Lutz Jesco Easychlorgen 4250 Installation, Operation & Maintenance Instructions Manual Download Page 1

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EASYCHLORGEN 4250, 8500

Electrolysis system for on-site hypochlorite generation

Installation, Operation &

Maintenance Instructions

Read these operation and maintenance instructions before start-up!

To be held for further reference

v1.0 11/2017

Summary of Contents for Jesco Easychlorgen 4250

Page 1: ...0 Electrolysis system for on site hypochlorite generation Installation Operation Maintenance Instructions EN Read these operation and maintenance instructions before start up To be held for further re...

Page 2: ...2 Installation Operation Maintenance Instructions EASYCHLORGEN...

Page 3: ...5 5 2 POWER SUPPLY UNIT 15 6 DIMENSIONS 16 6 2 INTERMEDIATE BRINE TANK 17 6 3 POWER SUPPLY UNIT PSU CABINET 17 7 INSTALLATION 18 7 1 INSTALLATION LOCATION 18 7 2 HYDRAULIC INSTALLATION 19 7 3 ELECTRIC...

Page 4: ...Identification of warnings Warnings are intended to help you recognize risks and avoid negative consequences This is how warnings are identified Warning sign SIGNAL WORD Description of danger Conseque...

Page 5: ...as existing safety regulations at the plant In doing so the different technical qualifications have to be taken into account The operating personnel must have understood the training and it must be e...

Page 6: ..._____________________ __________________________________________________________________________________________________ Date __________________________________________________________________________...

Page 7: ...ards due to non compliance with the safety instructions Failure to follow the safety instructions may endanger not only persons but also the environment and the device failure of important functions o...

Page 8: ...selves 2 5 2 Trained electricians Due to their professional training knowledge and experience as well as knowledge of speci c standards and provisions trained electricians are able to do the electrica...

Page 9: ...hypochlorite solution produced is 0 6 0 1 Cl2 by weight 3 3 Device Revision This operating instruction manual applies to the following devices Device Month year of manufacture EASYCHLORGEN 4250 8500 1...

Page 10: ...ric current to flow between the cell plates The generated product is delivered to the degassing tank 14 before transfer to an external product tank through the product outlet connection 16 When the pr...

Page 11: ...nturi 3 Brine solenoid valve 4 Dilution solenoid valve 5 Chilled water solenoid valve 6 Water meter 7 Pressure regulating valve 8 Product sample tap 9 Air blower 10 Air flow sensor 11 System run stop...

Page 12: ...ble The green generating indicator 5 is lit when the electrolyser D C output power is available A ventilation fan 3 operates continuously to draw in air at the base of the cabinet and discharge warm a...

Page 13: ...ation Operation Maintenance Instructions EASYCHLORGEN No Power On start up Normal Operation Fault Condition 4 2 4 Function sequence in automatic operation The Start Delay timer can be set in the engin...

Page 14: ...5 Rating Plate The rating plate contains information on the safety and functional method of the product The rating plate must be kept legible for the duration of the service life of the product No Des...

Page 15: ...switch assembly PVDF PVC FPM PPS 5 1 7 Other data 5 1 8 External product tank storage facility option Model 4250 8500 Product tank capacity L Recommended minimum size of 1000L Refer to product output...

Page 16: ...5 2 3 Other data Model 4250 8500 Net weight kg 210 270 6 Dimensions All dimensions in mm 6 1 EASYCHLORGEN 4250 8500 Key Description A Product outlet connection B DC power busbar connection ve C Acid w...

Page 17: ...______________________________________________________________ 17 Installation Operation Maintenance Instructions EASYCHLORGEN 6 2 Intermediate brine tank 6 3 Power Supply Unit PSU cabinet Side elevat...

Page 18: ...to installation schematics section 7 4 Perform the following steps 1 Locate the skid unit into its intended permanent position allowing sufficient space to connect services to the connection ports to...

Page 19: ...o that inlet outlet pipe connections are conveniently situated for connection to appropriate services Location of salt saturator complete 7 2 Hydraulic installation 7 2 1 Cold feed water supply Note D...

Page 20: ...aintenance Saturator plumbing complete 7 2 4 Intermediate brine tank The intermediate brine tank is vitally important to maintain a steady supply of brine to the EASYCHLORGEN skid system The level of...

Page 21: ...requirements the vent termination point on the external wall should not be located directly beneath any air intake and must be located at least 0 8m from any window or possible source of ignition If t...

Page 22: ...ments 5 Interconnect the 3 phase AC power supply from the PSU cabinet to the EASYCHLORGEN air blower rotary isolator A 3C E cable is factory fitted for this purpose and may be replaced to comply with...

Page 23: ...y the square flat connector plates supplied with the PSU Due to the high DC current output of the PSU it is vital that all DC connections are made with care Ensure all bare copper busbar surfaces are...

Page 24: ...pply for hydrogen sensor 30 N C Ext Alarm N C External N C Emergency alarm linked to terminal 15 when not in use 31 0V Common 0V 32 Sig Panel Temp panel temperature signal input 33 0V Common 0V 34 Sig...

