ProMinent CHLORINSITU IIa Assembly And Operating Instructions Manual

Brand: ProMinent

Model: CHLORINSITU IIa

Type: Assembly And Operating Instructions Manual

Chlorine electrolysis system

CHLORINSITU

IIa, 625 ... 2,500 g/h

Assembly and operating instructions

A2933

Original operating instructions (2006/42/EC)Part no. 981413 BA CI 019 12/19 EN

Please carefully read these operating instructions before use. · Do not discard.

The operator shall be liable for any damage caused by installation or operating errors.

The latest version of the operating instructions are available on our homepage.

In order to make it easier to read, this document uses the male

form in grammatical structures but with an implied neutral sense.

The document is always aimed equally at women, men and

gender-neutral persons. We kindly ask readers for their under‐

standing in this simplification of the text.

Please read the supplementary information in its entirety.

Information

This provides important information relating to the

correct operation of the unit or is intended to make

your work easier.

Warning information

Warning information includes detailed descriptions of the haz‐

ardous situation, see

Ä Chapter 1.2 ‘Labelling of Warning Informa‐

tion’ on page 6

The following symbols are used to highlight instructions, links, lists,

results and other elements in this document:

Tab. 1: More symbols

Symbol Description

Action, step by step.

⇨ Outcome of an action.

Links to elements or sections of these instructions or other applicable documents.

List without set order.

[Button]

Display element (e.g. indicators).

Operating element (e.g. button, switch).

‘Display/GUI’

Screen elements (e.g. buttons, assignment of function keys).

CODE

Presentation of software elements and/or texts.

General non-discriminatory approach

Supplementary information

Supplemental directives

Table of contents

1 Description of the system...................................................... 4

1.1 Description and operation............................................. 5

1.2 Labelling of Warning Information.................................. 6

1.3 User qualification.......................................................... 8

1.4 General safety information............................................ 9

2 Storage and Transport........................................................ 10

3 Components of the system................................................. 11

3.1

CHLORINSITU

IIa..................................................... 11

4 Preparation for use............................................................. 14

5 Installation and assembly.................................................... 15

5.1

Check-list for assembly of the Chlorinsitu

IIa............ 15

5.2

Assembly and installation of the Chlorinsitu

IIa........ 17

6 Operation............................................................................ 22

6.1 Navigation................................................................... 25

6.2 Status.......................................................................... 26

7 Commissioning................................................................... 27

7.1 Check-list for commissioning...................................... 28

7.2 Commissioning work................................................... 28

[ALARM]

/ Troubleshooting menu....................................... 32

8.1 Alarm messages......................................................... 32

8.1.1 Alarm:

[POWER UNIT]

............................................ 32

8.1.2 Alarm:

[POWER UNIT & CELL]

............................... 32

8.1.3 Electrolysis cells...................................................... 33

8.1.4 Alarm: Product storage tank.................................... 34

8.1.5 Alarm: External product storage tank...................... 34

8.1.6 Various alarms......................................................... 35

9 Maintenance and repair...................................................... 37

9.1 Maintaining the Operating Unit................................... 37

9.2 Maintenance............................................................... 37

9.3 Repair......................................................................... 38

10 Disposal of used parts........................................................ 39

11 Technical data..................................................................... 40

11.1

Specifications of the Chlorinsitu

IIa 625 ... 2500

g/h............................................................................. 40

12 Declaration of Conformity for Machinery............................. 41

13 Index................................................................................... 42

Table of contents

1 Description of the system

The system is used for water disinfection in:

n Potable water

n Cooling towers

n Various process water systems

n Swimming pools

n etc.

The system is used to electrochemically produce

‘free chlorine’

(NaOCl solution) from sodium chloride.

The quantity of

‘free chlorine’

is determined, among other things,

by the concentration of chloride ions, but also by the current

strength.

The system has the following features:

n The product is generated in situ where it is needed

n There is no need to transport concentrated chemicals

Description of the system

1.1 Description and operation

The system produces free chlorine from a sodium chloride solution,

as per the diagram below.

A2934

Electrolysis cell 1

External

product storage tank

Degasser

Leak sensor

Waste water duct

Brine

Brine storage tank

Water supply

Water pressure

Minimum flow

6 l/min

Optional

Fig. 1: P&I flow diagram presented in accordance with DIN EN ISO 10628.

Description of the system

Sodium chloride for the brine storage tank: Use CHLORINSITU

salt.

