ProMinent ProMaqua Chlorinsitu IV Compact 25 User manual

Chlorine Electrolysis System
Chlorinsitu® IV Compact
Operating instructions
EN
Original Operating Instructions (2006/42/EC)Part no. 985531 BA CI 015 12/16 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.

Table of contents
1 About This Product .............................................................. 5
1.1 Unit Identification.......................................................... 5
2 Storage and Transport.......................................................... 6
3 Safety Chapter...................................................................... 7
4 Overview of Equipment....................................................... 11
5 Functional Description........................................................ 13
5.1 The System................................................................. 13
5.2 Operating modes........................................................ 15
5.3 Options....................................................................... 15
5.3.1 pH correction........................................................... 16
5.3.2 Integrated chlorine / pH controller............................ 16
5.3.3 Booster pump.......................................................... 16
6 Requirements relating to the installation site ..................... 17
7 Installation........................................................................... 18
7.1 Installation, Hydraulic.................................................. 18
7.1.1 System Connectors................................................. 19
7.1.2 Connecting to the Circulation Line........................... 20
7.1.3 Brine storage tank.................................................... 22
7.2 Installation, electrical.................................................. 24
7.2.1 Booster Pump (Optional)......................................... 24
7.2.2 External Controller (if Fitted).................................... 25
7.2.3 Sensors for Integrated Chlorine and pH Controller
(Optional)................................................................. 25
7.2.4 Flow Switch of the Flow Valves............................... 26
7.2.5 External Enable....................................................... 27
7.2.6 Brine storage tank.................................................... 27
8 Setting................................................................................. 28
8.1 General....................................................................... 28
8.2 User Menu.................................................................. 32
8.3 mA Calibration Menu.................................................. 33
8.4 Installer Menu............................................................. 34
8.5 Calibrate Sensor Menu............................................... 35
8.6 Setup Menu................................................................ 35
8.7 Menu: „Testing“ .......................................................... 35
8.8 Rinse Menu................................................................. 38
8.9 Regenerate Menu....................................................... 39
9 Start Up............................................................................... 40
9.1 Batch brine.................................................................. 40
9.1.1 Requirements relating to the starting substances.... 41
9.2 Checking Conditions................................................... 41
9.3 Running Through the SETUP Menu........................... 42
9.4 Running Through the USER Menu............................. 44
9.4.1 Manual Operating Mode ("M")................................. 45
9.4.2 On / Off Operating Mode ("I").................................. 46
9.4.3 Pulse Signal Operating Mode ("F").......................... 46
9.4.4 Operating mode analog signal 4–20 mA ("A") ........ 47
9.4.5 Sensor Operating Mode ("R").................................. 47
9.4.6 Other Parameters.................................................... 48
Table of contents
2

9.5 Checking operating parameters.................................. 49
9.6 calibrate sensors......................................................... 50
9.6.1 pH Calibration.......................................................... 50
9.6.2 Chlorine calibration.................................................. 53
9.7 Rinse water softener................................................... 54
10 During use........................................................................... 56
11 Maintenance....................................................................... 57
11.1 General Maintenance Measures............................... 57
11.2 Check points............................................................. 58
11.2.1 Water pressure...................................................... 58
11.2.2 Water hardness..................................................... 58
11.2.3 Operating hour counter.......................................... 59
11.2.4 Voltage and current of the diaphragm cell ............ 59
11.3 Pre-maintenance Procedure..................................... 60
11.4 Brine storage tank..................................................... 61
11.4.1 Liquid level switch, low ......................................... 61
11.4.2 Filter meshes and non-return valve in brine pri‐
ming ...................................................................... 62
11.4.3 Solenoid Valve, Filling the Brine Storage Tank
(FSB) .................................................................... 62
11.5 Water Softener.......................................................... 63
11.5.1 Changing the O-rings ............................................ 63
11.5.2 Controlling Brine Priming with Regeneration ........ 64
11.5.3 Brine Priming Solenoid Valve (SS) ....................... 64
11.6 Water jet pump......................................................... 64
11.6.1 Maintenance of the Water Jet Pump..................... 65
11.6.2 Replacing the flat seals of the water jet pump ...... 65
11.6.3 Solenoid Valve on the Water Jet Pump ................ 66
11.7 Solenoid Valve and Float.......................................... 66
11.7.1 Solenoid Valve Supply Cable to the Cathode
(SL) ....................................................................... 66
11.7.2 Float ...................................................................... 67
11.7.3 O-rings of the float chamber ................................. 68
11.8 Carbon Filter and Fan Diaphragm Cell..................... 69
11.8.1 Replacing the Carbon Filter................................... 69
11.8.2 Replacing the Fan Diaphragm Cell........................ 70
11.9 O-rings...................................................................... 71
11.9.1 O-rings Three-part 20 mm Coupling ..................... 71
11.9.2 O-rings Three-part 16 mm Coupling...................... 72
11.10 Hose Couplings...................................................... 72
11.10.1 Replacing the Hose Coupling, PVDF 8x1/4" ....... 72
11.10.2 Replacing the Hose Coupling, PVDF 6x1/4"........ 73
11.11 Overhaul kits for the metering pumps..................... 73
11.12 Hoses...................................................................... 74
11.12.1 Replacing the Suction Bell Hose ........................ 74
11.12.2 Replacing the Cathode Outlet Hose ................... 74
11.12.3 Replacing the Anode Outlet Hose ...................... 74
11.12.4 Only with pH Correction: Replacing the Alkali
Pump................................................................... 74
11.13 General Work.......................................................... 75
11.13.1 General Checks................................................... 75
11.13.2 Testing the Safety Equipment.............................. 75
Table of contents
3

