ELECTROSEA CLEARLINE System CL-430-N1.0 User manual

[phone]
[phone]
[email protected]
www.electrosea.com
Operation Manual
Clearline®System
Model CL-430-N1.0 / Model CL-410-N0.5

U.S. Patent No. 11,027,991 and 11,345,621, Foreign Patent No. I782112 and other U.S. and Foreign Patents Pending
2
2
Table of Contents
Introduction
Table of Contents 2
ElectroSea and ClearLine 3
Safety Considerations 3
System Features
User Interface 4
Operating Modes and Feature Overview 5-6
Optimal Performance and Flow Alert 7
Cell Indicator 8
ClearCell Maintenance
ClearCell Internal Screen Care 9
ClearCell Internal Screen Access 10-14
System Updates
Factory Default and Firmware Updates 15
Inspection
Periodic Inspection 16
Important Information
Specifications 17
Modes & Troubleshooting
Modes, Descriptions and Actions 18-19
COPYRIGHT © 2020
No part of this publication may be reproduced, translated, stored in a retrieval system, or transmitted in any form or by any means electronic, mechanical, photocopying, recording, or otherwise without the
prior written consent of ElectroSea, LLC. Every precaution has been taken in the preparation of this manual to ensure its accuracy. ElectroSea assumes no responsibility for errors and omission. Neither is
any liability assumed for damages resulting from the use of this product and information contained herein.
Warranty Policy
Please visit our website at www.electrosea.com/warranty to
view our full warranty terms and conditions.

U.S. Patent No. 11,027,991 and 11,345,621, Foreign Patent No. I782112 and other U.S. and Foreign Patents Pending
3
3
Introduction
ElEctroSEa®
ElectroSea was created when the owners of a sportfishing vessel invented “a better way” to prevent biofouling in their seawater cooling system. Solving complex
technical problems is our expertise. With more than 100 issued U.S. patents and 350+ foreign patents in advanced technologies, our executive management team
has been developing innovative solutions for more than 50 years. With an expert team of “old salts” who eat, sleep, and breathe boating, ElectroSea will improve
your time on the water.
clEarlinE®System
ClearLine is an innovative marine electrochlorination system that prevents biofouling and barnacle growth in a vessel’s seawater lines. ClearLine keeps air
conditioners, chillers, and refrigerators operating at maximum flow rates and sea strainers clean longer. The patented ClearLine System includes the ClearLine
Control Unit, which is the brain, and the ClearCell®, which is the heart of the system. ClearLine operates automatically 24x7x365 and is built for flawless and
reliable performance.
Safety Considerations
WARNING Indicates a hazardous situation that, if not avoided, could result in death or serious injury.
CAUTION Indicates a hazardous situation that, if not avoided, could result in minor or moderate injury.
Indicates a hazardous situation that can cause damage to personal property, the environment, or equipment.
NOTICE

U.S. Patent No. 11,027,991 and 11,345,621, Foreign Patent No. I782112 and other U.S. and Foreign Patents Pending
4
4
Circuit Breaker
Status Screen
Operating Mode
User Interface
Selection Buttons
ON/OFF
USB Port
Programming Menu
Flow Rate
System Features
Features and Functions
1. Power ON ClearLine. The Control Unit will complete a diagnostic self-test, and then the green “POWER” light will be illuminated.
2. The main status screen will be displayed.

