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11.5.1 Preparation for Maintenance on the Lye Storage Tank

WARNING!
Danger due to lye residue
Possible consequence: Fatal or very serious inju‐

ries from lye
Measure: During maintenance on the production

tank, wear the goggles and gloves provided.
Ventilate the room during maintenance.

A1969

II.

III.

Fig. 63: Maintenance on the Lye Storage Tank
I. Chlorinsitu

-III 100 ... 500 g/h

II. Chlorinsitu

-III 600 ... 1750 g/h

III. Chlorinsitu

-III 2000 ... 3500 g/h

1. Production tank

2. Lye storage tank

Preventative maintenance

Summary of Contents for Chlorinsitu-III

Page 1: ...inal operating instructions 2006 42 EC 984350 Version BA Cl 023 09 21 EN Please carefully read these operating instructions before use Do not discard The operator shall be liable for any damage caused by installation or operating errors The latest version of the operating instructions are available on our homepage ...

Page 2: ...formation 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 docum...

Page 3: ...Alarms 35 8 Commissioning 36 8 1 Check list Preparation for commissioning 36 8 2 Check list Commissioning 39 8 3 Commissioning work 40 9 ALARM Troubleshooting menu 49 9 1 Alarm messages 49 9 1 1 Vacuum system 49 9 1 2 Production tank 50 9 1 3 Power Supply Unit 50 9 1 4 Product tank alarm 51 9 1 5 Caustic tank 51 9 1 6 Membrane cells 52 9 1 7 Various faults 54 9 2 Messages 54 9 2 1 Process Water Fl...

Page 4: ...k only Chlorinsitu III 600 g h 77 11 4 6 Replacing the O rings on the Transport Stop cock 77 11 4 7 Replacing the Transport Valve 78 11 4 8 Replacing the Seals on the Water Jet Pump 79 11 4 9 Cleaning the Water Jet Pump Nozzle 80 11 4 10 Replacing the O rings on the Stopcock Under the Production Tank 81 11 4 11 Replacing the O rings on the underside of the production tank 82 11 4 12 Checking the T...

Page 5: ...Anode Pipe 99 11 7 6 Replacing the O rings on the Bleed Valve 100 11 8 Maintenance on the product tank 100 11 8 1 Prerequisites for maintenance 100 11 8 2 Checking for leak tightness 100 11 8 3 Checking the lid on the product tank 101 11 8 4 Checking the Liquid Level Switch 101 11 8 5 Checking the Level Switch 101 11 8 6 Checking the chlorine suction unit 102 11 8 7 Replacing the sealing rings on ...

Page 6: ...he current strength The system has the following features n The product is generated in situ where it is needed n There is no need to transfer concentrated chemicals n The water quality is markedly improved resulting in fewer by products 1 1 Description and operation The system produces free chlorine from a brine solution by means of an electrochemical process in a membrane cell as per the dia gra...

Page 7: ...sure that the salt also meets the chemical specification below n Insoluble substances 100 ppm n Calcium Ca 70 ppm n Magnesium Mg 70 ppm The system is suitable for connection to the drinking water net work The water should be of drinking water quality or comparable The sound pressure level is 70 dB A at maximum speed and maximum back pressure using water as the medium Salt quality Water quality Sou...

Page 8: ...t 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 da...

Page 9: ... 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 ...

Page 10: ...orised 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 ...

Page 11: ...m Regularly check the continuity of the hydrogen dis charge line and the supply air to the system The system generates a small amount of a hydrogen air mixture It is essential that this hydrogen air mixture is safely discharged into the outside ambient air Ensure during installation that no air is drawn in from other equipment close to the outlet for instance by an air conditioning system The oper...

Page 12: ...fications are prohibited n Do not operate the system in conditions other than those described in these operating instructions n Only allow qualified personnel to operate the system n Please observe the information in the operating instructions at every phase of the system s service life n Please observe the relevant national regulations and guide lines at every phase of the system s service life S...

Page 13: ...omponents of the system 3 1 Chlorinsitu III 100 500 g h A1702 11 2 Fig 2 Installation of the system 7 1 6 5 12 9 4 3 13 14 15 18 16 17 10 6 A1701 Fig 3 Components of the system Components of the system 13 ...

Page 14: ...centration of approx 25 g l 9 Water venturi Generates negative pressure in the system so that product can be drawn in by suction 10 Booster pump Pumps the sodium hypochlorite from the product tank through the water venturi to produce negative pressure 11 Product tank Supply of sodium hypochlorite with a concentration of approx 25 g l 12 Flow meter The process water to the caustic tank is switched ...

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

Page 16: ...entration of approx 25 g l 9 Water venturi Generates negative pressure in the system so that product can be drawn in by suction 10 Booster pump Pumps the sodium hypochlorite from the product tank through the water venturi to produce negative pressure 11 Product tank Supply of sodium hypochlorite with a concentration of approx 25 g l 12 Flow meter The process water to the caustic tank is switched o...

