Lutz-Jesco C 7520 User manual

Dosing
Conveying
Control
Liquids
Gases
Systems
Original operating instructions
© Lutz-Jesco GmbH 2021
BA-22404-02-V03
Chlorine changeover unit
C 7520
Operating instructions
Read the operating manual!
The user is responsible for installation and operation related mistakes!
22700003_1
PL-Bild Elektrischer Chlorgasumschalter C 7520
für Überdrucksysteme

Table of Contents 3
© Lutz-Jesco GmbH 2021
Subject to technical changes.
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BA-22404-02-V03
Chlorine changeover unit C 7520 Operating instructions
Table of Contents
1 Notes for the Reader ..........................................................4
1.1 General non-discrimination......................................................4
1.2 Explanation of the signal words ................................................4
1.3 Explanation of the warning signs ..............................................4
1.4 Identification of warnings.........................................................4
1.5 Identification of action instructions ...........................................4
2 Safety .................................................................................5
2.1 General warnings.....................................................................5
2.2 Information about chlorine .......................................................5
2.3 Hazards due to non-compliance with the safety instructions .....5
2.4 Working in a safety-conscious manner .....................................6
2.5 Personal protective equipment.................................................6
2.6 Personnel qualification.............................................................6
2.7 Personnel tasks .......................................................................6
3 Intended use ......................................................................7
3.1 Notes on product warranty .......................................................7
3.2 Intended purpose.....................................................................7
3.3 Prohibited dosing media...........................................................7
4 Product description ...........................................................8
4.1 Scope of delivery .....................................................................8
4.2 Design and function .................................................................8
4.3 Rating plate .............................................................................9
5 Technical data..................................................................10
6 Dimensions ......................................................................11
7 Installation .......................................................................12
7.1 Installation location................................................................12
7.2 Installing the device ...............................................................12
7.3 Hydraulic installation..............................................................12
7.4 Electric installation.................................................................13
7.5 Completing the installation.....................................................16
7.6 Installation example...............................................................17
8 Control..............................................................................18
8.1 Controls.................................................................................18
8.2 Operating modes ...................................................................18
9 Commissioning ................................................................20
9.1 Inspecting the pressure system..............................................20
9.2 Turning on the device .............................................................21
9.3 Adjusting the switching contact..............................................21
10 Operation..........................................................................22
10.1 Tank change ........................................................................22
10.2 Shutting down in an emergency ...........................................22
10.3 Optical check.......................................................................22
11 Shutdown.........................................................................23
11.1 Short-term shutdown...........................................................23
11.2 Long-term shutdown ...........................................................23
11.3 Disposal of old equipment....................................................23
12 Maintenance ....................................................................24
12.1 Maintenance intervals..........................................................24
12.2 Maintenance accessories.....................................................24
12.3 Preparing the system for maintenance .................................24
12.4 Maintenance on the ball valve ..............................................24
12.5 Cleaning the pressure gauge................................................26
12.6 Functional control ................................................................27
12.7 Finishing maintenance.........................................................27
13 Troubleshooting ...............................................................28
14 Spare parts.......................................................................29
15 EU Declaration of Conformity...........................................30
16 Declaration of no objection..............................................31
17 Warranty claim.................................................................32
18 Index.................................................................................33

Notes for the Reader
4© Lutz-Jesco GmbH 2021
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Chlorine changeover unit C 7520 Operating instructions
1 Notes for the Reader
This operating manual contains information and behaviour rules for the
safe and designated operation of the device.
Observe the following principles:
nRead the entire operating manual prior to starting-up the device.
nEnsure that everyone who works with or on the device has read the
operating manual and follows it.
nMaintain the operating manual throughout the service life of the de-
vice.
nPass the operating manual on to any subsequent owner of the device.
1.1 General non-discrimination
In this operating manual, only the male gender is used where grammar
allows gender allocation. The purpose of this is to make the text easy to
read. Men and women are always referred to equally. We would like to
ask female readers for understanding of this text simplification.
1.2 Explanation of the signal words
Different signal words in combination with warning signs are used in this
operating manual. Signal words illustrate the gravity of possible injuries if
the risk is ignored:
Signal word Meaning
DANGER Refers to imminent danger. Ignoring this sign
may lead to death or the most serious injuries.
WARNING! Refers to a potentially hazardous situation.
Failure to follow this instruction may lead to
death or severe injuries.
CAUTION! Refers to a potentially hazardous situation.
Failure to follow this instruction may lead to
minor injury or damage to property.
PLEASE NOTE Refers to a danger which, if ignored, may lead to
risk to the machine and its function.
Tab. 1: Explanation of the signal words
1.3 Explanation of the warning signs
Warning signs represent the type and source of a danger:
Warning sign Type of danger
Danger to life from chlorine poisoning
Danger to life due to electric shock
General danger zone
Danger of damage to machine or functional
influences
Tab. 2: Explanation of the warning signs
1.4 Identification of warnings
Warnings are intended to help you recognise risks and avoid negative
consequences.
This is how warnings are identified:
Warning sign SIGNAL WORD
Description of danger
Consequences if ignored
ðThe arrow signals a safety precaution to be taken to eliminate the
danger.
1.5 Identification of action instructions
This is how pre-conditions for action are identified:
üPre-condition for action which must be met before taking action.
@A resource such as a tool or auxiliary materials required to perform
the operating instructions.
This is how instructions for action are identified:
èSeparate step with no follow-up action.
1. First step in a series of steps.
2. Second step in a series of steps.
4Result of the above action.
üAction completed, aim achieved.