U.S. Patent No. 11,027,991 and 11,345,621, Foreign Patent No. I782112 and other U.S. and Foreign Patents Pending
5
5
Operating Modes
The Operating Mode displays the state of the ClearLine System. Modes include
• OFF: ClearLine is powered, but it is in the OFF mode and not Cleaning.
• START-UP: ClearLine is performing a diagnostic self-test. This mode lasts for approximately 30 seconds.
• CLEANING: ClearLine is ON and Cleaning. This is the normal operating mode for the ClearLine System.
• FLOW ALERT: ClearLine is ON and Cleaning, but the flow rate measured is less than or equal to the value set manually in the Flow Alert feature.
• CELL INDICATOR: ClearLine is sensing low salinity (brackish or fresh water), high resistance, or disconnection of the ClearCell Cable. This indicator may also
mean that the ClearCell is at the end of its useful life. ClearLine will continuously attempt to generate chlorine and automatically resume standard operation
when conditions are resolved.
Feature Overview
• Flow Rate (GPM): The flow rate is monitored in gallons per minute (GPM) or liters per minute (LPM) of seawater at the output of the ClearLine System. The
ClearLine System should be used with flow rates as follows: CL-430-N1.0: up to 26 GPM (98.4 LPM) and CL-410-N0.5: up to 7 GPM (26.5 LPM).
• Flow Alert: Flow Alert indicates that the flow rate is at or below a threshold level for a period of time. The Flow Alert threshold level is manually set by the user.
• Display Contrast, Backlight, and Imperial/Metric Units: Use this feature to adjust the LCD display contrast and backlight levels from Lo to Hi and to select
between imperial and metric units for flow in GPM or LPM.
• Default Update: This feature is used to restore ClearLine to its original factory default settings or to update the ClearLine Control Unit firmware using a USB
memory drive supplied by ElectroSea.
System Features

U.S. Patent No. 11,027,991 and 11,345,621, Foreign Patent No. I782112 and other U.S. and Foreign Patents Pending
6
6
Set Backlight, Contrast, or Units: The LCD display backlight, contrast, and imperial/metric units can be set. Use the Up or Down arrows to select and
change settings.
Display Backlight, Contrast and Imperial/Metric Units
During normal operation the Control Unit will flash “CLEANING,” and the green Cleaning LED will be illuminated. This indicates the ClearLine System is
electrochemically generating a safe and effective level of chlorine to prevent biofouling in the vessel’s seawater circuit. The System will display the flow rate at the
output of the ClearLine System in gallons per minute (GPM) or liters per minute (LPM). If the flow rate drops below 2 GPM (7.6 LPM), the display will indicate “MIN
FLOW.” The ClearLine System will automatically stop chlorinating seawater if Min Flow (1–2 GPM/3.8–7.6 LPM) or No Flow (0 GPM) is reached.
Cleaning Mode
Power ON and Start-Up Delay
Power ON the ClearLine System. The Control Unit will complete a diagnostic self-test, and then the green “POWER” LED will be illuminated. “START-UP” will be
displayed for 30 seconds.
Auto Mode
The ClearLine System automatically and continuously calculates the optimal level of chlorinated seawater to prevent biofouling in seawater lines using multiple input
parameters, including seawater flow rate, key electrical parameters, and environmental temperature.
CLEARLINE -Menu
CLEANING XX GPM
Auto
>
System Features

U.S. Patent No. 11,027,991 and 11,345,621, Foreign Patent No. I782112 and other U.S. and Foreign Patents Pending
7
7
Optimal Performance
Constant Chlorinated Seawater Flow: The ClearLine System should be powered ON and have seawater flowing through the ClearCell whenever possible.
This provides the vessel’s seawater circuit with constant chlorinated seawater to prevent unwanted marine growth. Intermittent or stagnant seawater
that is not continuously electrochemically treated allows growth of marine microorganisms. Barnacles have the innate ability to close themselves off and survive
intermittent exposure to biocidal agents:
• DO NOT turn off seawater pumps, air conditioners, or chillers for an extended period of time.
Inspect the vessel for problem areas:
• Pre-existing biofouling in seawater lines prior to ClearLine installation
• Clogged seawater strainers and intakes
• Impacted, blocked, or occluded lines from debris lodged in plumbing
• Sporadic demand valve areas (Depending on the system, valves that turn on and off can foster unwanted marine growth.)
Flow Alert: The Flow Alert feature monitors seawater flow through the ClearCell. This feature allows the user to set a minimum flow rate threshold value and time
duration. If the seawater flow rate drops below a minimum value for a period of time, “FLOW ALERT” will appear on the display (no audible alert).
This feature notifies the user that some part of the seawater circuit, such as the intake, strainer, pump, or internal screen on the ClearCell, requires cleaning or is
not functioning properly. Flow rate can be set in GPM or LPM, with the time duration set in minutes. To set the Flow Alert value, go to Menu, Flow Alert and enter the
desired threshold flow rate and time duration for notification.
The Flow Alert feature is OFF by default and must be set up by the installer or end user.
ClearLine will continue generating chlorine even after a Flow Alert occurs. Flow Alert does not prevent ClearLine from operating.
If a Flow Alert occurs
1. Check vessel’s strainers and intake grates for blockage.
2. Check seawater pump operation.
3. Check ClearCell Internal Screen (see page 9).
Flow Alert
>-Flow Alert -Update
-Display
-Cell
-Default -Exit
NOTICE
NOTICE
System Features

