Dioxide Pacific
Electrochemical Chlorine Dioxide
Generation Systems
CDEB-2.5 Generator
Sydney (NSW) P: +612 9999 4594 F: +612 9999 4534 sales@dioxide.com
Unit 9, 5-7 Prosperity Pde, Warriewood NSW 2102 Australia
Perth (WA) P: +618 9337 5415 F: +612 9999 4534 saleswa@dioxide.com
Melbourne (Vic) P: +613 9005 1681 F: +612 9999 4534 salesvic@dioxide.com
United States P: 702-938-6418 F: 702-938-4118 salesus@dioxide.com
Suite B-562 / 2654 W Horizon Ridge Pkwy
Henderson NV 89052-2803
1
Typical Layout
CDEB-2.5 Generator
2
Generator Features
PVC vent scrubber with
mixing elements
Gas separator
HDPE Cabinet
Polycarbonate splash
shield for operator
protection
ClO2 solution tank
Electrolytic cell
CDEB-2.5 Generator
Drip tray with sump
UPVC Sch80 pipework for
anolyte and ClO2 gas loops
3
Chemical Connections
Anolyte waste – pH 4-6
containing chlorine dioxide,
chlorite, chlorate and
chloride
ClO2 solution 2,000 ppm
Catholyte waste – 10-14% pure caustic
solution
CDEB-2.5 Generator
4
Chemical Connections
0.5 micron filter on discharge of
Electricide-P1 dosing pump
CDEB-2.5 Generator
Electricide-P1 solution
connected to suction side of
dosing pump
5
Dilution Water
Dilution flow regulated with a maric
valve. This valve has unions either side
for easy removal and cleaning
Dilution flow measured with a flow
meter
Dilution water flow is isolated with a
solenoid valve
Some water is directed to the filter and
RO unit and some continues upwards
Dilution water at min 3.5 Bar (52 psi) is
connected with ¼” tube. This water
should be 5 micron filtered potable
quality
CDEB-2.5 Generator
6
Electrolytic Cell
The electrolytic cell receives current from
the power supply with connections on
the anode side (right hand side, red
cable, + label) and cathode side (left
hand side, black cable, - label
Anolyte solution is recirculated from the
base of the gas separator through a
mag drive pump, through the anode
side of the electrolytic cell and then into
the top of the gas separator
CDEB-2.5 Generator
7
Anolyte Circuit
Gas separator is reservoir for Electricide-P1 solution
which recirculates through anolyte pump and cell into
top of gas separator where ClO2 gas is removed with
air
Anolyte pump to recirculate through cell
CDEB-2.5 Generator
8
ClO2 Solution Preparation
Chlorine dioxide solution tank is
reservoir for chlorine dioxide solution.
Dilution water enters the base and is
recirculated around through a venturi
via a mag drive pump. The air/ClO2
mix is then sucked into the venturi
where ClO2 dissolves and air does
not. This solution/air mix is then
mixed back into the base of the
solution tank
Dilution water trickles down
through the vent scrubber and
then into the bottom of the
solution tank
High High and Low
Low level switches
protect the recirc
pump and tank from
overflow
CDEB-2.5 Generator
9
ClO2 Solution Tank Connections
Overflow from
solution tank
directed to anolyte
waste outlet
Gas flow meter
measures air flow from
head space of solution
tank into gas separator.
Correct gas flow
ensures maximum
solubility of ClO2 and
correct gas
concentration with
safety margin above
TEL
CDEB-2.5 Generator
Vent from solution
tank directed to base
of vent scrubber. Air
from solution tank
headspace
containing ClO2 is
directed upwards
through the vent
scrubber with water
trickling down to
scrub out the ClO2
and allow air to exit
with low ClO2
concentration
10
Control Panel
Output isolator button
Mains power isolator
FRP control panel NEMA4X (IP66) for
100% chemical resistance.
Touchscreen mounted in door
US: 120V, 1 phase, Aus: 240V, 1 phase
CDEB-2.5 Generator
11
Control Functionality from HMI
Menu Page
Click on button to go
to any page. Click
on Dioxide Pacific
logo to return to
Menu page
Click on any button
to go to that page
CDEB-2.5 Generator
12
Control Functionality from HMI
Shortcut Buttons
Menu Page
Menu
Control
Alarms
Overview
Status
Power
Supply
Trend
Screen Menu Button
CDEB-2.5 Generator
13
Control Functionality from HMI
Control Page
If this button is
enabled, all devices
are placed into Auto
after 30 mins
inactivity
All Auto button
places all devices
into Auto.
