year of maintenance: 20 City, Street, Street number: Device type:... Year of construction:... Serial no.:... Activity Maintenance interval in months Month 1 Month 2 Month 3 Month 4 Month 5 Month 6 Month 7 Month 8 Month 9 Month 10 Month 11 Month 12 Comment / additional work 1 Dissolving system 1.1 Check the level switch Check the pressure switch, adjust as required Check the flow switch Clean the switching unit Replace the sealing ring of the switching unit Replace the floater valve membrane and cone seal Check and adjust floater valve function Replace the hose to the suction pipe Check the pump impeller and lid (only for Calpeda pumps) Check floating ring seal for tightness Check pump roller bearings for noises Clean the dirt filter Replace all O-rings Check nozzle diameter diffuser, smaller 6mm; (use 5.5mm drill piece to inspect passage) 2 Chlorine dosing device Heating function: Dosing pipe warm Check the chlorine-empty switch Clean and check the dosing screw Measure the dosing motor power uptake: Imax.: 150 ± 30mA Dosing motor: Replace the seals Replace the dust cap seal 12 3 Acid dosing system 3.1 Check the hose pump for humidity and corrosion Check function of the empty switch Replace dosing hose Replace the seals of the acid dosing valve 12 Z:\org-wdt\02 Qualitätsmanagement\ISO 9001\MS - Originale - Formuale, Prüfbericht etc\wdt Wartungsprotokolle WP\WDT WP 27 Wartungsprotokoll GR 10-CPR Touch XL EN FO 00.doc Key: F= at each granular filling; 1 = every month, 3 = every 3 months, 6 = every 6 months, etc.; = work completed Page 1 of 2

56 Maintenance protocol WP 27 Granudos 10 CPR-Touch XL Activity Maintenance interval in months Month 1 Month 2 Month 3 Month 4 Month 5 Month 6 Month 7 Month 8 Month 9 Month 10 Month 11 Month 12 Comment / additional work 4 Flocculant dosing system 4.1 Check the hose pump for humidity and corrosion Check function of the empty switch Replace dosing hose Replace the seals of the flocculant dosing valve (on-site) 5 Buffer tank (optional) Check function of the level switch Clean the buffer tank with water and diluted acid Replace the active carbon filter 12 6 Control Check all inputs Check all outputs Check parameter settings and correct it if required 7 Measuring cell block Chlorine electrode, replace seal set Replace redox electrode, seal set Replace flow controller, maintenance set Check and clean preliminary filter DPD1 measurement, adjust free chlorine ph measurement, adjust the ph electrode 12 8 Other work 8.1 Thoroughly clean the dosing system. 1 9 Maintenance work due at each granulate filling 9.1 Check function of the monitoring switch 9.2 Test chlorine, flocculant and acid dosing F 9.3 Take note of pumping noises F 9.4 Check the system for tightness F Other comments: Maintenance performed by:...date:... Countersigned by operator:... Z:\org-wdt\02 Qualitätsmanagement\ISO 9001\MS - Originale - Formuale, Prüfbericht etc\wdt Wartungsprotokolle WP\WDT WP 27 Wartungsprotokoll GR 10-CPR Touch XL EN FO 00.doc Key: F= at each granular filling; 1 = every month, 3 = every 3 months, 6 = every 6 months, etc.; = work completed Page 2 of 2

57 Operating and assembly instructions Measuring and control unit CPR Touch XL with measuring cell block OI Part 2: for control unit Measuring technology for ph values, free chlorine, redox voltage and temperature Part 2, regarding the OI for the dosing devices: Granudos 10-CPR Touch XL, No.: BA SW 002 Granudos 45/100-CPR Touch XL, No.: BA SW 003 CPR Touch XL-2S, No.: BA SW 004 Item No.: --- Language: EN

58 Table of contents 1 About this manual / general Scope of applicability Target group Symbols used Warranty Further information Information regarding support queries Safety Intended use Safety notices Handling of chemicals, risks to humans and the environment Protective measures and rules of conduct Product description - scope of delivery Scope of delivery / accessories Product description Device overview Control CPR Touch XL (standard) The measuring cell block Identification of the device / nameplate Technical data Transport / storage Assembly Select the installation site Assembly instructions / installation suggestion Mechanical assembly Hydraulic assembly Electric assembly Commissioning Commissioning, - comments Commissioning tasks Insert the cleaning beads Insert ph and combination electrodes with glass shafts Set the measuring cell flow rate The control parameters Operation / service General The control unit CPR Touch XL Operation display - Display auto mode Automatic operation QuickInfo Start - Dosing delay Alarm Automatic - Startup Automatic Redox control (emergency programme) Manual dosing (emergency programme) Main menu Settings (overview) Main menu Service Main menu Login Main menu Log (event and data logging) Main menu Calibration Refill consumables Index: 01 Date of modification: 01/22/2016 BA No.: BA MR Steuereinheit CPR Touch XL EN.docx Page 2 of 68

59 7 Maintenance, care, faults Device maintenance Check and clean the prefilter DPD1 Measuring free chlorine calibration ph measurement calibrate ph electrode Combination reference-return electrode Chlorine electrode - exchange the gasket set Redox electrode - exchange the gasket set Flow regulator - exchange the maintenance set Open and close the casing Regular water check Disruption removal Decommissioning - storage - disposal General Decommissioning Disposal of used parts and operating materials Documents Declaration of conformity Terminal diagrams Terminal diagram power supply unit for device 2S Terminal diagram I/O Board for device 2S The measuring amplifier Terminal diagram power supply with connection to the IO circuit board for device GR 10-CPR Terminal diagram I/O circuit board GRD 7 for device GR 10-CPR Terminal diagram power supply with connection to the I/O circuit board for device GR 45/100-CPR Terminal diagram I/O circuit board GRD 7 for device GR 45/100-CPR Terminal diagram buffer tank GRD 7 for the devices GR 45-CPR and GR 45/100-CPR Terminal diagram measuring plate for the devices GR 45-CPR and GR 45/100-CPR Commissioning protocol Operation data sheet Maintenance protocol Spare parts list, wear parts list, consumables Appendices Imprint: All rights reserved Copyright by WDT Werner Dosiertechnik GmbH & Co KG Edition: see footer Reproduction of any kind and translation into other languages, even in excerpts, are only permitted with the express authorisation of the company WDT - Werner Dosiertechnik GmbH & Co. KG. These operating instructions are an English translation of the original German version by the company WDT. Responsible for the content: Co. WDT - Werner Dosiertechnik GmbH & Co. KG Hettlinger Str. 17 D Wertingen-Geratshofen Phone: +49 (0) / Fax: +49 (0) / info@werner-dosiertechnik.de Index: 01 Date of modification: 01/22/2016 BA No.: BA MR Steuereinheit CPR Touch XL EN.docx Page 3 of 68

60 1 About this manual / general 1.1 Scope of applicability This manual describes the function, assembly, commissioning and operation of the device. Read these operating instructions carefully prior to operating the device and keep them in close proximity of the device for immediate use! 1.2 Target group This system may only be operated by our authorised partners and persons instructed in the device functions after they have read and understood these operating instructions. Electrical connection work may only be carried out by appropriately trained specialists! 1.3 Symbols used This document uses the following types of safety notices as well as general notices: DANGER! DANGER denotes a safety notice whose non-observance may result in immediate, serious or life-threatening injuries or significant property damages! CAUTION! CAUTION denotes a safety notice whose non-observance may result in bodily injury, damages to health or property damages! ATTENTION! "ATTENTION" denotes a safety notice whose non-observance may result in property damages! CAUSTIC! "CAUSTIC" denotes a safety notice whose non-observance when handling chemicals may result in bodily injury or property damages. Index: 01 Date of modification: 01/22/2016 BA No.: BA MR Steuereinheit CPR Touch XL EN.docx Page 4 of 68

61 ESD SENSITIVE! ESD SENSITIVE denotes electronic components that may be damaged by electrostatic discharge. When handling the devices, the generally known safety precautions for ESD-sensitive devices must be observed! NOTICE! A notice denotes information whose non-observance may result in operational disruptions. Tip! A Tip denotes information that may result in improvements in the operating process. Mandatory sign Use face protection! Mandatory sign Use protective gloves! According to DIN EN 374, protective gloves against chemicals and microorganisms Mandatory sign Use protective apron! Mandatory sign Use protective boots! 1.4 Warranty All devices and systems of the Co. WDT are manufactured using state-of-the-art manufacturing methods and are subject to a comprehensive quality control. However, Index: 01 Date of modification: 01/22/2016 BA No.: BA MR Steuereinheit CPR Touch XL EN.docx Page 5 of 68

