ProMinent CHLORINSITU V User manual

Chlorine electrolysis system
CHLORINSITU V
Operating instructions
P_PMA_ECA_0016_SW
EN
Original operating instructions (2006/42/EC)983754 BA CI 025 02/23 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...................................................... 5
1.1 Description and operation............................................. 5
1.1.1 Basic substances required......................................... 6
1.1.2 Sound pressure level................................................. 7
1.1.3 Protection against contact and moisture (IP)............. 7
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............................................................... 11
3 Components of the system................................................. 13
4Storage and transport......................................................... 15
5 Preparation for use............................................................. 16
6 Installation and assembly.................................................... 17
6.1 Installation check-lists................................................. 17
6.2 Assembly and installation of the system..................... 18
7 Operation............................................................................ 29
7.1 Touchscreen............................................................... 29
7.2 CHLORINSITU®-V menu overview............................. 31
7.3 Operating principles.................................................... 31
7.4 Production parameters............................................... 32
8 Commissioning................................................................... 33
8.1 Check-list: preparation for commissioning.................. 33
8.2 Check-list: Commissioning......................................... 37
8.3 Commissioning work................................................... 38
9 [ALARM] menu / Troubleshooting....................................... 47
9.1 Alarm list..................................................................... 47
9.2 Vacuum system.......................................................... 47
9.3 Venturi pump.............................................................. 47
9.4 Power supply.............................................................. 48
9.5 Caustic tank................................................................ 48
9.6 Membrane cell............................................................ 49
9.7 Other faults................................................................. 50
9.8 Messages................................................................... 51
10 Maintenance checks and preparation................................. 52
10.1 Care of the Operating Unit........................................ 52
10.2 Maintenance............................................................. 52
10.2.1 Introduction............................................................ 52
10.2.2 Maintenance kits.................................................... 54
10.2.3 Note the production parameters............................ 55
10.2.4 Checking the brine tank......................................... 55
10.2.5 Cooling the Control Cabinet .................................. 55
10.2.6 Refresh control...................................................... 55
10.2.7 Check the amperage at the diaphragm cells......... 55
10.2.8 Monitoring the voltage at the membrane cells....... 56
10.2.9 Regeneration of the Water Hardness Meter ......... 57
10.2.10 Stopping production............................................. 57
10.3 Maintenance on the softener.................................... 58
Table of contents
3

10.3.1 Replacing the water filter....................................... 59
10.4 Maintenance on the Brine Storage Tank.................. 59
10.4.1 Checking the Float on the Level Switch................. 60
10.4.2 Cleaning the Suction Unit in the Brine Storage
Tank....................................................................... 61
10.5 Maintenance on the caustic tank.............................. 62
10.5.1 Emptying the caustic tank...................................... 62
10.5.2 Replacing the O-rings of the ball valves on the
base of the caustic tank......................................... 63
10.5.3 Replacing the O-rings of the couplings on the
base of the caustic tank......................................... 64
10.5.4 Replacing the O-rings on the top of the caustic
tank........................................................................ 64
10.5.5 Checking the temperature sensor on the caustic
tank........................................................................ 65
10.5.6 Replacing the level switch in the caustic tank........ 65
10.5.7 Maintenance on the fan......................................... 66
10.6 Maintenance on the membrane cell.......................... 67
10.6.1 Replacing the O-rings on the cathode side of the
membrane cell....................................................... 67
10.6.2 Replacing the O-rings on the anode side of the
membrane cell....................................................... 68
10.6.3 Replacing the O-rings on the brine valve............... 68
10.6.4 Replacing the O-rings on the brine ball valve........ 69
10.6.5 Replacing the O-rings on the chlorine check
valve...................................................................... 69
10.7 Maintenance on the anode pipe............................... 69
10.7.1 The PVDF Float and Stop Pipe............................. 70
10.7.2 Replacing the O-rings on the anode pipe.............. 71
10.7.3 Replacing the vent valve........................................ 72
10.8 Maintenance on the process water system.............. 72
10.8.1 Cleaning the booster pump filter insert.................. 72
10.8.2 Replacing the sealing rings of the water venturi.... 73
10.8.3 Cleaning the nozzle of the water venturi................ 74
10.8.4 Replacing the refresh valve................................... 75
10.8.5 Replacing the O-rings on the refresh ball valve..... 75
10.8.6 Replacing the lye valve.......................................... 76
10.8.7 Cleaning the flow meter for lye suction.................. 76
10.8.8 Replacing the O-rings on the control valve for lye
suction................................................................... 77
10.8.9 Maintenance on the Lye Pump.............................. 77
10.9 Maintenance on the control cabinet.......................... 78
10.9.1 Checking the Relay Contacts................................ 78
10.9.2 Cleaning the Filters ............................................... 79
10.10 Commissioning the system after maintenance....... 79
10.10.1 Commissioning process....................................... 79
10.11 Maintenance on the chlorine gas detector.............. 80
11 Disposal of used parts........................................................ 81
12 Technical data for the CHLORINSITU-V............................ 82
13 EC Declaration of Conformity for Machinery....................... 84
14 Index................................................................................... 85
Table of contents
4

