ProMinent Chlorinsitu-III User manual

Chlorine electrolysis system
Chlorinsitu-III
Assembly and operating instructions
Target group: Trained user
EN
Original operating instructions (2006/42/EC)984350 Version: BA Cl 023 09/21 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 8 .
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
1Description of the system...................................................... 6
1.1 Description and operation............................................. 6
2 Safety and responsibility....................................................... 8
2.1 Labelling of Warning Information.................................. 8
2.2 User qualification........................................................ 10
2.3 General safety information.......................................... 11
2.4 Intended use............................................................... 12
3 Components of the system................................................. 13
3.1 Chlorinsitu-III 100 ... 500 g/h....................................... 13
3.2 Chlorinsitu-III 600 ... 1750 g/h..................................... 15
3.3 Chlorinsitu-III 2000 ... 3500 g/h................................... 17
4 Storage and transport......................................................... 20
5Preparation for use............................................................. 21
6 Installation and assembly.................................................... 22
6.1 Assembly check-lists.................................................. 22
6.2 Assembly and installation of the system..................... 23
7 Operation............................................................................ 30
7.1 Navigation................................................................... 33
7.2 Status.......................................................................... 34
7.3 Manual operation........................................................ 34
7.4 Operating settings....................................................... 34
7.5 Alarms......................................................................... 35
8 Commissioning................................................................... 36
8.1 Check-list: Preparation for commissioning................. 36
8.2 Check-list: Commissioning......................................... 39
8.3 Commissioning work................................................... 40
9 [ALARM] / Troubleshooting menu....................................... 49
9.1 Alarm messages......................................................... 49
9.1.1 Vacuum system....................................................... 49
9.1.2 Production tank........................................................ 50
9.1.3 Power Supply Unit................................................... 50
9.1.4 Product tank alarm................................................... 51
9.1.5 Caustic tank............................................................. 51
9.1.6 Membrane cells....................................................... 52
9.1.7 Various faults........................................................... 54
9.2 Messages................................................................... 54
9.2.1 Process Water Flow Meter Faulty............................ 54
9.2.2 Brine Membrane Cell Flow Meter Faulty................. 55
9.2.3 Cooling Water Valve Faulty..................................... 55
10 Maintenance checks and preparation for maintenance...... 56
10.1 Care of the operating unit......................................... 56
10.2 Maintenance............................................................. 56
10.2.1 Introduction............................................................ 56
10.2.2 Maintenance kits.................................................... 57
10.2.3 Maintenance Schedule.......................................... 57
10.2.4 Measuring the pH of the product........................... 58
10.2.5 Checking the brine tank......................................... 58
10.2.6 Cooling the Control Cabinet .................................. 59
Table of contents
3

10.2.7 Check the amperage at the membrane cells......... 59
10.2.8 Monitoring the Amperage at the Membrane
Cells ...................................................................... 59
10.2.9 Regeneration of the Water Hardness Meter ......... 60
10.3 Commissioning the system after maintenance......... 61
10.3.1 Commissioning process......................................... 61
11 Preventative maintenance.................................................. 63
11.1 Stopping Production................................................. 63
11.2 Maintenance on the water softener.......................... 63
11.2.1 Maintenance on the Simplex water softener.......... 64
11.2.2 Maintenance on the Duplex water softener........... 68
11.2.3 Replacing the Water Filter..................................... 71
11.3 Maintenance on the Brine Storage Tank.................. 71
11.3.1 Checking the Float on the Level Switch................. 72
11.3.2 Cleaning the Suction Unit in the Brine Storage
Tank....................................................................... 73
11.4 Maintenance on the production tank......................... 74
11.4.1 Preparation for maintenance on the production
tank........................................................................ 74
11.4.2 Draining the production tank.................................. 74
11.4.3 Replacing the Booster Pump O-rings ................... 76
11.4.4 O-rings on the Three-part Coupling at the Meas‐
uring Point.............................................................. 76
11.4.5 Heat Exchanger O-rings on the Production Tank
(only Chlorinsitu®-III < 600 g/h).............................. 77
11.4.6 Replacing the O-rings on the Transport Stop‐
cock....................................................................... 77
11.4.7 Replacing the Transport Valve.............................. 78
11.4.8 Replacing the Seals on the Water Jet Pump......... 79
11.4.9 Cleaning the Water Jet Pump Nozzle.................... 80
11.4.10 Replacing the O-rings on the Stopcock Under
the Production Tank ............................................ 81
11.4.11 Replacing the O-rings on the underside of the
production tank.................................................... 82
11.4.12 Checking the Temperature Sensor in the Pro‐
duction Tank........................................................ 83
11.4.13 Replacing the Seals on the Upper Side of the
Production Tank................................................... 84
11.4.14 Checking the Level Switch in the Production
Tank .................................................................... 85
11.4.15 Replacing the Chlorine Gas Valve....................... 85
11.4.16 Fitting All Components......................................... 86
11.5 Maintenance on the Lye Storage Tank .................... 86
11.5.1 Preparation for Maintenance on the Lye Storage
Tank....................................................................... 87
11.5.2 Draining the Lye Storage Tank.............................. 88
11.5.3 Replacing the O-rings on the Stopcocks on the
Bottom of the Lye Storage Tank............................ 89
11.5.4 Replacing the O-rings on the Couplings on the
Bottom of the Lye Storage Tank............................ 89
11.5.5 Replacing the O-rings on the Heat Exchanger
(only Chlorinsitu®-III < 600 g/h).............................. 90
11.5.6 Replacing the Seals on the Upper Side of the Lye
Storage Tank......................................................... 91
Table of contents
4