62 should there be a reason for complaint, any compensation claims shall be directed to the company WDT in accordance with the general terms and conditions of warranty (see below). General terms and conditions of warranty The Co. WDT assumes a 2-year warranty, starting with the commissioning, up to 27 months after delivery; subject to correct installation and commissioning with a completed and signed commissioning protocol. Exempt from this are wear parts such as gaskets, hoses, membranes, dosing screws, electrodes, roller supports and other parts that are subject to mechanical or chemical wear and tear. For these we assume a warranty of 1/2 year. Our merchandise management programme requires an invoice for each delivery (including warranty services). When returning a defective component, upon review you will receive a corresponding credit, if applicable. We request a return within 14 days. The costs for subsequent damages and for the processing of warranty claims are excluded. There are no warranty claims for damages that were caused by frost, water and electrical overvoltage or by improper handling. Tip! In order to protect the warranty claims, please mail the completed commissioning protocol, along with the defective component, to the Co. WDT. Without the maintenance protocol, we reserve the right to assert a warranty regulation. CAUTION! It is not permitted to make any modifications to the device. Any violation of this provision voids the warranty obligation as well as the product liability! 1.5 Further information Further information about special topics, e.g., design of the dosing performance or description of the operating parameters, is available from your specialist supplier. 1.6 Information regarding support queries The CPR-Touch XL series constitutes a highly complex, electronic control unit. It is subject to continued further development of both its firmware and hardware. We always strive to preserve the compatibility of the components used, but we are unable to guarantee this over a period of several years! For spare part orders, we therefore always require the following data. You can find these on the nameplate. exact device designation device serial number year of manufacture Index: 01 Date of modification: 01/22/2016 BA No.: BA MR Steuereinheit CPR Touch XL EN.docx Page 6 of 68

63 For technical support queries, we also require the following data. You can find these in the menu item Menu Service Info. current firmware version current hardware version In the event of problems with the measuring values, we always require all current measuring values. Thus, you can help us in evaluating the disruption more quickly. This will enable us to quickly provide you with help. Index: 01 Date of modification: 01/22/2016 BA No.: BA MR Steuereinheit CPR Touch XL EN.docx Page 7 of 68

64 2 Safety 2.1 Intended use The measuring and control unit Touch XL may only be used for the purpose listed in the product description under Section 3.2, Product description! In this context, all locally applicable provisions regarding the prevention of accidents, occupational safety and protection of drinking water must be observed! 2.2 Safety notices Carefully read and comply with the operating instructions prior to assembly, maintenance and use of the device! Work on the device and changes in the settings may only be carried out by properly instructed persons! IT safety The CPR Touch XL controller series allows remote access to data and control parameters by means of network-compatible devices. The operator is responsible for ensuring that only authorised persons can access the device. The operator, or his authorised representative, is further responsible for the safety of all Internet or WLAN connections Handling of chemicals, risks to humans and the environment In case of emergency when handling chemicals, please contact the Poison Control Centre! Emergency telephone number: Poison Control Centre Munich (or any other poison control centre) Phone: Excerpt from the Accident Prevention Provisions, GUV-V D 5 Installation rooms for chlorination systems and storage rooms Section 3a. (1) Chlorination systems must be installed in lockable rooms and the chemicals intended for the chlorination must be stored in lockable rooms. Re Section 3a Para. 1: This requirement ensures that chlorination systems and chemicals shall be protected against weather effects and unauthorised access. (2) Rooms in accordance with Para. 1 must not be intended for the permanent presence of persons. Re Section 3a Para. 2: A permanent presence is given when persons are present in the room for more than 2 hours per day. Repair and maintenance work on the chlorination system are exempt from this. Index: 01 Date of modification: 01/22/2016 BA No.: BA MR Steuereinheit CPR Touch XL EN.docx Page 8 of 68

65 2.2.2 Protective measures and rules of conduct CAUSTIC! The control unit CPR Touch XL is used to control devices that dose caustic chemicals. Therefore, it is imperative that you observe the safety notices for the respective device! ESD SENSITIVE! The electronic components in the devices controls are sensitive to electrostatic discharge. Therefore, the generally known safety precautions for ESD-sensitive devices must be observed when handling the devices, such as: Discharge of personal static charge Dissipative clothing Disconnect the device from the voltage supply Index: 01 Date of modification: 01/22/2016 BA No.: BA MR Steuereinheit CPR Touch XL EN.docx Page 9 of 68

66 3 Product description - scope of delivery 3.1 Scope of delivery / accessories The measuring and control unit CPR-Touch XL is delivered with the following standard accessories. Buffer solutions ph7, ph4, redox test solution Electrode cleaner, distilled water Cleaning beads, electrolyte solution, replacement gaskets 2 pc. ½ measuring water ball valve with immersion pipe, (not included with Granudos variants) 7m each measuring water pipe 6x1mm of PE and PTFE, (not included with Granudos variants) In addition, customer-specific or order-related modifications are possible. 3.2 Product description The CPR-Touch XL controller series is intended exclusively for measuring and control tasks for the water treatment in swimming pools. It is used for the following 3 dosing devices: GRANUDOS 10-CPR Touch XL GRANUDOS 45/100-CPR Touch XL CPR Touch XL-2S The control has the following main functions: Regulation of the ph value by means of a hose pump directly from the supply canister Regulation of the disinfection dosing, with screw conveyor (type Granudos) or hose pump (type 2S) Regulation of the flocculant, by means of a hose pump directly from the supply canister Backwash disinfection / high-speed dosing controlled by a switching valve ECO operation for lowering the setpoint for free chlorine during extended pause times, e.g., night, weekend, rest day Filling of a buffer tank with chlorine solution for disinfecting additional small basins with dosing pumps (option) Fault message potential-free PC connection, remote display and access to the values and parameters via LAN Remote display (optional) Index: 01 Date of modification: 01/22/2016 BA No.: BA MR Steuereinheit CPR Touch XL EN.docx Page 10 of 68

67 3.2.1 Device overview The control unit CPR-Touch XL is delivered as a ready-assembled unit. All parts are mounted on a plastic plate or on the respective dosing device. This ensures a safe assembly of the device. It also goes toward preventing potential execution errors on the part of the assembly personnel, as far as possible. For the transport, the factory removed the two electrodes with a glass shaft from the measuring cell and delivered them in a separate packing box. In order to avoid deformation of the dosing hoses during extended storage, the hose pumps roller supports have been pulled off the motor shaft Figure 1, GRANUDOS 10-CPR Touch XL Figure 2, GRANUDOS 45/100-CPR Touch XL Index: 01 Date of modification: 01/22/2016 BA No.: BA MR Steuereinheit CPR Touch XL EN.docx Page 11 of 68

68 Figure 3, CPR Touch XL-2S 1. Control CPR Touch XL 2. Flow monitoring 3. Temperature sensor 4. Combination reference-return electrode (blue) 5. ph electrode (black) 6. Flow control valve 7. PMMA measuring cell block 8. Test water tap 9. Prefilter (with 2S optional for wall mounting) 10. Redox electrode 11. Chlorine electrode 12. Measuring water intake 13. Measuring water return flow 14. Redox test cylinder dosing pumps Sa (for Granudos 45/100 not shown in the figure) 16. Buffer solution and electrode cleaner 17. Dosing valves (only with 2S) 18. Suction kits (not shown in the figure) Control CPR Touch XL (standard) The microprocessor-supported control is contained in a dust-proof casing. The start view, also known as auto mode, displays the current measuring values, the operating status and the active in- and outputs (IN OUT). The in- and outputs can be operation messages or fault messages. Index: 01 Date of modification: 01/22/2016 BA No.: BA MR Steuereinheit CPR Touch XL EN.docx Page 12 of 68

69 3.2.3 The measuring cell block The compact measuring cell block (7) is made of acryl glass and serves to hold the electrodes, metering, beads and cleaning of the sampling valve. It is the flow regulated and the test water is led back. 3.3 Identification of the device / nameplate For spare part orders and troubleshooting, it is useful to know the device serial number and firmware version. The device serial number is located on the nameplate on the right side of the control casing. The firmware version can be called up via the menu item Menu Service Info. Nameplate see OI Part 1 for the dosing devices Granudos 10-CPR Touch XL, No.: BA SW 002 Granudos 45/100-CPR Touch XL, No.: BA SW 003 CPR Touch XL-2S, No.: BA SW 004 Index: 01 Date of modification: 01/22/2016 BA No.: BA MR Steuereinheit CPR Touch XL EN.docx Page 13 of 68