1 Description of the system
1.1 Description and operation
Water softener
nToo high a level of water hardness seriously damages the
membrane cell.
nOnly operate the system in accordance with the guidelines set
out in these operating instructions.
The system produces free chlorine from a salt solution, as per the
diagram below. The system produces chlorine by means of an
electrochemical process in a membrane cell.
P_PMA_ECA_0017_SW
H
J
Fig. 1: Flow chart for Chlorinsitu-V
No. Component Function
1 Water filter to combat impurities > 500 µm
2 Softener softens the supply water
3 Water hardness analyser
(optional)
measures and controls the water hardness
4 Brine tank brine is produced from salt and water
5 Membrane cell to produce chlorine and NaOH
6 Refresh pipework helps to regenerate the anode
7 Vacuum sensor measures the negative pressure
8 Caustic tank stores the lye
9 Caustic tank cooling system cools the caustic tank
10 Fan dilutes the hydrogen formed with air.
11 Chlorine gas water venturi dissolves the chlorine gas from the refresh pipework in the
process water
Description of the system
5

No. Component Function
12 Venturi pump keeps the process water flow through the electrolysis
system stable
13 Chlorine gas sensor (option) detects any chlorine gas leakage that may develop
14 Caustic metering pump pump to correct the pH value
15 Anode regeneration water venturi draws in brine and anode residue by suction
16 Brine membrane cell flow meter measures the volume of brine for the membrane cell
17 Flow meter for filling the lye tank measures the water flow to the lye tank
1.1.1 Basic substances required
1.1.1.1 Water
Water quality: The system is suitable for connection to the drinking
water network. The water must be of drinking water quality or com‐
parable. With a stable water pressure of 2.5 ... 5 bar and a max‐
imum water hardness of 30 °dH upstream of the softener.
Free chlorine reduces the lifetime of the softener resin
Tab. 2: Water quality
Parameter Limit values Unit of measurement
pH value: ≥ 6.5 - ≤ 9.5
Temperature: 15-18 C°
Inlet pressure: 2.5 < bar < 5 bar
Softened water flow: > 6 l/min
Hardness upstream of the
softener:
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: ClO20.25 mg/l
Chlorate: ClO30.25 mg/l
Description of the system
6

1.1.1.2 Salt
If calcium and/or magnesium are present in the brine, then these
elements precipitate as lime on the negative electrode (cathode)
and the membrane in the membrane cell is irreparably damaged.
Therefore install a softener upstream of the system. Use salt with
as low a calcium and magnesium content as possible in this soft‐
ener. We recommend using Marina® or Broxo-6-15® salt, which is
specifically supplied for water softeners.
Ensure that the salt also meets the chemical specification below:
nInsoluble substances < 100 ppm
nCalcium (Ca+) < 70 ppm
nMagnesium (Mg+) < 70 ppm
1.1.2 Sound pressure level
The sound pressure level is < 70 dB (A) at maximum speed and
maximum back pressure, using water as the medium.
1.1.3 Protection against contact and moisture (IP)
Degree of protection of the system: IP 55.
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.
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 by other equipment close to the outlet, for instance by an
air conditioning system.
Safely discharging the hydrogen/air mixture
nAlways properly discharge the hydrogen/air mixture produced
in the electrolysis system into the outside atmosphere through
a closed, continuously rising pipework system.
nRegularly check the continuity of the hydrogen discharge line
and the supply air to the 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.
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.
Handling the hydrogen in the system
Personal protective equipment
Information in the event of an emer‐
gency
Safety and responsibility
11