U.S. Patent No. 11,027,991 and 11,345,621, Foreign Patent No. I782112 and other U.S. and Foreign Patents Pending
8
8
System Features
Cell Indicator: The Control Unit will display “SALINITY/CELL,” “% OUTPUT,” and illuminate the red Cell LED in various conditions. This is not an immediate cause for
concern and may be temporary depending on seawater salinity level. ClearLine will continuously attempt to generate chlorine and automatically resume standard
operation when conditions are resolved. The Cell Indicator will be illuminated if any of the following conditions occur for multiple consecutive days:
• Water salinity is below 20 parts per thousand. (This is the most common cause of a ClearLine Cell Indicator notice.)
• ClearCell Cable or its connectors have been compromised.
• ClearCell Electrode has excessive mud or other debris.
• ClearCell Electrode is at the end of its useful life.
Water Salinity
• Vessels often encounter brackish or fresh water when cruising inland or from extended storms and freshwater runoff.
• Low salinity is the most frequent cause of the ClearLine Cell Indicator.
• ClearLine will not display “CLEANING” or generate chlorine while the vessel is operating in fresh water.
RESOLUTION: Return vessel to seawater with adequate salinity.
ClearCell Cable
• The ClearCell Cable and connections must not be spliced, cut, compromised, or damaged.
• Inspect the Control Unit-to-ClearCell Cable carefully. Look for any corrosion at the connectors.
RESOLUTION: Replace the ClearCell Cable if it is compromised.
Excessive Mud or Other Debris
• If there is excessive mud or other debris, the ClearCell Electrode may require a brief rinse with fresh water.
RESOLUTION: Follow instructions on pages 9-14.
ClearCell Electrode at End of Life
• When the ClearCell Electrode has reached the end of its useful life, it can no longer generate chlorine. The ClearCell Electrode life is dependent on flow rate, hours
of use, seawater quality, and other factors. The ClearCell Electrode will be effective for many years before replacement is required.
RESOLUTION: Contact your ElectroSea dealer.
Cell Indicator
ESTUARY
OCEAN

U.S. Patent No. 11,027,991 and 11,345,621, Foreign Patent No. I782112 and other U.S. and Foreign Patents Pending
9
9
ClearCell Maintenance
Low seawater flow may damage the cooling system and
other components that depend on this water for proper operation. It is
the owner’s responsibility to monitor the vessel’s seawater flow rate and
perform any maintenance on the vessel’s seawater pumps, strainers, and
internal screen on the ClearCell.
Internal Screen: The ClearCell contains an internal screen to catch debris (tiny shells or other foreign materials that pass through the vessel’s main strainer) before
it reaches the flow sensor. The internal screen should be cleaned periodically and whenever debris gets caught in the screen and decreases seawater flow. Before
accessing the ClearCell Electrode, double-check the list of Alerts and Indicators on pages 7 and 8 because the ClearCell infrequently requires rinsing.
Low Salinity is the most frequent cause of a Cell Indicator notice. Do not open the ClearCell canister if you suspect the Cell Indicator notice is due
to low salinity.
Internal Screen Care
NOTICE
NOTICE
NOTICE
• DO NOT PERFORM ACID DESCALING OF THE SEAWATER CIRCUIT AFTER THE
CLEARLINE SYSTEM HAS BEEN INSTALLED.
• DESCALING ACIDS OR CLEANING CHEMICALS WILL DAMAGE THE CLEARCELL
CANISTER AND CLEARCELL ELECTRODE AND VOID THE WARRANTY.
• DO NOT TOUCH THE CLEARCELL ELECTRODE PLATES OR USE ANY TYPE OF
MECHANICAL BRUSH.
• THE CLEARCELL ELECTRODE PLATES CONTAIN A SPECIAL METAL OXIDE
COATING THAT WILL BE PERMANENTLY DAMAGED IF YOU HANDLE IT.
Spray screen with
fresh water
to remove debris.

