Lutz Jesco C 2700-V User manual

Dosing
Conveying
Control
Liquids
Gases
Systems
Original Operating Instructions
© Lutz-Jesco GmbH 2016
BA-21210-02-V05
Vacuum Regulator for Chlorine Gas
C 2700-V
Operating Instructions
Read the Operating Instructions!
The user is responsible for installation and operation related mistakes!

3
© Lutz-Jesco GmbH 2016
Subject to technical changes.
160426
Vacuum Regulator for Chlorine Gas C 2700-V Operating Instructions
BA-21210-02-V05
Contents
1 Notes for the Reader ........................................................ 4
General non-discrimination .......................................................... 4
Explanation of the signal words .................................................... 4
Explanation of the warning signs .................................................. 4
Identification of warnings ............................................................. 4
Instruction for action identification ................................................ 4
2 Safety ............................................................................... 5
General warnings ......................................................................... 5
Information about chlorine............................................................ 5
Hazards due to non-compliance with the safety instructions......... 6
Working in a safety-conscious manner ......................................... 6
Personal protective equipment ..................................................... 6
Personnel qualification ................................................................. 6
3 Intended Use .................................................................... 7
Notes on product warranty ........................................................... 7
Intended purpose ......................................................................... 7
Device revision ............................................................................. 7
Prohibited dosing media ............................................................... 7
4 Product description ......................................................... 8
Scope of delivery .......................................................................... 8
Design and function ..................................................................... 8
Rating plate ................................................................................ 10
Technical data ........................................................................... 10
5Dimensions..................................................................... 11
Vacuum regulator with threaded connection ............................... 11
Vacuum regulator with flange connection ................................... 11
6 Installation ..................................................................... 12
Installation location .................................................................... 12
Mounting position.......................................................................12
Installing the device ...................................................................12
Completing the installation ......................................................... 15
Installation examples .................................................................. 16
7 Commissioning .............................................................. 18
Inspecting the pressure system .................................................. 18
Inspecting the vacuum system ...................................................19
Switching the system on ............................................................ 19
8Operation........................................................................ 20
Test intervals ............................................................................. 20
9Shutdown....................................................................... 21
Short-term shutdown .................................................................21
Long-term shutdown ..................................................................21
Disposal of the old device...........................................................21
10 Maintenance................................................................... 22
Maintenance intervals ................................................................22
Accessories for maintenance...................................................... 22
Preparing the system for maintenance ....................................... 22
Maintaining the inlet valve ..........................................................23
Maintaining the vacuum part ...................................................... 25
Conclusion of maintenance ........................................................27
11 Troubleshooting ............................................................. 28
12 Spare parts .................................................................... 29
Individual parts .......................................................................... 30
Complete assemblies ................................................................. 31
Maintenance sets ....................................................................... 31
13 Declaration of Incorporation ......................................... 32
14 Declaration of harmlessness ........................................ 33
15 Warranty application ..................................................... 35
16 Index .............................................................................. 37

Notes for the Reader
General non-discrimination
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Vacuum Regulator for Chlorine Gas C 2700-V
© Lutz-Jesco GmbH 2016
Operating Instructions
BA-21210-02-V05
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:
read the entire operating manual prior to commissioning the device.
ensure that everyone who works with or on the device has read the
operating manual and follows the instructions.
keep the operating manual throughout the service life of the device.
pass the operating manual on to any subsequent owner of the
device.
1.1 General non-discrimination
In these operating instructions, 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 simplifi-
cation.
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:
I
1.3 Explanation of the warning signs
Warning signs represent the type and source of a danger:
1.4 Identification of warnings
Warnings are intended to help you recognise risks and avoid negative
consequences.
This is how warnings are identified:
1.5 Instruction for action identification
This is how pre-conditions for action are identified:
Pre-condition for action which must be met before taking action.
This is how instructions for action are identified:
Separate step with no follow-up action.
1. First step in a series of steps.
2. Second step in a series of steps.
Result of the above action.
Action completed, aim achieved.
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.
NOTICE Refers to a danger which, if ignored, may lead to
risk to the machine and its function.
Warning sign Type of danger
Danger to life from chlorine poisoning
General danger zone
Danger of damage to machine or functional
influences
Warning
sign SIGNAL WORD
Description of danger.
Consequences if ignored.
The arrow signals a safety precaution to be taken to eliminate
the danger.