11.5.7 Checking the Temperature Sensor in the Lye
Storage Tank......................................................... 92
11.5.8 Checking the Level Switch in the Lye Storage
Tank ...................................................................... 93
11.5.9 Fitting All Components........................................... 93
11.5.10 Maintenance on the Fan...................................... 94
11.6 Maintenance on the Membrane Cell ........................ 94
11.6.1 Preparation for Maintenance on the Membrane
Cell ........................................................................ 95
11.6.2 Replacing the O-rings on the Anode Side of the
Membrane Cell...................................................... 95
11.6.3 Replacing the O-rings on the Brine Valve.............. 96
11.6.4 Replace the O-rings on the brine valve................. 96
11.7 Maintenance on the Anode Pipe .............................. 96
11.7.1 Preparation for Maintenance on the Anode Pipe .. 97
11.7.2 The PVDF Float and Stop Pipe............................. 97
11.7.3 Replacing the Refresh Valve................................. 98
11.7.4 Replace the O-rings on the Refresh Tap............... 98
11.7.5 Replace the O-rings on the Anode Pipe................ 99
11.7.6 Replacing the O-rings on the Bleed Valve........... 100
11.8 Maintenance on the product tank........................... 100
11.8.1 Prerequisites for maintenance............................. 100
11.8.2 Checking for leak-tightness................................. 100
11.8.3 Checking the lid on the product tank................... 101
11.8.4 Checking the Liquid Level Switch........................ 101
11.8.5 Checking the Level Switch .................................. 101
11.8.6 Checking the chlorine suction unit....................... 102
11.8.7 Replacing the sealing rings on the product suction
unit....................................................................... 103
11.9 Maintenance on the Control Cabinet...................... 103
11.9.1 Checking the Relay Contacts.............................. 104
11.9.2 Cleaning the Filters ............................................. 105
11.10 Maintenance on the chlorine gas detector............ 105
11.10.1 Renewing the chlorine gas sensor..................... 106
11.10.2 Testing the Chlorine Gas Sensor....................... 106
12 Repair............................................................................... 107
13 Spare parts....................................................................... 108
13.1 Maintenance kits..................................................... 108
14 Disposal of used parts...................................................... 109
15 Electrical data................................................................... 110
16 Technical data................................................................... 111
16.1 Flow chart............................................................... 113
17 EC Declaration of Conformity for Machinery..................... 115
18 Index................................................................................. 116
Table of contents
5

1 Description of the system
The system is used for water disinfection in:
nSwimming pools
nDrinking water
nWaste water
nF&B
nVarious process water systems
netc.
The system is used to electrochemically produce
‘free chlorine’ ,
which is referred to as the product throughout the operating
instructions.
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 generated in situ where it is needed.
nThere is no need to transfer concentrated chemicals
nThe water quality is markedly improved, resulting in fewer by-
products.
1.1 Description and operation
The system produces free chlorine from a brine solution by means
of an electrochemical process in a membrane cell, as per the dia‐
gram below
A1699
Fig. 1: Components
1. Softener
2. Brine tank
3. Membrane cell
4. Refresh pipe
5. Caustic tank
6. Heat exchanger
7. Fan
8. Production tank
9. Water venturi
10. Booster pump
11. Product tank
Description of the system
6

We recommend using Chlorinsitu salt, Marina® or Broxo-6-15® salt
or another suitable salt specifically supplied for water softeners.
The salt used must conform to one of the following standards:
nEN 16401,
nEN 973 (in tablet-form only),
nEN 16370.
Ensure that the salt also meets the chemical specification below:
nInsoluble substances < 100 ppm
nCalcium (Ca+) < 70 ppm
nMagnesium (Mg+) < 70 ppm
The system is suitable for connection to the drinking water net‐
work. The water should be of drinking water quality or comparable.
The sound pressure level is < 70 dB (A) at maximum speed and
maximum back pressure, using water as the medium.
Salt quality
Water quality
Sound pressure level
Description of the system
7