Page 25: ...Installation __________________________________________________________________________________________ 25 Installation Operation Maintenance Instructions EASYCHLORGEN 7 3 4 Control Panel PCB Termina...

Page 26: ...__________________________________________________________________________________________ 26 Installation Operation Maintenance Instructions EASYCHLORGEN 7 3 5 4250 8500 Power Supply Cabinet Compone...

Page 27: ...ion __________________________________________________________________________________________ 27 Installation Operation Maintenance Instructions EASYCHLORGEN 7 3 6 4250 Control Panel to Power Supply...

Page 28: ...Installation __________________________________________________________________________________________ 28 Installation Operation Maintenance Instructions EASYCHLORGEN 7 3 7 4250 Power Circuit Wiring...

Page 29: ...ion __________________________________________________________________________________________ 29 Installation Operation Maintenance Instructions EASYCHLORGEN 7 3 8 8500 Control Panel to Power Supply...

Page 30: ...Installation __________________________________________________________________________________________ 30 Installation Operation Maintenance Instructions EASYCHLORGEN 7 3 9 8500 Power Circuit Wiring...

Page 31: ...______________________________________________________________ 31 Installation Operation Maintenance Instructions EASYCHLORGEN 7 4 General installation layouts 7 4 1 Electrolytic plant Installation la...

Page 32: ...___________________________________________________________________________________ 32 Installation Operation Maintenance Instructions EASYCHLORGEN Single plant room facility Installation example 2 7...

Page 33: ...water supply 10 Saturator isolation valve 11 Intermediate brine tank isolation valve 12 Intermediate brine tank 13 EASYCHLORGEN potable softened water supply 14 EASYCHLORGEN saturated brine feed 15 B...

Page 34: ...tion __________________________________________________________________________________________ 34 Installation Operation Maintenance Instructions EASYCHLORGEN 7 4 3 General installation arrangement E...

Page 35: ...ection button ENTER selection confirmation button The control interface also indicates current operational system status via three bright LEDs Green LED system healthy Amber LED maintenance action Red...

Page 36: ...result for hard water The result MUST BE GREEN i e soft water DO NOT PROCEED further until a reliable softened water supply is available The salt saturator is filled with a pre charge of the correct...

Page 37: ...Program 1 End Program Mode is reached At this point press ENTER and the display will return to the MANUAL INHIBIT screen 6 To restart the system press and hold the scroll UP key for 5 seconds 7 EASYC...

Page 38: ...eneration cycle When the softener is in regeneration the EASYCHLORGEN should stop and the screen will display If the above screen is not displayed then this may be a result that the softener regenerat...

Page 39: ...t door main isolator 5 Disengage the Emergency Stop button by twisting and pulling outward 6 The Power On white lamp will illuminate indicating that there is power available to the system Perform the...

Page 40: ...process Whilst the system is displaying SYSTEM STOPPED the scroll UP key may be pressed for 5 seconds to place the system into MANUAL INHIBIT mode which halts the automatic operation Press the scroll...

Page 41: ...alarm device will activate The EASYCHLORGEN system will need to be reset on the panel by pressing the ENTER button once the Emergency Stop device has been released 10 6 Record Log of Operation To mai...

Page 42: ...sary any inlet outlet valves associated with product storage tank s System shut down for the long term 11 3 Storage Required actions The system has been shut down in accordance with the section 11 2 L...

Page 43: ...seals gaskets 12 1 1 Clean replace brine strainer screen Depending on quality of the softened cold water supply and salt specification the in line strainer screen protecting the brine control solenoi...

Page 44: ...ution WARNING Increased risk of accidents due to chemical exposure A residual of brine chlorine solution may drip from the pipe work and fittings Wear correct personal protective equipment Wipe away a...

Page 45: ...dure as per section 9 2 1 3 Replace the hydrogen sensor if a reading is above normal range 70 b sensor is known to have been damaged by exposure to water emersion or fire damage c sensor has been in o...

Page 46: ...owing working steps 1 Drain the brine product solution pipe work and electrolyser s by opening the brine salinity sample point valve Allow the contents to empty into a clean plastic container until th...

Page 47: ...ing steps 1 Make a note of the date and scope of the maintenance performed 2 Complete any operational service or commissioning log sheets associated with the EASYCHLORGEN system and as per any associa...

Page 48: ..._________________________________________ 48 Installation Operation Maintenance Instructions EASYCHLORGEN 12 4 Location of maintenance parts 12 4 1 Left side electrolyser compartment Detail A Detail B...

Page 49: ...ion Maintenance Instructions EASYCHLORGEN Detail F 12 4 3 Hydraulic control apparatus Detail G Detail H Table Maintenance Parts List Key Item description detail A H 1 DN25 Union O ring 2 DN15 NRV O ri...

Page 50: ...d Reset Wire Breakage Loose connection Check wiring and ensure switch is NC when Healthy System Fault Hydrogen Sensor Hydrogen Level has exceeded 100 of the alarm value 25 LEL Broken or damaged pipe w...

Page 51: ...ription 4250 8500 200 206 Biennial maintenance kit 14 2 Critical site spares Code Description 210 006 Ventilation air flow sensor 8 GP0219 Ventilation air blower 3 phase 210 018 Hydrogen gas sensor 21...