Safety
General warnings 5
© Lutz-Jesco GmbH 2016
Subject to technical changes.
160426
Vacuum Regulator for Chlorine Gas C 2700-V Operating Instructions
BA-21210-02-V05
2 Safety
2.1 General warnings
The following warnings are intended to help you to eliminate the
dangers that can arise while handling the device. Risk prevention meas-
ures 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.
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 pulmo-
nary alveolus (formation of hydrogen chloride or hydrochloride acid).
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.
Use sufficient personal protective equipment.
When carrying out any work on the system, use a respirator
mask with a Type B gas filter that complies with EN 14387.
Always comply with the accident prevention regulations that
apply at the place of use.
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 rapidly results in
increased leakage.
Only use chlorine-resistant seals.
Only use seals once. Reusing them leads to leaks.
DANGER
Danger to life from chlorine poisoning!
If chlorine gas escapes, a filter mask is ineffective, since it is not a
self-contained breathing apparatus.
If chlorine gas escapes, wear type 2 self-contained breathing
apparatus that complies with EN 137.
DANGER
Danger to life from chlorine poisoning!
Chlorinators without gas warning devices represent an increased
safety risk since escaping chlorine gas can either not be detected
at all or not in good time.
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. Insuffi-
cient qualification will increase the risk of accidents.
Ensure that all action is taken only by personnel with sufficient
and corresponding qualifications.
Prevent access to the system for unauthorised persons.
NOTICE
Damage to the system due to the formation of hydro-
chloric 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.
Damage to the devices is then inevitable.
Keep all the connections (in the vacuum system too) closed at all
times.
NOTICE
Faults due to insufficient chlorine quality
Impurities in the chlorine gas result in build-ups in devices and
valves and can chemically attack the components. This can cause
malfunctions.
Only use technically pure chlorine which satisfies the following
requirements:
- Chlorine mass content of at least 99.5%
- Max. chlorine water content of 20 mg/kg
Chlorine as per EN 937 satisfies these requirements.

Safety
Hazards due to non-compliance with the safety instructions
6
Vacuum Regulator for Chlorine Gas C 2700-V
© Lutz-Jesco GmbH 2016
Operating Instructions
BA-21210-02-V05
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:
failure of major device and corresponding system functions,
failure of required maintenance and repair methods,
danger to persons,
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:
accident prevention regulations
safety and operating provisions,
safety regulations on handling hazardous substances,
environmental protection provisions,
applicable standards and legislation.
2.5 Personal protective equipment
Depending on the type of work being performed, appropriate protective
equipment must be worn. Read the Accident Prevention Regulations and
the Safety Data Sheets on the dosing media to find out what protective
equipment is required.
As a minimum, the following protective equipment is recommended:
Mask Protective clothing Gloves Safety footwear
Corresponding protective equipment must be used during these tasks:
commissioning,
all work on gas-bearing sections of the system
changing the chlorine gas containers,
shutdown,
maintenance work,
disposal.
2.6 Personnel qualification
Any personnel who work with the device must have appropriate special
knowledge and skills.
Anybody who works with the device must meet the conditions below:
attendance at all the training courses offered by the owner,
personal suitability for the respective activity,
sufficient qualification for the respective activity,
training on the handling of the device.
knowledge of safety equipment and the way this equipment func-
tions,
knowledge of this operating manual, particularly of safety instruc-
tions and sections relevant for the activity,
knowledge of fundamental regulations regarding health and safety
and accident prevention.
All persons must generally have the following minimum qualification:
training as specialists to carry out work on the device unsupervised,
sufficient training that they can work on the device under the super-
vision and guidance of a trained specialist.
This operating manual distinguishes between these user groups:
2.6.1 Specialist staff
Specialist staff are able, thanks to their professional training, knowledge
and experience as well as knowledge of the respective provisions, to do
the job allocated to them and recognise and/or eliminate any possible
dangers by themselves.
2.6.2 Trained persons
Trained persons have been trained by the operator on the tasks they are
supposed to perform and on the dangers stemming from improper
behaviour.
Trained persons have attended all trainings offered by the operator.
2.6.3 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 Assembly
Commissioning
Taking out of operation
Maintenance
Repairs
Disposal
Fault rectification
Trained persons Storage
Transportation
Operation

Intended Use
Notes on product warranty 7
© Lutz-Jesco GmbH 2016
Subject to technical changes.
160426
Vacuum Regulator for Chlorine Gas C 2700-V Operating Instructions
BA-21210-02-V05
3 Intended Use
3.1 Notes on product warranty
Any non-designated use of the device can compromise its function or
intended protection. This leads to invalidation of any warranty claims!
Please note that liability passes to the user in the following cases:
The device is operated in a manner which is not consistent with this
operating manual, particularly the safety instructions, handling
instructions and chapter Intended Use.
Information on the usage and ambient conditions (see "Technical
data" on page 10) is not observed.
If people operate the device who are not adequately qualified to
carry out their respective activities.
No original spare parts or accessories of Lutz-Jesco GmbH are used.
Unauthorised changes are made to the device.
The user uses different dosing media than those indicated in the
order.
Maintenance and inspection intervals are either not adhered to at all
or not as prescribed.
The device is commissioned before it or the corresponding system
has been correctly and completely installed.
Safety equipment has been bridged, removed or made inoperative in
any other way.
3.2 Intended purpose
The vacuum regulator is designated exclusively for chlorinators based
on the vacuum procedure. The vacuum regulator is only supplied with
gaseous chlorine. It reduces the existing underpressure from the chlo-
rine gas supply to a lower pressure than the atmospheric air pressure.
Only technically pure chlorine with a mass chlorine content of at least
99.5% may be used.
3.3 Device revision
This operating manual applies to the following devices:
The date of production is stated on the rating plate.
3.4 Prohibited dosing media
The device must not be used for the following media and substances:
Any gases except chlorine gas,
Liquid chlorine
Chlorine of insufficient quality.
Device Month / year of manufacture
Vacuum Regulator for Chlorine Gas
C 2700-V
07/2007 onwards