2 Safety and responsibility
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 and responsibility
8

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 and responsibility
9

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 and responsibility
10

2.3 General safety information
WARNING!
Danger from hazardous substances!
Possible consequence: Fatal or very serious inju‐
ries.
Please ensure when handling hazardous sub‐
stances that you have read the latest safety data
sheets provided by the manufacture of the haz‐
ardous substance. The actions required are
described in the safety data sheet. Check the
safety data sheet regularly and replace, if neces‐
sary, as the hazard potential of a substance can be
re-evaluated at any time based on new findings.
The system operator is responsible for ensuring
that these safety data sheets are available and that
they are kept up to date, as well as for producing
an associated hazard assessment for the worksta‐
tions affected.
WARNING!
Safely discharging the hydrogen / air mixture
Always properly discharge the hydrogen / air mix‐
ture produced in the electrolysis system into the
outside atmosphere through a closed, continuously
rising pipework system.
Regularly check the continuity of the hydrogen dis‐
charge line and the supply air to the system.
The system generates a small amount of a hydrogen-air mixture. It
is essential that this hydrogen-air mixture is safely discharged into
the outside ambient air. Ensure during installation that no air is
drawn in from other equipment close to the outlet, for instance by
an air conditioning system.
The operator must provide personal protective equipment in line
with the hazards and in compliance with national regulations.
The operator must supplement the emergency information in line
with the hazards and in compliance with national regulations.
nShould you smell chlorine gas, safely and as quickly as pos‐
sible:
–switch off the electrolysis system,
– or press an Emergency Stop switch,
– or disconnect the mains power supply,
– or trigger an external fuse.
– Inform Service.
nIn an electrical emergency, securely disconnect the electrolysis
system from the mains power supply as quickly as possible.
Inform Service.
Handling the hydrogen in the system
Personal protective equipment
Information in the event of an emer‐
gency
Safety and responsibility
11

2.4 Intended use
nThe system is only intended for the production and metering of
a disinfection solution containing chlorine from sodium chloride.
This disinfection solution is used to disinfect water.
nAll other uses or modifications are prohibited.
nDo not operate the system in conditions other than those
described in these operating instructions.
nOnly allow qualified personnel to operate the system.
nPlease observe the information in the operating instructions at
every phase of the system's service life.
nPlease observe the relevant national regulations and guide‐
lines at every phase of the system's service life.
Safety and responsibility
12

3 Components of the system
3.1 Chlorinsitu-III 100 ... 500 g/h
A1702
11. 2.
Fig. 2: Installation of the system
7
16
5
12
9
4
3
13
14
15
18
16
17
10
6
A1701
Fig. 3: Components of the system
Components of the system
13

Number Component Function
1 Softener Softens the water. Removes calcium and magnesium.
2 Brine tank Salt stock. It produces a saturated salt solution together with the
softened water.
3 Membrane cell Sodium hypochlorite is produced from a salt solution in the mem‐
brane cell in an electrochemical process.
4 Refresh pipe Measurement and degassing of the diluted brine from the mem‐
brane cell.
5 Caustic tank A sodium hydroxide solution is transported from this tank to the
supply tank.
6 Heat exchanger External cooling which dissipates the heat produced by the electro‐
chemical process.
7 Fan Dilution of the hydrogen gas to up to 10 % of the explosion limit.
8 Production tank The production tank holds a supply with a concentration of approx.
25 g/l.
9 Water venturi Generates negative pressure in the system so that product can be
drawn in by suction.
10 Booster pump Pumps the sodium hypochlorite from the product tank through the
water venturi to produce negative pressure.
11 Product tank Supply of sodium hypochlorite with a concentration of approx. 25
g/l.
12 Flow meter The process water to the caustic tank is switched on and meas‐
ured after measurement of the flow volume.
13 Flow meter Measures the flow volume of the cooling water
14 Water filter Water filter in the water supply
15 Vacuum gauge Controls the negative pressure in the system
16 Manometer and pressure
reducer
Pressure reducer and manometer for adjustment of the water pres‐
sure.
17 Sampling tap Sampling tap for measuring the water hardness of the process
water.
18 Sensor air flow Measures the air flow to dilute the hydrogen concentration
Components of the system
14