Safety 5
© Lutz-Jesco GmbH 2021
Subject to technical changes.
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Chlorine changeover unit C 7520 Operating instructions
2 Safety
2.1 General warnings
The following warnings are intended to help you eliminate the dangers
that can arise while handling the device. Risk prevention measures al-
ways apply regardless of any specific action.
Safety instructions warning against risks arising from specific activities
or situations can be found in the respective sub-chapters.
DANGER
Danger to life from chlorine poisoning!
Chlorine is poisonous. In severe cases, breathing in chlorine may lead
to death. It irritates the eyes, the respiratory system and the skin.
ðUse sufficient personal protective equipment.
ðWhen carrying out any work on the system, use a respirator mask
with a Type B gas filter that complies with EN 14387.
ðAlways comply with the accident prevention regulations that apply
at the place of use.
ðGet rid of leaks without delay. You must get rid of even very minor
leaks without delay. Together with the humidity, chlorine forms hy-
drochloric acid and corrosion results in rapidly increasing leakage.
ðUse only chlorine-resistant seals.
ðOnly use seals once. Reusing them leads to leaks.
DANGER
Danger to life from missing safety device.
Chlorinators without gas warning devices are an increased safety risk,
since it is not possible to detect escaping chlorine gas in good time or
at all.
ðInstall a gas warning device.
WARNING!
Increased risk of accidents due to insufficient qualifica-
tion of personnel!
Chlorinators and their accessories must only be installed, operated and
maintained by personnel with sufficient qualifications. Insufficient qual-
ification will increase the risk of accidents.
ðEnsure that all action is taken only by personnel with sufficient and
corresponding qualifications.
ðPrevent access to the system for unauthorised persons.
PLEASE NOTE
Damage to the plant due to the formation of hydrochloric
acid
Chlorine gas is highly hygroscopic.This means that humidity enters the
system at any open connection on devices or pipes, which results in the
formation of hydrochloric acid and contamination. thus inevitably caus-
ing damage to the units.
ðKeep all connections (including in the vacuum system and on all
devices not currently in use) closed at all times.
2.2 Information about chlorine
Chlorine is a hazardous substance. The chemical element chlorine is a
greenish-yellow, toxic gas with a pungent odour, which can be detected
in the air at concentrations below 1 ppm (= 1 ml/m³).
Chlorine is 2.7 times heavier than air and accumulates at ground level.
Chlorine is extremely toxic for water organisms. The reason for the toxici-
ty of chlorine is its extraordinary reactivity. It reacts with animal and veg-
etable tissue and thus destroys it.
Air with a chlorine gas content of 0.5 – 1% leads to a quick death in
mammals and humans, as it attacks the respiratory tract and the pulmo-
nary alveolus (formation of hydrogen chloride or hydrochloride acid).
PLEASE NOTE
Faults due to insufficient chlorine quality
Impurities in the chlorine gas form deposits in devices and valves and
can attack the components chemically. This can lead to malfunctions.
ðOnly use technically pure chlorine that meets the following require-
ments:
- Mass content of chlorine at least 99.5%
- Water content max. 20 mg/kg
Chlorine that complies with EN 937 meets these requirements.
2.3 Hazards due to non-compliance with the safety
instructions
Failure to follow the safety instructions may endanger not only persons,
but also the environment and the device.
The specific consequences can be:
nFailure of important functions of the device and of the corresponding
system
nFailure of required maintenance and repair methods
nDanger to persons
nDanger to the environment caused by substances leaking from the
system