Page 52: ...e Part no Reason for repair Dosing medium Description Irritating Yes No Properties Corrosive Yes No Wehereby certify that the product has been cleaned thoroughly inside and outside before returning th...

Page 53: ...warranty application filled out Sender Company Phone Date Address Contact person Manufacturer order no Date of delivery Device type Serial number Nominal capacity nominal pressure Description of faul...

Page 54: ...ETER READING V AMP READING A TEMP READING o C HOURS RUN AIRFLOW RATE m3 hr HARDNESS TEST Green Red PRODUCT TEST Av Cl2 PRODUCT TEST S G HYDROGEN SENSOR TEST QUANTITY OF SALT ADDED WATER SOFTENER Setti...

Page 55: ...EASYCHLORGEN Appendix II Operators Log a When salt is added b When visiting site approximately weekly DATE OF VISIT VOLTMETER READING V AMP READING A AIRFLOW RATE m 3 hr HYDROGEN SENSOR PRODUCT TEMP o...

Page 56: ...id Valves 1 Water Correct operation 2 Brine Correct operation 3 Dilution Correct operation Hydrogen Sensor 1 Correct operation Brine Tank 1 Check for leaks and clean tank Control Panel Check 1 Termina...

Page 57: ...______________________________________________________ 57 Installation Operation Maintenance Instructions EASYCHLORGEN Appendix IV Softening Equipment Installation Operation Maintenance Guide Clack WS...

Page 58: ...checks Fitting the distribution systems Adding the media Fitting the valves Brine tank connections Duplex hydraulic connections DLFC drain line flow control Injectors Electrical Connections Quickstart...

Page 59: ...ystem Check that you have allowed space for access to the unit for possible future maintenance This installation may require plumbing work and will require an electrical outlet to be fitted near the s...

Page 60: ...has been added Fig A 1 Fig A 2 Fig A 3 2 3 Adding the Media Block the top of the riser tubes to stop media getting down the tubes see fig A 3 Add about 1 3 by volume of water to the vessels so when th...

Page 61: ...ghten by tapping the rear side of the valve with the palm of your hand fig A 6 Fig A 6 2 5 Brine Tank Connections Attach the brine line tubing to the brine tank and valves using the connectors fitted...

Page 62: ...k has been installed this will control the backwash flow rate and ensure the system will continue to function correctly The DLFC is fitted inside the drain line elbow See below picture of the drain li...

Page 63: ...late And strain relief as shown in Fig A 9a Fig A 9a You can now re install the drive bracket into its original position Please make sure that this has been replaced correctly as this can cause proble...

Page 64: ...nt should be made using the up and down arrows when the setting you wish to adjust is displayed on screen Set Time of Day Press SET CLOCK Adjust the hours and press NEXT to adjust the minutes press NE...

Page 65: ...EXT to adjust the minutes press NEXT to return to the normal TIME display Step 1 Cycle Sequence Press NEXT and DOWN simultaneously for 3 seconds and release The screen will display SOFTENING flashing...

Page 66: ...l requires a maximum of 150 litres of softener resin The duplex 1665 softener system is capable of treating a water volume of up to 18m3 at a hardness of 400 ppm CaCO3 Lower water hardness value resul...

Page 67: ...note 9 DP Setting Off or see note 2 for options Hardness PPM Set 1 Backwash Set 2 Brine Draw dn Set 3 Rinse Set 4 Fill Salt required Set 5 End Step 2 System Setup Press NEXT and DOWN simultaneously f...

Page 68: ...is closed a regeneration will be prevented 3 Auto Capacity is automatically calculated and a reserve will be estimated OFF Regenerations will be controlled from the day override setting user settings...

Page 69: ...ackwash the system will move through a brine draw routine rinse and fill before stopping in the service position For new systems or after a media change it maybe necessary to run two regenerations to...

Page 70: ...enance and does not normally require much adjustment Weekly Check the salt level this may need to be done more regularly dependant on consumption The salt level should always be above the water level...

Page 71: ...nstallation Operation Maintenance Instructions EASYCHLORGEN 6 Troubleshooting On the following pages you will find a guide as to the most common problems that may arise please consult this section bef...

Page 72: ...Appendix IV ____________________________________________________________________________________________ 72 Installation Operation Maintenance Instructions EASYCHLORGEN...

Page 73: ...Appendix IV ____________________________________________________________________________________________ 73 Installation Operation Maintenance Instructions EASYCHLORGEN...

Page 74: ...Appendix IV ____________________________________________________________________________________________ 74 Installation Operation Maintenance Instructions EASYCHLORGEN...

Page 75: ...Intended Use 10 L language 39 Long term shutdown 43 M Maintenance 44 47 Maintenance brine strainer 44 Maintenance finishing 48 Maintenance gaskets 45 Maintenance Hydrogen gas detector 46 Maintenance...

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Lutz Jesco Easychlorgen 4250, Installation, Operation & Maintenance Instructions Manual

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Summary of Contents for Jesco Easychlorgen 4250

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