ProMinent DULCOLyse User manual

Chlorine electrolysis system
DULCOLyse
Operating instructions
P_PMA_ECA_0015_SW_2
EN
Original operating instructions (2006/42/EC)985179 BA DZ 008 06/21 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 9 .
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...................................................... 4
1.1 Components of the system........................................... 4
1.2 Description and operation............................................. 5
1.2.1 Quality requirements of the feed water for DULCO‐
Lyse........................................................................... 8
2 Safety and responsibility....................................................... 9
2.1 Labelling of Warning Information.................................. 9
2.2 User qualification........................................................ 11
2.3 General safety information.......................................... 12
2.4 Intended use............................................................... 13
3 Storage and transport......................................................... 14
4 Preparation for use............................................................. 15
5 Installation and assembly.................................................... 16
5.1 Assembly check-list.................................................... 16
5.2 Assembly and installation of the system..................... 18
6 Operation............................................................................ 32
6.1 Touchscreen............................................................... 32
6.2 Menu overview of the DULCO®Lyse........................... 34
6.3 Operating principles.................................................... 35
6.4 Other settings............................................................. 35
6.5 Manual operation........................................................ 36
7 Commissioning................................................................... 37
7.1 Check-list: Preparation for commissioning................. 37
7.2 Check-list: Commissioning......................................... 40
7.3 Commissioning work................................................... 42
8 [ALARM] / Troubleshooting menu....................................... 51
8.1 Status messages........................................................ 51
8.2 Error messages.......................................................... 52
8.2.1 Vacuum system....................................................... 52
8.2.2 Power supply........................................................... 53
8.2.3 Caustic tank............................................................. 53
8.2.4 Product tank............................................................. 54
8.2.5 Separating tank........................................................ 55
8.2.6 Booster pump.......................................................... 55
8.2.7 Membrane cell......................................................... 56
8.2.8 Other faults.............................................................. 57
8.2.9 Response of the system.......................................... 57
9 Checks and preparation for maintenance/repair................. 59
9.1 Care of the Operating Unit.......................................... 59
9.2 Maintenance............................................................... 59
9.2.1 Maintenance kits...................................................... 59
9.3 Repair......................................................................... 60
10 Disposal of used parts........................................................ 61
11 Technical data..................................................................... 62
12 EU Declaration of Conformity............................................. 64
13 Calibrating the pH Measurement........................................ 65
14 Index................................................................................... 66
Table of contents
3

1 Description of the system
The system is used for water disinfection in:
nF&B
nBrewery industry
netc.
The system is used to produce a chlorine-based disinfectant.
1.1 Components of the system
P_PMA_ECA_0013_SW
Fig. 1: Components of the system in the system cabinet
JK
B0667_2
Fig. 2: Installation of the system
Description of the system
4

There is a stainless steel version of the system with a sealed con‐
trol cabinet (with doors): DULCO®Lyse. There is a stainless steel
version of the system, powder-coated, with clear PVC covers to
hang on: DULCO®Lyse OF
[ open frame] .
These operating instructions always show images of the
DULCO®LyseOF
[ open frame] .
# Component Function
A Softener Softens the water. Removes calcium and magnesium.
B Booster pump Keeps the process water flow through the electrolysis system stable
C Caustic metering pump Increases the pH value of the product.
D Flow meter The process water through the electrolysis system is measured by this
flow meter.
E pH sensor Measures the pH value of the product.
F Fan Dilution of the hydrogen gas up to 10 % of the explosion limit.
G Caustic tank Stores the sodium hydroxide solution produced.
H Refresh pipe Helps to regenerate the anode.
I Membrane cell Chlorine is produced from a salt solution in an electrochemical
process in the membrane cell.
J Separating tank The separating tank helps the booster pump to keep the water pres‐
sure constant in the system, should the water pressure fall at the pot‐
able water connector.
K Brine tank Salt stock. It produces a saturated salt solution together with the soft‐
ened water.
Not
shown
Product tank The DULCO®Lyt (product) is stored in the product tank.
1.2 Description and operation
The system produces chlorine in a membrane cell by means of an
electrochemical process.
Description of the system
5

Page
Chlorinsitu®-III 100-300 g/h
3
1900000
VDH Watertechnology
5
4 /
All rights reserved according to NEN ISO 16016 © copyright reserved.
Chlorinsitu®-III 100-300 g/h
Glashorst 114
3925 BV Scherpenzeel
[phone]Tel. Customer
Poject Name
Title
:
:
:
AvdB
V1.00 Prod. no.:
Version-number.:
9-12-2019
Drawn by
Date
As Built date
:
:
Modification Date Name
1 2 3 4 5 6 7 8 9 10 11 12 13 14
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Previous page Next page
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Mounting location:
:
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Fig. 3: Flowchart for DULCO®Lyse
Description of the system
6

