Lutz-Jesco C 2526 User manual

Dosing
Conveying
Control
Liquids
Gases
Systems
Original operating instructions
© Lutz-Jesco GmbH 2016
BA-20901-02-V01
Chlorinator
C 2526
Operating instructions
Read the operating manual!
The user is responsible for installation and operation related
mistakes!

Table of Contents 3
© Lutz-Jesco GmbH 2016
Subject to technical changes.
160520
BA-20901-02-V01
Chlorinator C 2526 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 Instruction for action identification ...........................................5
2 Safety .................................................................................6
2.1 General warnings.....................................................................6
2.2 Information about chlorine .......................................................6
2.3 Hazards due to non-compliance with the safety instructions .....7
2.4 Working in a safety-conscious manner .....................................7
2.5 Personal protective equipment.................................................7
2.6 Personnel qualification.............................................................7
3 Intended use ......................................................................9
3.1 Notes on product warranty .......................................................9
3.2 Intended purpose.....................................................................9
3.3 Prohibited dosing media...........................................................9
4 Product description .........................................................10
4.1 Scope of delivery ...................................................................10
4.2 Design and function ...............................................................10
4.3 Rating plate ...........................................................................12
5 Technical data..................................................................13
6 Dimensions ......................................................................14
7 Installation .......................................................................15
7.1 Installation location................................................................15
7.2 Installing the device ...............................................................16
7.3 Hydraulic installation..............................................................17
7.4 Electric installation.................................................................19
7.5 Completing the installation.....................................................20
7.6 Installation example...............................................................20
8 Control.............................................................................21
8.1 Controls.................................................................................21
8.2 Manual operation...................................................................21
8.3 Automatic operation...............................................................21
9 Start-up............................................................................22
9.1 Checking the vacuum system.................................................22
9.2 Turning on the device .............................................................22
9.3 Adapting the power output .....................................................22
10 Operation..........................................................................23
10.1 Setting the dosing quantity...................................................23
10.2 Shutting down in an emergency ...........................................23
10.3 Test intervals .......................................................................23
11 Shutdown.........................................................................24
11.1 Short-term shutdown...........................................................24
11.2 Long-term shutdown ...........................................................24
11.3 Disposal of old equipment....................................................24
12 Maintenance ....................................................................25
12.1 Maintenance intervals..........................................................25
12.2 Maintenance accessories.....................................................25
12.3 Preparing the system for maintenance .................................25
12.4 Minor maintenance:.............................................................25
12.5 Maintenance on the flow meter ............................................26
12.6 Maintenance on the electrical regulation valve......................27
12.7 Maintenance of the back-pressure regulator ........................27
12.8 Cleaning the vacuum meter..................................................28
12.9 Functional control ................................................................29
12.10 Finishing maintenance.......................................................29
13 Troubleshooting ...............................................................30
14 Spare parts.......................................................................32
14.1 Housing SL ..........................................................................32
14.2 Flow meter ..........................................................................33
14.3 Module overview SL.............................................................34
14.4 Overview of modules WL......................................................36
14.5 Back-pressure regulator ......................................................38
14.6 Vacuum meter SL / WL .........................................................40
14.7 Maintenance sets ................................................................41
15 EC Declaration of Conformity...........................................42
16 Declaration of no objection..............................................43
17 Warranty Application .......................................................44
18 Index.................................................................................45

Notes for the Reader
General non-discrimination
4© Lutz-Jesco GmbH 2016
BA-20901-02-V01
Chlorinator C 2526 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 instructions prior to inaugurating 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
device.
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.
Note Refers to a danger which, if ignored, may lead to
risk to the machine and its function.
Table 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 point
Danger from electrical voltage
Danger from poisonous substances
Danger from potentially-explosive substances
Danger from automatic startup
Danger from corrosive substances
Danger of damage to machine or functional
influences
Table 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.

Notes for the Reader
Instruction for action identification 5
© Lutz-Jesco GmbH 2016
Subject to technical changes.
160520
BA-20901-02-V01
Chlorinator C 2526 Operating instructions
1.5 Instruction for action identification
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
General warnings
6© Lutz-Jesco GmbH 2016
BA-20901-02-V01
Chlorinator C 2526 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
always 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Install a gas warning device.
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
hydrochloric 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!
Increased danger to life from chlorine escape
A fatal quantity of chlorine gas can be released from a leakage.
ðIf chlorine escapes, leave the room immediately.
ðUse sufficient personal protective equipment.
ðIf chlorine gas escapes, wear a Type 2 self-contained breathing
apparatus that complies with EN 137.
ðOnly initiate counter measures after putting on the protective
equipment.
ðGiven a serious escape and insufficient equipment or qualifica-
tions, leave the work to professional emergency services
personnel. Do not take any unnecessary risks.
DANGER!
Danger to life through explosions!
When using dosing devices without ATEX certification in a potentially
explosive area, explosions can occur that result in fatal injuries.
ðNever use the device in potentially explosive areas.
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
qualification 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.
Note
Damage to the system due to corrosion
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 causing 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.
ðAfter maintenance work is complete, remove all water residues
from the system before placing it into operation.
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 2.5 times heavier than air and accumulates at ground level.
Chlorine is extremely toxic for water organisms. The reason for the
toxicity of chlorine is its extraordinary reactivity. It reacts with animal and
vegetable 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
pulmonary alveolus (formation of hydrogen chloride or hydrochloride
acid).
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
requirements:
- Mass content of chlorine at least 99.5%
- Water content max. 20 mg/kg
Chlorine that complies with EN 937 meets these requirements