70 3.4 Technical data CPR Touch XL-2S control technology GRANUDOS 10-CPR control technology Connection data Electric connection data 230VAC/50Hz ± 10%, 35W, I max. 0.2A, standby 22VA, safety (Schukoplug 230VAC/50Hz ± 10 %, 320W, I max. 1.4A, standby 22VA, safety (Schukoplug Protection class Casing IP54 Casing IP54 Interface connection Modbus TCP, USB fore data export Modbus TCP, USB fore data export Measuring water supply From the swimming pool cycle from dosing device Operating data: Measuring range ph value: 2.00 to free chlorine: 0.01 to 2mg/l or 0 to 8.00mg/l, respectively Redox: 0 to 1000mV Temperature: to C Medium temperature Ambient temperature Humidity engineering room Concentration hypochloric acid Ventilation of the room (in and out) Material 0 C to 40 C 5 C to 35 C max. 80% non-condensing ---- max. 0.2% ph value: 2.00 to free chlorine: 0.01 to 2mg/l or 0 to 8.00mg/l, respectively Redox: 0 to 1000mV Temperature: to C 0 C to 40 C 5 C to 35 C max. 80% non-condensing According to DIN According to DIN Casing: PS Measuring water line: PE Dosing lines: PTFE Firmware version Hardware version Casing: PS Measuring water line: PE Connection data Electric connection data Protection class Interface connection Measuring water supply GRANUDOS 45/100-CPR control technology 230VAC/50Hz ± 10 %, 320W, I max. 1.4A, standby 22VA, safety (Schukoplug) Casing IP54 Modbus TCP, USB fore data export from dosing device Operating data: Measuring range ph value: 2.00 to free chlorine: 0.01 to 2mg/l or 0 to 8.00mg/l, respectively Redox: 0 to 1000mV Temperature: to C Medium temperature Ambient temperature Humidity engineering room Concentration hypochloric acid Ventilation of the room (in and out) Material 0 C to 40 C 5 C to 35 C max. 80% non-condensing Granudos 45: max. 0.2% Granudos 100: max. 0.35% According to DIN Casing: PS Measuring water line: PE Firmware version Hardware version Index: 01 Date of modification: 01/22/2016 BA No.: BA MR Steuereinheit CPR Touch XL EN.docx Page 14 of 68

71 3.5 Transport / storage Please check the devices immediately upon receipt for potential transport damage. ATTENTION! The systems and devices may be damaged by frost or high temperatures. Avoid exposure to frost during transport and storage! Do not store systems and devices next to objects with strong heat emission or in direct sunlight. The device may only be transported and stored in its original packaging. Please ensure careful handling. Storage of chemicals NOTICE! Please comply with the chemicals manufacturer s safety data sheets! In addition, please observe the provision regarding the storage of chemicals TRGS 515. Index: 01 Date of modification: 01/22/2016 BA No.: BA MR Steuereinheit CPR Touch XL EN.docx Page 15 of 68

72 4 Assembly 4.1 Select the installation site See operating instructions Part 1 Dosing technology, regarding the respective dosing device. 4.2 Assembly instructions / installation suggestion See operating instructions Part 1 Dosing technology, regarding the respective dosing device. 4.3 Mechanical assembly See operating instructions Part 1 Dosing technology, regarding the respective dosing device. 4.4 Hydraulic assembly See operating instructions Part 1 Dosing technology, regarding the respective dosing device. 4.5 Electric assembly See operating instructions Part 1 Dosing technology, regarding the respective dosing device. Index: 01 Date of modification: 01/22/2016 BA No.: BA MR Steuereinheit CPR Touch XL EN.docx Page 16 of 68

73 5 Commissioning 5.1 Commissioning, - comments The work described here may only be carried out by trained specialist personnel from a specialist company. Prior to commissioning, the installed devices must be checked for proper installation and leaks. Please use the commissioning protocol from Section 9.3 for the commissioning. The device was delivered with specific factory settings. You can find the setting values in the operation data sheet under Section 9.4. NOTICE! Please ensure that all hose screw connections of the measuring water pipes are firmly tightened. Check all screw connections on the device and on the two measuring water ball valves ½. Plastic screw connections may only be fastened hand-tight! 5.2 Commissioning tasks Carry out the commissioning tasks in the sequence indicated Insert the cleaning beads The included blue glass beads serve for cleaning the two metal electrodes screwed in from below (pos. 10 and 11). This concerns the chlorine and redox electrodes. Fill the measuring cell from above with a sufficient number of glass beads to ensure that at least the metal surface is covered, 20 to 30 pieces. Put in cleaning beads covered metal surface Figure 4, measuring cell block and cleaning beads Index: 01 Date of modification: 01/22/2016 BA No.: BA MR Steuereinheit CPR Touch XL EN.docx Page 17 of 68

74 5.2.2 Insert ph and combination electrodes with glass shafts Remove the two electrodes with glass shafts from the packing box and pull off the protective cap. The union nut of the electrode cables can be removed from the electrodes by twisting to the left. The electrodes are screwed into the measuring cell from above at position 4 (blue) and position 5 (black). Subsequently, the electrode plug must be placed back onto the respective electrode and the union nut must be tightened Figure 5, measuring cell block with installed electrodes Set the measuring cell flow rate Once all electrodes have been screwed hand-tight into the measuring cell and the measuring water pipes have been connected, the measuring water intake may be opened. The flow volume can be adjusted at the flow control valve (pos. 6). The flow mounting float (pos. 2) must be pushed toward the top in order to release the dosing. The cleaning beads must rotate extensively on the metal surfaces. A flow rate that is set too high causes the cleaning beads to lift off the surface, thus diminishing their cleaning efficiency The control parameters The device is loaded with factory-defined control parameters. Please adjust the control parameters for your basin according to the required dosing performance and the desired setpoints. NOTICE! Following a temperature adjustment and inflow time of approx. one hour, the electrodes must be calibrated. The mechanical commissioning is now completed. Continue with Section 6, Operation and service of the device in order to adjust the control parameters to your swimming pool and to optimise them. Index: 01 Date of modification: 01/22/2016 BA No.: BA MR Steuereinheit CPR Touch XL EN.docx Page 18 of 68

75 6 Operation / service NOTICE! The nationally applicable accident prevention provisions in Germany: Operation of swimming pools BGR/GUV-R 108 must be observed. 6.1 General Once all preparations for the commissioning have been completed, the settings can be adjusted at the dosing system CPR Touch XL. 6.2 The control unit CPR Touch XL The control unit CPR-Touch XL is equipped with a touch-sensitive display. By touching a symbol or a numeric value, this will be activated for parametrisation. The adjustment menus come with additional text-based instructions Operation display - Display auto mode A 7 touch display allows the clear and easy operation of the microprocessor-supported control of the CPR Touch XL. The operating states and disruptions are displayed directly on the start screen: see Figure 6, auto mode, page 20. In the auto mode, the current measuring values, the operating status and the active in- and outputs (IN OUT) are displayed. The in- and outputs can be operation messages or fault messages. Operating notes: The operating status is displayed in the status line. The following operating states are available: Dosing delay Automatic Manual dosing Menu Adjustment Output test Input test Index: 01 Date of modification: 01/22/2016 BA No.: BA MR Steuereinheit CPR Touch XL EN.docx Page 19 of 68

76 The device is operated by means of a resistive touch display. Desired parameter changes, calibrations and tests can be done simply by lightly touching the corresponding symbol or the numeric value. 1. QuickInfo 2. current measuring values 3. Bar display 7. Measuring value alarm low or high, respectively 8. Cancel alarm 4. IN list 9. Manually deactivate dosing 5. OUT list 10. Menu 6. Status line 11. Date/ time Figure 6, auto mode The IN list shows the input signals to the control unit. The OUT list shows the active output signals of the control unit. Symbols used: The symbols depend on the firmware, i.e., the device variant used IN list (general) red = ph level (container for ph regulation empty) yellow = disinfection level (container for disinfectant empty) blue = flocculation level (container for flocculant empty) 12. User level Hose rupture a chemical leak has occurred at one of the installed hose dosing pumps (variant 2S) The measuring cell flow is too low Shock chlorination (filter disinfection) active The request for ECO operation from the central control cabinet is pending. The controller is deactivated via the central control cabinet. No dosing, no heating of the basin water, no alarm message takes place. The dosing is blocked by an optional flow switch in the clean water line. No dosing takes place A dynamic dosing time has been exceeded. The respective output is blocked. To save space, no differentiation is made between the individual channels! Index: 01 Date of modification: 01/22/2016 BA No.: BA MR Steuereinheit CPR Touch XL EN.docx Page 20 of 68

77 OUT list (general) red = ph regulation output active yellow = disinfection output active blue = flocculation output active Temperature output active. The ECO operation is active. Feedback occurs to the central control cabinet regarding the ECO operation The alarm relay is active. NOTICE! The firmware is available in different device variants. Depending on the scope of functions, a larger or smaller number of icons is displayed in the individual menu items. The following symbols are only active in the device variant GRANUDOS. IN list (only for Granudos) The pressure at the GRANUDOS motive water pump is too low. The motive water pump is being stopped The level in the GRANUDOS flushing tank is too low. The motive water pump is being stopped The level in the GRANUDOS flushing tank is too high. The dosing of chlorine and acid is stopped The flow rate in GRANUDOS is too low. The dosing of chlorine and acid is stopped. The fuse of the chlorine dosing motor has tripped. OUT list (only for Granudos) The motive water pump is active The knocker is active. This symbol is only displayed very briefly Index: 01 Date of modification: 01/22/2016 BA No.: BA MR Steuereinheit CPR Touch XL EN.docx Page 21 of 68