This button Enables
the generator.
Remote Start
Enabled is the
remote start digital
input. Green tick
means it is on
CDEB-2.5 Generator
14
Control Functionality from HMI
Overview page shows all items
and their status. Items can be
stopped and started manually
from this screen.
Overview
ClO2 measured value
Flow
ClO2 PID setpoint
Flow Paced setpoint
Icon colours: Red –
stopped, Green –
On, Yellow - fault
Unacknowledged alarms are
displayed in sequence in
ticker tape bar at base of
page
CDEB-2.5 Generator
15
Control Functionality from HMI
Overview
If FLOW TRIM (Secure
Setpoints 3) is enabled,
dosing pump flow is trimmed
so it cannot exceed dilution
water inflow. When trimming
is occurring, the word
Adjusted is displayed and
the output % above the
word displays actual
trimmed output.
If Min Dosing Flow is
selected (Open Setpoints 2)
and flow is greater than min
flow, the words Min Flow
o.k is displayed.
CDEB-2.5 Generator
16
Control Functionality from HMI
Overview
At the end of each batch, 213-PU, 2-60-PU, 1-54-PU,
3-45-PU run on for set time.
When they are running on,
the words Running On
display and a timer counts
down.
CDEB-2.5 Generator
17
Control Functionality from HMI
Overview with Transfer
This is the version of the Overview Page displayed when an external solution tank with
transfer facility is enabled.
2-COS-12 is actuated ball
valve used for transfer to
external solution tank
CDEB-2.5 Generator
18
Control Functionality from HMI
Overview with Transfer
This page is displayed when an external solution tank with transfer facility is enabled.
External solution tank with dosing pumps are displayed.
CDEB-2.5 Generator
19
Control Functionality from HMI
Instrument Status
This page shows
measured values for
the generator
instruments
Status for analyser
flow switches.
Green – on
Red - off
CDEB-2.5 Generator
Solution Tank Volume PV, Grams PV and
Total Soln Outflow PV are measured values
20
Control Functionality from HMI
Device Status
Click on any device
to operate it
manually. Select
Manual and
Started/Stopped or
Open/Closed
If level in generator
solution tank is
lower than the low
low level switch (in
case of fault), press
fault reset then this
button. The dilution
water solenoid will
open and fill the
solution tank. When
level is above low
level switch, the
generator will start
as normal.
CDEB-2.5 Generator
21
Control Functionality from HMI
Device Status - Popups
Typical valve popup
window
In manual, 1-54-PU pump speed
can be set here
CDEB-2.5 Generator
In manual,
PW-44 current
22
Control Functionality from HMI
Devices can be
enabled or disabled
from this page
Maintenance 1
For pulse
operated
metering pumps
– solenoid or
stepper motor,
choose PULSE.
For peristaltic,
motor driven or
solenoid valves,
choose Timer
To start a batch
during
commissioning or
for testing, press
this button. It will
automatically
revert to Disabled
after 5 seconds.
If you are using
an external
solution tank with
transfer valve,
select here.
To test email alarm
function, press this
button once.
CDEB-2.5 Generator
To disable or enable
manual operation of the
generator healthy relay,
press this button. Default
position is Auto.
LSL-300 is the Electricide-P1
low low level switch from a
suction lance. Normally open
(NO) or Normally Closed (NC)
can be selected to suit the
switch functionality.
23
Control Functionality from HMI
Maintenance 1
It is possible to
override the door
switch for
maintenance
purposes. Auto is
default.
It is possible to
override the
dilution flow
meter for
maintenance
purposes. Note:
we do not
recommend
adjustment of this
button without
the assistance of
Dioxide Pacific.
