Alpha innotec impressed current anode Owner's manual

Brand: Alpha innotec

Model: impressed current anode

Type: Owner's manual

Alpha innotec impressed current anode:

Protects stainless steel storage water heaters from corrosion. Ensures a long service life of the water heater. Simple installation. No maintenance required. Suitable for use in enclosed and dry rooms.

Alpha innotec impressed current anode:

83034400aUK– Translation into English of the original German operating manual – Subject to technical change without notice. © ait-deutschland GmbH

Operating Manual

for PWZS

IMPRESSED CURRENT

ANODE

2 83034400aUK– Translation into English of the original German operating manual – Subject to technical change without notice. © ait-deutschland GmbH

Contents

INFORMATION FOR USERS AND QUALIFIED

PERSONNEL

PLEASE READ FIRST .................................................................... 2

SYMBOLS .......................................................................................3

Scope ........................................................................................3

Illustration of the installation principle .......................................3

SAFETY INSTRUCTIONS ..............................................................3

Installation by skilled personnel only ......................................... 3

Functional safety instructions .................................................... 3

Intended use ..............................................................................3

HOW IT WORKS .............................................................................4

SCOPE OF SUPPLY ....................................................................... 4

Scope of supply of impressed current anode for socket

installation ............................................................................4

INSTALLATION AND STARTUP ....................................................5

The impressed current anode for socket installation ................5

Safety instructions for installation:.............................................5

Installation principle of the impressed current anode for socket

installation: ...........................................................................5

Installation and startup ..............................................................5

OPERATION AND MAINTENANCE ............................................... 7

FAULTS DURING OPERATION OF THE IMPRESSED CURRENT

ANODE ......................................................................................7

Fault messages, possible causes and troubleshooting

measures .............................................................................7

Measurement measures ............................................................ 8

TECHNICAL DATA .......................................................................... 9

Interrupter potentiostat

for stainless steel storage water heaters .............................9

Titanium anodes ........................................................................9

Please read rst

This operating manual provides important information on handling the

unit. It is an integral part of the product and must be kept ready to hand

in the immediate vicinity of the unit. It must remain available throughout

the entire service life of the unit. It must be handed over to subsequent

owners or users of the unit.

Read this operating manual before starting any work on or with the

unit, especially the chapter on safety. Follow all instructions in full and

unreservedly.

This operating manual may contain descriptions, which seem

incomprehensible or unclear. If you have any questions or if any details

are unclear, contact the factory customer service department or the

manufacturer's local partner.

As this operating manual has been written for several unit models,

always comply with the parameters for the respective model.

This operating manual is intended only for persons assigned to work

on or with the unit. Treat all its constituent parts condentially. They

are protected by copyright. They may not be reproduced, transmitted,

copied, stored in electronic systems or translated into another language,

either wholly or in part, without the express written permission of the

manufacturer.

383034400aUK– Translation into English of the original German operating manual – Subject to technical change without notice. © ait-deutschland GmbH

Symbols

Information for users.

Information or instructions for qualied personnel.

DANGER!

Risk of fatal electric shock!

DANGER!

Indicates imminent danger resulting in severe injuries or death.

WARNING!

Indicates a potentially dangerous situation, which could result in

severe injuries or death.

CAUTION!

Indicates a potentially dangerous situation, which could result in

moderate or slight injuries.

ATTENTION

Indicates a potentially dangerous situation, which could result in

property damage.

NOTE

Emphasised information.

Reference to other sections of the operating manual.

Reference to other documents of the manufacturer.

SCOPE

This installation and operating manual is valid for the impressed

current anode with the components shown in the appendix.

It concerns the following types of installation/assembly:

– Socket installation with G 3/4" screw plug, brass

– Insulated hole installation with M8 threaded bolt for 10.5 mm

drilled mounting hole

ILLUSTRATION OF THE INSTALLATION PRINCIPLE

All installation instructions and sketches merely represent the

installation principle in schematic form.

Safety instructions

These instructions must be read and followed before any further

chapters!

INSTALLATION BY SKILLED PERSONNEL ONLY

Installation and any necessary repairs to the impressed current

anode system may only be carried out by qualied skilled personnel!