If you do not wish or are unable to do this, only use salt that is cer‐

tified in accordance with the EU Regulation 528/2012. Ensure that

the salt meets the following specifications: min. 99.4 % NaCl,

max. 0.05 % insoluble parts, max. 10 mg/kg iron, max. 10 mg/kg

manganese, max. 100 mg/kg calcium + magnesium

Water quality: The water should be of potable water quality or com‐

parable.

The sound pressure level is < 70 dB (A) at maximum speed, at

maximum back pressure, using water as the medium.

Degree of protection of the system: IP 54.

1.2 Labelling of Warning Information

These operating instructions provide information on the technical

data and functions of the product. These operating instructions pro‐

vide detailed warning information and are provided as clear step-

by-step instructions.

The warning information and notes are categorised according to

the following scheme. A number of different symbols are used to

denote different situations. The symbols shown here serve only as

examples.

DANGER!

Nature and source of the danger

Consequence: Fatal or very serious injuries.

Measure to be taken to avoid this danger.

Description of hazard

– Denotes an immediate threatening danger. If

the situation is disregarded, it will result in fatal

or very serious injuries.

WARNING!

Nature and source of the danger

Possible consequence: Fatal or very serious inju‐

ries.

Measure to be taken to avoid this danger.

– Denotes a possibly hazardous situation. If the

situation is disregarded, it could result in fatal

or very serious injuries.

Basic substances required

Sound pressure level

Protection against contact and mois‐

ture (IP)

Introduction

Description of the system

CAUTION!

Nature and source of the danger

Possible consequence: Slight or minor injuries.

Material damage.

Measure to be taken to avoid this danger.

– Denotes a possibly hazardous situation. If the

situation is disregarded, it could result in slight

or minor injuries. May also be used as a

warning about material damage.

NOTICE!

Nature and source of the danger

Damage to the product or its surroundings.

Measure to be taken to avoid this danger.

– Denotes a possibly damaging situation. If the

situation is disregarded, the product or an

object in its vicinity could be damaged.

Type of information

Hints on use and additional information.

Source of the information. Additional measures.

–

Denotes hints on use and other useful informa‐

tion. It does not indicate a hazardous or dam‐

aging situation.

Description of the system

1.3 User qualification

WARNING!

Danger of injury with inadequately qualified per‐

sonnel

The operator of the system / equipment is respon‐

sible for ensuring that the qualifications are ful‐

filled.

If inadequately qualified personnel work on the unit

or loiter in the hazard zone of the unit, this could

result in dangers that could cause serious injuries

and material damage.

– All work on the unit should therefore only be

conducted by qualified personnel.

– Unqualified personnel should be kept away

from the hazard zone.

The pertinent accident prevention regulations, as

well as all other generally acknowledged safety

regulations, must be adhered to.

Training Definition

Instructed personnel An instructed person is deemed to be a person who has been instructed and,

if required, trained in the tasks assigned to him and possible dangers that

could result from improper behaviour, as well as having been instructed in the

required protective equipment and protective measures.

Trained user A trained user is a person who fulfils the requirements made of an instructed

person and who has also received additional training specific to the system

from the manufacturer or another authorised distribution partner.

Trained, qualified per‐

sonnel

A trained, qualified employee is deemed to be a person who is able to assess

the tasks assigned to him and recognize possible hazards based on his

training, knowledge and experience, as well as knowledge of pertinent regula‐

tions. A trained, qualified employee must be able to perform the tasks

assigned to him independently with the assistance of drawing documentation

and parts lists. The assessment of a person's technical training can also be

based on several years of work in the relevant field.

Electrical technician An electrical technician is able to complete work on electrical systems and rec‐

ognise and avoid possible dangers independently based on his technical

training and experience as well as knowledge of pertinent standards and regu‐

lations. An electrical technician must be able to perform the tasks assigned to

him independently with the assistance of drawing documentation, parts lists,

terminal and circuit diagrams. The electrical technician must be specifically

trained for the working environment in which the electrical technician is

employed and be conversant with the relevant standards and regulations.

Service The Service department refers to service technicians, who have received

proven training and have been authorised by the manufacturer to work on the

system.

Description of the system

1.4 General safety information

WARNING!

Warning of hydrogen and mains voltage

Only allow authorised technical personnel to open

the system cabinet.

WARNING!