11.13.3 Final Checks........................................................ 75
11.14 Spare parts drawings.............................................. 76
12 Troubleshooting.................................................................. 81
13 Decommissioning and Disposal.......................................... 83
14 Substances Produced......................................................... 84
15 Technical data..................................................................... 86
16 Wiring diagrams.................................................................. 88
17 Ordering information........................................................... 91
18 Factory settings................................................................... 92
19 EC Declaration of Conformity............................................. 93
20 Index................................................................................... 94
Table of contents
4

1 About This Product
Electrolysis systems produce chlorine gas by electrolysis. A satu‐
rated solution of sodium chloride (brine) is produced in the brine
storage tank included in the scope of delivery. The sodium chloride
solution is then electrically decomposed (electrolysis). The
resulting chlorine gas and the residual sodium chloride solution
brine is siphoned off in the electrolysis system and is mixed
together with the water to be treated to form a disinfection solution
containing chlorine.
The microprocessor controller integrated in the electrolysis system
displays the current output and monitors all functions. All operating
and error messages are shown in plain text on the display. The
output can be controlled manually or externally.
Electrolysis systems are especially suitable for use with smaller
swimming pools in residential properties and hotels.
The system is available with an output of 25 g/h or 50 g/h.
1.1 Unit Identification
Unit type Order No.
Chlorinsitu® IV Compact 25 1036461
Chlorinsitu® IV Compact 25 with pH correction 1036462
Chlorinsitu® IV Compact 50 1036463
Chlorinsitu® IV Compact 50 with pH correction 1036464
Chlorinsitu® IV Compact 25 with integral chlorine and pH controller 1041405
Chlorinsitu® IV Compact 25 with integral chlorine and pH controller with pH correction 1041403
Chlorinsitu® IV Compact 50 with integral chlorine and pH controller 1041406
Chlorinsitu® IV Compact 50 with integral chlorine and pH controller with pH correction 1041404
Chlorinsitu® IV Compact
About This Product
5

2 Storage and Transport
The system is packaged and shipped with all components on a
single pallet.
The system does not contain any chemicals or water when
shipped.
Specification Value
Minimum ambient temperature + 10 °C
Maximum ambient temperature + 35 °C
Max. air humidity, non-condensing 85% relative air humidity
Miscellaneous: Protect against sunlight
nChlorine electrolysis system mounted on a wall panel.
nBrine storage tank.
nBooster pump (optional).
nIntegrated chlorine / pH controller (optional).
Important note
Ambient conditions
Scope of delivery
Storage and Transport
6