Before the impressed current anode system / impressed current

anode is installed, ensure that:

1. the impressed current anode system is operated in an enclosed

and dry room,

2. the mains voltage corresponds to the voltage given on the

nameplate,

3. the mains voltage is applied continuously.

FUNCTIONAL SAFETY INSTRUCTIONS

The following safety instructions must be followed at all times to

ensure faultless functioning of the impressed current anode:

1. The storage water heater must not be operated for longer than

2 months without any water being drawn off. Otherwise spurious

gas accumulations can occur, which are often identied by

bubbling noises in the tank and pipe system.

2. The plug-in potentiostat must not be disconnected from the

mains supply while the storage water heater is lled! Otherwise

there is no longer any protection against corrosion.

3. The connection cables between the plug-in potentiostat and

tank must not be disconnected while the storage water heater

is lled. Otherwise there is no longer any protection against

corrosion.

4. The impressed current anode must not be withdrawn from

service even during lengthy stoppages (e.g. holiday). Otherwise

there is no longer any protection against corrosion.

INTENDED USE

The impressed current anode system / the impressed current anode

is used for permanent cathodic corrosion protection of storage

water heaters made of stainless steel. The impressed current anode

may only be used for this purpose and only in conformity with this

installation and operating manual.

The manufacturer accepts no liability whatsoever for damage

caused by misuse or disregarding this manual!

4 83034400aUK– Translation into English of the original German operating manual – Subject to technical change without notice. © ait-deutschland GmbH

How it works

The impressed current anode consists of an interrupter-potentiostat

and a titanium anode, which are connected by a connection cable.

The impressed current is generated with the help of the interrupter-

potentiostat, the protective current infeed into the tank takes

place via the virtually wear-free titanium anode. Electrochemical

reactions take place at the titanium anode (positive terminal) and

the inner surface of the tank connected as the cathode (negative

terminal), which result in transport of the charge (electrons) to

the inner surface of the tank in contact with water. As a result the

electrochemical surface potential in the area of the tank surface in

contact with water is reduced to such an extent that the corrosion

rate of the steel tank wall virtually stops. Depending on the water

quality, additional scale-like deposits can form. The system

operates as a so-called interrupter-potentiostat, i.e. the protective

current infeed via the titanium anode is interrupted periodically

with short-term intervals. During these interruptions the potential

between the titanium anode and the inner wall of the tank of the

storage water heater is measured and is fed to the potentiostat as

the actual voltage. There the actual voltage is compared with the set

voltage predened inside the unit. The supplied protective current is

then set automatically so that the actual tank potential corresponds

to the setpoint.

Scope of supply

SCOPE OF SUPPLY OF IMPRESSED CURRENT ANODE FOR

SOCKET INSTALLATION

Before installation, please check the delivery against the following

table and the gure in Chapter 1.2 for completeness and intactness!

Item Quantity Description

1 1 Plug-in potentiostat with indicator lamp

2 1 Titanium anode with insulated installed screw

plug unit

3 1 Connection cable with plug-in connectors

4 1 Operating manual

583034400aUK– Translation into English of the original German operating manual – Subject to technical change without notice. © ait-deutschland GmbH

Installation and startup

THE IMPRESSED CURRENT ANODE FOR SOCKET

INSTALL ATION

NOTE

It is imperative that you note and follow the Illustration of

the installation principle chapter!

SAFETY INSTRUCTIONS FOR INSTALLATION:

1. The titanium anode must not have any direct contact with

installations in the tank or the tank wall. Faultless insulation

must be checked using a suitable measuring device (e.g. digital

multimeter)! When taking this measurement the titanium anode

must not dip into the water.

2. The function of the impressed current anode is only ensured

if a faultless, metallic conducting connection of all electrical

connections exists. Faultless metal conducting connection

must be checked using a suitable measuring device (e.g. digital

multimeter)!

3. Use original connection cables only!

4. Never lengthen the connection cables under any circumstances

whatsoever, otherwise there is a possibility of pole reversal and

therefore the risk of corrosion!

5. Before starting up check that the cable connections are not

mixed up. If the cable connections are mixed up there is an

increased risk of corrosion.