Page 17: ...3 3 Chlorinsitu III 2000 3500 g h A1707 11 2 Fig 6 Installation of the system 5 1 10 14 9 8 7 18 A1705 Fig 7 Components of the system side A Components of the system 17 ...

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

Page 19: ...entration of approx 25 g l 9 Water venturi Generates negative pressure in the system so that product can be drawn in by suction 10 Booster pump Pumps the sodium hypochlorite from the product tank through the water venturi to produce negative pressure 11 Product tank Supply of sodium hypochlorite with a concentration of approx 25 g l 12 Flow meter The process water to the caustic tank is switched o...

Page 20: ...tions and faults in the installed system When the system is in operation this can also lead to hazards to personnel n Only connect appropriate lifting equipment to the lifting eyes on the top of the system n Carefully transport the system vertically see label on the trans portation packaging n Avoid mechanical impacts n Protect the system from direct sunlight rain and moisture during transportatio...

Page 21: ...stances accumulating in the ambient air n Allow a minimum gap of 30 cm for the cooling fan and for maintenance to the left and right of the control cabinet n Ensure that the room has suitable and adequate mains voltage connections for operation of the relevant system n Ensure that the room has an adequate supply of cooling water if cooling water is needed n Prevent the system from toppling over fo...

Page 22: ...CU line with 20 mm to vent the production tank outside 17 Route a PVCU line with 20 mm to vent the product tank 18 Connect the 50 mm PVCU discharge line with 40 50 mm and the 90 PVCU bend with 40 50 mm on the system 19 Route the 50 mm PVCU discharge line with 40 50 mm into the sewerage system 20 Connect a water supply line with the PVCU connector 20 mm to the system 21 Connect a PVCU line with 20 ...

Page 23: ... only authorised personnel have access n An ambient temperature of 10 35 C otherwise install an air conditioning system n It should be possible to fit a sewerage drain a vent valve and vent openings INFORMATION An assembly drawing showing the correct dimensions can also be produced to ensure correct assembly The assembly area and position are determined using the drawings provided 2 Check that the...

Page 24: ...sition the brine tank 3 in its intended position 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 11 Position the product tank 2 in its intended position Pref erably position the product tank in the direct vicinity o...

Page 25: ...the perfect operation of the floats This applies to the brine tank the product tank the production tank and the caustic tank Do not connect the vent lines from the production tank and product tank to the fan connector Route the vent lines sepa rately outside Route the vent line of the product tank with the vent line of the production tank outside The vent lines of the production tank and the produ...

Page 26: ... level switch from transport damage 23 Fit the level switch in the product tank The system includes the following n Threaded cable connector n Tank sleeve section Ø63 mm n PVCU pipe Ø20 mm with a pressure sensor Fit the Ø50 mm Ø63 mm tank sleeve section into a Ø65 mm hole in the product tank The pressure sensor comes complete with a Ø20 mm PVCU pipe Shorten the 20 mm PVCU pipe to the dimension bet...

Page 27: ...evel switch to the control cabinet 25 Connect a PVCU cooling water drainage line between the Cooling water outlet connector and the sewerage system or a buffer 26 Connect the 1 8 mm PE hose Ø 16 mm between the Brine storage tank filling connector on the system and the con nector Ø 16 mm on the brine tank Connecting 1 8 mm PE hoses A1717 1 2 Fig 13 PE coupling 1 and 2 for PE hose shown for the 100 ...

Page 28: ...tor 1 on the brine tank Connect the 1 8 mm PE hose 2 between the Brine mem brane cell connector on the system and the Ø16 mm con nector on the brine tank 28 Connect the transparent 8 mm nylon hose 3 between the Brine softener connector on the system and the Ø10 mm connector on the brine tank A white transparent 8 mm nylon hose Ø10 mm 3 is located in the brine tank in Fig 16 Connect the white trans...

Page 29: ... the cable ducts of the system on com pletion of installation n 3F N and PE are connected at the bottom right of the control cabinet Capacity Main fuse Voltage Output 100 g h 16 A 3 x 400 V AC 1 65 kW 200 g h 16 A 3 x 400 V AC 2 25 kW 300 g h 16 A 3 x 400 V AC 2 85 kW 400 g h 16 A 3 x 400 V AC 3 45 kW 500 g h 16 A 3 x 400 V AC 4 05 kW 600 g h 20 A 3 x 400 V AC 4 65 kW 750 g h 25 A 3 x 400 V AC 5 5...

Page 30: ...ct on the touchscreen Operating objects are touch sensitive visuals on the touchscreen of the control unit They are essentially operated in a similar way to pressing mechan ical keys Use your finger to operate operating objects As soon as the touchscreen detects that an operating object has been touched the touchscreen reacts with visual feedback The visual feedback is independent of communication...

Page 31: ...u structure of the user interface n STATUS Press STATUS to read off different operating parameters n MANUAL OPERATION Press MANUAL OPERATION to manually perform actions n OPERATION Press OPERATING SETTINGS to set different operating parameters n ALARM Press ALARM to read off localise and if possible acknowledge different alarm messages The main menu of the user interface Operation 31 ...