3.2 Chlorinsitu-III 600 ... 1750 g/h
11. 2.
A1704
Fig. 4: Installation of the system
A1703
16.
17.
1.
3. 10.
9.
14.
8.
13.
18.
7.
5.
15.
12.
4.
Fig. 5: Components of the system
Components of the system
15

Number Component Function
1 Softener Softens the water. Removes calcium and magnesium.
2 Brine tank Salt stock. It produces a saturated salt solution together with the
softened water.
3 Membrane cell Sodium hypochlorite is produced from a salt solution in the mem‐
brane cell in an electrochemical process.
4 Refresh pipe Measurement and degassing of the diluted brine from the mem‐
brane cell.
5 Caustic tank A sodium hydroxide solution is transported from this tank to the
supply tank.
6 Heat exchanger External cooling which dissipates the heat produced by the electro‐
chemical process.
7 Fan Dilution of the hydrogen gas to up to 10 % of the explosion limit.
8 Production tank The production tank holds a store with a concentration of approx.
25 g/l.
9 Water venturi Generates negative pressure in the system so that product can be
drawn in by suction.
10 Booster pump Pumps the sodium hypochlorite from the product tank through the
water venturi to produce negative pressure.
11 Product tank Supply of sodium hypochlorite with a concentration of approx. 25
g/l.
12 Flow meter The process water to the caustic tank is switched on and meas‐
ured after measurement of the flow volume.
13 Flow meter Measures the flow volume of the cooling water
14 Water filter Water filter in the water supply
15 Vacuum gauge Controls the negative pressure in the system
16 Manometer and pressure
reducer
Pressure reducer and manometer for adjustment of the water pres‐
sure.
17 Sampling tap Sampling tap for measuring the water hardness of the process
water.
18 Sensor air flow Measures the air flow to dilute the hydrogen concentration
Components of the system
16

3.3 Chlorinsitu-III 2000 ... 3500 g/h
A1707
11. 2.
Fig. 6: Installation of the system
5.
1.
10.
14.
9.
8.
7.
18.
A1705
Fig. 7: Components of the system (side A)
Components of the system
17

A1706
15.
4.
13.
3.
3.
16.
12.
17.
Fig. 8: Components of the system (side B)
Components of the system
18

Number Component Function
1 Softener Softens the water. Removes calcium and magnesium.
2 Brine tank Salt stock. It produces a saturated salt solution together with the
softened water.
3 Membrane cell Sodium hypochlorite is produced from a salt solution in the mem‐
brane cell in an electrochemical process.
4 Refresh pipe Measurement and degassing of the diluted brine from the mem‐
brane cell.
5 Caustic tank A sodium hydroxide solution is transported from this tank to the
supply tank.
6 Heat exchanger External cooling which dissipates the heat produced by the electro‐
chemical process.
7 Fan Dilution of the hydrogen gas to up to 10 % of the explosion limit.
8 Production tank The production tank holds a store with a concentration of approx.
25 g/l.
9 Water venturi Generates negative pressure in the system so that product can be
drawn in by suction.
10 Booster pump Pumps the sodium hypochlorite from the product tank through the
water venturi to produce negative pressure.
11 Product tank Supply of sodium hypochlorite with a concentration of approx. 25
g/l.
12 Flow meter The process water to the caustic tank is switched on and meas‐
ured after measurement of the flow volume.
13 Flow meter Measures the flow volume of the cooling water
14 Water filter Water filter in the water supply
15 Vacuum gauge Controls the negative pressure in the system
16 Manometer and pressure
reducer
Pressure reducer and manometer for adjustment of the water pres‐
sure.
17 Sampling tap Sampling tap for measuring the water hardness of the process
water.
18 Sensor air flow Measures the air flow to dilute the hydrogen concentration
Components of the system
19

4 Storage and transport
Store the system in its original transport packaging in a sealed
room, observing the following conditions:
nat a temperature of between 5 °C ... 50 °C
nat a relative air humidity below 85 % without condensation
nin a non-aggressive environment (no harmful vapours, chemi‐
cals, etc.)
nprotected from direct sunlight, rain and moisture
nstore the system upright.
Unsuitable ambient conditions can result in malfunctions and faults
in the installed system. When the system is in operation, this can
also lead to hazards to personnel.
nOnly connect appropriate lifting equipment to the lifting eyes on
the top of the system.
nCarefully transport the system vertically; see label on the trans‐
portation packaging.
nAvoid mechanical impacts.
nProtect the system from direct sunlight, rain and moisture
during transportation.
Incorrect transportation can result in personal injuries and material
damage.
Once the system has been unpacked, secure the system with
lashing straps to prevent it from toppling over.
Storage
Transport
Storage and transport
20