6. A 60° chamfer at the socket is required for optimum insertion of

the sealing ring.

INSTALLATION PRINCIPLE OF THE IMPRESSED CURRENT

ANODE FOR SOCKET INSTALLATION:

1. Empty the storage water heater, if necessary.

2. Screw the titanium anode with installed screw plug pressure-

tight up to the collar in the threaded socket of the tank.

NOTE

Depending on the type, the screw plug G 3/4" may be tted

with a PTFE sealing ring. If this sealing ring is damaged,

e.g. after being screwed in several times, it must be

resealed using a thread sealant such as hemp or PTFE

sealing tape.

3. Fasten the cable stop part with the “tank earth connection”

information tab to the earthing screw of the tank. If there is no

earthing screw an alternative reliable electrical contact between

the earth cable and tank must be made. Without a fully intact

metal conducting connection the function of the impressed

current anode is not ensured.

4. Push the stop part on the other side of the tank onto the at

connector of the anode toothed disc.

5. Plug the two-pin connector at the other end of the connection

cable in the connection opening (of the plug-in potentiostat)

provided. Align the guide lug upwards; the two-pin connector

can be xed in the housing of the plug-in potentiostat without

applying force only if it is aligned in this direction.

INSTALLATION AND STARTUP

The gures show the installation of the impressed current anode:

Remove the foam cover from the access to the foreign anode.

The arrow indicates where the foreign anode is introduced. Screw

in with a ratchet.

Screwed in impressed current anode:

6 83034400aUK– Translation into English of the original German operating manual – Subject to technical change without notice. © ait-deutschland GmbH

Fix the earthing to the screw above the impressed current anode:

Plug the cable onto the foreign anode ...

11a

C0RREX

MP 1.9-900

and feed to the right and up

out of the unit.

Cut into the foam cover to make space for the cable:

Use it to close off the foreign anode opening once again:

Connect the cable to the mains plug. The impressed current anode

is ready for connection.

11a

C0RREX

MP 1.9-900

The following are required for the installation:

1. Titanium anode with G 3/4" screw plug (see scope of supply)

2. Connection cable (3) (see scope of supply)

3. Plug-in potentiostat (2)

4. Fill the tank with water and check for leaks.

5. Check the indicator lamps on the plug housing.

6. Functional test required: The correct polarity must be checked

by measurement using a direct voltage meter (e.g. digital

multimeter or CorroScout

500) to measure the amount and sign

of the applied drive voltage. To do this the meter must be set

within the measurement range 20 V direct voltage, the negative

input of the meter connected with the tank and the positive input

of the meter with the titanium anode. The value of the applied

drive voltage must be U > + 1.9 V DC. Note “+” sign! The tank

must be lled with water and the plug-in potentiostat plugged in

before this measurement is taken.

783034400aUK– Translation into English of the original German operating manual – Subject to technical change without notice. © ait-deutschland GmbH

NOTE

The impressed current anode does not function until the

tank is lled with water.

- The top indicator lamp lights up green: Power supply connected

and the impressed current anode is ready for use.

- If none of the indicator lamps lights up there it is probable that no

mains voltage has been applied.

- If the bottom indicator lamp lights up red a malfunction exists.

In this case carry out the checks described in the “Faults during

operation” chapter.

NOTE

If the red indicator lamp then lights up following re-

installation it is probably an installation-related fault. Check

and correct this as per the notes in the “Faults during

operation” chapter.

NOTE

If the malfunction indicator lamp lights up red following re-

installation it is probably an installation-related fault. Check

and correct this as per the notes in the “Faults during

operation” chapter.

Operation and maintenance

The coating of the titanium anode is subjected to virtually no wear.

The indicator lamps must be checked once a month:

- The indicator lamp lights up green: Power supply connected and

the impressed current anode is ready for use.

- If neither of the two indicator lamps lights up phone your installer

or customer service.

- If the indicator lamp lights up red: phone your installer or

customer service for troubleshooting information.

To ensure faultless functioning of the impressed current anode the

following safety instructions must be followed:

1. Do not operate the storage water heater for longer than 2

months without drawing off any water. Otherwise spurious gas

accumulations can occur.

