JRG GF Hycleen Des 30 User manual

Hycleen Des 30
Instruction manual
Standard version 9800.030
Industrial design 9800.002
Mobile system 9800.003
Version 2.4

Operating instructions Intended Use
Original instruction manual
Observe the instruction manual
The instruction manual is part of the product and an important component in the safety
concept.
Read and follow the instruction manual.
Keep the operating manual always available on the product.
Pass operating manual on to any subsequent users of the product.

Intended Use Operating instructions
Table of contents
1Intended Use................................................................................1
2About this document.................................................................... 1
2.1 Warnings ................................................................................................... 1
2.2 Applicable documents............................................................................... 2
2.3 Description of product version and types ................................................. 2
2.4 Abbreviations and acronyms..................................................................... 2
3Safety and responsibility .............................................................3
4Transportation and storage.........................................................4
5Design and function ..................................................................... 5
5.1 Peripherals of the Hycleen Des 30 ........................................................... 5
5.2 Design versions......................................................................................... 6
5.2.1 Hycleen Des 30 Standard version......................................................................... 6
5.2.2 Hycleen Des 30 Industrial version........................................................................ 7
5.2.3 Hycleen Des 30 Mobile device .............................................................................. 8
5.3 Structure ................................................................................................... 9
5.3.1 Control cabinet and process cabinet ................................................................... 9
5.3.2 Tanks for operating fluids................................................................................... 13
5.4 Principle of operation.............................................................................. 14
5.5 Disinfectant production modes............................................................... 15
5.5.1 Anolyte & Catholyte............................................................................................. 15
5.5.2 Anolyte neutral .................................................................................................... 15
6Specifications............................................................................. 16
6.1 Operating fluids....................................................................................... 17

Operating instructions Intended Use
7Scope of supply.......................................................................... 19
7.1 Scope of supply Hycleen Des 30 Standard version ................................ 19
7.2 Scope of supply Hycleen Des 30 Industrial version................................ 21
7.3 Hycleen Des 30 Mobile device................................................................. 22
7.4 Flow meter scope of supply .................................................................... 23
7.5 Anolyte dosing pump scope of supply .................................................... 23
7.6 Dosing unit scope of supply .................................................................... 23
7.7 Dosing lance scope of supply ................................................................. 23
8Installation................................................................................. 24
8.1 Tools and aids ........................................................................................ 24
8.2 Installation............................................................................................... 24
8.2.1 Preliminary checks.............................................................................................. 24
8.2.2 Wiring diagram .................................................................................................... 25
8.2.3 Installing the flow meter with impulse transmitter.......................................... 25
8.2.4 Assembly instructions for the dosing unit with dosing lance........................... 26
8.2.5 Cutting the dosing lance to length ..................................................................... 27
8.2.6 Assembly instructions Hycleen Des 30.............................................................. 28
8.2.7 Assembly instructions Hycleen Des 30 Industrial version ............................... 33
8.2.8 Installing the dosing pump ................................................................................. 34
8.2.9 Installing the filling level sensor ........................................................................ 35
8.3 Making hose connections ....................................................................... 35
8.4 Making the cable connections ................................................................ 38
8.5 Hycleen Des 30 Mobile............................................................................ 43
9Commissioning .......................................................................... 44
9.1 Preparing................................................................................................. 44
9.2 Commissioning the system..................................................................... 44
9.3 Performing a test run ............................................................................. 47

