Lutz Jesco Easychlorgen 4250 Guide

EASYCHLORGEN 4250, 8500
Electrolysis system for on-site hypochlorite generation
Installation, Operation &
Maintenance Instructions
EN
Read these operation and maintenance instructions before start-up!
To be held for further reference.
v1.0 11/2017

2 | Installation, Operation & Maintenance Instructions EASYCHLORGEN

Table of Contents
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3 | Installation, Operation & Maintenance Instructions EASYCHLORGEN
Contents
1. NOTES FOR THE READER..................................................4
1.1 INTRODUCTION ...................................................................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 .............................4
1.6 REFERENCES TO INTELLECTUAL PROPERTY RIGHTS.................4
1.7 DETAILS FOR THE OPERATOR ...............................................4
1.8 INSTRUCTION &TRAINING COURSE ASSISTANCE......................5
1.9 EXAMPLE OF TRAINING COURSE TOPICS.................................5
2. SAFETY................................................................................7
2.1 GENERAL WARNINGS...........................................................7
2.2 HAZARDS DUE TO NON-COMPLIANCE WITH THE SAFETY
INSTRUCTIONS .........................................................................7
2.3 WORKING IN A SAFETY-CONSCIOUS MANNER ..........................7
2.4 PERSONAL PROTECTIVE EQUIPMENT......................................7
2.5 PERSONNEL QUALIfiCATION..................................................7
3. INTENDED USE....................................................................9
3.1 NOTES ON PRODUCT WARRANTY...........................................9
3.2 INTENDED PURPOSE............................................................9
3.3 DEVICE REVISION ...............................................................9
3.4 SODIUM CHLORIDE CHEMICAL SPECIFICATION .........................9
3.5 WATER QUALITY.................................................................9
3.6 STANDARD WARRANTY CONDITIONS ......................................9
4. PRODUCT DESCRIPTION..................................................10
4.1 SCOPE OF DELIVERY .........................................................10
4.2 DESIGN AND FUNCTION......................................................10
5. TECHNICAL DATA..............................................................15
5.1 EASYCHLORGEN SKID UNIT ...........................................15
5.2 POWER SUPPLY UNIT.........................................................15
6. DIMENSIONS .....................................................................16
6.2 INTERMEDIATE BRINE TANK ................................................17
6.3 POWER SUPPLY UNIT (PSU) CABINET .................................17
7. INSTALLATION...................................................................18
7.1 INSTALLATION LOCATION....................................................18
7.2 HYDRAULIC INSTALLATION..................................................19
7.3 ELECTRICAL INSTALLATION ...............................................22
7.4 GENERAL INSTALLATION LAYOUTS.......................................31
8. CONTROL ..........................................................................35
8.1 CONTROL DISPLAY ............................................................35
9. START UP...........................................................................36
9.1 COMMISSIONING AND INITIAL START-UP...............................36
9.2 NORMAL START-UP..........................................................39
10. OPERATION.....................................................................40
10.1 AUTOMATIC OPERATION ..................................................40
10.2 MANUAL INHIBIT..............................................................40
10.3 REMOTE INHIBIT .............................................................40
10.4 SOFTENER REGENERATION..............................................40
10.5 EMERGENCY SHUTDOWN.................................................41
10.6 RECORD LOG OF OPERATION...........................................41
11. SHUTDOWN.....................................................................42
11.1 SHORT-TERM SHUTDOWN (UP TO 6MONTHS)......................42
11.2 LONG-TERM SHUTDOWN ..................................................42
11.3 STORAGE ......................................................................42
11.4 TRANSPORTATION ..........................................................42
11.5 DISPOSAL OF OLD EQUIPMENT..........................................42
12. MAINTENANCE................................................................43
12.1 MAINTENANCE INTERVALS ...............................................43
12.2 ELECTROLYSER CLEANING ...............................................46
12.3 FINISHING MAINTENANCE .................................................47
12.4 LOCATION OF MAINTENANCE PARTS...................................48
13. TROUBLE-SHOOTING .....................................................50
14. SPARE PARTS...........................................................51
14.1 MAINTENANCE SETS...................................................51
14.2 CRITICAL SITE SPARES ....................................................51
15. DECLARATION OF NO OBJECTION..........................52
16. WARRANTY CLAIM ...................................................53
APPENDIX I – COMMISSIONING LOG....................................54
COMMISSIONING /SERVICE SHEET TO BE COMPLETED AND KEPT ON
SITE.....................................................................................54
APPENDIX II – OPERATORS LOG..........................................55
OPERATORS LOG TO BE COMPLETED AND KEPT ON SITE............55
APPENDIX III – SERVICE LOG ...............................................56
SERVICE CHECK SHEET..........................................................56
APPENDIX IV – SOFTENING EQUIPMENT.............................57
INDEX .....................................................................................75