CDEB-2.5 Generator
24
Control Functionality from HMI
Maintenance 2
ClO2 analyzers can be
set for dosing to
Continue or Stop if High
ClO2 residual alarm is
present
Generator can be set to
Continue or Stop if High
ClO2 gas (leak) alarm is
present
CDEB-2.5 Generator
25
Control Functionality from HMI
Power Supply
Green tick means
the power supply is
running. Red cross
means it is stopped
Enable or disable
the power supply
here
Click to reset hours
log for power supply
Trickle should always be
enabled
CDEB-2.5 Generator
26
Control Functionality from HMI
Power Supply
Click here to reset
accumulated total
g/hr of ClO2
CDEB-2.5 Generator
Should always be running
in constant current mode
(red X)
27
Control Functionality from HMI
Security
Log in and log out to
access setpoints
pages. Logs page is
history of who has
logged on and when
CDEB-2.5 Generator
28
Control Functionality from HMI
Alarms
All active alarms are
listed in order at the
top of the page,
scrolling down
All alarms have to
be accepted by
pressing Next and
then Accept at the
base of the page
No active alarms display does not
mean there are no alarms. It
means there are alarms which
have been accepted but are still
present. When there are truly no
alarms, the display is blank
CDEB-2.5 Generator
Once accepted,
press the Fault
Reset button a few
times to clear the
alarms
29
Control Functionality from HMI
General Inhibit Alarms
All of these alarms
should have red x
against them for the
generator to run
CDEB-2.5 Generator
30
Control Functionality from HMI
Alarm History
Alarms are shown in
sequential order as
history
Scroll through
historical pages
using the buttons at
the base of the page
CDEB-2.5 Generator
All historical record of alarms can be
cleared by pressing the clear button.
We do not recommend this as a
historical record is good for
troubleshooting.
31
Control Functionality from HMI
Level Trend
Level %
•
•
Electricide tank
ClO2 solution tank
CDEB-2.5 Generator
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Control Functionality from HMI
Flows Trend
Trends for:
•
•
•
Dilution water flow
Anolyte flow
Gas Separator air flow
CDEB-2.5 Generator
33
Control Functionality from HMI
Power Supply Trend
Trends for:
•
•
Power supply amps
Power supply volts
CDEB-2.5 Generator
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Control Functionality from HMI
Concentration Trend
Trend for:
•
ClO2 solution
concentration
CDEB-2.5 Generator
35
Control Functionality from HMI
Temperature Trend
Trends for:
•
•
Anolyte temperature
Gas temperature
CDEB-2.5 Generator
36
Control Functionality from HMI
Dosing Pumps Trend
Trends for:
•
•
•
Dosing pump 1 speed
Dosing pump 2 speed
Dosing pump 3 speed
CDEB-2.5 Generator
37
Control Functionality from HMI
ClO2 Residual Trend
Trends for:
•
•
•
•
ClO2 gas monitor
Circuit 1 Residual
Analyser
Circuit 2 Residual
Analyser
Circuit 3 Residual
Analyser
CDEB-2.5 Generator
38
Control Functionality from HMI
Level Switching Options
If level transmitter is
enabled, choose
between switches or
transmitter for the switch
points. Default: switches
CDEB-2.5 Generator
If level transmitter is
enabled, enter level
switchpoints
Delay times for level
switches on ClO2
solution tank
39
Control Functionality from HMI
Open Setpoints
Select the page you wish
to go to
CDEB-2.5 Generator
40
Control Functionality from HMI
Open Setpoints 1
High, low alarm
setpoints with delay
times and PID control
setpoint for each
analyser are entered.
Scale Max is the 20mA
point for the ClO2
measured values
Use the
toggle
buttons to
select
between and
ORP or ClO2
analyzer
Electricide-P1 dosing
pump. Max stroke rate is
entered and calibrated
max output (obtained by
drop test). Flow setpoint
is a calculated value
CDEB-2.5 Generator
41
Control Functionality from HMI
Open Setpoints 1
High and low alarms can
be enabled or disabled.
Green icon is enabled,
red icon is disabled
CDEB-2.5 Generator
42
Control Functionality from HMI
Open Setpoints 2
For flow inputs, select
either Analogue or
Pulsed.
Determine max output of
the ClO2 solution dosing
pump and enter here
Enter max pulse input
for each dosing pump
When flow input is
analogue, enter the
water flow at 20mA
If using Minimum Dosing
Flow, enter the min.
water flow that dosing
will start
CDEB-2.5 Generator
To enable minimum
dosing flow ensure this
button displays green
43
Control Functionality from HMI
Open Setpoints 2
For PID or FPRT control,
enter the PID constants
If flow input is PULSED,
enter flow meter k factor
CDEB-2.5 Generator
44
Control Functionality from HMI
Open Setpoints 3
ENABLE dosing pumps
if they are being used.
DISABLE if not used.
Manual SP is the dosing
pump output if Manual
control mode is selected
Ratio SP is used for
FPRT control and is
usually between 0.01
and 1.00
Select the control mode
for the dosing pump by
pressing here.