78 The following symbols are only of interest in the buffer filling OPTION. IN list (optional, design with buffer tank) The buffer filling is started The buffer filling is terminated The level in the buffer tank has dropped too low. The dosing of chlorine is stopped The level in the buffer tank is too high. The optical sensor at the cyclone did not recognise any chlorine during the buffer filling. The filling was deactivated. The buffer filling was cancelled by the system. The filling occurred too slowly. OUT list (optional, design with buffer tank) The filling of the buffer tank is active. The function buttons on the start screen Manually cancel the dosing delay, dosing starts Manually deactivate the dosing for service tasks Deactivate alarm relay Call up the main menu Operation display: Depending on the operation state, the display shows different views. The following illustrates and describes the main display views. Index: 01 Date of modification: 01/22/2016 BA No.: BA MR Steuereinheit CPR Touch XL EN.docx Page 22 of 68

79 6.2.2 Automatic operation The device is in the operating state Automatic. The auxiliary hygiene parameters and the temperature are regulated based on set parameters. There is no disruption. The Out list shows the currently active outputs and/or actuators as an example QuickInfo In automatic operation, the set control parameters can be viewed quickly and without a password prompt via the QuickInfo function by touching the corresponding symbol. QuickInfo only serves for the query of the control parameters; no changes can be made Start - Dosing delay If the device is restarted, the dosing delay is running, during which no dosing output is activated. Software alarms are suppressed during this time. The dosing delay must be set high enough to ensure that after the start of the filter system actual basin water flows through the measuring cell. The dosing delay can be cancelled with set to automatic operation. and the device is Index: 01 Date of modification: 01/22/2016 BA No.: BA MR Steuereinheit CPR Touch XL EN.docx Page 23 of 68

80 6.2.5 Alarm If an alarm occurs, this is signalled by the symbol in the OUT list. The alarm relay is activated. A differentiation is made between alarms (software alarms, e.g., alarm high, alarm low) and disruptions (switch inputs). In the event of measuring value alarms, the respective measuring value is additionally illustrated in red. In the event of disruptions, the corresponding symbol appears in the In list. Alarms or disruptions must be pending for approx. 5 seconds before an alarm is triggered. With the button, the alarm can be temporarily deactivated without remedying the disruption. If a subsequent disruption occurs, the alarm relay will be reactivated. Tip! An alarm will be automatically deleted when its cause has been remedied. This is the case, e.g., if the empty chemical container was replaced or if measuring water resumes its flow through the measuring cell. However, the alarm Switch-off time monitoring must be acknowledged manually! Automatic - Startup If one of the two measuring values ph or Cl falls outside the control range, the start routine Startup is started. During the start routine, the dynamic dosing time monitoring is active. If a measuring value does not reach the control range within the selected time, e.g., due to a malfunction, the dosing stops with an alarm. The dosing time monitoring alarm is signalled by. This malfunction is only reset through a device restart or a manual acknowledgement. Index: 01 Date of modification: 01/22/2016 BA No.: BA MR Steuereinheit CPR Touch XL EN.docx Page 24 of 68

81 6.2.7 Automatic Redox control (emergency programme) In the event of an irreparable defect in the measuring of free chlorine, e.g., a broken electrode, the disinfection dosing for temporary operation may be done via the emergency function of the redox control. If this operation mode is selected, the display in the start screen changes. The measuring value for free chlorine is faded out Manual dosing (emergency programme) In the event of an irreparable defect in the general measuring technology, both the disinfection dosing and the dosing of the ph regulation for temporary operation may be done via the emergency function Manual operation. If this operation mode is selected (see Section ), the display in the start screen changes. For type Granudos: Instead of the measuring values, a flow chart of a Granudos dosing device with a buffer tank is displayed. For type 2S: The measuring values are faded out. Index: 01 Date of modification: 01/22/2016 BA No.: BA MR Steuereinheit CPR Touch XL EN.docx Page 25 of 68

82 The main menu Automatic Navigates to the start screen and automatic operation Settings For adjusting the control parameters and system settings Service Input and output test, info Login For the password assignment; no password is assigned in the delivery state. Log For the query of events and data logging Calibration Calibration of the ph and redox electrode, DPD1 calibration Main menu Settings (overview) In the Settings menu, you can adjust the desired settings for the dosing device. Using the white arrow keys on the side, you can navigate to the next screen menu. ph Set ph control parameter Chlorine disinfection Set disinfection control parameter Dosing performance Adjust the dosing performance to the basin size mv Redox Set redox voltage control parameter Temperature Set basin temperature control parameters Dosing delay Set the dosing delay Flocculation Set flocculation dosing parameter ECO operation Set parameter for ECO operation Index: 01 Date of modification: 01/22/2016 BA No.: BA MR Steuereinheit CPR Touch XL EN.docx Page 26 of 68

83 System Set date/ time, password, display, network and language Shock chlorination Set dosing performance for the Shock chlorination function Buffer (only for Granudos) Set dosing performance for the Buffer filling function NOTICE! After a password has been assigned, the controller is blocked against unauthorised access. The setting buttons will appear in grey. Desired changes can only be made after the password has been entered. After a password has been assigned, please enter it in the operation data sheet. Main menu Settings ph Alarm low: lower alarm value P range: The dosing works proportionally, i.e., the higher the difference between setpoint and actual value, the longer the dosing time (max. 8 seconds). The smaller the selected control range, the faster the measuring value will react, which can easily lead to overdosing. Setpoint: the device attempts to reach this value Alarm high: upper alarm value Dosing time limit: if the control range is not reached within three x the set time, the dosing is blocked. Important: This disruption must be acknowledged manually! Tip! ph priority dosing! To protect against overdosing with disinfectants that contain chlorine, the dosing is only released once the ph value has entered the control range. For this reason the control range must not be set too high. Index: 01 Date of modification: 01/22/2016 BA No.: BA MR Steuereinheit CPR Touch XL EN.docx Page 27 of 68

84 Main menu Settings Disinfection chlorine Alarm low: lower alarm value P range: The dosing works proportionally, i.e., the higher the difference between setpoint and actual value, the longer the dosing time (max. 15 seconds). The smaller the selected control range, the faster the measuring value will react, which can easily lead to overdosing. Setpoint: the device attempts to reach this value Alarm high: upper alarm value Dosing time limit: if the control range is not reached within three x the set time, the dosing is blocked. Important! This disruption must be acknowledged manually! Main menu Settings Dosing performance The Dosing performance menu serves for adjusting the dosing performance to the expected consumption of chemicals in the pool. Especially in case of lower water content, it is very important to adjust the dosing performance. The required dosing performance depends on several factors, e.g., the basin volume, location, type of use and of course the frequency of use by pool visitors. ph: Acid dosing time in seconds Disinfection: Chlorine dosing time in seconds Cycle time: Length of the overall cycle in seconds Manual dosing: Change between automatic and manual dosing Explanation regarding the cycle time The shortest cycle time is 30 seconds, i.e., every 30 seconds the dosing is proportionally activated for a varying length of time, depending on the deviation from the setpoint. It can be set for a dosing time between 1 and 8 seconds for the acid dosing, followed by a pause of 4 seconds. This is followed by a dosing time between 1 and 15 seconds for the chlorine dosing, followed by a pause of 3 seconds. This is followed by an additional pause time until the entire cycle time has elapsed. An extension of the cycle time extends the second pause time, thus reducing the maximum available dosing performance. This will be shown in %. Example 1: 30 seconds Example 2: 90 seconds ph Cl ph Cl sec. 30 sec. 0 sec. 90 sec. Index: 01 Date of modification: 01/22/2016 BA No.: BA MR Steuereinheit CPR Touch XL EN.docx Page 28 of 68

85 ATTENTION! The use of sulphuric acid is generally possible up to a concentration of 50%. For higher concentrations or when using other acids (e.g., hydrochloric acid, dissolved sodium bisulphate, etc.), the changed dosing performance and/or increased corrosiveness must be observed! We recommend to consult with the company WDT! Manual dosing Off On There is the option of switching to a continuous manual dosing. This may be necessary in the event of an irreparable defect in the measuring technology, e.g., a broken electrode. For a limited period of time, both the disinfection dosing and the dosing of the ph regulation may be done via the emergency function Manual operation. After activation of Manual dosing, the display in the start screen changes. For Granudos: Instead of the measuring values, a flow chart of a dosing device with a buffer tank is displayed. For type 2S: The measuring values are faded out. In the operation mode Manual dosing, it is essential to adjust the dosing performance to the actual consumption. It is a known fact that the consumption changes between the operating phases bathing operation and non-bathing operation, e.g., at night or on rest days. CAUTION! In the operation mode Manual dosing, the operating personnel must continually check the water quality and adjust the dosing amounts. Non-compliance with this may result in significant overdosing! Index: 01 Date of modification: 01/22/2016 BA No.: BA MR Steuereinheit CPR Touch XL EN.docx Page 29 of 68

