ProMinent CHLORINSITU IIa XL User manual

Chlorine electrolysis system
CHLORINSITU IIa XL
Assembly and operating instructions
A3326
Target group: trained users
EN
Original operating instructions (2006/42/EC)Part no. 990307 Version: BA CI 024 09/22 EN
Please carefully read these operating instructions before use. · Do not discard.
The operator shall be liable for any damage caused by installation or operating errors.
The latest version of the operating instructions are available on our homepage.

In order to make it easier to read, this document uses the male
form in grammatical structures but with an implied neutral sense.
The document is always aimed equally at women, men and
gender-neutral persons. We kindly ask readers for their under‐
standing in this simplification of the text.
Please read the supplementary information in its entirety.
Information
This provides important information relating to the
correct operation of the unit or is intended to make
your work easier.
Warning information
Warning information includes detailed descriptions of the haz‐
ardous situation, see
Ä Chapter 2.1 ‘Labelling of Warning Informa‐
tion’ on page 11 .
The following symbols are used to highlight instructions, links, lists,
results and other elements in this document:
Tab. 1: More symbols
Symbol Description
Action, step by step.
⇨Outcome of an action.
Links to elements or sections of these instructions or other applicable documents.
nList without set order.
[Button] Display element (e.g. indicators).
Operating element (e.g. button, switch).
‘Display/GUI’ Screen elements (e.g. buttons, assignment of function keys).
CODE Presentation of software elements and/or texts.
General non-discriminatory approach
Supplementary information
Supplemental directives
2

Table of contents
1 Description of the system...................................................... 5
1.1 Product......................................................................... 5
1.2 Operation and monitoring............................................. 6
1.3 PID flow diagram.......................................................... 7
1.4 Description.................................................................... 9
1.4.1 Basic substances required......................................... 9
1.4.2 Water quality.............................................................. 9
1.4.3 Sound pressure level............................................... 10
1.4.4 Protection against contact and moisture (IP)........... 10
2 Safety.................................................................................. 11
2.1 Labelling of Warning Information................................ 11
2.2 User qualification........................................................ 13
2.3 General safety information.......................................... 14
3 Storage and transport......................................................... 15
3.1 Storage....................................................................... 15
3.2 Transport.................................................................... 15
4 Components of the system................................................. 16
4.1 Softener system.......................................................... 16
4.2 Brine tank.................................................................... 16
4.3 Degassing tank........................................................... 17
4.3.1 Routing the degassing tank pipework...................... 17
4.4 Rectifier....................................................................... 19
4.5 Brine metering station................................................. 20
4.6 Rinsing unit, acid (optional)........................................ 20
5 Requirements regarding the installation place.................... 21
6 Installation and assembly.................................................... 22
6.1 Assembly and installation........................................... 22
6.2 Installation check-list................................................... 24
7 Operation............................................................................ 25
7.1 Screen saver............................................................... 25
7.2 Main screen................................................................ 25
7.2.1 System bar............................................................... 26
7.3 Menu navigation screen.............................................. 26
7.4 Overview..................................................................... 26
7.5 Cell overview.............................................................. 27
7.6 Degassing tank overview............................................ 28
7.7 On/off switch............................................................... 28
7.8 Alarms......................................................................... 29
8 Commissioning................................................................... 30
8.1 Actions prior to commissioning................................... 30
8.2 Water hardness measurement................................... 31
8.3 Water supply............................................................... 32
8.4 Electrical power.......................................................... 32
8.5 Hydraulics................................................................... 32
8.6 Signals and setpoints.................................................. 32
8.7 Commissioning work................................................... 33
8.8 Adjustments................................................................ 34
8.9 Monitoring................................................................... 35
Table of contents
3

8.9.1 After 10 minutes of production................................. 35
8.9.2 After 30 minutes of production................................. 35
8.9.3 After 1 hour of production........................................ 35
8.9.4 After 4 hours of production...................................... 36
8.9.5 After 1 day of production.......................................... 36
9 Maintenance and repair...................................................... 37
9.1 Preparation for maintenance...................................... 37
9.2 Spare parts................................................................. 37
9.3 Maintenance packages............................................... 37
9.4 Maintenance contracts................................................ 38
9.5 Care of the operating unit........................................... 38
9.6 Checks........................................................................ 39
9.6.1 Daily checks............................................................. 39
9.6.2 Weekly checks......................................................... 39
9.7 Repair......................................................................... 39
10 Decommissioning................................................................ 40
11 Disposal of used parts........................................................ 42
12 EC Declaration of Conformity for Machinery....................... 43
13 Index................................................................................... 44
Table of contents
4