Intended Use Operating instructions
10 Operation ................................................................................... 50
10.1 Control elements on the control cabinet................................................ 50
10.2 Control elements on the PLC ................................................................. 51
10.3 Switching on the system ......................................................................... 52
10.4 Switching off the system......................................................................... 54
10.5 Decommissioning during prolonged periods of non-use (downtime > 3
days) ........................................................................................................ 55
10.6 Cleaning process .................................................................................... 56
10.7 Automatic descaling cycle ...................................................................... 57
10.8 Manual descaling cycle........................................................................... 58
10.9 Acknowledging fault messages .............................................................. 58
10.10 Viewing messages on the PLC................................................................ 59
11 Maintenance .............................................................................. 60
11.1 Maintenance schedule ............................................................................ 60
11.2 Maintenance work................................................................................... 61
11.2.1 Preparatory steps................................................................................................ 61
11.2.2 Refilling operating fluids..................................................................................... 62
11.2.3 Replacing the reactor.......................................................................................... 63
11.2.4 Cleaning the Salisol level sensor ....................................................................... 64
12 Troubleshooting ........................................................................ 65
13 Spare parts list .......................................................................... 69
13.1 Hycleen Des 30........................................................................................ 69
13.2 Accessories required .............................................................................. 73
13.3 Operating fluids....................................................................................... 77
14 Removal..................................................................................... 78
15 Disposal ..................................................................................... 79
16 Operating log (template) ........................................................... 80
17 Maintenance log (template)....................................................... 81
18 EC declaration of incorporation for partly completed machinery
82

Operating instructions Intended Use

Operating instructions Intended Use
1Intended Use
The Hycleen Des 30 uses diaphragm electrolysis technology to produce an electro activated
disinfectant solution, which is then continuously injected into the drinking water circuit where
it kills off bacteria, biofilms and germs. The diaphragm electrolysis technology uses softened
water and high-purity salt to produce an electro activated disinfectant solution containing
sodium hypochlorite.
2About this document
This document includes all information for the user necessary for installing, commissioning,
maintaining and decommissioning the Hycleen Des 30 system.
2.1 Warnings
This instruction manual contains warning signs that draw attention to risks of fatal or physical
injuries or material damage. Read and pay attention to these warning signs!
Risk of death or risk of serious physical injury!
Failure to comply may result in death or serious physical injury!
Risk of minor physical injury!
Failure to comply may lead to physical injury!
Risk of damage to property!
Failure to comply may lead to damage to property (loss of time, loss of data, machine failure
etc.)!
Other symbols
Symbol
Meaning
1.

Actions required in a numbered sequence.
Actions required

Items listed on various levels
WARNING
CAUTION

About this document Operating instructions
2
2.2 Applicable documents
Safety data sheets
•Catholyte
•Anolyte
•Anolyte neutral (pH 7)
•Calzid-Ex
•Salisol
•High-purity salt for diaphragm electrolysis technology
OEM documentations
•Flow meter
•Dosing unit
•Dosing pump 12
•Dosing pump 60
GF JRG tendering documents
These documents are available from agents of GF JRG or at www.jrg.ch.
2.3 Description of product version and types
Type
Code No. [Item No.]
Property
Hycleen Des 30
351 120 030 [9800.030]
Standard version
Hycleen Des 30 Industrial
351 120 260 [9800.002]
Industrial version
Hycleen Des 30 Mobile
351 120 250 [9800.003]
Mobile device
2.4 Abbreviations and acronyms
Abbreviation
Explanation
Calzid-Ex
Organic acid mixture
DN
Nominal diameter
ECA
Electrically activated disinfectant solution
NaCl
Sodium chloride
NaClO
Sodium hypochlorite
OEM
Original Equipment Manufacturer
PE
Polyethylene
PTFE
Polytetrafluoroethylene
PVC
Polyvinyl chloride
PVDF
Polyvinylidene fluoride
PLC
Programmable logic controller

Operating instructions Safety and responsibility
3
3Safety and responsibility
The product is only to be used for its intended purpose, see Chapter 1 "Intended use" on
page 1.
Make sure that the Hycleen Des 30 is installed and operated properly.
Have the installation and parameter adjustments carried out only by qualified personnel
who have the required training, knowledge or experience.
Instruct the operator regularly on all matters relating to the local regulations on
installation, occupational health and safety and environmental protection.
Risk of poisoning!
If the people present experience slight dizziness and nausea, it is an indication that there is
inadequate ventilation in the room in which the Hycleen Des 30is installed.
If these symptoms occur, switch off the system immediately, leave the room and breathe
fresh air for more than 1 h.
Always operate the Hycleen Des 30in a well ventilated room, as production can give off
small amounts of hydrogen and chlorine vapours!
In rooms with a volume less than 50 m3, ensure that the air circulation provides a fresh
air proportion of at least 30% / h; in larger rooms, the proportion should be at least 20% /
h.
Risk of explosion!
The diaphragm electrolysis process can give off small amounts of hydrogen and chlorine. An
exhaust air system shall be provided for, in addition, contact with acids should be avoided
since this may lead to gassing.
Smoking and naked flames are forbidden in the area around the Hycleen Des 30.
Environmental damage caused by improper disposal of liquids!
Concentrated Anolyte must be neutralised with the corresponding quantity of Catholyte to
obtain a pH value of 6.5 - 9.5.
Neutralise fluids and dispose of them according to the applicable regional and national
disposal regulations.
WARNING
WARNING