3 Safety Chapter
Symbol Meaning Explanation
Warning Danger to operating personnel, bystanders or third parties.
Danger zone Rules and regulations governing access and equipment used apply in
this zone.
Attention Danger of material damage to the product.
Note / Tip Special remark
nThe system is only intended for the production of a disinfection
solution containing chlorine from sodium chloride and its sub‐
sequent metering for the disinfection of swimming pool water.
nAny other uses or modifications to the system are prohibited!
nMoreover, do not operate the system in conditions other than
those described in these operating instructions.
nOnly allow the system to be operated by sufficiently qualified
personnel - see table below.
nYou have a duty to observe the information contained in the
operating instructions during the different phases of the sys‐
tem's service life.
nPlease observe the relevant national regulations and guide‐
lines throughout every phase of the system's service life.
Task Qualification
Storage, transport Qualified employee
Assembly, installation Service
Initial commissioning Service
Operation Instructed personnel
Maintenance Qualified employee
Carrying out repairs Service
Decommissioning, disposal Qualified employee
Troubleshooting Qualified electrical technician or instructed person -
depending on the fault
Qualified employee
A qualified employee is deemed to be a person who is able to
assess the tasks assigned to him and recognise possible dangers
based on his/her technical training, knowledge and experience, as
well as knowledge of pertinent regulations.
Electrical technician
Symbols used
Intended use
Qualification of personnel
Safety Chapter
7

An electrical technician is able to complete work on electrical sys‐
tems and recognise and avoid possible dangers independently
based on his technical training and experience, as well as knowl‐
edge of pertinent standards and regulations.
The electrical technician should be specifically trained for the
working environment in which he is employed and be conversant
with the relevant standards and regulations.
Make sure that the electrical technician complies with the provi‐
sions of the applicable statutory directives on accident prevention.
Instructed person
An instructed person is someone who has completely read through
and understood the operating instructions and has been briefed by
Service during start up.
Service
Service refers to service technicians who have received certificated
training and have been authorised by ProMinent or van den Heuvel
to work on the system.
The system has the following safety equipment:
nReed switch for internal flow
nMotor protection switch in the terminal box
nHydrogen exhaust line
The maintenance manual describes how these are tested.
WARNING!
The liquid in the drainage system may contain
sodium hydroxide solution.
Always discharge sodium hydroxide solution pro‐
duced during the electrolysis process through a
closed pipeline system into a sewer junction or a
floor drain.
Take appropriate precautions when working on the
drainage system after start up.
WARNING!
Avoid excess chlorine gas.
Only switch off the electrolysis device with the
[START/STOP] key. It cannot be switched off via
the "Output" setting and chlorine gas may continue
to be produced.
WARNING!
Safely discharge any waste hydrogen produced.
Always discharge any hydrogen produced during
the electrolysis process via a closed, continuously
rising, pipeline system to the outside and away
from dangerous areas.
Annually check the leak-tightness of the "hydrogen
disposal pipe".
Safety equipment
General safety information
Safety Chapter
8

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!
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.
Keywords when searching for the necessary regulations:
nChlorination
nExplosion protection
nPotable water
nSwimming pool
nSodium hydroxide solution
nHydrogen
nHazardous substances
nPersonal protective equipment
The system generates a small amount of hydrogen.
Ensure that this hydrogen is safely discharged into the open air.
Always carry out checks during installation to ascertain that there
are no suction points (e.g. from an air conditioning system) near
the hydrogen discharge line.
If hydrogen is released due to a damaged pipeline or due to
another cause, it can produce an explosive gas mixture with the
ambient air.
Note for the system operator
Explosion safety
Safety Chapter
9

nAccording to ATEX 137, it is the responsibility of the operator
to draw up an explosion safety document.
nThe operator should include the system in the Emergency Plan
and state the outlined safety plans.
nThe Emergency Plan should not run any escape routes past
the system.
nThe operator should appoint a Safety Coordinator. This person
is responsible for monitoring work that affects the system's
explosion safety.
The operator must match the personal protective equipment to the
hazards, in accordance with the national regulations, see also
Ä „Note for the system operator“ on page 9 .
The operator must supplement the emergency information to
match the hazards, in accordance with the national regulations,
see also Ä „Note for the system operator“ on page 9 .
nAs soon as a chlorine gas smell is detected, switch off the elec‐
trolysis system using the [START/STOP] key, by pulling out the
plug, activating an emergency stop switch or triggering an
external fuse and then inform Service.
nIf an electrical emergency occurs, immediately de-energise the
electrolysis system: either pull out the plug, activate an emer‐
gency stop switch or trigger an external fuse and then inform
Service.
The sound pressure level is < 70 dB (A) at maximum power
(without the booster pump).
Organisational requirements
Personal protective equipment
Information in the event of an emer‐
gency
Sound pressure level
Safety Chapter
10