86 Main menu Settings mv Redox - Alarm values Alarm low: lower alarm value Alarm high: upper alarm value Off - On: select disinfection dosing via redox control (emergency operation) Main menu Settings mv Redox - Emergency operation In the event of an irreparable defect in the measuring of free chlorine, the disinfection dosing for temporary operation may be done via the emergency function of the redox control. If this operation mode is selected, the display in the automatic operation changes. The measuring value for free chlorine is faded out. Alarm low: lower alarm value P range: The dosing works proportionally, i.e., the higher the difference between setpoint and actual value, the longer the dosing time (max. 15 seconds). The smaller the selected control range, the faster the measuring value will react, which can easily lead to overdosing. Setpoint: the device attempts to reach this value Alarm high: upper alarm value Dosing time limit: if the control range is not reached within three x the set time, the dosing is blocked. Important! This disruption must be acknowledged manually! Main menu Settings Temperature Alarm low: lower alarm value Setpoint: the device attempts to reach this value Control range: if the temperature falls below the setpoint minus the control range (hysteresis), the Temperature output will be activated Example: Setpoint 25 C 2.0K actual value 23 C = output active Alarm high: upper alarm value Offset: for fine-tuning the temperature display Off - On: operation mode Temperature display or Regulation on-off Index: 01 Date of modification: 01/22/2016 BA No.: BA MR Steuereinheit CPR Touch XL EN.docx Page 30 of 68

87 Main menu Settings Dosing delay If the device is restarted, the dosing delay is running. No dosing occurs during this time, so that no stale water will be used for the measurement. Software alarms are suppressed during this time. The dosing delay must be set high enough to ensure that after the start of the filter system actual basin water flows through the measuring cell. Main menu Settings Flocculation This menu allows the activation or deactivation of the flocculation pump. The dosing release of the flocculation is monitored by the control unit. Main menu Settings ECO operation Night-time operation (DIN contact) The ECO function enables an operation with optimised energy cost and consumption. There are two operation modes: the Master and the Slave operation. Operation mode: Master In the Master operation mode, the controller switches to night-time operation in accordance with the time blocks selected in the Times menu. Operation mode: Slave In the Slave operation mode, a signal from the central swimming pool control initiates the ECO operation. The ECO output (DIN contact) serves for feedback to the central swimming pool control. It may be used for reducing the circulation volume. The feedback only occurs if the switching threshold of the redox voltage has been exceeded. Chlorine: second parameter set for the reduced setpoint mv Redox: Switching threshold for the DIN release contact in Slave operation mode. Times: Implemented week timer to specify the night-time operation times. Index: 01 Date of modification: 01/22/2016 BA No.: BA MR Steuereinheit CPR Touch XL EN.docx Page 31 of 68

88 A second parameter set is available for the optimisation of the consumption of the chemical chlorine. A reduced setpoint reduces the consumption of disinfectant. Since the night-time operation should only be initiated at a reasonable level of water quality, a switching threshold is specified for the redox voltage. The controller will only switch to night-time operation if the actual value the level value. If the redox voltage drops below the switching threshold during the night-time operation, the night-time operation is terminated The figure graphically displays the set switching times for the ECO operation. The green bars show the set time blocks. In addition, the green check mark indicates that the switching times have been activated for this day. While the red bar indicates a set time block, the day is deactivated. There are 4 time blocks available for each day. Times can be selected between 00:00 and 24:00. The colon must be entered as well! Times that cover more than one day must be entered as two blocks for both days. Example: A desired night-time operation between Mon 21:00 and Tue 06:00 Required settings: Mon 21:00 to 24:00 and Tue 00:00 to 06:00 Index: 01 Date of modification: 01/22/2016 BA No.: BA MR Steuereinheit CPR Touch XL EN.docx Page 32 of 68

89 Main menu Settings System Date/ time Set date and time Password Assign a password Display brightness Adjust the display brightness to the ambient conditions Network Set network parameters Language Select the user language a) Main menu Settings System Date/ time Adjust date and time. You can activate the automatic switch from winter time to summer time. b) Main menu Settings System Password End user There is no factory setting for an end user password. We recommend the assignation of an end user password to protect the system against unauthorised access. Enter the password in the operation data sheet. Technician 1 The Technician 1 password consists of five digits and has a factory default setting of This password is intended for service partners. We recommend that you change this password as well and enter it in the operation data sheet. Index: 01 Date of modification: 01/22/2016 BA No.: BA MR Steuereinheit CPR Touch XL EN.docx Page 33 of 68

90 The individual end user password must consist of four digits between 0000 and In the second line, the password must be entered once again. If you place a green check mark next to Clear text, the entered numbers are shown instead of white dots. In order to change the current end user password, it must be entered in the uppermost line. The new password must be entered in the two following lines. If you want to delete the end user password, you only have to enter the active password in the uppermost line. The other two lines remain clear. When a wrong password is entered, an error message displays. NOTICE! Please store the individually chosen passwords safely in the operation data sheet. Lost passwords can only be reset by the factory customer service! c) Main menu Settings System Display After the selected delay time, the screensaver dims the background lighting to the configured brightness. The Backlight setting permanently reduces the background lighting in the operation mode. NOTICE! Please reduce the background lighting to the minimal brightness required by you. This significantly increases the lifespan of the background lighting. Index: 01 Date of modification: 01/22/2016 BA No.: BA MR Steuereinheit CPR Touch XL EN.docx Page 34 of 68

91 d) Main menu Settings System Network e) Main menu Settings System Language The touch panel contains a LAN interface with an RJ45 socket. Via this interface, the current measuring values and status messages can be transmitted to an external remote display. The terminal device can be a PC monitor, a tablet PC or a smartphone, e.g. Further information about this topic is available upon request. The operator must establish the necessary IT requirements for remote access! (e.g., VNP connection, data security, etc.) Select your desired operator language. Main menu Settings Shock chlorination With this menu you can adjust the dosing performance during a shock chlorination. Please select a dosing performance that ensures the availability of the desired concentration during the shock chlorination. For control purposes, the concentration must be determined repeatedly during the shock chlorination by means of photometry! Main menu Settings Buffer tank (for Granudos, optional) With this menu you can adjust the dosing performance during a buffer tank filling. Please select a dosing performance that ensures the availability of the desired concentration in the buffer tank after the buffer filling. For control purposes, the concentration must be analytically determined repeatedly after the buffer tank filling! Off - On: permanently activate or deactivate the Buffer tank filling function. The filling is regulated automatically via the level control in the buffer tank. Index: 01 Date of modification: 01/22/2016 BA No.: BA MR Steuereinheit CPR Touch XL EN.docx Page 35 of 68

92 Main menu Service Input test A test programme for switch inputs (electrical signals). Output test A test programme for pumps and relay outputs. Info For querying the firmware versions. Main menu Service Input test The input test serves for checking the connected inputs (switches). The changing activation of the switch inputs is indicated by 0 (open) or 1 (closed). The fourth column displays the pin header (SLx) and the connectors (Pinx/x) to which the switch is connected. The fifth column shows the function of the switches NO or NC, respectively. NO (normally open) indicates open in the operation state and closed in the event of a disruption. NC (normally closed) indicates closed in the operation state and open in the event of a disruption. Use the + and - buttons to flip through the pages. Main menu Service Output test The output test serves for checking the connected outputs (pumps and relays). The selected output is activated for 30 seconds. The activation may be cancelled at any time with the Stop button. For safety reasons (generation of chlorine gas), the output test for the chemical-dosing outputs is only released if no disruption exists that could prevent the dosing. Index: 01 Date of modification: 01/22/2016 BA No.: BA MR Steuereinheit CPR Touch XL EN.docx Page 36 of 68

93 Main menu Service Info Info allows you to query the currently used software versions. A differentiation is made between DSP version: The firmware version I/O version: The version of the co-processor on the I/O board HTTP version: The web front end version (software version of the user interface) Main menu Login A personal password assigned under Settings System Password protects the controller against unauthorised access. Without password, no further settings, calibrations, output tests, etc., are possible. You can still browse the menu and view the data logging. For future changes and adjustments, you must sign in with your personal password under Login. If you switch to the start screen, the password must be re-entered Main menu Log (event and data logging) Event Log Displays a chronological list of the events that occurred Data Log Traces the measuring values in the form of a table or graph Export Serves for exporting the collected data to a USB stick Delete Serves to delete the stored data Index: 01 Date of modification: 01/22/2016 BA No.: BA MR Steuereinheit CPR Touch XL EN.docx Page 37 of 68

94 Main menu Log Event Log When calling up the menu, a list of events that occurred on this day will be displayed. You can use the Calendar ICON to view events from previous days. The current day is shown on a white background. Days on which the control was activated are shown on a green background. If you select another day by touching it, that day will be shown on a white background. You can use the Event Log ICON to view the events of the selected day. Main menu Log Data Log If Data Log is activated, the measuring values are recorded every minute. The measuring values can be traced in the form of a table or graph. Use the arrow keys to navigate up or down through the pages. Main menu Log Export You can use the Export menu item to load the stored log files onto an empty USB stick. If the USB stick is not empty, formatting is suggested and will be carried out after you confirm with OK. The USB stick will subsequently contain the daily event files and the CSV files. Index: 01 Date of modification: 01/22/2016 BA No.: BA MR Steuereinheit CPR Touch XL EN.docx Page 38 of 68