Safety
6© Lutz-Jesco GmbH 2021
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Chlorine changeover unit C 7520 Operating instructions
2.4 Working in a safety-conscious manner
Besides the safety instructions specified in this operating manual, further
safety rules apply and must be followed:
nAccident prevention regulations
nSafety and operating provisions
nSafety regulations on handling hazardous substances
nEnvironmental protection provisions
nApplicable standards and legislation
2.5 Personal protective equipment
Based on the degree of risk posed by the dosing medium and the type of
work you are carrying out, you must use corresponding protective equip-
ment. Read the Accident Prevention Regulations and the Safety Data
Sheets to the dosing media find out what protective equipment you need.
You will require the minimum of the following personal protective equip-
ment:
Personal protective equipment required
Respirator mask
Protective clothing
Safety shoes
Protective gloves
Tab. 3: Personal protective equipment required
Wear the following personal protective equipment when performing the
following tasks:
nCommissioning
nAll work on gas-bearing sections of the plant
nChanging the chlorine tank
nShut-down
nMaintenance work
nDisposal
2.6 Personnel qualification
Any personnel who work on the device must have appropriate special
knowledge and skills.
Anybody who works on the device must meet the conditions below:
nAttendance at all the training courses offered by the owner
nSufficient qualification for the respective activity
nTraining in how to handle the device
nKnowledge of safety equipment and the way this equipment functions
nFamiliar with this operating manual
nKnowledge of fundamental regulations regarding health and safety
and accident prevention
All persons must generally have the following minimum qualification:
nTraining as specialists to carry out work on the device unsupervised
nSufficient training that they can work on the device under the supervi-
sion and guidance of a trained specialist
These operating instructions differentiate between these user groups:
2.6.1 Specialist staff
Thanks to their professional training, knowledge, experience and knowl-
edge of the relevant specifications, specialist staff are able to perform the
job allocated to them and recognise and/or eliminate any possible dan-
gers by themselves.
2.6.2 Trained electricians
Due to their professional training, knowledge and experience as well as
knowledge of specific standards and provisions, trained electricians are
able to do the electrical work assigned to them and to recognise and
avoid any potential dangers by themselves.
They are specially trained for their specific working environment and are
familiar with relevant standards and provisions.
They must comply with the legally binding regulations on accident pre-
vention.
2.6.3 Trained persons
Trained persons have received training from the operator about the tasks
they are to perform and about the dangers stemming from improper be-
haviour.
Trained persons have attended all trainings offered by the operator.
2.7 Personnel tasks
In the table below, you can check what personnel qualifications are re-
quired for the respective tasks. Only people with appropriate qualifica-
tions are allowed to perform these tasks!
Qualification Activities
Specialist staff nTransportation
nAssembly
nHydraulic installations
nCommissioning
nTaking out of operation
nFault rectification
nMaintenance
nRepairs
nDisposal
Trained electricians nElectrical installation
nRectifying electrical faults
nElectrical repairs
Trained persons nStorage
nControl
Tab. 4: Personnel qualification

Intended use 7
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Chlorine changeover unit C 7520 Operating instructions
3 Intended use
3.1 Notes on product warranty
Any non-designated use of the device can impair its function and the pro-
tection provided. This leads to invalidation of any warranty claims!
Please note that liability is on the side of the user in the following cases:
nthe device is operated in a manner which is not consistent with these
operating instructions, particularly safety instructions, handling in-
structions and the section "Intended Use".
nInformation on usage and environment (see section 5 „Technical
data“ on page 10) is not adhered to.
nIf people operate the device who are not adequately qualified to carry
out their respective activities.
nNo original spare parts or accessories of Lutz-Jesco GmbH are used.
nUnauthorised changes are made to the device.
nThe user uses different dosing media than those indicated in the or-
der.
nMaintenance and inspection intervals are not adhered to as required
or not adhered to at all.
nThe device is commissioned before it or the corresponding system
has been correctly and completely installed.
nSafety equipment has been bridged, removed or made inoperative in
any other way.
3.2 Intended purpose
The C 7520 changeover unit is intended for chlorine gas dosing systems
only. It serves to switch between two positive pressure supply batteries.
It may only be used with technically pure chlorine with a minimum mass
content of 99.5 %
3.3 Prohibited dosing media
The device must not be used for the following media and substances:
nAll media apart from chlorine
nNot technically pure chlorine with a mass content of less than 99.5 %