Chapter 1: General
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4 | Installation, Operation & Maintenance Instructions EASYCHLORGEN
1. Notes for the Reader
1.1 Introduction
This operating manual provides significant assistance in the
successful and smooth running of the EASYCHLORGEN
electrolysis systems, also referred to, in short, as “system” in the
following instructional text.
The operating manual for the EASYCHLORGEN electrolysis
systems must always be available where the system is located
and it has to be read and used by every person who is assigned
to working on the system. This includes amongst other things:
•the installation
•the servicing and repair work
•the maintenance (maintenance, care, repair)
•the transport
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.
1.3 Explanation of the warning signs
Signal Word Meaning
General danger zone
Danger of electric shock
Danger of explosion
Danger of damage to machine or functional
influences
1.4 Identification of warnings
Warnings are intended to help you recognize risks and avoid
negative consequences.
This is how warnings are identified:-
Warning sign SIGNAL WORD
Description of danger.
Consequences if ignored.
The arrow signals a safety precaution to be taken to eliminate
the danger.
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.
1.6 References to intellectual property rights
This operating manual must be treated confidentially.
All documents are protected in the sense of the copyright law. It
is forbidden to forward on and copy the documents, even in part,
as well as to use and communicate their contents, insofar as this
is not expressly conceded in writing. Violations are punishable
and incur an obligatory payment of damages.
1.7 Details for the operator
The operating manual is a significant component of the
EASYCHLORGEN electrolysis system. The operator must
ensure that the service personnel learn these guidelines.
The operating manual is to be supplemented by the operator
regarding the operating instructions; national regulations for
Health and Safety at Work and Environmental Protection,
including information on the responsibilities of supervision and
the observance of operational specifics, e.g. concerning labour
organisations, operational sequences and appointed personnel.
Besides the operating manual and the obligatory regulations for
Health and Safety at Work applicable in the country of use, as
well as in the place of use, the recognised specialist technical

Chapter 1: General
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5 | Installation, Operation & Maintenance Instructions EASYCHLORGEN
regulations for safe and professional work must also be
observed.
The operator of the EASYCHLORGEN system may not make
any changes, attach fittings or make alterations to the
construction of the EASYCHLORGEN system that may impair
security, without the written consent of Lutz-Jesco. This also
applies to the installation and setup of safety devices.
Any replacement parts to be used have to correspond to the
technical requirements specified by Lutz-Jesco. This is always
guaranteed in the case of original spare parts. Only appoint
trained or instructed personnel. Clearly specify the
responsibilities of the personnel for operating, servicing and
repairing the system.
1.8 Instruction & training course assistance
As a contractor/operator you are obligated to inform and/or
instruct the operating personnel about existing provisions of law
and accident prevention regulations, as well as existing safety
regulations at the plant. In doing so, the different technical
qualifications have to be taken into account. The operating
personnel must have understood the training and it must be
ensured that the training is adhered to.
Only in this way can you ensure that your personnel work in a
safety conscious and risk aware manner. This should be
controlled on a regular basis. As the contractor/operator you
should therefore obtain confirmation of each of the employee’s
attendance in writing.
On the following pages you will find examples of the training
course topics, as well as a main form to copy for the confirmation
of attendance.
If the operating personnel still require further training after the
system has been delivered to the operator, please contact Lutz-
Jesco.
1.9 Example of training course topics
For safety:
•Accident prevention regulations
•General safety precautions
•Action to be taken in an emergency
•Safety precautions for operating
•Safety devices
•Definition of symbols and signs
To operate
•How to operate the controls
•Elimination of operational disturbances
•Interpretation of fault indications
For maintenance and service instructions:
•Inspection/testing of the system
•Cleaning the system and exchange of replacement
parts

Chapter 1: General
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6 | Installation, Operation & Maintenance Instructions EASYCHLORGEN
Confirmation of the training instruction
Topic of the training instruction:
__________________________________________________________________________________________________
__________________________________________________________________________________________________
Date: _____________________________________________________________________________________________
Training instructor:
__________________________________________________________________________________________________
Training instructor’s signature:
__________________________________________________________________________________________________
No.
Surname
First Name
Signature
1
2
3
4
5
6
7
8
9
10

Chapter 2: Safety
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7 | Installation, Operation & Maintenance Instructions EASYCHLORGEN
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
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!
Mortal danger from electric shock!
Live parts can inflict fatal injuries.