Warning of chemicals

The lid of the product storage tank must be tightly

closed as soon as product or hydrogen may be

present in the product storage tank.

– Prior to opening by authorised technical per‐

sonnel, allow the ventilator to continue to

aerate for 10 min with the production switched

off.

Description of the system

2 Storage and Transport

WARNING!

Storage of the system in unsuitable ambient condi‐

tions.

– It is mandatory that the following storage

instructions are adhered to.

Unsuitable ambient conditions can result in mal‐

functions and faults in the installed system. When

the system is in operation, this can also lead to

hazards to the personnel.

Store the system in its original transport packaging in a sealed

room, observing the following conditions:

n At a temperature between 5 °C ... 50 °C

n At a relative air humidity below 85 % without condensation

n In a non-aggressive environment (no harmful vapours, chemi‐

cals, etc.)

n Protected from direct sunlight, rain and moisture

n Store the system upright.

WARNING!

Incorrect transport

Incorrect transport of the system by non-seaworthy

packaging or horizontal packaging.

– It is mandatory that the following instructions

are adhered to.

Incorrect transportation can result in personal inju‐

ries and material damage.

n Carefully transport the system in a vertical position and only tilt

briefly at an angle of no more than 30 degrees - see label on

the transportation packaging.

n Avoid mechanical impacts.

n Protect the system from direct sunlight, rain and moisture

during transportation.

Storage

Transport

Storage and Transport

3 Components of the system

3.1

CHLORINSITU

IIa

G / H / I

A2935

Fig. 2: The connectors must be made on site

Components of the system

# Connectors, to be installed on site. Installation

side

External pipework Specification

A Connectors, softened water (potable

water quality).

DN15/Ø20

Ø20 mm, PN16, PVCU,

PVCU

2 ... 5 bar (g); > 10

l/min.

Max. 0.05 °dH;

15 ... 25 °C

A suitable non-return valve is needed for the water connector.

B Connector for water from the softener

into the brine storage tank.

6/12 mm

hose

Connector from the

brine storage tank to

the system cabinet

10 m not included

in the scope of

delivery

C Connector for product from the product

metering pump to the external storage

tank.

DN15/Ø20

Ø20 mm, PN16, PVCU,

PVCU

D Connector for brine from the brine

storage tank to the brine metering

pump.

PE hose,

transparent

9x12 mm

PE hose, transparent

9x12 mm

E Exhaust air line for diluted hydrogen Ø125 mm Max. 10 metres and 3 knee/bends.

At the outlet point: rain and wind protection.

Ø125 mm, PVCU pipework, continuously

rising (>1%) and leading outside

F Overflow of the brine storage tank Ø32 mm, PN16, PVCU, PVCU

G Power supply 3x400 V AC, N, PE, 50

H1 LL, L, H, H, HH signals for external

product storage tanks

H2 LL tank empty signal (metering stop)

H3 External activation

H4 Alarm contact

H5 Softening output 17 VDC and control

I Ethernet cable One of the following ports must be open: UDP1193, TCP

443, TCP 80. For more information:

http://www.remoteengineer.eu/en

J Optional: external product storage tank

K Brine storage tank Dimensions:

at 625 g/h: 200 l

at 1250 g/h: 380 l

at 2500 g/h: 520 l

R Control cabinet Includes internal power supply, control,

etc.

M Production cabinet Includes cells.

Also includes the degasser.

N Optional: Softener frame

Components of the system

A2936

N L / M

Fig. 3: Cabinets and tanks.

Components of the system

4 Preparation for use

WARNING!

Danger due to operation of the system in unsuit‐

able locations.

– Adhere to all national and local regulations

relating to the use of chlorine.

– In particular, it is the responsibility of the oper‐

ator to draw up an Explosion Protection Docu‐

ment according to ATEX. An information docu‐

ment is available from the manufacturer on

request.

– The operator of the system is responsible for

ensuring that the regulations are implemented.