Product description
8© Lutz-Jesco GmbH 2021
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Chlorine changeover unit C 7520 Operating instructions
4 Product description
4.1 Scope of delivery
The chlorine gas changeover unit C 7520 is delivered either as a ready-
to-connect unit with a mounting plate or an assembly kit for integration in
the pipe line.
Please compare the delivery note with the scope of delivery. The follow-
ing items are part of the scope of delivery:
Plate-mounted changeover unit
n2x motor ball valves
nContact pressure gauge
nControl with fitted cables (2 m)
n1.5 m power cord with Europlug
nInstallation material for wall fixing
nPlastic wall panel
nOperating instructions
Assembly kit
n2x motor ball valves
nChlorine gas changeover unit installation kit (pipework with contact
pressure gauge)
nControl with fitted cables (2 m)
n1.5 m power cord with Europlug
nInstallation material for wall fixing
nOperating instructions
C 7520 with 5 service valves
nWelded piping system with 2 motor ball valves and a contact pressure
gauge
nControl with fitted cables (2 m)
n1.5 m power cord with Europlug
nInstallation material for wall fixing
nOperating instructions
4.2 Design and function
Chlorine gas dosing systems in a water treatment system must be per-
manently ready for operation so that the water can be disinfected at any
point. This explains the fitting of the systems with two supply batteries -
one side in operation, the other on stand-by. The electrical chlorine
changeover unit, type C 7520, ensures the automatic changeover be-
tween both batteries (cylinder or drum batteries). The chlorine can either
be liquid or gaseous.
22700003_1
PL-Bild Elektrischer Chlorgasumschalter C 7520
für Überdrucksysteme
1
2
3
Fig. 1: Structure of the device
The control (1) of the C 7520 employs the contact pressure gauge (2) in
order to detect when the power supply from the operating battery comes
to an end, in which case the control activates the motor ball valves (3).
The battery, which has been in use up to that point in time and has now
become discharged, is disconnected and the standby battery is connect-
ed.
The control signals the operating state with coloured LEDs in the flow
chart (see section 8 „Control“ on page 18). The most important operat-
ing signals are available for remote indication via relay contact if re-
quired. Manual changeover can be triggered by the push of a button. Me-
chanical changeover by hand is possible given a power outage. The
residue discharge function can be activated on the control. This function
resets at periodic intervals to the battery registered as empty following
the changeover. In this way, any remaining residue is used from the chlo-
rine cylinder, but the cylinder cannot permanently cover the chlorine re-
quirements alone.
The C 7520 is available in one version, in a welded pipe system with 5
service valves integrated. This variant allows the chlorinator to be operat-
ed even during maintenance of the changeover unit.

Product description 9
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Chlorine changeover unit C 7520 Operating instructions
4.3 Rating plate
The rating plate contains information on the safety and functional method
of the product. The rating plate must be kept legible for the duration of the
service life of the product.
Material:
100-240 V, 1~, 50/60 Hz
PN 16 DN 25
S/N:
P/N:
Made in Germany
*12345678012345*
C 7520
Lutz-Jesco GmbH 30900 Wedemark
Am Bostelberge 19 Germany
*102A12345678*
1
3
8
7
6
5
2
4
Fig. 2: Rating plate C 7520
No. Description
1Product name
2Part number
3Components coming into contact with the media
4Voltage supply and frequency
5Pressure class and nominal width
6Label showing conformity with applicable European directives
7Serial number
8Month/year of manufacture
Tab. 5: Rating plate

Technical data
10 © Lutz-Jesco GmbH 2021
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Chlorine changeover unit C 7520 Operating instructions
5 Technical data
Description Value
Throughput
Chlorine gas kg/h up to 200
Fluid chlorine kg/h up to 1400
Connections depending on the
version
of the device.
Threaded connection 1" NPT male
Flange connection
Flange DN25 / PN40 with key and slot according to EN1092
Inputs: Groove flange (Form D)
Output: Tongue flange (Form C)
Voltage supply V AC 100 – 240
Power consumption
In standby W 5
During changeover Wmax. 100
Material in contact with the media steel, Monel, stainless steel, PTFE, silver
Pressure gauge
Measuring range bar 0 – 16 (vacuum resistant)
Accuracy % ±2.5
Nominal size mm Ø63
Load capacity of the relay contacts max. 3 A/250 V AC
Switching time smax. 25
Operating pressure bar 0 – 16
Protection class IP65
Permissible ambient temperature °C 0 – 60
Weight with mounting plate kg 17 approx.
Weight with 5 service valves kg 35 approx.
Tab. 6: Technical data