Ensure that the mains voltage is switched off before
opening the control cabinet door.
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.
Never use the device in potentially explosive areas
DANGER!
Increased risk of accidents due to insufficient
qualification of personnel!
The equipment and accessories may only be installed, operated
and maintained by personnel with sufficient qualifications.
Insufficient 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.
2.2 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.
•failure of important functions of the device and of the
corresponding system
•failure of required maintenance and repair methods
•danger to persons
•danger to the environment caused by substances
leaking from the system.
2.3 Working in a safety-conscious manner
Besides the safety instructions specified in these operating
instructions, further safety rules apply and must be followed:
•accident prevention regulations
•safety and operating provisions
•environmental protection provisions
•applicable standards and legislation
2.4 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. Although the dosing media produced by
the EASYCHLORGEN system is classified non-hazardous, the
following protective equipment is recommended when carrying
out certain tasks:
•Commissioning
•Working on pressurised dosing devices
•Shutdown
•Maintenance
•Disposal
Protective clothing Protective Gloves Goggles
2.5 Personnel qualification
Any personnel who work on the device must have appropriate
special knowledge and skills. Anybody who works on the product
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 in how to handle the device

Chapter 2: Safety
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8 | Installation, Operation & Maintenance Instructions EASYCHLORGEN
knowledge of safety equipment and the way this
equipment functions
knowledge of these operating instructions, particularly
of safety instructions 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 supervision and guidance of a trained
specialist
These operating instructions differentiate between these user
groups:
2.5.1 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.
2.5.2 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.
2.5.3 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.
2.5.4 Personnel tasks
In the table below, you can check what personnel qualifications
are the pre-condition for the respective tasks. Only people with
appropriate qualifications are allowed to perform these tasks!
Specialist staff Installation
Hydraulic installations
Commissioning
Taking out of operation
Fault rectification
Maintenance
Repairs
Disposal
Trained electricians Electrical installation
Rectifying electrical faults
Electrical repairs
Trained persons Control
Storage
Transportation

Chapter 3: Intended Use
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9 | Installation, Operation & Maintenance Instructions EASYCHLORGEN
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:
•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".
•Information on usage and environment (see section 5
“Technical data“) is not adhered to.
•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 are
used.
•Unauthorised changes are made to the device.
•The user uses different salt quality than that indicated in this
instruction manual.
•Maintenance and inspection intervals are not adhered to as
required or not adhered to at all.
•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 EASYCHLORGEN on-site electrolytic chlorination system is
intended for the following purpose: Generation of a <1% sodium
hypochlorite solution using salt, water and electrical energy, with
the resulting media to be used as a disinfection agent for the
chlorination of drinking water, swimming pool and industrial
waters.
The concentration of the sodium hypochlorite solution produced
is 0.6% (+/-0.1%) Cl2by weight.
3.3 Device Revision
This operating instruction manual applies to the following
devices:
Device
Month /year of
manufacture
EASYCHLORGEN 4250/8500 10/2017 onwards
3.4 Sodium chloride chemical specification
The EASYCHLORGEN system is designed to be used with dry
crystalline/granular salt. Salt can be purchased in bulk/ pallet
quantities to obtain best economy. When ordering salt from your
supplier always specify the brand or specific quality you require,
so that, in the unlikely event of any shortage of stock, you will still
receive an equivalent grade of salt. The use of pure vacuum
dried (PVD) salt, or compressed PVD salt chips is not
recommended.
Note: Within the European Union the supply of salt for use as a
precursor for in-situ generated active chlorine falls under the
Biocidal Products Regulation (BPR). Please consult your salt
supplier to check for compliance with this regulation!
Property
Unit
Specification
Arsenic (As)
mg/kg
<13
Cadmium (Cd)
mg/kg
<1.3
Chromium (Cr)
mg/kg
<13
Iron (Fe)
mg/kg
<10
Mercury (Hg)
mg/kg
<0.26
Nickel(Ni)
mg/kg
<13
Manganese (Mn)
mg/kg
<0,5
Lead (Pb)
mg/kg
<13
Antimony (Sb)
mg/kg
<2.6
Selenium (Se)
mg/kg
<2.6
Bromide
% of NaCl
<0.01
Calcium
% of NaCl
<0.01
Magnesium
% of NaCl
<0.01
Note
Damage to the system due to incorrect salt.
Using the incorrect grade of salt may cause damage to the
electrolyser cell and invalidate your warranty!