95 Main menu Log Delete The current day is shown on a white background. Days on which the log files were stored are shown on a green background. If you select the desired day by touching it, that day will be shown on a white background. You can use the Selected ICON to delete the event log events and the data log events of the selected day. With the ICON, all event log events and data log events can be deleted at once Main menu Calibration ph Two-point calibration of the ph electrode phenol red One-point calibration of the ph display DPD1 Calibration of the free chlorine display mv - Redox Calibration of the redox measurement The calibrations are graphically guided and are accompanied by a help text. Use the OK button to acknowledge the completed steps. Main menu Calibration ph electrode Carry out the calibration according to the instructions. At the end of the ph calibration, the measuring results of the offset voltage and the conductance voltage are displayed and an electrode evaluation is carried out. In case of minor deviations, the calibration is adopted immediately. In case of "medium" deviations, a cleaning notice is displayed. In case of major deviations, the exchange of the ph electrode is suggested. If the exchange of the electrode does not remedy the problem, the fault may be with the electrode cable or the measuring amplifier. Index: 01 Date of modification: 01/22/2016 BA No.: BA MR Steuereinheit CPR Touch XL EN.docx Page 39 of 68

96 ph7 = buffer solution for determining the offset voltage. The optimal offset voltage is at 0mV up to +/-30mV. ph4 = second buffer solution for determining the conductance voltage. Inclination mv/ph = conductance voltage The optimal conductance voltage at 25 C is at approx. 59mV/pH. Example: (ph7 ph4 = 3pH x 59mV = 177mV) NOTICE! Notice regarding the evaluation of the electrodes Cleaning notice At an offset voltage > +/-41mV, the voltage value is shown in yellow and the calibration ends with a cleaning notice. At a calibration voltage < 52 mv or > 63mV/pH, the voltage value is shown in yellow and the calibration ends with a cleaning notice. Error notice At an offset voltage > +/-61mV, the voltage value is shown in red and the calibration is rejected with an error notice! At a calibration voltage < 50mV or > 65mV/pH, the voltage value is shown in red and the calibration is rejected with an error notice! If the calibration is rejected with an error notice, the device continues the regulation using the values from the most recent successful calibration. It is necessary to investigate the cause of the failed calibration! Notice regarding the phenol red calibration A two-point calibration of the ph electrode overrides the most recent phenol red calibration. Main menu Calibration Phenol red Carry out the calibration according to the instructions. Please observe the displayed notices and follow the menu navigation. Index: 01 Date of modification: 01/22/2016 BA No.: BA MR Steuereinheit CPR Touch XL EN.docx Page 40 of 68

97 At the end of the menu, the set deviation is shown as Offset. In case of minor deviations, the calibration is adopted immediately. In case of deviations larger than +/- 41mV, a cleaning notice is displayed. In case of deviations larger than +/- 61mV, the exchange of the ph electrode is suggested. If the exchange of the electrode does not remedy the problem, the fault may be with the electrode cable or the measuring amplifier. Main menu Calibration DPD1 free chlorine During the first step of the DPD1 calibration, three illustrations are displayed in sequence. They show an example of the procedure for a DPD1 measurement by means of a photometer and tablet measuring. The exact procedure is explained in the operation manual of your control measuring device! At the end of the menu, the chlorine measuring current, the DPD1 value entered by you and the resulting electrode signal are displayed. Depending on the water quality, an electrode signal between 10 and 30 µa/mg/l will be shown. If the electrode signal is too weak, the calibration will be rejected with an error message. Index: 01 Date of modification: 01/22/2016 BA No.: BA MR Steuereinheit CPR Touch XL EN.docx Page 41 of 68

98 Main menu Calibration mv Redox There are two basically different types of redox electrodes. There is the normal redox combination electrode (electrode with a glass shaft) and the ½ Redox electrode preferred by WDT. Select the type of electrode used. The calibrations are explained graphically and with a help text. The menu Calibration Redox electrode enables a finetuning of the redox measuring. The redox test solution supplied by WDT supplies a voltage of 468mV at 25 C, see bottle label. Since the voltage can be chosen freely, the fine-tuning may also be done with other redox test solutions, e.g., 220mV or 640mV. When making a comparison, please note the temperature dependence of the test solution! See label. At the end of the menu, the set deviation is shown as Offset. In case of minor deviations, the calibration is adopted immediately. In case of deviations larger than +/- 41mV, a cleaning notice is displayed. In case of deviations larger than +/- 61mV, the exchange of the ph electrode is suggested. If the exchange of the electrode does not remedy the problem, the fault may be with the electrode cable or the measuring amplifier. NOTICE! The redox electrode does not deliver a reliable measuring signal after a calibration. A regeneration time of up to two hours is required before a stable redox potential is achieved again! 6.3 Refill consumables see operating instructions Part 1 regarding the respective dosing device. Granudos 10-CPR Touch XL, No.: BA SW 002 Granudos 45/100-CPR Touch XL, No.: BA SW 003 CPR Touch XL-2S, No.: BA SW 004 Index: 01 Date of modification: 01/22/2016 BA No.: BA MR Steuereinheit CPR Touch XL EN.docx Page 42 of 68

99 7 Maintenance, care, faults 7.1 Device maintenance It is recommended to commission a specialist firm with the regular maintenance. All required maintenance and repair tasks may only be carried out by properly qualified personnel from a specialist company. Required spare parts are available from your specialist supplier. Please observe the safety notices when handling chemicals and make sure to wear appropriate protective clothing. Tip! Please use the maintenance protocol under Section 9.5 for the execution of maintenance tasks. Document these tasks in the maintenance protocol Check and clean the prefilter The prefilter prevents the contamination of the measuring cell. It must be inspected at regular intervals and cleaned as needed. Especially in the spring and fall, a higher level of contamination through flying seeds and falling leaves can occur in outdoor pools. During these times, shorter cleaning intervals must be applied. Figure 7, Prefilter When working on lines that carry water, always close the in- and outlet valves! Place a bucket under the filter. Unscrew the filter hood from the bracket. Remove the filter insert from the filter hood and wash the filter insert under running water. Reinstall in the reverse order. NOTICE! A soiled prefilter may lead to a chlorine depletion. This, in turn, may result in falsified measuring values DPD1 Measuring free chlorine calibration According to the nationally applicable provisions (such as DIN, ÖNORM, Sia, ), a manual measurement of the free chlorine must be conducted at regular intervals and the result must be documented in the operating log. The determination of the free chlorine is done by means of the DPD1 method. For this measurement, various photometric measuring procedures are available. If a major deviation is detected between the display and the determined free chlorine measurement, a DPD1 calibration must be carried out. Index: 01 Date of modification: 01/22/2016 BA No.: BA MR Steuereinheit CPR Touch XL EN.docx Page 43 of 68

100 7.1.3 ph measurement calibrate ph electrode Each ph electrode is a wear part. It is subject to a certain degree of ageing, which is due to a variety of factors. In the area of swimming pool water treatment, a life span of 6 months to 2 years may be expected. The contamination of the electrode may be one reason for measuring value deviations. These contaminations can usually be removed by means of the included electrode cleaner. For this purpose, the glass shaft of the ph electrode is submerged in the electrode cleaner for a few minutes. Depending on the state and age of the electrode, the electrode's characteristics may change. This leads to measuring value deviations that can be compensated by means of a calibration. ATTENTION! During all work on the ph electrode it must be ensured that neither the electrode's screw plug head nor the plug of the electrode cable are exposed to moisture! Even the smallest amount of moisture in the electrode head may lead to a falsification of the measuring value or even to a premature failure of the electrode! All contacts in the electrode's plug head and on the electrode plug must display a shiny golden colour and may not show any signs of corrosion NOTICE! After each cleaning or exchange of the electrode, a calibration must be carried out! Do not touch the glass top (sensor part) and the diaphragm with your fingers. Dab the glass top with a clean and soft cloth Combination reference-return electrode For the combination reference-return electrode (PG13,5 blue), a service life of one to two years may be expected, as well. The same safety measures as for the ph electrode apply. NOTICE! After each cleaning or exchange of the electrode, a calibration must be carried out! Do not touch the glass top (sensor part) and the diaphragm with your fingers. Dab the glass top with a clean and soft cloth. Index: 01 Date of modification: 01/22/2016 BA No.: BA MR Steuereinheit CPR Touch XL EN.docx Page 44 of 68

101 7.1.5 Chlorine electrode - exchange the gasket set As part of the annual maintenance, the flat gasket in the chlorine electrode ¾ and the corresponding O ring in the measuring cell must be exchanged Redox electrode - exchange the gasket set As part of the annual maintenance, the flat gasket in the redox electrode ½ and the corresponding O ring in the measuring cell must be exchanged Flow regulator - exchange the maintenance set The membrane in the flow control valve tends to age and become brittle. This results in an inadequate flow regulation at different operation states. A maintenance set with the required components is available Open and close the casing DANGER! Risk of death due to high voltage. All electrical work on the device may only be conducted by properly trained specialists under compliance with the applicable safety regulations! Fuses in the interior of the control casing may only be exchanged by maintenance or repair personnel. For type GR 10-CPR and 2S Figure 8, control casing, type GR 10-CPR and 2S Depending on the type of device, the display lid can be swivelled to the left or right for installation and maintenance work. The locking axle must be removed for swivelling. The locking axle is identified by the plastic slotted screws on both sides. The other side is equipped with two expanding rivets as pivot bearings. Index: 01 Date of modification: 01/22/2016 BA No.: BA MR Steuereinheit CPR Touch XL EN.docx Page 45 of 68