Dimensions 11
© Lutz-Jesco GmbH 2021
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Chlorine changeover unit C 7520 Operating instructions
6 Dimensions
All dimensions in mm
600
600
1" NPT
~600
300
550
309
Ø7
1" NPT
255
550
1" NPT
~242
Fig. 3: Dimensioned drawing C 7520 on mounting plate
848
388
462
A
B
B
A
Fig. 4: Dimensioned drawing C 7520 with service valves
Version Input ØA Output ØB
Panel-mounted 1" NPT
With service valves flange DN25/PN40
with groove
flange DN25/PN40
with a spring
Tab. 7: Technical data

Installation
12 © Lutz-Jesco GmbH 2021
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Chlorine changeover unit C 7520 Operating instructions
7 Installation
PLEASE NOTE
Damage to the system due to incorrect installation
The failure to observe installation instructions (e.g. use of unsuitable
tools, incorrect torque) can damage the system parts.
ðUse suitable tools.
ðNote the specified torque.
7.1 Installation location
The changeover unit is fitted in the room of the chlorine supply.
The room must fulfil the following requirements:
nSecured against access by unauthorised persons
nProtected against weather conditions
nFrost-free
nPermissible ambient temperature adhered to (see Section 5 "Techni-
cal data" on page 10)
nRoom of sufficient size to allow trouble-free assembly as well as in-
spection and maintenance of the device at all times
nPower supply available
nRoom must comply with the locally valid prescriptions
7.2 Installing the device
i
This section applies to devices with a mounting plate. Devices
without a mounting plate are supported by the pipe line. The
pipe line requires adequate support.
Fit the device on an easily-accessible, vertical wall surface. The control
should be mounted at roughly at eye-level.
Precondition for action:
üA flat wall
üThe mounting material is suitable for the wall.
Resources required:
@Water level
@Drill
@2 open-end spanners SW10
Perform the following working steps:
1. Hold the device against the wall and align it horizontally.
2. Mark the mounting point on the wall.
3. Drill in the marked holes and insert the rawlplug.
4. Place a washer on each screw.
5. Screw the screws through the mounting plate into the anchors until
the mounting plate is flush with the wall.
6. Tighten the screws.
üThe device is fitted on the wall.
7.3 Hydraulic installation
You can use the following connection types:
nFixed piping with NPT thread
nFixed piping with flange connection
All connection types are suitable for gaseous chlorine and liquid chlorine.
The maximum flow rate of the device is stated in section 5 „Technical
data“ on page 10. It has been calculated for the entire piping system:
from the chlorine drum to the vacuum regulator. The calculation was per-
formed with the usual pipe lengths:
Where required, a large distance can be bridged with pipes of a higher
nominal width. A pipe line with a connection nominal width is only used
for shorter sections shortly before and after the device.
7.3.1 Creating the threaded connection
PLEASE NOTE
Leakage due to incorrect installation
In order to provide safe and long-term effective sealing,the thread seal-
ant must form an even layer. Errors during installation can result in the
thread sealant losing its sealant properties (uneven application or air
bubbles) which will result in leakages.
ðOnly turn the thread clockwise and never in two directions.This can
result in air bubble formation.
ðIf the orientation needs to be corrected after the connection has
been tightened, repeat steps 1 – 5.
DANGER
Leakage due to incorrect sealant.
Pipe connections and fittings in pressurized lines must be sealed with
chlorine-resistant substances. Unsuitable sealants react with the chlo-
rine and lead to leakages.
ðUse only sealants that are resistant in contact with chlorine (e.g.
anaerobic sealants).
Precondition for action:
üThe inside of the line is clean and dry.
üThe threads are metallic bright.
üThe pipe line is fixed with pipe clamps and meets the connection in
an voltage-free state.