Please check with your supplier that the salt product supplied
meets the minimum specification above.
3.5 Water Quality
Drinking water or water of a similar quality should be used. It
should be free of solids and suspended matter. The temperature
of the water entering the system must be in the range of 5-20°C.
3.6 Standard warranty conditions
Equipment
Warranty Period
Electronic devices
2 years
Electrolyser
5 years limited, pro-rata
Wearable items
12 months

Chapter 4: Product description
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10 | Installation, Operation & Maintenance Instructions EASYCHLORGEN
4. Product description
4.1 Scope of delivery
Please compare the delivery note with the scope of delivery:
•EASYCHLORGEN electrolyser cabinet
•EASYCHLORGEN DC power supply cabinet
•Insulated DC power busbars (2m), clamps, self-
amalgamating tape.
•Brine break tank with float valve assy
•Duplex softening system
•Operating Instructions
•Selectable Options: Brine saturator tank, external
product tank, dosing pump/s & accessories.
4.2 Design and function
4.2.1 Function description
EASYCHLORGEN is a fully automatic system for the
preparation of dilute sodium hypochlorite solution containing
0.6% (+/-0.1%) Cl2, from the raw materials of salt, softened
water and electrical energy. Sodium hypochlorite solution (the
product) is prepared by a simple, once through batch process,
initiated by the level switch within the Product Tank. Refer to
the diagram 4.2.3 in conjunction with the description below.
When the product level in the degassing tank (14), or optionally
the external product tank, falls below the start/stop fill level
switch (11) the water solenoid valve (4) and brine solenoid
valve (3) are energised simultaneously, allowing softened
water to flow through the pressure reducing valve (7) and
through the volumetric flow meter (6). The water stream flows
through the brine inductor (2) to create a vacuum which draws
in a set amount of brine from the external brine saturator tank.
Once the predetermined quantity of brine is drawn, the water
and brine solenoid valves (4 & 3) are closed, whilst the water
dilution valve (5) is opened to allow a predetermined quantity of
dilution water to be delivered directly to the electrolyser
vessel/s, before closing. The resultant diluted brine solution
passes through the electrolyser/s (13). At the same time, d.c.
voltage is applied across the electrolyser cells where the
diluted brine solution completes the electrical path and allows
an electric current to flow between the cell plates. The
generated product is delivered to the degassing tank (14)
before transfer to an external product tank through the product
outlet connection (16). When the product reaches the start/stop
fill level (11) in the product/degassing tank, or, the start/stop
level switch in the external product tank, the generating
process is stopped. The process is restarted after a
predetermined time delay period has elapsed, initiated when
the liquid level in the product/degassing tank falls below the
start/stop fill level (11). The process can also be re-started and
stopped manually by pressing and holding the ‘scroll up’ arrow
key on the control panel keypad (1) for 3 seconds.
Hot climates: In hot climates where water supply temperatures
may exceed 20°C, an external water chiller (supplied by
others) should be installed on the incoming water supply. The
water chiller must be correctly sized according to the liquid
output capacity of the model (refer to 5.1.1), the ambient air
temperature and the desired water temperature differential.
On 4250 & 8500 models the temperature of the generated
product is monitored by a PT100 sensor located close to the
degassing tank inlet (12); the reading can be viewed on the
EASYCHLORGEN control panel by using the ‘scroll’ keys. A
high temperature alarm set-point (adjusted in the control panel
Engineering menu) is provided to shut down production in the
event of abnormal temperature conditions.
Whilst the unit is generating sodium hypochlorite product,
hydrogen gas is produced as a by-product. Hydrogen gas is
diluted as it enters the degassing tank with a continuous flow of
fresh air from a centrifugal ventilation fan (9) and is vented
safely to atmosphere via ducting connected to the ventilation
outlet (15) to an external exhaust point (atmosphere). The
system is designed so that there are no external areas where
hydrogen levels can reach the LEL (lower explosive limit). An
air-flow sensor (10) is provided to shut down production in the
event the air flow fails to remain within normal operating
parameters.
A text display on the control panel (1) will advise of the reason
for the fault and initiate a volt-free contact which can be used
for connection of a remote alarm device.