No. Component Function
1 Water filter to combat impurities > 500 µm
2 Softener softens the supply water
3 Caustic metering pump Pump to correct the pH value
4 Brine tank prepares and stores brine
5 Membrane cell to produce chlorine and NaOH
6 Refresh pipe helps to regenerate the anode
7 Vacuum sensor measures the negative pressure
8 Caustic tank stores the lye
9 Airflow
sensor
continuously monitors the hydrogen gas/air mixture
10 Fan mixes hydrogen gas with air until the mixture is no longer
reactive.
11 Water venturi, chlorine gas dissolves the chlorine gas from the refresh pipe in the
process water
12 Static mixer mixes the lye with the process water
13 pH sensor measures the pH value of the pH-neutralised process
water
14 Product tank (accessory) stores the DULCO®Lyt (product)
15 Water venturi, anode regeneration draws in brine and anode residue by suction
16 Manometer measures the pressure in the supply water
17 Pressure reducer used to adjust the pressure in the supply water
18 Conductivity sensor used to keep the caustic concentration constant in the
caustic tank
19 Booster pump keeps the process water flow through the electrolysis
system stable
20 Separating tank stores the drinking water for the booster pump
21 Flow meter, process water measures the process water flow, kept constant by the
booster pump
22 Flow meter, brine softener measures the volume of brine for regeneration of the soft‐
ener
23 Flow meter, brine membrane cell measures the volume of brine for the membrane cell
24 Flow meter, caustic metering measures the flow of lye, by means of which the process
water can be adjusted to be pH-neutral via the metering
tap
25 Sample valve can be used to take a sample of process water
Only use salt that is certified in accordance with the EU Regulation
528/2012.
Use a salt in accordance with EN 16370 or a salt with as low a cal‐
cium and magnesium content as possible. Salt in accordance with
EN 973 is not always sufficient.
Basic substances required
Description of the system
7

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 will be irreparably dam‐
aged.
Make sure that the following limit values for the salt are not
exceeded:
nInsoluble substances < 100 ppm
nCalcium (Ca+) < 70 ppm
nMagnesium (Mg+) < 70 ppm
The sound pressure level is < 70 dB (A) at maximum speed, at
maximum back pressure, using water as the medium (without
booster pump)
Degree of protection of the system: see nameplate.
1.2.1 Quality requirements of the feed water for DULCOLyse
It is necessary to operate the system with feed water that meets
certain minimum requirements for the safe and correct production
of DULCOLyt.
It is important to adhere to these qualities as only then can the
service life of the membrane cell be guaranteed. It is the responsi‐
bility of the operator to comply with these operational quality
requirements with the correct water quality.
The specification of the feed water needs to meet the WHO’s
Guidelines for Drinking Water Quality (GDWQ) ( www.who.int ) or
the latest EU Drinking Water Directive ( https://eur-lex.europa.eu )
for safe and long-term operation.
Make sure that the feed water is free of chlorinated solvents in
addition to the parameters listed in the table.
The calcium and magnesium content is controlled by the softener
system supplied.
Please contact your system supplier if in doubt.
Parameter Limit Unit
pH 6.5 ... 9.5 pH
Temperature 10 ... 25 C°
Hardness Ca + Mg < 25 dH°
Hardness Ca + Mg 0.05* dH°
Free chlorine < 1** ppm
Iron Fe 0.2 ppm
Manganese Mn 0.05 ppm
Chlorite ClO2- 0.7 ppm
* after softening.
** free chlorine reduces the lifetime of the softener resin
Sound pressure level
Protection against contact and mois‐
ture (IP)
Description of the system
8

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
9

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
10

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
11

2.3 General safety information
WARNING!
Danger due to hazardous substances
By operating this system the operator generates
hazardous substances.
The operator is responsible for adapting the oper‐
ating instructions to their system in the event that
more recent knowledge about the dangers associ‐
ated with a hazardous substance and its avoid‐
ance become available or national regulations pre‐
scribe something else to that stated in the supplied
operating instructions.
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.
Check the continuity of the hydrogen discharge
line and the supply air to the system annually.
WARNING!
Danger from hazardous substances!
Possible consequence: fatal or very serious inju‐
ries.
The system operator is responsible for ensuring
that the material safety data sheets are available
and that they are kept up to date, as well as for
producing an associated hazard assessment for
the workplaces affected.
The sound pressure level is < 70 dB (A) at maximum power
(without the booster pump).
The system generates a small volume 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.
Sound pressure level
Handling the hydrogen in the system
Personal protective equipment
Information in the event of an emer‐
gency
Safety and responsibility
12

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, immediately disconnect the elec‐
trolysis system from the mains power supply. 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.
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
13

3 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
14

4 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 room has an adequately dimensioned 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 the permissible limits. Install an air conditioning system
in the room if this cannot be guaranteed.
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.
nEnsure that the floor is even and horizontal and has a solid
base surface.
nPrevent the system from toppling over by, for example, fixing
the control cabinet to the wall or floor. Secure it in another way
should the latter 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 is at least ⋝ 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 bar behind
the non-return valve.
nSet up the system, as described on the installation plan.
Preparation for use
15