Installation 13
© Lutz-Jesco GmbH 2021
Subject to technical changes.
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Chlorine changeover unit C 7520 Operating instructions
Resources required:
@Grease-dissolving cleaner
@Liquid thread sealant
Perform the following working steps:
1. Clean the thread with a fat-dissolving cleaning agent, e.g. alcohol.
2. Allow the thread to dry completely.
3. Apply the thread sealant to the external thread in a circular motion to
the start of the thread. Leave the first thread clear. Apply the thread
sealant all the way down to the root of the thread to thoroughly
grease the thread flank.
Fig. 5: Seal in the thread
4. Insert the threaded pin into the internal thread and apply a little
thread sealant to the internal thread. Screw the parts by hand.
5. Use a tool to tighten the connection. The necessary tightening torque
depends on the thread size. For a 1" NPT pipe thread, the tightening
torque is up to 150 Nm.
6. Remove excess thread sealant with a cloth.
7. Allow the bond to harden for at least 12 hours prior to the leak test.
üThe threaded connection is now complete.
7.3.2 Creating the flange connection
Fig. 6: Installing the flange connection
Precondition for action:
üThe inside of the line is clean and dry.
üThe sealing surfaces are free of contamination and damage.
üSeals must be clean, undamaged and dry.
üBolts, nuts and washers are clean and undamaged.
i
Any bolts, nuts and washers that are removed during
assembly work must be replaced with new ones if they are
damaged. Install only new screws, nuts and washers.
Resources required:
@Torque wrench AF 19 (10 – 25 Nm)
1. Lubricate the sliding faces and thread of bolts, nuts and washers e.g.
using fitting grease or PTFE grease.
2. Place the flat gasket (2) into the groove of the connection flange (3).
Assemble the seal in dry condition.
3. Mount the tongue flange (1). Make sure that the flat gasket (2) does
not slip.
4. Fit the bolts (7), washers (6, 5) and nuts (4) by hand.
5. Tighten the bolts evenly alternately crosswise in three stages: 10 Nm,
18 Nm, 25 Nm.
6. Retighten all the bolts to the full target tightening torque (25 Nm).
7. Setting the seal (adapting to the flange seal surface) can make it nec-
essary to retighten the bolts. For this reason, retighten the bolts to 25
Nm after a few hours.
üFlange connection assembled
7.4 Electric installation
DANGER
Mortal danger from electric shock!
Improperly installed or damaged components in the electronics instal-
lation can cause injury.
ðEnsure that all work on the electrical installation is performed by a
qualified electrician.
ðEnsure that all work on the electrical installation is performed in a
de-energised state.
ðEnsure that the power supply is secured with a fault current protec-
tive circuit.
ðReplace damaged cables or components without delay.
Open the control housing
Resources required:
@Flat-bladed screwdriver, size 3
Perform the following working steps:
1. Hold the screwdriver in the right-hand clearance on the front of the
housing.
2. Move the screwdriver grip towards the lid of the housing until the
hinge part disconnects from the adjustment lock.
3. Pivot the housing lid to the left.
üHousing opened.
1
4 5 6 7
2 3

Installation
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Chlorine changeover unit C 7520 Operating instructions
Close the control housing
Perform the following working steps:
1. Pivot the housing lid towards the housing floor.
2. Pivot the hinge part towards the lid until it snaps in audibly.
3. Press against the hinge part with your hand until it locks audibly in
place.
üHousing closed.
i
The changeover unit is ready for operation immediately after
connection of the supply voltage. The motors need only be
connected with devices without a mounting plate. The plugs
are already fitted to the cable and marked as follows:
No. 1: Left valve
No. 2: Right valve
i
Where required, the relay contacts for remote indication of the
operating state can be connected. The assignment and
function of the individual terminals can be taken from the
terminal connection plan.

Installation 15
© Lutz-Jesco GmbH 2021
Subject to technical changes.
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Chlorine changeover unit C 7520 Operating instructions
7.4.1 Terminal plan
Processor
LED
vacuum JP5
JP3
LED
pressure
110
9876
5
4
32 19
18
17
16
151312
11 21
20
14 30
29
28
27
26
25
24
23
22
JP2
JP4
Fig. 7: Control circuit board
Terminal Description Function
1+2 N
Voltage supply input3+4 L
5+6 PE
7 PE
Voltage supply for motor 2
(ball valve right)
8 N
9 Close
10 Open
11 PE
Voltage supply for motor 1
(ball valve left)
12 N
13 Close
14 Open
15 Com Relay output "alarm"
max. 3 A/250 VAC
NC (15– 17 closed with power failure)
16 Off
17 On
18 Com Relay output "empty"
max. 3 A / 250 VAC
NC (18– 20 closed with power failure)
19 Off
20 On
21 close
Position switch in motor 2
(ball valve right)
22 open
23 GND
24 close
Position switch in motor 1
(ball valve left)
25 open
26 GND
27 GasW. Gas warning device input
closed = alarm
28 GND
Tab. 8: Terminal connection
Terminal Description Function
29 Mano. Contact pressure gauge switch
closed = chlorine shortage
30 GND
Tab. 8: Terminal connection
7.4.2 Jumper settings
The jumpers were set voltage-free The change becomes active once the
voltage supply has been switched on.
Jumper Name Position Function
JP1 almost closed Both motors activate at the
same time.
open (state of
delivery)
The reserve battery valve opens
only after the valve of the active
battery has closed.
JP3 Pressure closed (state of
delivery)
The software of the C 7520 is
activated. JP1 and JP5 must be
open.
open The software of the C 7522 is
activated.
JP 5 Rest
evacua-
tion
closed Residual emptying activated
open (state of
delivery) Residual emptying deactivated
Tab. 9: Jumper settings
JP1 (open) JP3 (closed) JP5 (open)
Tab. 10: Mating diagram jumper
JP1