2. Do not disconnect the plug housing from the main supply while

the storage water heater is lled. Otherwise there is no longer

any protection against corrosion.

3. Never disconnect the connection cables if the storage water

heater is full. Otherwise there is no longer any protection against

corrosion.

4. Do not withdraw the impressed current anode from service even

during lengthy stoppages (e.g. holiday). Otherwise there is no

longer any protection against corrosion.

5. Do not disconnect the plug housing or connection cable unless

the storage tank is empty.

Faults during operation of the impressed current

anode

Operating faults in the impressed current anode are normally

indicated by a red LED on the connector housing of the potentiostat.

NOTE

Many causes of faults can be found and corrected directly

at the system with the help of direct voltage, direct current,

polarity, insulation and resistance measurements. The

methods required are described in the “measurement

measures” chapter. Disconnect any installed electrical

tubular heaters from the power supply. The inspections

described may only be carried out by the installer or

competent customer service.

Fault messages, their possible causes and appropriate

troubleshooting measures are described in the following.

FAULT MESSAGES, POSSIBLE CAUSES AND

TROUBLESHOOTING MEASURES

Fault message: Indicator lights do not light up

Possible cause: no mains voltage applied.

Troubleshooting: Ensure continuous mains power supply.

Fault message: Indicator light is lit red

“Reset” the potentiostat by disconnecting the unit from the mains for

approx. 30 seconds to set a dened starting situation. Then supply

the unit with mains voltage once more.

If the LED is still lit red, check the possible causes of faults described

in the following and carry out the troubleshooting measures given.

1. The storage water heater is not lled with water.

Check: Determine whether the storage water heater is

completely lled with water.

Troubleshooting: if necessary ll the storage water heater

completely with water.

2. Electrical continuity between the plug-in potentiostat and anode

/ tank connection is not ensured along the whole connection

cable. Check: All connections and contacts for faultless, metallic

conducting, electrical contact. Troubleshooting: Establish

electrical contact, if not already done, if necessary install new

connection cable.

3. The electrode is not insulated properly from the tank wall or

tank installations. Check: Insulation of the electrode when tank

is drained of water; measurement troubleshooting measures:

Correct the position of the installations and anode if necessary.

NOTE

If the tank is dry the electrical resistance between the

titanium anode and the tank earth must be very high-

resistance, ideally: innite.

4. Check for overloading of the plug-in potentiostat: Check the

protective current actually output

Troubleshooting: Check the use of a more powerful potentiostat

to protect storage tanks made of stainless steel.

Background: The plug-in potentiostat is overloaded if protective

currents within the range of approx. 100 mA and higher are

demanded, whereby the actual overload value depends on

the respective drive voltage. A safe value for drinking water

applications is 50 mA protective current for each square metre

of stainless steel storage water heater surface to be protected.

The impressed current anode can therefore cathodically protect

2 m

surface reliably, possibly more depending on the water

8 83034400aUK– Translation into English of the original German operating manual – Subject to technical change without notice. © ait-deutschland GmbH

conditions. The CORREX

UP 1.9-924 tends to discharge a

protective current that is roughly twice as high

5. Poor insulation of the titanium anode as the result of damage to

the seal that has occurred

Check: test the insulation by measurement. Troubleshooting:

Provide adequate insulation.

Background: The titanium anode is no longer installed

adequately isolated electrically, e.g. as a result of incorrectly

installed sealing material (install the original seal only!) or aged

material. This causes a short-circuit between the anode and

tank earth, the protective current tends to zero.

6. Interrupted connection cable

Check: Examine the connection cable; test by measurement.

Troubleshooting: Replace the connection cable; use original

connection cables only for the impressed current anode!

NOTE

If the fault is not corrected by these measures, contact the

tank supplier or dealer without delay!

MEASUREMENT MEASURES

The analysis of faults is facilitated by the measurement measures

described in the following.

Deviations from the given setpoints are indications of functionally

incompatible installation conditions.

NOTE

A digital multimeter or the anode tester is required to take

the measurements!