1 Description of the system
A3358
Fig. 1: Schematic diagram of a system.
The system is used for water disinfection:
nDrinking water
nCooling tower
nDifferent types of process water
nSwimming pools
netc.
INFORMATION: NaOCl is susceptible to ageing. We recommend
continuously consuming the NaOCl to minimise the production of
by-products.
The system is used to electrochemically produce ‘free chlorine’
(NaOCl solution) from sodium chloride. The quantity of ‘free
chlorine’ is determined, among other things, by the concentration
of chloride ions, but also by the current strength.
The system has the following features:
nThe product is produced in situ where it is needed.
nThere is no need to transport concentrated chemicals.
1.1 Product
The NaOCl solution produced will be referred to as the [product]
throughout these installation and operating instructions.
Description of the system
5

1.2 Operation and monitoring
All components and safety functions are monitored and operated
using a multicoloured touchscreen. The system stops if a fault
occurs. A message is shown on the touchscreen. The systems are
equipped as standard with a VPN router and thus also with remote
control. The viewer can be used by the operator to remotely mon‐
itor the system. Remote support of the system by the manufacturer
is available on request.
The system should be connected to the operator’s local LAN. This
connection is recommended for service purposes. If required, the
system can also be connected to other systems with a Modbus or
Profibus connector. There is also a possibility of connecting the
system to the mobile network, such as the 4G mobile network as
well as the LAN connection.
Description of the system
6

1.3 PID flow diagram
A3327
Fig. 2: PID flow diagram showing the CIIa 5 kg/h
Description of the system
7

Tab. 2: PID flow diagram legend
Number Name Description Standard
FCV3 Check valve, electrolysis cells To avoid NaCIO backwashing x
FT3 Total flow Measurement of the product flow x
FT7 Water flow and temperature Measurement of the incoming water flow
and the temperature
x
HV31 Volumetric adjustment valve To adjust the product flow to the required
setpoint
x
HV3 Electrolysis cell manual valve A manual valve to close the electrolysis cell
inlet to maintain all components upstream
of the electrolysis cell
x
HV32 Sampling/drain valve Sampling valve for brine sampling, drainage
and cell cleaning
x
HV6 Manual valve for incoming brine Manual valve to close the brine metering
line
x
HV61 Water inlet manual valve Manual valve to close the water supply x
LS10 Leak monitor, collection pan,
float-1
Detects leaks in the collection pan x
LS11 Leak monitor, collection pan,
float-2
Detects leaks in the collection pan x
LS3 Flow detector Detects that all electrolysis cells are filled x
LS31 Low-voltage electrolysis cells Electrolysis cells empty x
PIC6 Pressure reducer Pressure reducer to adjust to smooth and
even pressure
x
SV7 Water solenoid valve Solenoid valve for water supply x
TT10 Ambient temperature Ambient temperature measurement x
TT3 Anode cell 2 temperature sensor Temperature measurement of the anode
electrode, electrolysis cell 2
x
TT31 Cathode cell temperature sensor Temperature measurement of the cathode
electrodes, electrolysis cells
x
TT32 Temperature at the product outlet Temperature measurement of the NaCIO
solution
x
TT41 Anode cell 1 temperature sensor Temperature measurement of the anode
electrode, electrolysis cell 1
x
U6 Conductivity sensor Conductivity measurement x
FS13 Digital air flow sensor Digital air flow sensor for safety measure‐
ment
x
FT13 Analogue air flow sensor Analogue air flow sensor for fan control x
LAH14 High-level degassing tank Float switch in the degassing tank to stop
production
Optional
LAL14 Low-level degassing tank Float switch in the degassing tank to start
production
Optional
LS12 Degassing tank flow sensor Detects flow in the degassing tank x
LS14 Level, degassing tank, high Float switch, level in the degassing tank is
too high
x
Description of the system
8