Installation
16 © Lutz-Jesco GmbH 2021
BA-22404-02-V03
Chlorine changeover unit C 7520 Operating instructions
In its delivery state, the motor of the ball valve is connected in accordance
with the following plan.
1
2
3
1
3
2
11 13
14
12
12
3
PE
1
3
2
242526
12
3
1
3
2
79
10
8
12
3
PE
1
3
2
21
22
23
12
3
Motor 1 (left) Motor 2 (right)
Fig. 8: Motor connection
Position Description
1Control circuit board
2Large Stretcher on the Engines
3Small stretcher on the Engines
Tab. 11: Motor connection
7.5 Completing the installation
Perform the following working steps:
1. Tighten all cable screw connections to guarantee the IP protection
class of the installation.
2. Check all connections for leak-tightness (see section 9 „Commis-
sioning“ on page 20).
3. Touch up damaged paint.
i
All exposed bright metal surfaces must be painted as the
atmosphere in chlorine gas rooms is highly corrosive. A
suitable paint is e.g. 2-Component epoxy resin lacquer
RAL1003 (yellow). Paint must only be applied after a
successful leak test has been completed.
üInstallation completed.

Installation 17
© Lutz-Jesco GmbH 2021
Subject to technical changes.
210527
BA-22404-02-V03
Chlorine changeover unit C 7520 Operating instructions
7.6 Installation example
Fig. 9:
M
Installation example
A B
12
2
13
4
11
13
10
14
9
5 6
7
8
Position Description Position Description
ARoom for the chlorine gas supply 7Vacuum regulator
BDosing device room 8Moisture eliminator with heating collar
1Pressurized manifold 9Entrance port of the chlorine eliminator
2Chlorine barrel 10 Horn
3Changeover unit with 5 service valves 11 Dosing device
4Chlorine barrel scale 12 Gas warning device
5Chlorine gas filter 13 Injector with non-return valve
6Pressure reducing valve 14 Motive water pump
Tab. 12: Designation of components

Control
18 © Lutz-Jesco GmbH 2021
BA-22404-02-V03
Chlorine changeover unit C 7520 Operating instructions
8 Control
8.1 Controls
8.1.1 Operator controls of the control unit
All operating states are displayed on the control.
4
2
BA
1
C3
Fig. 10: Control elements
No. Type Function
1 LED green: Cylinder filled
red: Cylinder empty
2 LED
3LED green: Valve open
yellow: Motor works
red: Valve closed
4LED
A Key 1. notify full cylinder
4LED switches to green
2. switch manually
BKey
C Key Close both valves.
Tab. 13: Functions of the controls
8.1.2 Motor operating elements
88813_2
Hauptansicht Elektroschwenkantrieb Typ J2 H10
1
2
4
3
Fig. 11: Motor operating elements
Position Description Meaning
1Hand lever Manual operation, if the selector
lever (5) is set to MAN
2Plug large Voltage supply
3Plug small Position switch
4Selector lever
MAN Manual operation
AUTO Automatic operation
Tab. 14: Motor operating elements
8.2 Operating modes
8.2.1 Automatic operation
The selector switch on the engine is in the "Auto" position.
Automatic battery changeover
The changeover switch reacts to the switching status of the manometer.
Should a chlorine supply battery run empty, the pressure in the system
will fall and the contact pressure gauge will issue an electrical contact.
The control changes the motor ball valves and ensures supply from the
other supply battery.
nOn the control board, the relay "empty" drops out and a remote indi-
cation of the empty supply battery occurs.
nThe empty supply battery is indicated by a red LED in the cylinder
symbol. Until the operating pressure is normalised, the LED in the cyl-
inder symbol of the full battery flashes green.
nAfter connecting full chlorine tank, the operator presses the key in the
cylinder symbol, the LED switches from red to green and the device
can switch back to this side if required.
Manual battery changeover
The button in the cylinder symbol of the inactive supply battery has been
pressed.
nThere is a manual changeover to the previously inactive supply bat-
tery.