Chapter 4: Product description
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11 | Installation, Operation & Maintenance Instructions EASYCHLORGEN
4.2.2 EASYCHLORGEN description
Item
Description
1
Control panel display
2
Brine venturi
3
Brine solenoid valve
4
Dilution solenoid valve
5
Chilled water solenoid valve
6
Water meter
7
Pressure regulating valve
8
Product sample tap
9
Air blower
10
Air-flow sensor
11
System run/stop level switch
12
Temperature probe
13
Electrolyser
14
Product de-gassing tank
15
Vent outlet
16
Product outlet
17
Brine inlet connection
18
Water inlet connection
19
Acid wash outlet
20
DC power busbar connection (+ve)
21
DC power busbar connection (-ve)
22
Acid wash inlet

Chapter 4: Product description
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12 | Installation, Operation & Maintenance Instructions EASYCHLORGEN
4.2.3 Power supply description
A dedicated, stand-alone power supply unit (PSU) is provided.
The PSU cabinet provides power for the whole of the
electrolyser system; AC power to the EASYCHLORGEN
control panel and DC power to the electrolyser. The cabinet
requires a 3Ø+N+E supply rated according to the model
capacity (refer to 5.1.3 Electrical Specifications).
The PSU cabinet should be located according to the installation
examples in section 7.4, in close proximity to the electrolyser
cabinet. DC connections between the PSU and the electrolyser
cabinet are facilitated by the flexible DC busbar (2m) and
clamp system provided.
Key:
1. + DC busbar clamp
2. – DC busbar clamp
3. Ventilation fan
4. Control cable ports
5. Generating indicator lamp, green.
6. Power indicator lamp, white.
7. Emergency Stop button, red
8. Main electrical isolator
The white power indicator (6) is lit when a 3 phase AC power
source is available. The green generating indicator (5) is lit
when the electrolyser D.C. output power is available. A
ventilation fan (3) operates continuously to draw in air at the
base of the cabinet and discharge warm air through the vent
louvres at the top of the cabinet. The DC power supply
operation can be disabled by pressing the Emergency Stop
button.
NOTE: When the Emergency Stop button is engaged, AC
power remains available to the EASYCHLORGEN control
panel for the purpose of communicating fault conditions and
allowing remote monitoring (option) via RS485/Modbus to
continue.
The operation of the main isolator (4) will disconnect power to
all circuits within the PSU cabinet.
For ease of maintenance the PSU contains modular DC power-
packs with self-regulating current output, short circuit and high
temperature protection. Each power-pack is equipped with
variable speed cooling fans which automatically regulate
according to internal temperatures. It is normal for changes in
the fan speed to occur during operation.
Cable Entry
The incoming 3Ø+N+E cable may enter the lower section of
the PSU cabinet only. For convenience of installation the entry
location of the cable may be at the discretion of the electrical
installation engineer and must be completed according to local
electrical codes.

Chapter 4: Product description
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13 | Installation, Operation & Maintenance Instructions EASYCHLORGEN
No
Power On (start-up) Normal Operation Fault Condition
4.2.4 Function sequence in automatic operation
* The Start Delay timer can be set
in the engineer’s menu to prevent
frequent stop/starting of the
generating cycle once the product
tank is full (default setting 60
minutes).
Yes

Chapter 4: Product description
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14 | Installation, Operation & Maintenance Instructions EASYCHLORGEN
4.2.5 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.
No.
Description
1
Product name
2
Nominal size
3
Month/ year of manufacture
4
Serial number
5
Label showing conformity with European directives
6
WEEE label
7
Power and voltage rating
8
Part number