102 Tip! It is not necessary to completely remove the display lid for maintenance tasks! Only the locking axle must be removed. Afterwards, the display can be swivelled to the side. For type GR 45/100-CPR Standing bracket Press. Bottom lid lugs Click Figure 9, Control casing Type GR 45/100- CPR The casing is equipped with an easy latch lock. To open the display lid or the small connection compartment lid, gently lift the lateral lid lugs from the base casing toward the outside. Then you can pull the display lid toward the front. In this process, the upper lid lugs run in guiding grooves to the anterior resting point. Afterwards, the display lid is raised. A support bracket allows to prop up the display lid on the base casing, thus keeping it in an open position for terminal work. To close the casing again, release the support bracket toward the rear and lower the lid. Then unlock the upper lid lugs and push the lid backwards onto the base casing. In order to tightly seal the casing, exert light pressure on the four corners of the casing. The casing lid will close with a soft, audible click. Please ensure that all lid lugs are always locked with the safety bolt. 7.2 Regular water check The components of the measuring device are subject to a natural ageing process. This can lead to the falsification of the displayed measuring values. To ensure a problem- and disruption-free operation of the system, a regular water check and calibration of the measuring device is urgently required (see maintenance protocol under Section 9.5). Please observe the country-specific provisions in this regard! The ph value in the buffer tank must be checked every 2 months. (optional) Index: 01 Date of modification: 01/22/2016 BA No.: BA MR Steuereinheit CPR Touch XL EN.docx Page 46 of 68

103 7.3 Disruption removal Tip! All disruptions and messages are displayed on the touch screen in the IN list. In addition, they may be queries in the Event Log. It is also possible that switches or sensors are faulty and thus do not transmit any electric signals. An error will only be displayed once it has occurred uninterrupted for at least 6 seconds. Fault display Effect Cause / measures 1. Disinfectant empty ALARM: Chlorine tank empty 2. Acid empty ALARM: Acid container empty 3. Flocculation empty ALARM: Flocculant container empty 4. Pressure minimal ALARM: The flowpressure for the motive water pump is too low. 5. Level flushing tank minimal ALARM: The water level in the flushing tank is to low; more water is suctioned off than runs into the flushing tank through the float valve. 6. Level flushing tank maximal ALARM: The water level in the flushing tank is to high; less water is suctioned off than runs into the flushing tank through the float valve. This notification serves for information purposes only, no action ensues. The disinfectant dosing and the motive water pump continue to run. The acid dosing stops and the motive water pump continues to run. The flocculant dosing stops and the motive water pump continues to run. The dosing is stopped. The motive water pump has been switched off. The dosing is stopped. The motive water pump has been switched off. The dosing is stopped. The motive water pump continues to run. 1. Refill disinfectant, or replace container 2. If the disinfectant is not empty, recalibrate the empty switch or 3. renew the empty switch. 1. replace the empty acid container with a full one 2. If the acid container is not empty, the empty switch is defective. 3. In the event of a new suction lance, check the functional direction of the float. 1. replace the empty flocculant container with a full one 2. If the flocculant container is not empty, the empty switch is defective. 3. In the event of a new suction lance, check the functional direction of the float 1. Supply pressure too low 2. Motive water pump faulty 3. Pressure switch faulty 4. Set a lower response pressure at the pressure switch 1. Float valve function: a) The water inflow should gently follow the float's movement. When OK, calibrate the water level. See OI Dosing unit, section Commissioning b) If this is not the case, insert a new membrane in the float valve. 2. Insert a pinhole aperture with a small drill hole 3. Prefilter (Pos. 9) dirty clean 1. If the injector's suction performance is OK: a) Float valve function: The water inflow should gently follow the float's movement. When OK, calibrate the water level. See OI Dosing unit, section Commissioning b) If this is not the case, insert a new membrane in the float valve. 2. If the suction performance is insufficient, see under fault display Flow rate suction pipe minimal ALARM Index: 01 Date of modification: 01/22/2016 BA No.: BA MR Steuereinheit CPR Touch XL EN.docx Page 47 of 68

104 7. Flow rate suction pipe minimal ALARM: The water flow in the suction pipe is to low. The switch body of the flow switch does not rise, the switch LED is illuminated. 8. Dosing monitoring chlorine in cyclone ALARM: The optical sensor at the cyclone responds. 9. Fuse chlorine dosing motor ALARM: 10. Buffer tank filling start NOTIFICATION: 11. Buffer tank filling stop NOTIFICATION: 12. Level buffer tank minimal ALARM: 13. Level buffer tank maximal ALARM: or Alarm collecting basin 14. Timeout buffer tank filling ALARM: 15. Flow measuring cell ALARM: 16. Pure water external ALARM: The dosing is stopped. The motive water pump continues to run. The Sensor at the cyclone indicates that an insufficient amount of chlorine is in the cyclone during the 2nddosing interval The chlorine dosing stops and the motive water pump continues to run. The filling starts The filling stops The lower control switch for starting the filling has not triggered. During the filling, the upper control switch Level maximal for the stopping of the filling has not triggered. The level switch in the collecting basin reports fluid in the collecting basin The puffer tank filling was aborted by the system. The filling was too slow. The flow through the measuring cell is too low. The dosing stops. External flow sensor signals to low flow. The dosing and the booster pump stops. 1. Check the function of the motive water pump. 2. Prefilter dirty clean (GR only) 3. Blocked suction opening in the flushing tank 4. It is possible that particles are present in the injector and/or in the suction pipe, due to particles released during assembly or from the chlorine 5. Insert a pinhole aperture with a larger drill hole or remove it entirely 6. Blocked check valve at the buffer tank 7. Worn diffusor; if D > 6.5mm, replace diffusor 1. Disruption during dosing: a) Clotting in the chlorine granulate b) Dosing screw blocked due to poor chlorine quality (too fine, moist) 2. The dosing motor is defective. 3. Calibrate the optical sensor Check chlorine motor for blockage, remove blockage and replace fuse, if applicable. The dosing device starts to generate the chlorine solution The rinse cycle starts; afterwards, the dosing device stops generating the chlorine solution Check switch function: If the tank is empty, the switch contact must be closed (measure at the terminal). If open: Switch or terminal contact faulty 1. Check Level Buffer tank filling stop : If the tank is full, the switch contact of the Level Buffer tank filling stop -switch must be closed (measure at the terminal). If the switch contact is open when the buffer tank is full, the switch or the terminal contact is defective. 2. Level switch Level Buffer tank filling stop is OK: Check the function of the switching valves 1. Buffer tank is overflowing or leaks a) Level switches Level Buffer tank filling stop and Level maximal alarm at the buffer tank defective. Replace level switches b) Leaking check valve at a dosing pump replace check valve c) Leaking buffer tank replace buffer tank 2. Control valve to the buffer tank does not close 1. Check the switching valves. 2. Check the sensor "buffer tank Start": This contact has to be opened again 3 minutes after the start of the filling! Increase the flow rate on the flow control valve (Pos. 6). Check pool circulation; If this is okay, then check the flow sensor. Index: 01 Date of modification: 01/22/2016 BA No.: BA MR Steuereinheit CPR Touch XL EN.docx Page 48 of 68

105 17. Flocculation leakage ALARM: 18. Acid leakage ALARM: 19. Disinfection leakage ALARM: (only for type 2S) 20. External OFF NOTIFICATION: 21. Dosing time monitoring ALARM: 22. Shock chlorination active NOTIFICATION: 23. ECO operation NOTIFICATION: On the flocculant dosing pump the hose rupture sensor has triggered. The flocculation dosing stops. On the acid dosing pump, the hose rupture sensor has triggered. The acid dosing stops. On the disinfection dosing pump, the hose rupture sensor has triggered. The disinfection dosing stops. The control unit is disabled by the central control system. There is no dosing, no pool water heating, no alarm message. The dosing device stops. A dynamic dosing time has been exceeded. The respective output is blocked. To save space, no differentiation is made between the individual channels! The shock chlorination / filter disinfection is active. The request for ECO operation from the central control cabinet is pending Check the dosing hose of the pump and replace if necessary; If this is OK, so check the dosing valve. Check the dosing hose of the pump and replace if necessary: If this is OK, so check the dosing valve. Check the dosing hose of the pump and replace if necessary: If this is OK, so check the dosing valve. No action, because an external shutdown occurred. Check dosing screw and dosing pumps for damage and blockage. Eliminate defect or blockage. (see also section 7 to relevant Dosing unit). Check the setting of the dosing capacity, whether this is too low. No action No action Malfunction without display in the device: 1. The display is dark and the device is turned off: a) No supply voltage: Restore the supply voltage b) The main fuse at the lower left of the casing has blown: Replace fuse c) The fuse F1 at the power supply unit has blown: Replace fuse d) The power supply unit is defective: Replace power supply unit 2. The flushing tank overflows when shutting down the GRANUDOS: In this case, one of the following elements is leaking: a) Float valve: Replace membrane b) Switch body in the suction pipe: Replace gasket c) Pressure retention valve at the motive water pump is leaking or adjusted incorrectly: Replace membrane and adjust pressure retention valve For the procedure, see operating instructions Part 1 Dosing technology, under Section 7.1, Device maintenance. Index: 01 Date of modification: 01/22/2016 BA No.: BA MR Steuereinheit CPR Touch XL EN.docx Page 49 of 68