Control 19
© Lutz-Jesco GmbH 2021
Subject to technical changes.
210527
BA-22404-02-V03
Chlorine changeover unit C 7520 Operating instructions
Manual stop
The C button in the centre of the control unit was pressed
nClose both motor ball valves.
nBoth arrow LEDs light up red.
nBoth bottle LEDs light up unchanged.
8.2.2 Manual operation
üThe selector switch on the engine is in the "Man" position.
The ball valve on the hand lever of the motor is activated in manual oper-
ation. The motor no longer follows the signals of the control.
nAll LEDs flash red.
nRemote signalling of an empty supply battery is not possible.
8.2.3 Special operating states
All Empty
Both supply batteries are empty or the pressure gauge does not give a
contact.
nBoth bottle LEDs light up red.
nArrow LED on the side of the open motor ball valve lights up green.
nArrow LED on the side of the closed motor ball valve lights up green.
nThe relay "empty" drops out.
nThe relay "alarm" drops out.
Gas alarm
If the relay contact of a gas warning device is connected to terminal
27/28, both motor ball valves close in the event of a gas alarm.
nAll LEDs flash red.
nThe relay "alarm" drops out.
Fault
The motor is in the "Man" position, the end positions in the motor are ad-
justed or there is no electrical connection between the motor and the
control device.
nAll LEDs flash red.
nThe relay "alarm" drops out.
Jumper error
The jumpers on the circuit board of the control were set to an impermis-
sible combination.
nAll LEDs flash red in a clockwise directio

Commissioning
20 © Lutz-Jesco GmbH 2021
BA-22404-02-V03
Chlorine changeover unit C 7520 Operating instructions
9 Commissioning
9.1 Inspecting the pressure system
Check the pressure system of the chlorine tank for leaks up to the vacu-
um regulator in two stages:
1. Leakage test with nitrogen
2. Leakage test with chlorine
9.1.1 Performing the leakage test with nitrogen
i
You are strongly recommended to carry out this inspection
before carrying out the leak test with chlorine, since it shows
leaks in the pressure system without the risk of chlorine
escaping. As an alternative, you can carry out the inspection
using dry compressed air.
Precondition for action:
üAll the open connections of the pressure system were closed correct-
ly.
üAll the shut-off valves in the pipe system were opened.
Resources required:
@Nitrogen cylinder with pressure-relief valve (e.g. 0 – 25 bar)
@Leak detection spray
Perform the following working steps:
1. Connect the nitrogen cylinder to the left-hand collecting pipe.
2. Interrupt the voltage supply of the changeover unit.
i
If the voltage supply is activated, the behaviour of the control
can be distracting during the inspection.
3. Switch the selection lever on the motor of the changeover unit to
MAN (= manual operation)
4. Turn the hand lever on the engine until the left supply battery is con-
nected.
5. Slowly raise the system pressure at the nitrogen cylinder's pressure
reducer to 10 bar.
6. Close the nitrogen cylinder's valve.
7. Spray all the locations of a potential leakage with leak detection
spray.
4Bubbles will appear at leak locations.
8. Close the outlet on the nitrogen cylinder's pressure reducer and ob-
serve the pressure gauge in the installation.
4The pressure must not drop within one hour.
9. Repeat steps 1 to 9 for the right-hand supply side.
üLeak test with nitrogen carried out.
Leaks found:
Repair the leak. Allow any adhesive surfaces to harden sufficiently and
repeat the leak test.
i
Given a leakage on the control rod of the ball valve, the control
rod seal can be tightened. See section 12.4.4 „Fit new seals“
on page 26.
9.1.2 Carrying out the leak test with chlorine gas
DANGER
Danger to life from chlorine gas!
If you start the leakage test with chlorine gas before the entire system
has been installed and the injectors are ready for operation, the chlorine
gas cannot be extracted from the piping system in the case of a leakage.
ðMake sure that all the components in the plant are installed correct-
ly and the injectors are ready for operation.
ðPut on protective clothing before carrying out the leak test with chlo-
rine gas.
Precondition for action:
üThe leak test with nitrogen has been carried out successfully.
üAll the open connections of the pressure system were closed correct-
ly.
üAll shutoff valves in the piping system have been closed.
üA chlorine tank (gaseous) is connected to every collecting pipe.
üThe injector is ready for operation.
Resources required:
@Cylinder with ammonia solution
Perform the following working steps:
1. Interrupt the voltage supply of the changeover unit.
i
If the voltage supply is activated, the behaviour of the control
can be distracting during the inspection.
2. Switch the selection lever on the motor of the changeover unit to
MAN (= manual operation)
3. Turn the hand lever on the engine until the left supply battery is con-
nected.
4. Briefly open the chlorine container valve and close it again.
5. Open the first valve in the pipe line, starting from the chlorine tank.
6. Carry out the ammonia test at the pipeline section up to the first
closed valve: Hold an open bottle containing the ammonia solution
close to the pipe and make slight pumping motions with the plastic
bottle. Ammonia steam forms a white vapour and makes even very
small leaks visible.