Chapter 5: Technical data
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15 | Installation, Operation & Maintenance Instructions EASYCHLORGEN
5. Technical data
5.1 EASYCHLORGEN skid unit
5.1.1 Output data
Model:
4250
8500
Chlorine capacity
Kg/h
4.25
8.5
Chlorine concentration
g/l
≈7
Liquid product output
l/h
650
1300
Degassing tank capacity
l
210
210
5.1.2 Operating conditions and limits
5.1.3 Control Panel electrical specification
5.1.4 Air blower electrical specification
5.1.5 Connection dimensions
Model:
4250
8500
Cold water feed
25mm
Product outlet
50mm
Saturated brine inlet
20mm
Hydrogen vent line
160mm
Electrical connection point
M20
Control panel cable terminations
2.5 – 4mm
2
Acid wash inlet/outlet connection
32mm
5.1.6 Components in contact with the media
Description [all models] Material
Electrolytic cell
PVC, titanium, PTFE,
FPM
Product transfer pipe
PVC
Product tank
MDPE
Product tank level switch
assembly
PVDF/PVC, FPM/PPS
5.1.7 Other data
5.1.8 External product tank storage facility option
Model:
4250
8500
Product tank capacity (L)
Recommended minimum
size of 1000L (Refer to
product output in table
5.1.1 for suitable size)
5.1.9 Intermediate brine tank option
Model:
4250
8500
Softened water feed
connection
G½” BSPm
Saturated brine outlet
connection
G½” BSPf
Net weight
3
5.2 Power supply unit
5.2.1 Operating conditions and limits
Model:
4250
8500
Ambient temp
°C
+5 to +40
Humidity
%
<90
5.2.2 Electrical specifications
Model:
4250
8500
Nominal power supply VAC
4 wire Y 340-530
*3 wire ∆ 196-305
*special order
Phase
Ø
3
Cable
5x16mm
2
5x25mm
2
Power consumption
kWh
24
47
Protection class
IP
21
Model:
4250
8500
Net weight
260
325
Model:
4250
8500
Softened water consumption
l/h
650
1300
Nominal salt consumption
kg/h
3.5
Operating pressure
Bar
1.5 – 8.5
Ambient temperature
°C
+5 to +40
Water supply temperature
°C
+8 to +20
Model:
4250
8500
Nominal power supply
V ac
115v
Frequency
Hz
50-60
Phase
Ø
1
Power consumption
W
90
160
Protection class
IP
65
Model:
4250
8500
Nominal power supply
V ac
380-480
Phase
Ø
3
Power consumption
W
660
Protection class
IP
55

Chapter 5: Technical data
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16 | Installation, Operation & Maintenance Instructions EASYCHLORGEN
5.2.3 Other data
Model: 4250 8500
Net weight
kg
210
270
6. Dimensions
All dimensions in mm.
6.1 EASYCHLORGEN 4250/8500
Key Description
A
Product outlet connection
B
DC power busbar connection (-ve)
C
Acid wash inlet connection
D
DC power busbar connection (+ve)
E
Acid wash outlet connection
F
Brine inlet connection
G Water inlet connection
Side elevation
Front elevation
Plan elevation

Chapter 6: Dimensions
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17 | Installation, Operation & Maintenance Instructions EASYCHLORGEN
6.2 Intermediate brine tank
6.3 Power Supply Unit (PSU) cabinet
Side elevation
Rear elevation
Side elevation
Plan elevation