Safety
Hazards due to non-compliance with the safety instructions 7
© Lutz-Jesco GmbH 2016
Subject to technical changes.
160520
BA-20901-02-V01
Chlorinator C 2526 Operating instructions
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.
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
equipment. 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
equipment:
Personal protective equipment required
Respirator mask
Protective clothing
Safety shoes
Protective gloves
Table 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Shutdown
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personal suitability for the respective activity,
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knowledge of this operating manual, particularly of safety instructions
and sections relevant for the activity,
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
supervision 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
knowledge of the relevant specifications, specialist staff are able to
perform the job allocated to them and recognise and/or eliminate any
possible dangers 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
prevention.
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
behaviour.
Trained persons have attended all trainings offered by the operator.

Safety
Personnel qualification
8© Lutz-Jesco GmbH 2016
BA-20901-02-V01
Chlorinator C 2526 Operating instructions
2.6.4 Personnel tasks
In the table below you can check what qualifications are the pre-condi-
tion for the respective tasks. Only people with appropriate qualifications
are allowed to perform these tasks!
Qualification Activities
Specialist staff nTransportation
nAssembly
nHydraulic installation
nCommissioning
nTaking out of operation
nFault rectification
nMaintenance
nRepairs
nDisposal
Trained electricians nElectric installation
nRectifying electrical faults
nRepairing the electrics
Trained persons nStorage
nControl
Table 4: Personnel qualification

Intended use
Notes on product warranty 9
© Lutz-Jesco GmbH 2016
Subject to technical changes.
160520
BA-20901-02-V01
Chlorinator C 2526 Operating instructions
3 Intended use
3.1 Notes on product warranty
Any non-designated use of the device can impair its function and the
protection 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
instructions and the section "Intended Use".
nInformation on usage and environment (see section 5 „Technical
data“ on page 13) 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
order.
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 device is exclusively intended for the dosing of a chlorine dioxide
solution in a vacuum procedure. It serves the adjustment and display of
the dosing quantity.
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Any gases except chlorine gas,
nMedia with a pressure not less than the atmospheric pressure.
nChlorine of insufficient quality

Product description
Scope of delivery
10 © Lutz-Jesco GmbH 2016
BA-20901-02-V01
Chlorinator C 2526 Operating instructions
4 Product description
4.1 Scope of delivery
Please compare the delivery note with the scope of delivery.The
following items are part of the scope of delivery:
nDosing device with flow meter, manual adjustment valve, backpres-
sure regulator and vacuum meter.
nAutomatic regulation valve (optional).
nSignal converter (optional).
nInstallation material for wall mounting or fixing to the floor.
nOperating instructions.
4.2 Design and function
4.2.1 Structure of a vacuum dosing system
Fig. 1:
Cl2
H2O
M
Structure of a vacuum dosing system
The chlorine gas leaves the chlorine tank with positive pressure. The
vacuum regulator aonly permits the chlorine to flow if a vacuum at the
output of the device generates suction. A chlorine leak is not possible
following a line fracture behind the vacuum regulator.
The dosing device consists of a flow meter bwith a manual regulation
valve, usually an electrically-actuated regulation valve cand a pressure
regulator d.
The injector fgenerates the vacuum in accordance with the Venturi
effect and mixes the chlorine gas in the motive water flow. Chlorine
dosing is aborted immediately following water stand still.The non-return
valve eprevents water from entering the dosing devices.
4.2.2 Structure of the device
Fig. 2: Structure C 2526/WL
Fig. 3: Structure C 2526/SL fore and rear view
No. Description
1Manual dosing valve
2Flow meter
3 Input
4Electrical regulation valve (optional=
5Connection box for the contact pressure gauge (optional)
6Vacuum meter
7 Output
8Back-pressure regulator
9Signal converter (optional)
Table 5: Elements in the device
1
2
3
4
5
6
1
4
5
7
8
6
2
3
9
64
5
8
7
1
9
2
3