106 8 Decommissioning - storage - disposal 8.1 General In the event of decommissioning or risk of frost, the devices must be emptied completely and protected against frost! 8.2 Decommissioning If the device is decommissioned for an extended period of time (more than approx. 14 days), the following tasks must be conducted. Depending on the device version, different measures are required for decommissioning. The following tasks relate exclusively to the measuring and control technology. For required work on the dosing devices, please consult the corresponding device manuals. The diaphragm of the combination electrode (electrode with glass shaft) must never dry out. The longest service life for electrodes when not in use can be reached if the glass shaft is stored in the electrolyte. For this, fill the protective cap about halfway with electrolyte and push it on the glass shaft of the ph electrode or the combination reference-return electrode, respectively. The combination electrodes are frost-resistant to approx. -15 C; if the temperature falls below this value, the electrodes must be stored in a frost-safe environment. If condensation moisture can be expected at the installation site, the device must be supplied with continuous voltage in order to protect the electronics. Alternatively, the device may be dismounted and stored in a dry location. If frost can be expected at the installation site, all water-bearing parts, such as the measuring water pipes and the measuring cell, must be emptied completely. 8.3 Disposal of used parts and operating materials Dismounted, contaminated parts must be thoroughly cleaned and then disposed of according to the regulations applicable at the site of operation or they must be recycled. For the operating materials, observe the corresponding packaging notices. In case of doubt, information is available at your local institution responsible for disposal. If this is not possible, dispose the components/materials as hazardous waste. Index: 01 Date of modification: 01/22/2016 BA No.: BA MR Steuereinheit CPR Touch XL EN.docx Page 50 of 68

107 9 Documents 9.1 Declaration of conformity See operating instructions Part 1 regarding the respective dosing device. 9.2 Terminal diagrams DANGER! Risk of death due to high voltage. All electrical work on the device may only be conducted by properly trained specialists under compliance with the applicable safety regulations! Internal fuses may only be replaced with interrupted voltage that is protected against reactivation! Index: 01 Date of modification: 01/22/2016 BA No.: BA MR Steuereinheit CPR Touch XL EN.docx Page 51 of 68

108 9.2.1 Terminal diagram power supply unit for device 2S DANGER! Risk of death due to high voltage. All electrical work on the device may only be conducted by properly trained specialists under compliance with the applicable safety regulations! Internal fuses may only be replaced with interrupted voltage that is protected against reactivation! The figure shows the connection of a 230 volt circulation pump for the heating of the basin water and the chlorine output 230 V 50 Hz as an example. Fuses Current Fuse type Function F1 1.0A slow 5 x 20mm Supply of the switching power supplies on the power supply s circuit board; Index: 01 Date of modification: 01/22/2016 BA No.: BA MR Steuereinheit CPR Touch XL EN.docx Page 52 of 68

109 9.2.2 Terminal diagram I/O Board for device 2S The figure shows the connected sensors or consumers, respectively, of the device version 2S (with two hose pumps). Fuses Current Fuse type Function F1 315mA slow Micro-fuse Output disinfection 24V, SL08 Index: 01 Date of modification: 01/22/2016 BA No.: BA MR Steuereinheit CPR Touch XL EN.docx Page 53 of 68

110 9.2.3 The measuring amplifier The measuring amplifier is constructed of several circuit boards. MV_CPRT_PR_Cl The basic circuit board MV_CPRT_V1.1 contains the measuring transformer for temperature and pressure measurements. It also serves to accommodate the two measuring transformers MV_pR and MV_Cl. 1 = free = Temperature sensor 2 Pt1000 (OPTION not available for all device variants) = Temperature sensor 1 Pt1000 6,7,8 = Pressure switch (OPTION not available for all device variants) MV_pR_V1 The circuit board MV_pR_V1 contains the measuring transformer for ph and redox measurements. mv = Redox electrode (black line to redox electrode) Platinum round blank GND = Mass (shielding of the coaxial line mv - OPTION) GND = Mass (shielding of the coaxial line ph) ph = ph electrode (internal conductor of the coaxial line) MV_Cl_V1 The circuit board MV_Cl_V1 contains the measuring transformer for the free chlorine measurements. ME = Measuring electrode chlorine (blue line to the gold electrode) Gold round blank GE = Return electrode (internal conductor of the coaxial line) Metal sensor of the combination electrode BE = Reference electrode (shielding of the coaxial line) Reference system of the combination electrode Index: 01 Date of modification: 01/22/2016 BA No.: BA MR Steuereinheit CPR Touch XL EN.docx Page 54 of 68

111 9.2.4 Terminal diagram power supply with connection to the IO circuit board for device GR 10-CPR Fuses Current Fuse type Function F0 3.15A slow 5 x 20mm Main fuse control casing F1 1.0A slow 5 x 20mm Primary fuse Index: 01 Date of modification: 01/22/2016 BA No.: BA MR Steuereinheit CPR Touch XL EN.docx Page 55 of 68

112 9.2.5 Terminal diagram I/O circuit board GRD 7 for device GR 10-CPR Index: 01 Date of modification: 01/22/2016 BA No.: BA MR Steuereinheit CPR Touch XL EN.docx Page 56 of 68

113 9.2.6 Terminal diagram power supply with connection to the I/O circuit board for device GR 45/100-CPR Fuses Current Fuse type Function F0 3.15A slow 5 x 20mm Main fuse front panel F1 1.0A slow 5 x 20mm Primary fuse Index: 01 Date of modification: 01/22/2016 BA No.: BA MR Steuereinheit CPR Touch XL EN.docx Page 57 of 68

114 9.2.7 Terminal diagram I/O circuit board GRD 7 for device GR 45/100-CPR Index: 01 Date of modification: 01/22/2016 BA No.: BA MR Steuereinheit CPR Touch XL EN.docx Page 58 of 68

115 9.2.8 Terminal diagram buffer tank GRD 7 for the devices GR 45-CPR and GR 45/100-CPR Terminal diagram measuring plate for the devices GR 45-CPR and GR 45/100-CPR Index: 01 Date of modification: 01/22/2016 BA No.: BA MR Steuereinheit CPR Touch XL EN.docx Page 59 of 68

116 9.3 Commissioning protocol See operating instructions Part 1 Dosing technology, regarding the respective dosing device. Index: 01 Date of modification: 01/22/2016 BA No.: BA MR Steuereinheit CPR Touch XL EN.docx Page 60 of 68

117 9.4 Operation data sheet During a firmware update, all parameters are reset to the factory setting. After an "update," all parameters must therefore be checked and readjusted to the basin. We therefore recommend that you enter the optimised, basin-specific parameters in this list. In addition, the electrodes must be calibrated after an "firmware update! Settings menu Factory setting Setting ranges Step during commissioning Optimised during operation 1 Parameter chlorine Date: Date: - Range or Setpoint 0.6mg/l / P-range Alarm low 0.2 off Alarm high /8.0/off Dosing performance - ph 100% = 8 sec % - Disinfection 100% = 15 sec % - Cycle time 30 Sec sec. 30 Manual dosing Off Off On 3 Parameter mv - Redox - Alarm low 600mV mV 10 - Alarm high 800mV mV 10 Regulation Off Off - On 4 Parameter mv - Redox Redox control Emergency operation - Setpoint 750mV mV 5 - P-range 100mV Alarm low 600mV mV 10 - Alarm high 800mV mV 10 - Dosing time limit 30 minutes off 60 min 2 5 Parameter Temperature - Setpoint 25 C C P-range 1 K 1 10K Alarm low 10 C 5 50 C Alarm high 30 C C Offset 0 C -5 C - +5 C 0.1 Regulation Off Off - On 6 Dosing delay - Dosing delay 600 seconds seconds 10 7 Flocculation - Off On On Off - On 8 ECO operation - Range or Setpoint 0.6mg/l / P-range Alarm low 0.2 off Alarm high /8.0/off Dosing time limit 30 minutes off 60 min 2 Param. mv Redox ECO - Level value 750mV mV 5 - Alarm low 600mV mV 10 - Alarm high 800mV mV 10 Index: 01 Date of modification: 01/22/2016 BA No.: BA MR Steuereinheit CPR Touch XL EN.docx Page 61 of 68