Product description
Scope of delivery
8
Vacuum Regulator for Chlorine Gas C 2700-V
© Lutz-Jesco GmbH 2016
Operating Instructions
BA-21210-02-V05
4 Product description
4.1 Scope of delivery
Carefully check the delivery prior to installation and refer to the delivery
note to ensure the delivery is complete and to check for any transport
damage. Contact the supplier and/or carrier regarding any questions
concerning the delivery and/or transport damage. Do not operate defec-
tive devices.
The device is assembled ready-to-install. All the openings are closed by
transportation locks.
The scope of delivery includes:
Vacuum regulator with inlet valve and integrated safety valve.
Pressure gauge (optional)
Flange connection on chlorine gas input including screws and seal
(optional)
5-m tube with mounting material as blow-off line
Ammonia solution for leakage test
Operating manual
4.2 Design and function
4.2.1 Design of a vacuum chlorinator
Fig. 4-1: Design of a vacuum chlorinator
The chlorine gas is under overpressure when it comes from the chlorine
barrels. The vacuum regulator (1) only allows the chlorine to flow if
there is a suctioning vacuum at the device’s output. Therefore, if a line
behind the vacuum regulator breaks, there is no need to fear a chlorine
leak.
The dosing device comprises a flow meter (2) with manual control
valve, and also often an electrically actuated control valve (3) and a
pressure regulator (4).
The injector (6) creates the vacuum based on the Venturi effect and
mixes the chlorine gas in the motive water flow. If the water does not
move, chlorination is stopped immediately. Then the non-return valve
(5) prevents water from penetrating into the dosing devices.
4.2.2 Structure of the device
Fig. 4-2: Structure of the device
Cl 2
H
2
O
M
1
2
3
44
6
5
Item Description
1 Input
2 Pressure gauge (optional)
3 Safety valve output
4Plug
5 Output
2
5
1
4
3

Product description
Design and function 9
© Lutz-Jesco GmbH 2016
Subject to technical changes.
160426
Vacuum Regulator for Chlorine Gas C 2700-V Operating Instructions
BA-21210-02-V05
4.2.3 Function description
Fig. 4-3: Vacuum Regulator for Chlorine Gas C 2700-V - cross-sectional view
Pressurised chlorine gas flows from the chlorine barrel to the vacuum
regulator. The vacuum regulator comprises the inlet valve (1) and the
membrane chamber (3). In the inlet valve the chlorine gas is under
overpressure, in the membrane chamber there is a vacuum.
The PVC output of the vacuum regulator is connected to the injector. A
sufficient vacuum draws the diaphragm disc (4) upwards and pushes
the valve cone (2) downward against the spring force. The inlet valve (1)
opens and the amount of chlorine required flows into the membrane
chamber (3). If the vacuum is not sufficient, the spring closes the
system again. This results in a constant vacuum in the piping down-
stream of the vacuum regulator.
A constant vacuum ensures maximum system safety: In the event of a
leak, ambient air is drawn into the tube without enabling a dangerous
amount of chlorine gas to escape into the atmosphere.
If the valve cone (2) does not close properly due to heavy soiling, slight
overpressure builds up in the membrane chamber (3). In the event of
such faults, the safety valve (5) in the diaphragm disc opens and vents
the system vents to a neutralisation system, e.g., a chlorine eliminator
or an activated carbon cartridge.
Atmosphere
Chlorine (vacuum)
Chlorine (overpressure)
4
3
2
5
1

Product description
Rating plate
10
Vacuum Regulator for Chlorine Gas C 2700-V
© Lutz-Jesco GmbH 2016
Operating Instructions
BA-21210-02-V05
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.
Fig. 4-4: Rating plate
4.4 Technical data
Item Meaning
1 Product designation
2 Part number
3 Serial number
4 Materials
5 Month of manufacture
6 Year of manufacture
Description Value
Throughput up to 200 kg/hr
Inlet pressure 1.5 – 16 bar
Operating vacuum -50 mbar
Response pressure of the safety valve 500 mbar
Pressure gauge (optional) 0 – 16 bar / Ø 63 mm
Materials Inlet valve Brass (chemically nickel-
plated), Monel, Hastelloy
Vacuum housing PVC
Seals FPM, PTFE
Weight with flange and pressure
gauge
approx. 8 kg
Ambient temperature 10 – 50°C
(no direct sunlight)
Lutz-Jesco GmbH 30900 Wedemark
Am Bostelberge 19 Germany
Chlorine Gas Vacuum Regulator C 2700-V
12/2008
P/N: 1234567890
S/N: 102A12345 Made in Germany
*102A12345678*
Material: PVC/FPM/Monel/Ms58
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3
1
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