U.S. Patent No. 11,027,991 and 11,345,621, Foreign Patent No. I782112 and other U.S. and Foreign Patents Pending
10
10
ClearCell Maintenance
Internal Screen Access
Before accessing the ClearCell Electrode, double-check the list of Alerts and Indicators on pages 7 and 8 because
the ClearCell infrequently requires rinsing.
To Access the ClearCell Electrode:
1. Power OFF the ClearLine Control Unit.
2. Turn OFF ALL seacock valves in the seawater circuit at or below the waterline. This includes
any output seacocks to prevent back siphoning.
Failure to turn OFF ALL seacock valves in the seawater circuit could
result in sinking the vessel.
3. Locate the 1’ (30.5-cm) cable labeled “CELL” that is located at the top of the ClearCell
unit. Disconnect this cable at the cable connector.
DO NOT UNSCREW THE TWO BLACK PLASTIC CAP NUTS ON TOP OF THE
LID OR TITANIUM HARDWARE UNDER THE LID. 2
WARNING
NOTICE
3
1
DO NOT UNSCREW
PLASTIC CAP NUTS.

U.S. Patent No. 11,027,991 and 11,345,621, Foreign Patent No. I782112 and other U.S. and Foreign Patents Pending
11
11
ClearCell Maintenance
4. Turn the wing nuts counterclockwise
to release the Electrode Assembly.
5. Remove the Electrode Assembly and pressure ring by lifting it straight up by the sides
of the black plastic top. Do not lift or pull on the top cable connectors.
5
4

U.S. Patent No. 11,027,991 and 11,345,621, Foreign Patent No. I782112 and other U.S. and Foreign Patents Pending
12
12
DO NOT TOUCH THE SURFACE BETWEEN THE
ELECTRODE PLATES OR USE ANY TYPE OF MECHANICAL BRUSH.
THE CLEARCELL ELECTRODE PLATES CONTAIN A SPECIAL METAL
OXIDE COATING THAT WILL BE PERMANENTLY DAMAGED IF YOU
HANDLE IT.
DO NOT PUT ANY CHEMICALS, ACIDS,
DESCALING SOLUTIONS, OR ZINCS IN THE CLEARCELL CANISTER
OR ON THE ELECTRODES. THIS WILL DAMAGE THE ELECTRODE.
ClearCell Maintenance
6. Spray the ClearCell Electrode Assembly with fresh water to remove any dirt or mud
between the plates or debris in the internal screen.
Spray plates and screen with fresh water.
NOTICE
NOTICE
6

U.S. Patent No. 11,027,991 and 11,345,621, Foreign Patent No. I782112 and other U.S. and Foreign Patents Pending
13
13
ClearCell Maintenance
7. Insert the ClearCell Electrode Assembly back into ClearCell canister. The Electrode
Assembly and Canister are keyed and can only be inserted in one direction.
Align the Electrode Assembly key and the ClearCell canister key and insert it into
the ClearCell canister.
8. Add the pressure ring and begin tightening down the wing nuts evenly.
Bleed all air out of the ClearCell canister and then finish securing the wing nuts.
DO NOT use any tools to perform this tightening process. Work in a star pattern
so they are all evenly secure.
9. Double-check to ensure all fittings, hose clamps, and wing nuts are secure.
9
8
Electrode
Assembly Key
7