Chapter 7: Installation
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18 | Installation, Operation & Maintenance Instructions EASYCHLORGEN
7. Installation
WARNING
Increased risk of accidents due to insufficient
qualification of personnel!
The equipment and accessories may only be installed, operated
and maintained by personnel with sufficient qualifications.
Insufficient 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.
WARNING
Danger of personal injury and damage to property!
The devices are extremely heavy. The failure to take adequate
safety precautions during transportation and to act with caution
can lead to accidents involving personal injuries and damage to
property. Limbs can be crushed when the device is set up.
Transport the device using a floor conveyor that is suitable for
the load such as a pallet truck or forklift truck.
Wear safety shoes while transporting the device
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.
Use suitable tools.
Take care not to over-tighten fittings
7.1 Installation location
7.1.1 EASYCHLORGEN electrolysis skid unit
Precondition for action:-
A firm and level floor are required for the skid mounted unit.
Refer to dimensions in section 6.
The plant room has high level natural ventilation.
The system must be accessible for operation and
maintenance.
Refer to installation schematics, section 7.4.
Perform the following steps:-
1. Locate the skid unit into its intended permanent position
allowing sufficient space to connect services to the
connection ports to the side and top of the system.
2. Install the hydrogen gas detector above the location of the
EASYCHLORGEN system, preferably up against the
underside of the room ceiling or at the highest point in the
immediate room. The sensor head unit is supplied with a
fixing bracket that must be used in order to facilitate quick
and easy replacement of the sensor head at the time of
future maintenance/replacement. Avoid locating the gas
detector immediately above an external salt saturator/brine
tank.
Location of skid unit complete
7.1.2 EASYCHLORGEN power supply unit (PSU)
The PSU range in size from 20kW to 40kW 3 phase power
supplies according to model capacity. Ideally, the PSU is located
in an electrical room immediately adjacent to the electrolysis skid
unit plant room area. In warm and humid climates, electrical
rooms often offer environmentally/airconditioned controlled
conditions ideal for the PSU long term performance, where
exposure to unnecessary heat and corrosion can be avoided.
Precondition for action:-
A firm and level floor is required for the PSU. Refer to
dimensions in section 6.
Refer to installation arrangements, section 7.4.
Perform the following steps:-
1. The PSU should be installed ideally at the same floor
height as the main electrolysis unit.
2. The PSU electrical DC busbar connections should ideally
be directly in-line with the corresponding connections of the
main electrolysis unit and both units ideally within 1150mm
adjacent of each other essentially to minimise electrical
resistance and maintain good efficient electrolytic system
performance.
EASYCHLORGEN / PSU BUSBAR ALIGNMENT PLAN VIEW
EXAMPLE

Chapter 7: Installation
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19 | Installation, Operation & Maintenance Instructions EASYCHLORGEN
1. The PSU fan ventilator lower inlet grille and upper exhaust
grilles must not be obstructed. Allow a minimum of 400mm
(3ft) clearance from any nearby wall/surface.
2. The PSU must be bolted firmly at its base to the floor or
plinth on which it is positioned.
Location of PSU complete
7.1.3 Intermediate brine tank
Precondition for action:-
A firm and level floor is required for the intermediate brine
tank facility. Refer to dimensions section 6.
The system must be accessible for regular/routine
maintenance procedures.
Refer to installation schematic, section 7.4.The intermediate
brine tank must be on the same floor level as the
EASYCHLORGEN.
Perform the following steps:-
1. Locate the intermediate brine tank into position ≤1m
adjacent to the EASYCHLORGEN brine inlet connection.
Location of intermediate brine tank complete
7.1.4 Salt saturator (for electrolysis)
The EASYCHLORGEN 4250 and 8500 high capacity systems
may consume large quantities of salt as part of the chlorine
generation process. It is recommended that the site installs a
bulk saturator for vehicle delivery direct to the saturator.
Alternatively, a large open tank saturator (typically >2000kg salt
capacity) with the facility for overhead dispensing of one tonne
bulk bags is installed.
Precondition for action:-
A firm and level floor are required for the external saturator
tank facility. Refer to dimensions section 6.
The system must be accessible for operation, day-to-day
filling with salt and for regular/routine maintenance procedures.
Refer to installation schematic, section 7.4.
Perform the following steps:-
1. Locate the tank into position preferably near/adjacent to the
EASYCHLORGEN.
2. Align the tank so that inlet & outlet pipe connections are
conveniently situated for connection to appropriate services.
Location of salt saturator complete
7.2 Hydraulic installation
7.2.1 Cold feed water supply
Note
Damage to the system due to sediment in water.
Water containing sediment may damage or adversely impact on
the performance of the system.
Make sure that the water is always free of sediment.
Precondition for action:
A minimum cold water supply pressure of 4.0 Bar is required
for the softening system and EASYCHLORGEN.A drop in
pressure across any softening and pre-filter equipment must be
considered to ensure a minimum operating run pressure of >3.0
bar can be sustained at the EASYCHLORGEN skid softened
water inlet.
 The temperature of the incoming water supply must be
maintained ≤ 20°C upstream of the EASYCHLORGEN. A water
chiller may be required in warm climates, or where the water
supply temperature may be affected by other heat sources in the
installation area.
The equipment must be supplied with a clean potable water
quality supply. Waters which are high in magnesium content may
reduce the life of the water softener resin.
A verifiable double check valve or pipe disconnector in the
drinking water supply is fitted upstream of the entire
EASYCHLORGEN system and any ancillary softener equipment
if the local conditions require it.
A pressure reducing valve should be fitted to the water supply
if the supply pressure is greater than 8.5 bar upstream of the
softening equipment.
Perform the following steps:-
1. Connect a 25mm (3/4”) uPVC solvent cement softened cold
water pipe supply to the EASYCHLORGEN connection point
as indicated in the schematic in section 6.1.Ensure an
isolation valve is fitted upstream to enable safe isolation
during future system maintenance.
EASYCHLORGEN softened water supply
7.2.2 Duplex Softener System (Clack 1665 type if supplied with
EASYCHLORGEN refer to Appendix IV for further information)
Precondition for action:-
A local waste water drain is available at floor level and within
10m of the softener system.