Transportation and storage Operating instructions
4
4Transportation and storage
Danger of physical injury or damage to the environment due to leaking media!
Damage to the product can cause leaking of the salt solution in the hydraulic cabinet.
When transporting, protect the Hycleen Des 30from external force (impact, shock,
vibration etc.).
Before each use, check that the Hycleen Des 30 has not been damaged either by
mechanical or thermal influences.
Transport and/or store the Hycleen Des 30in its unopened original packaging.
After transport, always check the Hycleen Des 30 for transport damage.
Protect the Hycleen Des 30 from dust, dirt, moisture, cold as well as from heat and
ultraviolet radiation.
The Hycleen Des 30 must not be operated, transported or stored at temperatures below
5 °C.
The reactor (reserve or replacement reactor) must also never be below 5 °C.
The reactor must never run dry. When replacing, insert sealing plugs into the
connections of the replaced reactor. During storage, make sure that the reactor is
completely filled with distilled water and well-sealed.
CAUTION

Operating instructions Design and function
5
5Design and function
5.1 Peripherals of the Hycleen Des 30
Peripherals
1
Power supply 230 VAC, 50 Hz
2
System shut-off valve
3
Softening unit (ion exchanger)
4
Pre-filter (5 µm)
5
Flow meter with impulse transmitter
6
Hycleen Des 30 Standard version
7
Venting into the open air
8
Dosing unit with shut-off valve and backflow preventer
9
Anolyte dosing pump
10
Drain outlet
11
Monitoring: e.g. monitoring the concentration of free chlorine or other drinking water
parameters (ORP, pH value, conductivity, or total chlorine content)
We recommend using a limescale sensor (for connection to the control unit see Chapter 8.4)
to protect the Hycleen Des 30 from hardness dips / malfunction of the water softening system
(3).
Shut-off valve (2), ion exchanger (3) and optional measuring unit for monitoring the
concentration of free chlorine (11) are not included. All other components, as well as
operating fluids, can be obtained from GF JRG, see Chapter 13.2 "Accessories required" on
page 73.

Design and function Operating instructions
6
5.2 Design versions
5.2.1 Hycleen Des 30 Standard version
1
Control cabinet with control panel
Controls
2
Process cabinet
4
Main switch I = ON / O = OFF
3
Cover (removable)
5
Production Start/Stop rotary switch
9
Storage tank 60 L Calzid-Ex
6
Illuminated push-button Operation
status
10
Storage tank 100 L Salisol
7
Illuminated push-button Reset
11
Storage tank 60 L Anolyte
8
Rotary selector switch ECA: Anolyte &
Catholyte / anolyte neutral

Operating instructions Design and function
7
5.2.2 Hycleen Des 30 Industrial version
Controls
1
Control cabinet with control panel
2
Main switch I = ON / O = OFF
7
Process cabinet
3
Production Start/Stop rotary switch
8
Storage tank 60 L Calzid-Ex
4
Illuminated push-button Operation
status
9
Storage tank 100 L Salisol
5
Illuminated push-button Reset
10
Storage tank 60 L Anolyte
6
Rotary selector switch ECA: Anolyte &
Catholyte / Anolyte neutral

Design and function Operating instructions
8
5.2.3 Hycleen Des 30 Mobile device
1
Control cabinet with control panel
Controls
7
Process cabinet
2
Main switch I = ON / O = OFF
8
Anolyte dosing pump
3
Production Start/Stop rotary switch
9
Casters
4
Illuminated push-button Operation
status
10
Storage tank 25 L Salisol
5
Illuminated push-button Reset
11
Storage tank 14 L Calzid-Ex
6
Rotary selector switch ECA: Anolyte &
Catholyte / Anolyte neutral
12
Storage tank 25 L Anolyte
1
2
3
4
5
6
7
8
9
10
11
12