1. Measure the drive voltage

Procedure: Switch the meter to the measurement range “Direct

voltage 20 V”. Connect the positive terminal of the meter with

the anode and the negative terminal of the meter with the tank.

Setpoint: minimum + 1.9 V direct voltage. Depending on the

conductivity of the water, drive voltages within the range of

1.9 and around 3 V are common - these gures can be used

for orientation. Higher drive voltages are possible if the water

conductivity is very low.

Deviation from the setpoint: If the drive voltage is almost zero the

cathodic corrosion protection is not functioning. This can occur,

among other things, if the titanium anode and tank are short-

circuited, e.g. as a result of seal damage or contact between the

anode and installations.

2. Measure the protection current

Procedure: Set the meter within the range 200 mA or 20 mA and

connect in series in the circuit between the plug-in potentiostat

and the tank or optionally between the plug-in potentiostat and

anode.

Setpoint: Depending on the drinking water conditions, tank steel

and workmanship, protective current densities between several

mA and up to 50 mA per square metre inner tank surface in

contact with water are possible in tanks made of stainless steel.

Deviation from the setpoint: If the absolute protective current is

zero (mA), the cathodic corrosion protection is not functioning.

Check connection cable and contacts.

3. Check polarity

Procedure: Connect the positive terminal of the meter with the

anode and the negative terminal of the meter with the tank.

Setpoint: Drive voltage >/= +1.9 V = (plus!). The sign in the

display must be positive (plus).

Deviation from the setpoint: If negative values (e.g.: -2.5 V)

poles are reversed. Risk of accelerated tank corrosion; switch

off the impressed current anode immediately and call out the

tank customer service.

4. Check insulation of the titanium anode

Procedure: Switch the meter to the resistance measurement

range. Drain the water to prevent indirect electrical contact via

the aqueous phase. Contact the test cables of the meter with the

titanium anode and stainless steel tank. Measure the electrical

resistance.

Setpoint: high-resistance; k up to partially M range

Deviation from the setpoint: A short-circuited titanium anode

should produce a resistance of virtually 0.

983034400aUK– Translation into English of the original German operating manual – Subject to technical change without notice. © ait-deutschland GmbH

Technical data

INTERRUPTER POTENTIOSTAT FOR STAINLESS STEEL

STORAGE WATER HEATERS

FUNCTION

Plug-in potentiostat for use in stainless steel storage water heaters

(interrupter potentiostat with potential-controlled protective current

control) with integrated red/green LED functional display.

MAIN S S UPPLY

Voltage: 230 V ± 10 %

Frequency: 50/60 Hz

Power consumption: < 4 VA

CHARACTERISTICS

Set potential: 1.9 V

Nominal current (secondary): 100 mA

Drive voltage (secondary): max. 10 V at 100 mA

DISPLAYS/INDICATORS

Two LEDs in the housing cover

green: Mains supply applied, functionally ready

red: fault

OPERATION

Temperature range (plug-in potentiostat): 0 to 40 °C

Protection class: II (operation in enclosed rooms)

HOUSING

Dimensions (not including Euro plug): L 80 x B 50 x H 45 mm

Weight (not including anode cable): approx. 160 g

TITANIUM ANODES

FUNCTION

Infeed and reference electrode with noble metal mixed oxide

coating; virtually wear-free current infeed during the current infeed

phase, effect as reference electrode for measurement of the actual

potential in the tank in case of power failure

Threaded bolt M8 x 30

Electrode dimensions

Diameter: 2 mm and 3 mm

Lengths: 200 mm and 400 mm respectively

Length of the coating: variable, according to the use case

Installation options:

– Socket installation

– Insulated hole installation

10 83034400aUK– Translation into English of the original German operating manual – Subject to technical change without notice. © ait-deutschland GmbH

1183034400aUK– Translation into English of the original German operating manual – Subject to technical change without notice. © ait-deutschland GmbH

Alpha innotec impressed current anode Owner's manual

Brand: Alpha innotec

Model: impressed current anode

Type: Owner's manual

Alpha innotec impressed current anode:

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Alpha innotec impressed current anode Owner's manual

Alpha innotec impressed current anode Owner's manual

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