Disregarding the safety requirements can lead to

personal injuries or material damage.

n Ensure that the floor of the room has sufficient load-bearing

capacity to bear the weight of the filled system.

n Ensure that the floor is even and horizontal and has a solid

base surface.

n At a height of 100 cm, the system may be deflected by a max‐

imum of 0.4 cm.

n Ensure that the room has an adequately dimensioned floor

drain to safely drain any escaping water in the event of a pipe

leak.

n Do not locate permanent workplaces in rooms in which the

system is situated.

n Ensure that the room is free of aggressive vapours and chemi‐

cals.

n Ensure that the room contains minimal dust.

n Ensure that the room has an adequate air supply; total cross-

sectional area of the air intake openings > 1875 cm². With a

grid, take into account the area that allows for effective air flow.

n It must be possible to run an exhaust line for the hydrogen from

the room toward the ceiling. Ensure that there is no danger due

to the hydrogen at the end of the exhaust line.

n Ensure that the room temperature and air humidity do not

exceed the permissible limits. Install an air conditioning system

in the room if this cannot be guaranteed.

n Protect the system from direct sunlight.

n Allow a minimum clearance of ⋝ 75 cm for the ventilator and for

service and maintenance to the left and right of the system's

control cabinet. Take into account the installation plan as well.

n Ensure that there is sufficient room for the brine storage tank

next to the system cabinet, as well as an optional space for an

external product storage tank.

n Ensure that the room has a suitable and adequate mains

voltage connection for operation of the relevant system.

n Use a non-return valve type BA for connection to the potable

water network, as described in the German version of EN

1717:2000 or the German Technical and Scientific Association

for Gas and Water (DVGW) Technical Regulations or compa‐

rable national standards.

The system requires a stable water pressure of 2 ... 5 bar.

n Ensure that the potable water hardness does not exceed 30

°dH.

Otherwise contact "van den Heuvel Watertechnologie bv".

Preparation for use

5 Installation and assembly

5.1

Check-list for assembly of the Chlorinsitu

IIa

# Installation process Tick

1 Check whether the assembly location complies with the guidelines governing tempera‐

ture, safety, space, humidity etc.

2 Clear the area in which the system is to be installed.

3 Remove all packaging from and out of the system.

4 Check whether the system has suffered damage during transport or exhibits other

damage.

5 Remove the securing material from the transport crate.

6 Lift the system cabinet into its fitting position.

7 Check whether the system is standing on the platform (optional) and is horizontal (max.

4 mm deviation from the vertical per 100 cm).

8 Clear the space in which the system is to be installed.

9 Place the brine storage tank (K) and the external product storage tank (J) into their

intended positions.

10 Route the PVCU exhaust air line (E) Ø 125 from the system cabinet outside.

11 Glue an H system (pipework) to the exterior air outlet to prevent dirt or rain water from

penetrating inside.

B1016

12 Connect a Ø 20 mm PVCU pipe between the softener frame (N) and the “Softened water

supply” connector (A).

13 Connect a potable water line, Ø 20 mm PVCU, to the softener frame (N).

14 For the “external product storage tank”: Connect a PVCU connector Ø 32 (C) "Product,

outlet” and the connector on the external product storage tank (J).

15 Connect a reinforced PVC hose Ø 6x12 mm between the "Fill brine storage tank” con‐

nector (B) and the connector Ø 6x12 mm on the brine storage tank (K).

16 Connect a reinforced 9x12 mm PE hose to the brine storage tank (J) and the “Brine inlet”

connector (D).

17 Connect a 9x12 mm PE hose from the brine storage tank (J) to the softener frame (N).

18 Route a PVCU line Ø 32 mm from the brine storage tank (K) into the sewage system.

Make sure that the brine storage tank contains salt as soon as the PVCU line has been

connected.

Electrical connectors - as per the wiring diagram:

19 Connect the external alarm contact to the control cabinet - via the housing section (H).

Installation and assembly

# Installation process Tick

20 Connect the actuator contact to the control cabinet - via the housing section (H).

Remove the wire jumper between the contacts.

21 Connect the “Level too low” level switch of the external product storage tank to the

external product metering pump - via the housing section (H). Remove the wire jumper.

22 The doors of the system need to be closed for the system’s ventilation system to work.

The error message “Airflow too low” is displayed if the doors are not closed.

Installation and assembly

5.2

Assembly and installation of the Chlorinsitu

IIa

n User qualifications, mechanical/hydraulic installation: trained

skilled personnel, see

Ä Chapter 1.3 ‘User qualification’

on page 8

n User qualification, electrical installation: electrical technician,

see

Ä Chapter 1.3 ‘User qualification’ on page 8

1. Check whether the assembly location complies with the

guidelines governing temperature, safety, space, humidity,

etc.

Specification of the assembly location

Ensure that the assembly location preferably

complies with the following conditions:

–

A dry area, which does not necessarily

have to be a separate room.