Number Name Description Standard
LS141 Leak monitor, collection pan,
degassing tank
Float switch in the collection pan of the
degassing tank
Optional
LT12 Degassing tank ultrasound
sensor
Liquid level measurement in the degassing
tank
x
P13 Degassing tank fan Fan to dilute hydrogen to 25% of the LEL
(Lower Explosion Limit)
x
QAH12 Gas detector Unit for the measurement of hydrogen Optional
-101 FF4 Water filter Water filter Optional
+A8 FT3 Softener brine suction Softener brine suction Optional
+A8 HV3 Water supply manual valve Valve to close the water supply upstream of
the softener
Optional
LAH3 High-level brine tank Float switch stops the brine tank from filling Optional
LAL3 Low-level brine tank Float switch starts the brine tank filling Optional
P2 Brine metering pump Brine metering pump, controlled by conduc‐
tivity
Optional
PI4 Manometer Pressure measurement x
Q5 Softener Softener to reduce the hardness to <0.05
°dH
Optional
QAH5 Water hardness measurement Measurement of the water hardness to
ensure <0.05 °dH
Optional
SV3 Softener brine suction valve Solenoid valve in the softener’s brine suc‐
tion line to control brine suction
Optional
SV5 Valve, filling, brine tank Solenoid valve to fill the brine tank Optional
H1 Electrolysis cell 1 Production unit electrolysis cell 1 X
1.4 Description
1.4.1 Basic substances required
Sodium chloride for the brine tank: We recommend using
CHLORINSITU salt.
If you do not wish to or are unable to do this, only use salt that is
certified in accordance with the EU Regulation 528/2012.
The salt needs to meet the following specifications:
nmin. 99.4 % NaCl,
nmax. 10 mg/kg manganese,
nmax. 0.05 % insoluble parts,
nmax. 10 mg/kg iron,
nmax. 100 mg/kg calcium + magnesium.
1.4.2 Water quality
The water should be of drinking water quality or comparable.
Description of the system
9

It is necessary to feed water that meets certain specifications for
the safe and correct operation of the system. It is important to
adhere to these specifications as only then can the service life of
the membrane cell be guaranteed.
Tab. 3: Water quality: The water should be of drinking water quality or comparable.
Parameter Name Limit Unit
pH value: ≥ 6.5 - ≤ 9.5
Temperature: 15 ... 18 C°
Inlet pressure: 2.5 < bar < 5 bar
Softened water flow: > 6 l/min
Hardness: Ca + Mg < 30 °dH
Hardness downstream of the softener: Ca + Mg 0 °dH
Free chlorine: Cl2<1 * ppm
Iron: Fe 200 µg/l
Manganese: Mn 50 µg/l
Chlorite: ClO2-0.25 mg/l
Chlorate: ClO3-0.25 mg/l
1.4.3 Sound pressure level
The sound pressure level is < 70 dB at maximum speed, at max‐
imum back pressure, and using water as the medium.
1.4.4 Protection against contact and moisture (IP)
Degree of protection of the system: IP 54.
Degree of protection of the control and rectifier cabinets: IP20.
Description of the system
10

2 Safety
2.1 Labelling of Warning Information
These operating instructions provide information on the technical
data and functions of the product. These operating instructions pro‐
vide detailed warning information and are provided as clear step-
by-step instructions.
The warning information and notes are categorised according to
the following scheme. A number of different symbols are used to
denote different situations. The symbols shown here serve only as
examples.
DANGER!
Nature and source of the danger
Consequence: Fatal or very serious injuries.
Measure to be taken to avoid this danger.
Description of hazard
– Denotes an immediate threatening danger. If
the situation is disregarded, it will result in fatal
or very serious injuries.
WARNING!
Nature and source of the danger
Possible consequence: Fatal or very serious inju‐
ries.
Measure to be taken to avoid this danger.
– Denotes a possibly hazardous situation. If the
situation is disregarded, it could result in fatal
or very serious injuries.
CAUTION!
Nature and source of the danger
Possible consequence: Slight or minor injuries.
Material damage.
Measure to be taken to avoid this danger.
– Denotes a possibly hazardous situation. If the
situation is disregarded, it could result in slight
or minor injuries. May also be used as a
warning about material damage.
NOTICE!
Nature and source of the danger
Damage to the product or its surroundings.
Measure to be taken to avoid this danger.
– Denotes a possibly damaging situation. If the
situation is disregarded, the product or an
object in its vicinity could be damaged.
Introduction
Safety
11

Type of information
Hints on use and additional information.
Source of the information. Additional measures.
– Denotes hints on use and other useful informa‐
tion. It does not indicate a hazardous or dam‐
aging situation.
Safety
12