Operating instructions Design and function
9
5.3 Structure
5.3.1 Control cabinet and process cabinet
A
Control cabinet
B
Process cabinet
1
Back of control panel
7
Reactor
2
Power supply unit, large
8
Valve block
3
Power supply unit, small
9
Static mixer
4
PLC
10
Manometer system pressure
5
Circuit breaker, relays, fuses, terminal
blocks
11
Pressure reducing valve
12
Solenoid valves
6
Cabinet fan
13
Dosing pump for Salisol & Calzid-Ex
14
Volume flow regulator valve
15
Flow meter
16
Solenoid valve V1 water
17
Solenoid valve V7 Salisol
1
2
3
4
5
6
10
7
8
9
11
12
13
14
15
16
17
A
B

Design and function Operating instructions
10
Bushings and connections
A
Control cabinet
B
Process cabinet (connections)
1
Water meter impulse transmitter
bushing
7
Softened water inlet
2
Salisol level sensor bushing
8
Salisol tank outlet
3
Anolyte level sensor bushing
9
Calzid-Ex inlet
4
Calzid-Ex level switch connection
10
Salisol inlet
5
Dosing pump bushing
11
Catholyte outlet
6
Power supply 230 VAC, 50 Hz bushing
12
Anolyte / Anolyte neutral outlet

Operating instructions Design and function
11
Installation diagram
1
Tap water
2
Softened water (<2 °dH) from the softening unit (ion exchanger)
3
Control cabinet
4
Process cabinet
5
Calzid-Ex tank
6
Salisol tank
7
Anolyte / Anolyte neutral tank
8
Dosing unit with shut-off valve and backflow preventer

Design and function Operating instructions
12
PLC connections
The Hycleen Des 30 is automatically controlled by the PLC. For this purpose, all sensors and
actuators are connected to the PLC. The display on the front panel of the PLC shows current
production information and fault messages.
A
Inputs (DC INPUT)
C
Control panel with display
B
Outputs (RELAY OUTPUT)
Inputs A
Outputs B
1
Production Start rotary switch
EO1
1 + 2
Potential-free contact for
fault indication (hardness
sensor or softening unit)
2
ECA rotary switch
EO2
1 + 2
General fault*
3
Illuminated push-button indicating
Operation status of descale
function
EO4
1 + 2
Salisol pump
OUT1
2
Solenoid valve V1
4
Illuminated push-button Reset
OUT2
2
Solenoid valve V2
5
Flow meter
OUT3
1
Solenoid valve V3
6
Analogue value reactor power
OUT4
1
Solenoid valve V4
7
Salisol level analogue value
OUT
5
Solenoid valve V5
8
Anolyte level analogue value
6
Solenoid valve V6
10
Potential-free contact
7
Solenoid valve V7
11
Calzid-Ex float switch
8
LED illuminated push-button
Operation status
12
Enable external connections
9
Electrolysis protection
* The EO2 signal is permanently off during proper operation. In case of malfunction, a group error contact is
signalled after 5 min. The signal is now open and can be detected by an external signalling device.

Operating instructions Design and function
13
5.3.2 Tanks for operating fluids
The tanks shown below are used in the standard and industrial versions; in the mobile version
smaller tanks will suffice.
A
Calzid-Ex tank
C
Anolyte tank
1
Calzid-Ex tank (60 L)
8
Anolyte tank (60 L)
2
Lid
9
Level sensor
3
Suction pipe
10
Lid
4
Run-dry float switch
11
Degassing pipe connection
12
Dosing pump connection
B
Salisol tank
13
Additional connection for a second
dosing pump
5
Salisol tank (100 L)
brine pipeline connection inside
6
Mains connection
14
Anolyte connection inlet
7
Level sensor
1
2
3
4
5
6
7
8
9
10
11
12
13
14
A
B
C