–

An area that can be locked/cordoned off

so that only authorised personnel have

access.

–

An ambient temperature of 10 ... 40 °C;

otherwise install an air conditioning

system.

–

It should be possible to install a sewage

drain and a bleed line.

An assembly drawing showing the correct

dimensions can also be produced to ensure

correct assembly. The assembly area and

position are determined using the drawings

provided. An assembly drawing for the Chlor‐

insitu

IIa can be found at the end of the

chapter.

2. Clear the area in which the system is to be installed.

Check that there are no obstacles around the

system.

Provide a minimum clearance of 75 cm in

front of and at the side of the system cabinet

for maintenance purposes.

Provide a clearance of around 75 cm in front

of the brine storage tank and the optional

product storage tank.

3. Remove all packaging from the system.

4. Check whether the system has suffered damage during

transport or exhibits other damage. Check that the scope of

delivery is complete.

5. Remove the securing material of the transport crate.

6. Lift the system cabinet into its installation position.

7. Check whether the system is upright and horizontal. Max.

deviation from the vertical of 4 mm per 100 cm.

8. Remove the transport protection from the softener and the

product storage tank.

Installation and assembly

A2936

N L / M

Fig. 4: Cabinets and tanks.

J Product storage tank

K Brine storage tank

R Control cabinet

M Production cabinet

N Softener with frame

9. Place the brine storage tank (K) and optionally an external

product storage tank in their intended positions. Preferably

position the brine storage tank in the direct vicinity of the

system. Remove all objects from the contact faces of the

brine storage tank and the external product storage tank -

even the smallest foreign objects. Due to the heavy weight of

the filled storage tanks, the components can be damaged by

these objects.

Installation and assembly

G / H / I

A2935

Fig. 5: Connectors for the Chlorinsitu

IIa system cabinet

A Connector, inlet for softened water

B Connector, softened water discharge to the

brine storage tank

C Connector, brine to the softener

D Connector, product output from product pump

E Connector, exhaust air line

F Connector, brine inlet to brine pump

G -

H Connector, waste water outlet

I Sleeve section, electrical power supply line

J, K Sleeve section, electrical control lines

10. Route a Ø 32 mm PVCU line from the Ø 32 mm PVCU con‐

nector (H) on the system cabinet (N) into the sewage system.

11. Route a Ø 125 PVCU exhaust air line (maximum 10 metres)

outside above the system cabinet.

CAUTION!

Do not position the outlet inside the building.

Glue the output of the device (F) to the exhaust air line.

Installation and assembly

B1016

Fig. 6: H system

12. Glue an H system (pipework) to the outside air outlet to pre‐

vent dirt or rain water from penetrating inside (e.g. may be

assembled using 3 T-pieces).

CAUTION!

– Do not position the air outlet in the

vicinity of:

– Suction openings

– Windows

– Chimney openings

– Take into account the wind dynamic

pressure, e.g. at the side of a building

– Use a Ø160 mm pipe if lines are too long

or there are more than 3 bends

Contact van der Heuvel Watertechnologie bv.

should you have further questions.

13.

Non-return valve

Install a non-return valve in the potable water

supply line in compliance with national regu‐

lations.

Connect a potable water line with the system's Ø 20 mm

PVCU “water supply” connector. The connector should be

combined with a stopcock.

n Maximum pressure = 6 bar

n Minimum flow = 8 l/min

n Temperature = Potable water, 15 ... 25 °C

n Minimum pressure downstream of the non-return valve =

2 bar

14. For the “external product storage tank”: Connect the PVCU

connector Ø 32 (C) "Product outlet” and the connector on the

external product storage tank (J).

15. Connect a reinforced PVC hose Ø 6x12 mm between the "Fill

brine storage tank” connector (B) and the connector Ø 6x12

mm on the brine storage tank (K).

16. Connect a reinforced 9x12 mm PE hose between the brine

storage tank (K) and the “Brine inlet” connector (D).

19. Electrical connectors - as per the electrical circuit diagram:

Connect the external alarm contact to the control cabinet -

via the housing section (H).

Installation and assembly

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ProMinent CHLORINSITU IIa Assembly And Operating Instructions Manual

ProMinent CHLORINSITU IIa Assembly And Operating Instructions Manual

ProMinent CHLORINSITU IIa Assembly And Operating Instructions Manual

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