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
A
B
C
D
E
F
G
P_PMA_ECA_0018_SW
Fig. 2: Components of the system in the system cabinet
P_PMA_ECA_0019_SW
Fig. 3: Suggested installation of the system
Number Component Function
A Softener Softens the water. Removes calcium and magnesium.
B Flow meter The process water to the caustic tank is switched on and meas‐
ured after measurement of the flow volume.
C Caustic tank Stores the sodium hydroxide solution produced.
D Fan Dilutes the hydrogen gas.
E Refresh pipework Helps to regenerate the anode.
Components of the system
13

Number Component Function
F Membrane cell Chlorine is produced from a salt solution in an electrochemical
process in the membrane cell.
G Venturi pump Keeps the process water flow through the electrolysis system
stable
Components of the system
14

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
15

5 Preparation for use
nAdhere to all national and local regulations relating to the use
of chlorine.
nThe operator of the system is responsible for ensuring that the
regulations are implemented.
nEnsure that the floor of the room has sufficient load-bearing
capacity to bear the weight of the filled system.
nEnsure that the floor is even and horizontal and has a solid
base surface.
nEnsure that the room has an adequately sized floor drain to
safely drain any escaping water in the event of a pipe leak.
nDo not locate permanent workplaces in rooms in which the
system is situated.
nEnsure that the room is free of aggressive vapours and chemi‐
cals.
nEnsure that the room contains minimal dust.
nEnsure that the room temperature and air humidity do not
exceed or fall below the permissible limits. The room may also
need to be air conditioned.
nProtect the system from direct sunlight.
nEnsure that there is adequate mechanical ventilation in the
room to prevent harmful substances accumulating in the
ambient air.
nAllow a minimum gap of ≧ 30 cm for the cooling fan and for
maintenance to the left and right of the control cabinet.
nEnsure that the room has suitable and adequate mains voltage
connections for operation of the relevant system.
nEnsure that the room has an adequate supply of cooling water,
if cooling water is needed.
nPrevent the system from toppling over, for example by fixing
the control cabinet to the wall or floor. Secure it in another way
should this not be possible.
nCheck the requirements relating to accessories, operated
together with the system in the same room, such as air separa‐
tion systems. Refer to the literature for the accessories.
nEnsure that the rear wall of the system has a minimum dis‐
tance of ≧ 15 cm from the wall.
nUse a non-return valve type BA for connection to the drinking
water network, as described in the German version of EN
1717:2000 or the German Technical and Scientific Association
for Gas and Water (DVGW) Technical Regulations. The
system requires a stable water pressure of 2.5 ... 5 bar down‐
stream of the non-return valve.
nSet up the system, as described on the installation plan.
Preparation for use
16

6 Installation and assembly
6.1 Installation check-lists
# Installation process Tick
1 Check whether the installation site complies with the guidelines governing temperature,
safety, space, humidity etc.
2 Clear the area in which the system is to be installed.
3 Remove the plastic wrapping from the system.
4 Check whether the system has suffered damage during transport or exhibits other
damage.
5 Remove the securing material fixing the system to the pallet.
6 Lift the system into its installation position.
7 Ensure that the system is horizontal. Use the support blocks supplied if necessary.
8 Remove the lifting gear from the system.
9 Position the brine tank in its intended position.
10 Connect the pipe supplied (Ø75/Ø110) to the air flow sensor at the fan outlet.
11 Connect the pipework system to the pipe supplied (Ø75/Ø110) and route the discharge
line outside.
12 Make sure that the discharge line (Ø75/Ø110) routed outside is connected in accord‐
ance with ATEX regulations.
13 Connect the Ø20 mm PVCU pipe to the vent valve.
14 Connect the PVCU waste water pipe (Ø40/Ø50 mm) and the angle piece supplied to the
system.
15 Connect the PVCU discharge pipe (Ø40/Ø50 mm) of the system to the waste water
channel.
16 Connect a water line to the Ø20 mm PVCU “Feed water line” coupling on the system.
17 Connect the Ø20 mm PVCU pipe from the “waste water” coupling of the system to the
waste water channel.
18 Connect the PVCU pipe (Ø25/Ø32) of the circulation line to the suction side of the ven‐
turi pump.
19 Connect the PVCU line (Ø20/Ø25) between the "dosing line" connector of the system
and the metering point.
20 Use the (Ø16 mm x 1.8 mm) PE hose to join the “Fill brine tank” connector on the
system to the Ø16 mm connector on the brine tank.
21 Use the (Ø16 mm x 1.8 mm) PE hose to join the “Brine membrane cell” connector on the
system to the Ø16 mm connector on the brine tank.
22 Use the transparent nylon hose (Ø10 x 8 mm) to connect the “Brine softener” connector
on the system to the ⌀10 mm connector on the brine tank.
23 Connect a PVCU pipe (Ø40 mm) to the brine tank overflow. There should be salt in the
brine tank when the PVCU lines are being connected.
24 Connect the brine tank level switch.
25 Connect the metering enable contact in the control cabinet.
Installation and assembly
17