U.S. Patent No. 11,027,991 and 11,345,621, Foreign Patent No. I782112 and other U.S. and Foreign Patents Pending
14
14
ClearCell Maintenance
10
11
12
10. Reconnect the ClearCell Cable to the ClearLine Control Unit.
11. Open the seacocks and check for any leaks.
12. Turn the seawater intake pump on. The seawater intake pump must be on and
pumping seawater at normal flow rates for the ClearLine System to operate.
13. Turn ON the ClearLine System. The ClearLine “CLEANING” LED should be
illuminated in green, and the display should state it is in the Cleaning Mode.
14. If the Cell Indicator is still active, then one of the following conditions still
persists:
• Water salinity is below 20 parts per thousand.
• ClearCell Cable or its connectors have been compromised.
• ClearCell Electrode has excessive mud or other debris.
• ClearCell Electrode is at the end of its useful life.
For further troubleshooting, see pages 8 or 19 or contact your
ElectroSea dealer.
Any air trapped in the ClearCell Canister must be bled out.
Cycle the seawater intake pump and/or loosen the ClearCell Canister wing
nuts to bleed out excess air then re-tighten the ClearCell Canister.
DO NOT restrict seawater flow to ClearCell Canister.
13
NOTICE
NOTICE

U.S. Patent No. 11,027,991 and 11,345,621, Foreign Patent No. I782112 and other U.S. and Foreign Patents Pending
15
15
System Updates
1. Default: This is the process to restore ClearLine to its original factory default settings. The user will press and hold the Up and Down arrows simultaneously for
10 seconds to restore factory default settings.
2. Update: This allows the user to update the firmware using a USB memory drive supplied by ElectroSea. To perform a firmware update
a. Insert the ElectroSea USB memory drive.
b. Go to the Update menu. Line 1 displays the current firmware version of the unit. Line 2 displays the available firmware version that is on the USB memory
drive. It is possible to upgrade or downgrade the firmware version.
c. Press and hold the Up and Down keys simultaneously for 10 seconds, then release the keys once the update begins.
d. During the update, the Control Unit is in a locked mode and cannot be used. The bottom line of the display will show the update progress.
e. Once the update is complete, the Control Unit will reboot.
f. Confirm the update was successful by going back to the Update menu. The display will show that the FW X.X is up to date.
In the event that the firmware update fails, the Control Unit maintains a redundant copy of the existing firmware. The screen will
display a result message at the end of an update attempt to confirm the update was successful. Repeat the steps above to retry the firmware update
if required.
-Flow Alert -Update
-Display
-Cell
-Default -Exit
-Flow Alert -Update
-Display
-Cell
-Default -Exit
Factory Default and Firmware Updates
>
Reset to Factory
HOLD UP & DOWN
for 10 seconds
OK to Exit
FW X.X Current
OK to Exit
>
NOTICE

U.S. Patent No. 11,027,991 and 11,345,621, Foreign Patent No. I782112 and other U.S. and Foreign Patents Pending
16
16
Inspection
The ClearLine System should be viewed during regular inspection of the vessel’s engine room. During normal operation, the ClearLine System status screen will flash
the message “CLEANING,” and the green LED will be illuminated. This indicates the ClearLine System is generating a safe and effective low level of chlorine preventing
unwanted marine growth, barnacles, and biofilm in the seawater lines.
If there are any concerns during the regular inspection noted above, then perform a more thorough process:
• Visually inspect all wires and connections between the ClearLine Control Unit and the ClearCell.
• Disassemble the ClearCell and thoroughly flush and clean the internal screen. (See pages 9-14.)
• Visually inspect the Flow Sensor.
• Visually inspect seawater conduits to confirm marine growth prevention.
Inspection and maintenance are the responsibility of the vessel owner.
NOTICE
Periodic Inspection

U.S. Patent No. 11,027,991 and 11,345,621, Foreign Patent No. I782112 and other U.S. and Foreign Patents Pending
17
17
Important Information
Specifications
CLEARLINE SYSTEM
Power: 12 VDC or 24 VDC
5 amps max peak current
Normal Operating Flow: CL-430-N1.0: 5–26 GPM (18.9 – 98.4 LPM)
CL-410-N0.5: 3–7 GPM (11.4 – 26.5 LPM)
Maximum Pressure: 35 psi
CLEARCELL
Size: 6.8 inches (17.3 cm) – height
5.3 inches (13.5 cm) – diameter/width
CLEARLINE CONTROL UNIT
Size: 10.0 inches (25.4 cm) – width
7.0 inches (17.8 cm) – height (without cables)
3.3 inches (8.4 cm) – depth