Chapter 7: Installation
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20 | Installation, Operation & Maintenance Instructions EASYCHLORGEN
Perform the following steps:-
1. Install 25mm (1”) pipework to the 1”BSPm threaded softener
raw water inlet of the duplex softener valve head. Fit a
suitable isolation valve upstream of the softener system to
provide a means of isolating the water supply for future
service requirements.
2. Install and fit a 19mmID (3/4”) flexible drain pipe to the
backwash hose connector and allow to discharge to gravity
to a waste water open drain trap.
3. Install 25mm (1”) interconnecting pipework to the saturator
and to the EASYCHLORGEN softened water inlet
connection.
Softener plumbing complete
7.2.3 Salt saturator
The external salt saturator requires a softened water supply.
Note
Damage to the system due to water scaling.
Hard water may damage or adversely impact on the performance
of the system.
Make sure that the saturator is always supplied with softened
water.
Precondition for action:
EASYCHLORGEN and external salt saturator located
correctly.
Perform the following action:-
1. The saturator will require a softened cold water supply with
pipework feed of minimum diameter 15mm (1/2”). The
softened water can be provided by the softening system
used for the EASYCHLORGEN electrolysis system.
2. At the inlet of the saturator, fit a suitable isolation valve.
3. Connect the saturator’s brine outlet to the
EASYCHLORGEN intermediate brine tank inlet connection
using minimum 25mm (¾”) rigid plastic pipe work. Install a
plastic isolating ball valve inline to provide safe isolation
during future maintenance.
Saturator plumbing complete
7.2.4 Intermediate brine tank
The intermediate brine tank is vitally important to maintain a
steady supply of brine to the EASYCHLORGEN skid system.
The level of brine inside the brine tank is controlled by a ball float
valve assembly.
Precondition for action:-
Refer to installation layout schematic, section 7.4
1. The brine tank is fed from the main electrolysis salt saturator
via 25mm (3/4”) rigid plastic pipe work.
2. Install minimum 20mm (1/2”) rigid plastic pipe at the brine
tank outlet and connect up to the EASYCHLORGEN brine
inlet connection.
Intermediate brine tank plumbing complete
7.2.5 Product tank and liquid level measuring column
The product tank facility must be installed strictly in accordance
to: ventilation instructions section 7.2 and the use of the external
tank liquid level column intended for the insertion of level sensor
switches for the correct signalling/switching of the
EASYCHLORGEN. Refer to installation schematics section 7.4
The product tank should be installed so that the product inlet
pipework from the EASYCHLORGEN is independent of the
product outlet pipework used for the flooded suction to dosing
pump and/or transfer pump equipment.
Precondition for action:-
Refer to installation layout schematic, section 7.4
Any pipe unions, valves or other pipe fittings must be
supplied with either EPDM or FPM elastomer seals and
gaskets.
Perform the following steps:-
1. Interconnect the liquid level measuring column to the outlet
of the EASYCHLORGEN and the inlet of the product tank
using a minimum 50mm (1½”) rigid PVC pipework. Fit an
isolating ball valve at both the inlet and outlet of the
measuring column.
2. Fit a suitable isolation ball valve at the product tank outlet in
preparation for the installation of a suitable dosing pump
manifold assembly.
product tank plumbing complete