2.2 User qualification
WARNING!
Danger of injury with inadequately qualified per‐
sonnel
The operator of the system / equipment is respon‐
sible for ensuring that the qualifications are ful‐
filled.
If inadequately qualified personnel work on the unit
or loiter in the hazard zone of the unit, this could
result in dangers that could cause serious injuries
and material damage.
– All work on the unit should therefore only be
conducted by qualified personnel.
– Unqualified personnel should be kept away
from the hazard zone.
The pertinent accident prevention regulations, as
well as all other generally acknowledged safety
regulations, must be adhered to.
Training Definition
Instructed personnel An instructed person is deemed to be a person who has been instructed and,
if required, trained in the tasks assigned to him and possible dangers that
could result from improper behaviour, as well as having been instructed in the
required protective equipment and protective measures.
Trained user A trained user is a person who fulfils the requirements made of an instructed
person and who has also received additional training specific to the system
from the manufacturer or another authorised distribution partner.
Trained, qualified per‐
sonnel
A trained, qualified employee is deemed to be a person who is able to assess
the tasks assigned to him and recognize possible hazards based on his
training, knowledge and experience, as well as knowledge of pertinent regula‐
tions. A trained, qualified employee must be able to perform the tasks
assigned to him independently with the assistance of drawing documentation
and parts lists. The assessment of a person's technical training can also be
based on several years of work in the relevant field.
Electrical technician An electrical technician is able to complete work on electrical systems and rec‐
ognise and avoid possible dangers independently based on his technical
training and experience as well as knowledge of pertinent standards and regu‐
lations. An electrical technician must be able to perform the tasks assigned to
him independently with the assistance of drawing documentation, parts lists,
terminal and circuit diagrams. The electrical technician must be specifically
trained for the working environment in which the electrical technician is
employed and be conversant with the relevant standards and regulations.
Service The Service department refers to service technicians, who have received
proven training and have been authorised by the manufacturer to work on the
system.
Safety
13

2.3 General safety information
WARNING!
Warning of hydrogen and supply voltage
Only allow authorised technical personnel to open
the system cabinet.
WARNING!
Warning of chemicals
The lid of the product tank must be tightly closed
as soon as product or hydrogen is present in the
product tank.
– Allow the fan to ventilate the system cabinet for
a further 10 minutes before opening the system
cabinet with production switched off.
Safety
14

3 Storage and transport
3.1 Storage
Storage of the system in unsuitable ambient conditions.
nUnsuitable ambient conditions can result in malfunctions and
faults in the installed system. When the system is in operation,
these malfunctions and faults can lead to hazards to personnel.
Store the system in its original transport packaging in a sealed
room:
nAt a temperature of between 5 °C ... 50 °C,
nAt a relative air humidity below 85 % without condensation,
nIn a non-aggressive environment, e.g. no harmful vapours,
chemicals etc.,
nProtected from direct sunlight, rain and moisture,
nStore the system upright.
3.2 Transport
Incorrect transport
nIncorrect transport of the system by unsuitable transport pack‐
aging or horizontal transport.
nAdhere to the following instructions.
Incorrect transportation can result in personal injury and material
damage.
nTransport the system upright and only tilt it briefly to an angle
of no more than 30 ° - see the label on the transport packaging.
nAvoid mechanical knocks.
nProtect the system from direct sunlight, rain and moisture
during transport.
nEnsure that the system, including the electrolysis cells, is
drained and dry before transport.
Storage and transport
15

4 Components of the system
4.1 Softener system
The system comprises a minimum of 2 cabinets:
nThe production cabinet,
nThe safety control cabinet (SCC).
– With smaller systems (≦10 kg) the rectifier is also accom‐
modated in this SCC cabinet.
There are additional cabinets for the rectifier for systems with a
production rate of ≧ 15 kg. Refer to the data sheet for information
on the number of additional cabinets. The system also requires
certain other components supplied by the manufacturer in addition
to these cabinets. If these components are not supplied by the
manufacturer, please make sure that the components meet the
requirements stipulated on the data sheet. The components are
described on the data sheet and additional information is explained
in this section.
4.2 Brine tank
The brine tank is used for the storage and treatment of the brine
solution for the production of the product. The brine tank must be
filled with salt that meets the required specifications, see the data
sheet for the system and Ä Further information on page 9
Ensure that the brine is filtered and clean for transport to the
system. Put in place appropriate measures, such as a filter in the
suction line. Make sure that the brine tank is filled with softened
water from the water softening system for a minimum of 8 hours
prior to commissioning to generate an adequate brine solution con‐
centration of > 280 g/l.
Components of the system
16