# Installation process Tick
26 Connect the chlorine (Cl2) and pH control in the control cabinet.
27 Connect the main power supply (with the necessary power and amperage) to the ter‐
minal strip in the control cabinet in accordance with the voltage and current specification.
THIS PART WAS ACCEPTED BY: NAME: SIGNATURE:
Project number:
System:
6.2 Assembly and installation of the system
nUser qualification, mechanical/hydraulic installation: trained
and qualified personnel
Ä Chapter 2.2 ‘User qualification’
on page 10
nUser qualification, electrical installation: electrical technician
Ä Chapter 2.2 ‘User qualification’ on page 10
1. Check whether the installation site complies with the guide‐
lines governing temperature, safety, space, humidity etc.
Specification of the installation site
nEnsure that the installation site meets the following condi‐
tions:
nA dry area, which does not necessarily have to be a sep‐
arate room.
nAn area that can be locked/cordoned off so that only
authorised personnel have access.
nAn ambient temperature of at least +10 °C up to a max‐
imum of +35 °C, otherwise an air conditioning system is
required.
nIt should be possible to fit a sewerage drain, a vent valve
and vent openings.
nContamination and impurities in the lines can seriously
damage components in the system.
nEnsure that all lines are free from burrs, chips or other
impurities before connecting the lines to the system.
CAUTION!
The level switches can fail.
–Make sure that no dirt remains in the
tanks after installation.
2. Clear the area in which the system is to be installed.
Check that there are no obstacles around the system.
Provide a clearance of around 1 metre in front of and beside
the system for maintenance purposes.
Always leave room for a waste water connection, drain con‐
duits and a ventilation system. The waste water connection is
located underneath the system.
3. Remove the plastic wrapping from the system.
Installation and assembly
18

4. Check whether the system has suffered damage during
transport or exhibits other damage.
Check that the scope of delivery is complete.
P_PMA_ECA_0018_SW
Fig. 4: Removing transport securing material
5. Remove the securing material fixing the system to the pallet.
In the system cabinet, remove:
nThe tensioning straps on the lye tank,
nThe securing material between the membrane cell and
frame,
nThe plastic around the couplings.
Fig. 5: Lifting the system into its installation position.
6. Lift the system into its installation position.
The system features load hooks, by means of which the
system can be lifted and moved to the correct position.
You can also use a fork-lift to position the system, taking into
account the fact that there is a PVC connector on the under‐
side of the system that can be damaged.
Installation and assembly
19

P_PMA_ECA_0021_SW
Fig. 6: Horizontal system
7. Ensure that the system is horizontal. Use the support blocks
supplied if necessary.
8. Remove the lifting gear from the system.
9. Position the brine tank in its intended position, see section
“Overview of equipment”. Preferably position the brine tank in
the direct vicinity of the system. Remove all objects, even
smaller foreign bodies, from the area under the brine tank.
The tank can be damaged by these objects, owing to the
heavy weight of the tank.
Fig. 7: The pipe supplied (Ø75)
10. Connect the pipe supplied (Ø75) to the air flow sensor at the
fan outlet.
Connect the discharge channel to the fan outlet. Tighten the
threaded connector on the discharge channel tightly to the
outlet of the system. Connect the other end of the discharge
channel to the connecting straight union and tighten the hose
clamp firmly.
11. Connect the pipework system to the pipe supplied (Ø75/
Ø110) and route the discharge line outside.
Route the line outside so that nothing can fall into it.
nContamination and impurities in the lines can seriously
damage components in the system.
nEnsure that all lines are free from burrs, chips or other
impurities before connecting the lines to the system.
Installation and assembly
20