CDEB-2.5 Generator
45
Control Functionality from HMI
Open Setpoints 3
This popup enables
selection of the
operating mode of ClO2
solution dosing pumps
CDEB-2.5 Generator
46
Control Functionality from HMI
Secure Setpoints
Select the page you wish
to go to
CDEB-2.5 Generator
47
Control Functionality from HMI
Secure Setpoints 1
Devices will “run on”
after ClO2 production is
complete. Time setpoints
are adjusted here
Low low alarm delay
time for Electricide-P1
storage tank. Low low
alarm stops dosing
pump 1-54-PU and
generator
High temperature alarm
setpoints and delay
times for anolyte and
gas.
CDEB-2.5 Generator
48
Control Functionality from HMI
Setpoints 1
Current Amps is
automatically calculated
Enter high alarm
setpoint, delay and
range for the gas
monitor (leak detector)
Enter generator output in
g/hr or pounds per day.
CDEB-2.5 is 47 g/hr, 2.5
pounds per day.
High and low current
alarm setpoints with
delay times.
Trickle setpoint is 0.1A.
CDEB-2.5 Generator
49
Control Functionality from HMI
Secure Setpoints 2
K factors for dilution
water, anolyte and gas
flow meters with high
and low alarm setpoints
and delay times. These
numbers should not be
altered.
During ClO2 production
standby, the anolyte
pump will turn on every
Standby Period for Run
Time
CDEB-2.5 Generator
50
Control Functionality from HMI
Secure Setpoints 2
During ClO2 production, the
catholyte solenoid will open
for Run Time and Close for
Off Time.
CDEB-2.5 Generator
51
Control Functionality from HMI
Secure Setpoints 2
For timer controlled
Electricide pump, enter the
period (generally 60 s)
Enter the delay time for the door switch
missing
CDEB-2.5 Generator
During ClO2 production, the generator will
run for Run Period and stop for Wait Time.
52
Control Functionality from HMI
Secure Setpoints 3
ClO2 Current Output Ratio is
how many grams (lb) of ClO2
per Amp.hr will be produced.
Electricide-P1 Consumption
is how many Litres (Gal) of
Electricide-P1 are required to
produce 1kg (1lb) of ClO2
Target Solution
Concentration = 2,000 mg/L
CDEB-2.5 Generator
53
Control Functionality from HMI
Secure Setpoints 3
Solution Adjustment
Factor is usually 0.95
and is only used when
FLOW TRIM is Enabled
Solution Tank Low Level
SP and Low Low Level
SP are set by Dioxide
Pacific and should not
be altered
Enter the names for the Site and each of
the three dosing points
CDEB-2.5 Generator
FLOW TRIM reduces the output of the
solution metering pumps automatically so
the solution tank is not drained by pumps
operating at output greater than inflow
54
Control Functionality from HMI
Scaling
This page shows the
raw measured value
for each of the
analog inputs.
Nominally, 4-20mA =
800 – 4000. The 0%
raw value of 800
and 100% raw value
of 4000 are
adjustable so
scaling can be
“tweaked” at each
end as required
CDEB-2.5 Generator
55
Control Functionality from HMI
Scaling
Example
CDEB-2.5 Generator
56
Plumbing Connections
Anolyte waste ½ inch
thread or solvent. Run in
PVC pipe or tube downhill
to waste. Do not run uphill
or reduce pipe size
ClO2 solution 2,000 ppm. ½ inch
thread or solvent. Connect to
suction side of ClO2 solution dosing
pump
Catholyte waste – 10-14% pure caustic
solution. ½ inch thread or solvent. Run
in PVC pipe or tube downhill to waste.
Do not run uphill or reduce pipe size
CDEB-2.5 Generator
57
Plumbing Connections
Hydrogen vent 2 inch PVC. Run
up and out of cabinet (and
through roof if required). Use two
elbows as shown. No need to
glue pipe, just chamfer and push
in tight. Ensure outlet of vent is
outside into area with good
ventilation
ClO2 solution tank vent 1.5 inch
PVC. Run up and out of cabinet
(and through roof if required).
Use two elbows as shown. Glue
pipe into tee inside generator. No
need to glue elbows outside
generator. Ensure outlet of vent
is outside into area with good
ventilation
Electricide-P1 solution
connected to suction side of
dosing pump. Use correct tube
size with foot valve or suction
lance into drum. If suction lance
provided, wire into panel.
CDEB-2.5 Generator
58
Plumbing Connections
Connect dilution water at min 3.5 Bar,
52 psi to the ¼” tube connection. This
water should be filtered (5 micron)
potable quality
CDEB-2.5 Generator
59