4.3 Degassing tank
A3334
G.
FT13 FS13
H
F
D
Fig. 3: Degassing tank
The fan, air flow sensor and other connectors can be mounted as
shown on the drawing.
Make sure that the position of the degassing tank is stable and that
there are no foreign bodies that could cause a leak in the tank
floor.
All the parts supplied need to be installed, such as the:
n“High level” float switch LAH 13
nUltrasound liquid level sensor LT12.
nNaClO overflow T-piece F.
nNaClO line to the T-piece D.
nFan with line connected to the degassing tank G.
nVentilation line from the tank to the outside of the building H.
nPosition both air flow sensors in the ventilation line FS13 and
FT13.
4.3.1 Routing the degassing tank pipework
Diagram Status
A3337
The NaClO line coming from the system may not be routed downwards.
Components of the system
17

Diagram Status
A3336
The installation of a trap in the NaClO line coming from the system is not permitted
A3335
The line should always be installed upwards. If you are using a higher degassing tank,
the upward line may not exceed a height difference of 5 metres because of problems
with back pressure.
A3338
Make sure that the pipework is either routed horizontally or with a constant slight
upward incline to a safe discharge point outside the building. This rising pipework
routing is crucial for the safety of the entire system, as it prevents hydrogen from
accumulating in the lines. Hydrogen is lighter than air and rises in the horizontal or
inclined lines to the safe discharge point, even if the forced ventilation system fails.
A3339
A flow detector is fitted in the NaCIO overflow T-piece. This flow detector should
always be fitted pointing vertically downwards. The adjustment screw and the LEDs
are used to adjust and display during commissioning and normal production.
The pipework must:
nComply with the diameter specified on the data sheet,
nBe routed preferably direct and straight,
nHave no bends,
nBe ≦ than 10 metres long.
Contact the manufacturer for appropriate solutions in the event of
distances of ≧ 10 metres. Only use smooth bends to avid turbulent
air flows. The air flow sensors need to be fitted in the ventilation
line in accordance with the direction of air flow. First the analogue
air flow sensor (FT13) and then the digital air flow sensor (FS13),
with a minimum spacing of 1.5 metres from each other. They
should be close to the mains junction box so that the cable does
not need to be lengthened.
4.3.1.1 Sampling point
We strongly recommend making provision in the operator’s system
to take a sample of the NaCIO concentration.
Components of the system
18

4.4 Rectifier
WARNING!
Danger of electric shock.
Make sure that no main power cable is energised
before connecting the main power cable of the
safety control cabinet (SCC). A part of the safety
control cabinet (SCC) remains energised during
maintenance or repair even if the main switch is
turned off.
Make sure that the installation location of the rectifier is load-
bearing and situated in a clean environment. The location needs to
conform to the specifications, see system data sheet.
The main power supply for the rectifier is connected inside the
safety control cabinet. This unit controls the power supply to the
rectifier in the event of an emergency. There is a connection from
the safety control cabinet to the rectifier.
The control cable to control the rectifier can be connected to the
system control. This is a Profibus connection fitted with Profibus
plugs.
The direct current cables of the rectifier to the system need to be
permanently connected to the copper electrode adapter plate on
the cells and to the copper connection plate on the rectifier. Use a
torque wrench to do this, tightening the direct current cables to
approx. 80 Nm. Cable connectors are located above the cells in
the system to route the cables to the cell connectors. The cross-
sectional area of the cables needs to be approx. 120 mm2, with the
cable diameter including insulation being between 19 mm and 24
mm. 16 cables are needed for each cell configuration. 8x anodes
and 8x cathodes.
A3342
Fig. 4: Rectifier and safety control
cabinet (SCC) 15 kg
A3343
Fig. 5: Direct current cables of the rec‐
tifier to the system
Components of the system
19

The cables need to be routed in a stable cable conduit with a min‐
imum spacing of 0.5 cm from each other. No cables are included in
the scope of delivery. Please contact the manufacturer of the
system if cables are required.
4.5 Brine metering station
The brine metering station is responsible for supplying the produc‐
tion unit with brine water. The pump is actuated and controlled by
the system control. Find out in section 6 how to connect the pump.
4.6 Rinsing unit, acid (optional)
There is an option to perform acid rinsing of the cells to remove
deposits from the electrolysis cells. The cleaning process is
described in the Service Manual.
The rinsing unit, acid (optional), can be electrically connected to
the control via a plug. You can route this plug into the control cab‐
inet through the underside of the control cabinet. To do so, simply
remove the blue cover under the control cabinet.
A3344
Fig. 6: Minimum spacing of 0.5 cm
Components of the system
20