4 Overview of Equipment
A2327
23
16
10
4
53
Fig. 1: View without protective cowling
4 Brine pump
10 Brine pump (optional for pH correction)
16 Fan, diaphragm cell
23 Micro-processor control
53 Terminal box
not shown Brine storage tank with suction lance
Overview of Equipment
11

A2328
50
2
7
11 21
17 520
22
9
8
12
19
6
24
13
Fig. 2: Internal parts
2 Water softener unit
5 Diaphragm cell
6 Float housing
7 Active carbon filter
8 Water jet pump
9 Alkali (lye) storage tank (optional for pH correction)
11 Manometer
12 Valve block
13 Plunger
17 Metering point for chlorine
18 Metering point for alkali (lye) (optional for pH correction)
19 Bleed valve
20 Drain
21 Circulation water, inlet
22 Circulation water, outlet
24 Valve for chlorine
50 Reed switch, internal flow
Overview of Equipment
12

5 Functional Description
5.1 The System
The system requires potable water for the process. A stable pres‐
sure of approx. 1.7 bar can be set with the aid of a manometer and
reducing valve. The potable water is softened in the softener. The
control first fills the brine storage tank wit the softened water. The
brine is formed from salt and water in the brine storage tank (3).
Using the brine pump (4), the brine is pumped into the anode
chamber (+) of the diaphragm cell (5). Chlorine gas separates out
in the diaphragm cell (5). Pumping fresh brine into the anode
chamber causes the depleted brine to be transported through the
diaphragm cell and then siphoned off together with the chlorine
gas.
Water is continuously pumped into the cathode chamber and the
concentration is maintained at an optimum level within it. The alkali
(lye) and hydrogen are separated at the output of the diaphragm
cell (5). The hydrogen is discharged to the outside (19). Optionally
the alkali (lye) can be trapped in the alkali tank (9) and metered
into the circulating water as required using the alkali pump (10)
depending on demand (pH correction).
The fan (13) is used to cool the diaphragm cell.
The system is connected to the circulation pipe. Water is pumped
by a water jet pump through this circulation pipe, which produces
vacuum pressure in the anode chamber and the chlorine gas is
siphoned off.
Functional Description
13

P_PMA_EL_0033_SW
1
2
3
4
5
8
76
Fig. 3: Hydraulic circuit diagram
1 Brine storage tank
2 Booster pump
3 Water softener unit
4 Diaphragm cell
5 Exhaust air
6 Rinsing water
7 Drain
8 Water jet pump
9 Circulation water
10 Potable water
Functional Description
14

5.2 Operating modes
In the standard set-up, production in the system is regulated by an
external chlorine and pH controller. The operating mode can be
selected in the user menu. There are four standard operating
modes:
nManual mode "M"
nOn / Off "I"
nPulse signal "F"
nAnalogue signal "A"
Additionally, it is possible to equip the system with an internal
chlorine and pH-control. In the user menu, this option is located
under:
nSensor "R"
WARNING!
As no chlorine measurement system is available,
over-metering may occur.
Adjust the system to the required chlorine production volume (as a
percentage). As soon as there is an external release (ENABLE),
the desired quantity of chlorine is produced.
Adjust the system, as with "M" manual mode to the required
volume of chlorine. An external potential-free control contact of a
chlorine and pH controller is used to switch the system on and off.
Many chlorine and pH controllers operate with an output signal in
the form of pulses. The maximum number of pulses from the con‐
troller (for 100% production) must be set in the control unit of the
system.
The system can be connected to an analogue standard signal (4–
20 mA). Please note: 20 mA corresponds to maximum chlorine and
pH metering (100%).
The system can be equipped with an internal chlorine and pH con‐
troller see the following chapter. The system then meters
depending on the chlorine and pH value.
5.3 Options
The standard version of the system can be extended by 3 options:
npH correction
nIntegrated chlorine / pH controller
nBooster pump
All 3 options can also be combined with each other.
Manual mode "M"
On / Off "I"
Pulse signal "F"
Analogue signal "A"
Sensor "R" (optional)
Functional Description
15