U.S. Patent No. 11,027,991 and 11,345,621, Foreign Patent No. I782112 and other U.S. and Foreign Patents Pending
18
18
Modes & Troubleshooting
Modes, Descriptions and Actions
Mode Description Action
OFF The unit is powered ON, but it is in the OFF state. No seawater is
flowing through the ClearLine System. This is a normal operating mode, provided there is no seawater flow.
Cleaning The unit is in the mode for Cleaning and preventing biofouling by
chlorinating seawater. This is a normal operating mode. See page 6 for Cleaning Mode.
Auto
The unit is automatically optimizing the level of chlorinated
seawater based on multiple input parameters, including flow
rate, key electrical parameters, and environmental temperature.
This is a normal operating mode. See page 6 for Auto Mode.
Min Flow The flow rate is 1–2 GPM (3.8–7.6 LPM) and is too low to
chlorinate seawater.
The Min Flow indicator will disappear when the seawater flow rate is
>2 GPM (7.6 LPM).
No Flow The flow rate is 0 GPM. The No Flow indicator will disappear when the seawater flow returns.
Flow Alert
Flow Alert is a user-defined threshold value for visual alert and
notification purposes. The user should manually set the desired
Flow Alert value and time duration.
ClearLine will continue generating chlorine even after a Flow Alert occurs.
Flow Alert does not prevent ClearLine from operating.
Note: If the flow rate is less than or equal to 2 GPM (7.6 LPM), then a Min
Flow alert will occur, and ClearLine will stop chlorinating seawater.
If a Flow Alert occurs
1. Check vessel’s strainers and intake grates for blockage.
2. Check seawater pump operation.
3. Check all other components in the seawater intake fluid path.
4. Check ClearCell Internal Screen and rinse according to ClearCell Internal
Screen instructions on pages 9-14.

U.S. Patent No. 11,027,991 and 11,345,621, Foreign Patent No. I782112 and other U.S. and Foreign Patents Pending
19
19
Modes & Troubleshooting
Modes, Descriptions and Actions
Mode Description Action
Cell Indicator
The Control Unit will display
“SALINITY/CELL,” “% OUTPUT,”
and illuminate the red Cell LED
in various conditions. This is
not an immediate cause for
concern and may be temporary
depending on seawater salinity
level. ClearLine will continuously
attempt to generate chlorine
and automatically resume
standard operation when
conditions are resolved.
Water Salinity
• Vessels often encounter brackish or fresh water when cruising inland or from extended storms and
freshwater runoff.
• Low salinity is the most frequent cause of the ClearLine Cell Indicator.
• ClearLine will not display “CLEANING” or generate chlorine while the vessel is operating in fresh water.
RESOLUTION: Return vessel to seawater with adequate salinity.
ClearCell Cable
• The ClearCell Cable and connections must not be spliced, cut, compromised, or damaged.
• Inspect the Control Unit-to-ClearCell Cable carefully. Look for any corrosion at the connectors.
RESOLUTION: Replace the ClearCell Cable if it is compromised.
Excessive Mud or Other Debris
• If there is excessive mud or other debris, the ClearCell Electrode may require a brief rinse with
fresh water.
RESOLUTION: Follow instructions on pages 9-14.
ClearCell Electrode at End of Life
• When the ClearCell Electrode has reached the end of its useful life, it can no longer generate chlorine.
The ClearCell Electrode life is dependent on flow rate, hours of use, seawater quality, and other
factors. The ClearCell Electrode will be effective for many years before replacement is required.
RESOLUTION: Contact your ElectroSea dealer.
High Temperature ClearLine internal temperature
is high.
Contact your ElectroSea dealer or ElectroSea directly as the ClearCell Electrode may be at the end of its
useful life.

[phone]
[phone]
[email protected]
www.electrosea.com
750070-015