5 Installation and assembly
5.1 Assembly check-list
# Assembly process Tick
1 Check whether the assembly location complies with the guidelines governing tempera‐
ture, 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 Lift the system into its installation position.
6 Level the system horizontally.
7 Remove the transport protection from within the system cabinet.
8 Position the separating tank (J) in its intended position.
9 Position the brine tank (K) in its intended position.
10 Position the product tank (accessory) to the right of the brine tank.
11 Connect a PVCU pipe (Ø63 mm) to the PVCU connector (Ø63 mm) of the system and
lead it outside.
12 Make sure that the PVCU pipe (Ø63 mm) routed outside complies with the regulations.
13 Lead the PVCU line (Ø20 mm) to the outside.
14 Connect a PVCU line (Ø20 mm) between the "Fill separating tank" connector on the
system and the separating tank (A).
15 Connect the overflow (B) of the separating tank to the sewerage channel.
16 Connect the terminal box cable of the separating tank in the control cabinet.
17 Connect a PVCU line (Ø32 mm) between the "Process water" connector on the system
and the separating tank.
18 Connect the Ø50 mm PVCU discharge line on the system to the sewerage channel.
19 Connect a water line to the "Feed water line" PVCU coupling on the system
20 Connect a PVCU line (Ø20 mm) between the "Fill separating tank" connector on the
system and the separating tank.
21 Connect a PVCU line (Ø20 mm) between the "Drain line" connector (1) on the system
and the line to the waste water system.
22 Connect a PVCU line (Ø20 mm) between the "DULCO®Lyt" connector (2) on the system
and the product tank.
23 Connect a PVCU line ( Ø20 mm) to the vent valve on the product tank and route to the
outside.
24 Fit the level switch for the product tank.
25 Connect the retaining tank detector supplied potential-free to terminal X1-18.
26 Fit the liquid level sensor (ultrasound) into the product tank.
27 Electrically connect the liquid level sensor to the terminal box X13 of the product tank.
28 Use the black PE hose (Ø16 mm x 1.8 mm) from the brine tank to join the "Fill brine
tank" connector (3) on the system to the Ø16 mm connector on the brine tank.
29 Use the PE hose (Ø16 mm x 1.8 mm) to join the "Brine membrane cell" connector on the
system to the Ø16 mm connector on the brine tank.
Installation and assembly
16

# Assembly process Tick
30 Connect the transparent 8 mm nylon hose Ø10 mm between the "Brine softener" con‐
nector on the system and the Ø10 mm connector on the brine tank.
31 Connect a Ø40 mm PVCU line to the brine tank and to the sewerage system as an over‐
flow line. There should be salt in the brine tank once the PVCU lines have been con‐
nected.
32 Connect the brine tank level switch.
33 Remove the pH sensor from its transparent tubular housing and fit it into the sensor
straight union on the system.
34 Electrically wire the system.
35 Connect an Ethernet cable to the modem in the control cabinet as per the wiring dia‐
gram.
THIS PART WAS ACCEPTED BY: NAME: SIGNATURE:
Project number:
Serial number:
Installation and assembly
17

5.2 Assembly and installation of the system
nUser qualification, mechanical/hydraulic installation: trained
and qualified personnel
Ä Chapter 2.2 ‘User qualification’
on page 11
nUser qualification, electrical installation: electrical technician
Ä Chapter 2.2 ‘User qualification’ on page 11
CAUTION!
Contamination and impurities in the lines can sub‐
sequently seriously damage components in the
system.
Note the following with all assembly steps:
–Ensure that all lines are free from burrs, chips
or other impurities before connecting the lines
to the system.
1. Check whether the assembly location complies with the
guidelines governing temperature, safety, space, humidity,
etc.
Ensure that the assembly location preferably complies with
the following conditions:
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 10 ... 35 °C; otherwise install
an air conditioning system.
nIt should be possible to fit a sewerage drain, a vent valve
and vent openings.
CAUTION!
The level switches can subsequently 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, discharge
conduits and ventilation system. The waste water connection
is located underneath the system.
3. Remove the plastic packaging from the system.
Installation and assembly
18

Fig. 4: Transport monitoring set
4. Check whether the system has suffered damage during
transport or exhibits other damage. Should you detect any
damage, report it immediately to the freight forwarder and
submit your claims.
Check that the scope of delivery is complete.
Check the transport monitoring set on the transport crate.
Fig. 5: Lift the system into its installation position.
5. The system has 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

Fig. 6: Screw feet
6. Level the system horizontally. Use the screw feet shown here
to do so.
Fig. 7: Transport protection
7. Remove the transport protection from within the system cab‐
inet.
Remove the blanking plate on the vacuum sensor in the
system cabinet.
Installation and assembly
20