5.3.1 pH correction
The system optionally has an alkali (lye) metering pump (10), an
alkali (lye) tank (9), in which the alkali from the diaphragm cell is
collected. The system optionally has an alkali metering pump (18).
The alkali metering pump meters the alkali downstream of the
water jet pump into the process value (where the pH value is low)
according to the pH value displayed.
5.3.2 Integrated chlorine / pH controller
The optional integrated chlorine / pH controller comprises an in-line
probe housing with a chlorine sensor, a pH sensor and a software
add-on. It is also possible to connect an external acid pump so that
the pH correction operates in both directions.
2 chlorine sensors are optionally available:
n0 ... 2 ppm
n0 ... 10 ppm
5.3.3 Booster pump
A booster pump is generally required to achieve the value of ≥ 1.5
bar.
The system requires a priming pressure of ≥ 1.5 bar and a circula‐
tion capacity of at least 500 litres per hour. The booster pump per
se also requires a priming pressure of 0.2 to 1.0 bar to ensure that
the booster pump can function.
Chlorine sensor
Functional Description
16

6 Requirements relating to the installation site
NOTICE!
The system's installation site should be sufficiently
well ventilated. Ventilation can be done technically
or naturally. The adequate design of the ventilation
system is the responsibility of the operator for the
system.
nIt must be possible to seal off the installation site to prevent the
access of unauthorised persons access.
nThe climatic data for the system and brine storage tank must
correspond to the values given in the chapter "Technical Data".
nThe installation site must be ventilated with at least 5 m³/h per
m³ room volume.
nIt must be ensured that the hydrogen can rise upwards into the
outdoor air or into a suitable ventilation line.
Requirements relating to the installation site
17

7 Installation
7.1 Installation, Hydraulic
Install the system horizontally on a flat wall.
After a week, check whether the hoses are still cor‐
rectly sealed, if necessary tighten the hoses.
Refer to the following overview as a guide to the
hydraulic installation.
A2346
AB
C
D
E
Fig. 4: Pipe layout
A Hydrogen drainage
B Process water to the booster pump (circulation pipe)
C Potable water (2 ... 5 bar)
D Process water from the booster pump (circulation pipe)
E Drainage line
Installation
18

K
J
I
L
Fig. 5: Overview drawing, large figure: Overview of the overall hydraulic installation with opened system, left
above the brine storage tank (H). Small figure: View of the opened front part with the metering pumps.
A Route the hydrogen drainage line rising uniformly
upwards to the outside with the EX-sticker sup‐
plied on the outside of the pipe.
B Separate potable water connection with pressure
reducing valve to set a stable potable water pres‐
sure of 1.7 bar.
C Circulation pipe with 2 ... 5 bar. Supply pressure
to the booster pump (optional) ≥ 1.5 bar.
D The flow fitting with the sensors (optional).
E The returning sample water can be fed to the
drain or back to the surge water tank.
F Metering line into the circulation water.
G Lead the brine storage tank overflow into the
drainage pipe.
H Brine storage tank.
I Booster pump with non-return valve (optional).
J Process water, inlet.
K Provide an alkali (lye) pump (optional) for pH cor‐
rection.
R Brine pump.
7.1.1 System Connectors
CAUTION!
The hydrogen drainage line must be fed to the out‐
side. Lead the hydrogen drainage line directly
upwards through the roof to the outside. In all
cases, the hydrogen drainage line must rise contin‐
uously.
Attach the EX-sticker supplied clearly visibly to the
exit point of the hydrogen drainage pipe on the
roof.
Installation
19

Design the drainage line to the sewer system with
a diameter of at least Ø 40 mm. The system
drainage line and the brine storage tank overflow
can be combined. This provides an effective way
of checking whether the drain is blocked.
7.1.2 Connecting to the Circulation Line
Connect the system to a circulation line. If a filter is
fitted in the circulation line, connect it downstream
of the filter.
Depending on the size of the pipe, the system is connected to the
circulation pipe or do a bypass on the circulation pipe.
parameters Required value Minimum
value
Maximum value
Input pressure P1 [bar] 1.5 1.0 6
Pressure difference on the booster pump Δp [bar] 1.0 0.8 4.5
Water flow through the booster pump [l/h] approx. 500 approx. 450 approx. 1500
It is recommended that an input pressure of ≥ 1.5 bar is maintained
directly upstream of the system for the operational safety of the
system. The water flow automatically adjusts itself due to the pres‐
sure difference at the booster pump. If there is no pressure differ‐
ence relative to the circulation line, a booster pump must be
installed.
There are 2 options to achieve the pressure difference:
nWith booster pump, see
Ä „A booster pump is
required: “ on page 21
nWithout booster pump, see Ä „No booster pump is
needed:“ on page 22
The following drawings show the integration of the
system in the circulation line.
Installation
20