Page 32: ...ODUCTION PARAMETER 1 PRODUCTION TANK VENTURI PUMP BRINE TANK PRODUCTION PRODUCT TANK STATUS MANUAL OPERATION OPERATING SETTINGS ALARM MAIN MENU OTHER ALARMS POWER SUPPLY CAUSTIC TANK I I SUPPLY TANK SETTINGS LANGUAGE CUSTOMER SETTINGS Fig 20 Menu structure of the user interface Touch the A1789 house key to switch from the menu displayed directly back to the main menu Menu structure of the user int...

Page 33: ...BOOSTER PUMP THERMAL OVERLOAD RELAY ALARMS RESET Serial number g hour STATUS OPERATING SETTINGS LOGIN OPERATING SETTINGS CUSTOMER SETTINGS VDHW FACTORY SETTINGS TIME AND DATE MAINTENANCE CZECH POLISH FINNISH FRENCH GERMAN ENGLISH DUTCH SPANISH ITALIAN SWEDISH MANUAL OPERATION STATUS ALARM OPERATING SETTINGS SUPPLY TANK SETTINGS MANUAL OPERATION PRODUCTION FILL CAUSTIC TANK ANODE REFRESH HYDROGEN F...

Page 34: ...ifferent parameters in the MANUAL OPERATION view MANUAL OPERATION STATUS ALARM OPERATING SETTINGS SUPPLY TANK SETTINGS MANUAL OPERATION PRODUCTION FILL CAUSTIC TANK ANODE REFRESH HYDROGEN FAN BOOSTER PUMP TEST VACUUM SENSOR A3437 Fig 25 Manual operation 7 4 Operating settings You can call up and adjust different parameters in the OPERATING SETTINGS view Operation 34 ...

Page 35: ...RMAN ENGLISH DUTCH SPANISH ITALIAN SWEDISH A3436 Fig 26 Operating settings 7 5 Alarms You can call up and acknowledge different error messages in the ALARMS view A1794 ALARM VACUUM SYSTEM MEMBRANE CELL CHLORINE TANK PRODUCTION TANK BRINE TANK POWER UNIT OTHER ALARMS BOOSTER PUMP THERMAL OVERLOAD RELAY ALARMS RESET Fig 27 Alarms Operation 35 ...

Page 36: ...0 1 100 6 200 3 16 200 HMC 10 2 100 11 400 3 16 300 HMC 10 3 100 17 600 3 16 400 HMC 10 4 100 22 800 3 16 500 HMC 10 4 125 22 800 3 16 600 HMC 25 2 300 11 1100 8 20 750 HMC 25 3 250 17 1600 8 25 1000 HMC 25 4 250 22 2200 9 25 1250 HMC 25 4 313 22 2200 9 35 1500 HMC 25 5 300 27 2700 9 35 1750 HMC 25 5 350 27 2700 9 35 2000 2HMC 25 4 250 44 2200 13 50 2500 2HMC 25 4 300 44 2200 13 63 3000 2HMC 25 5 ...

Page 37: ...the filling line to the product tank 11 Check the connector of the production lines 12 Check the level switch in the production tank caustic tank brine tank and product tank 13 Check the check valve in the membrane cells of the suction line 14 Check all other electrical connections made on site 15 Check that the main fuse kW I of the system corresponds to the specification in the basic settings li...

Page 38: ...ioning Work to be performed Remark Take into consideration the remarks on this page and take appropriate action before commencing commis sioning THIS PART WAS ACCEPTED BY NAME SIGNATURE Project number System Commissioning 38 ...

Page 39: ... Open all ball valves except for the sample valve and the control valve for the cooling water 15 Enter the SMART Production parameters 16 Wear safety clothing Open the lid of the caustic tank and fill the tank with lye in accordance with the basic setting list for the quantity of lye 17 Replace the lid on the caustic tank 18 Switch on the booster pump and fan on the display 19 Check the direction ...

Page 40: ...onds to the specifica tion in the list of basic settings 30 Measure the mains current at full production 31 Check the modem or internet connection if available 32 Take a sample of the product 33 Measure the free chlorine and pH value of the sample from the production tank 34 If the free chlorine is approx 25 g l then sign the handover report 35 Photograph the system 8 3 Commissioning work n User q...

Page 41: ...he regulations and the room is sufficiently ventilated Check that all lines comply with the P ID 2 Switch on the main switch Check that the voltage is 230 V AC between the phases 400 V AC and between a phase and the neutral conductor and between a phase and the protective earth 3 Main fuse Note that different main fuses can be fitted depending on the power supply used partic ularly in relation to ...

Page 42: ...set the regeneration time to 4 days Water hardness test Follow the instructions for the water hardness test in the test kit manual provided or in the manual for the measuring instrument you are using Set the regeneration time of the softener in line with the hard ness of the supply water measured Now set the regenera tion time in accordance with the parameter list below Programming the softener te...

Page 43: ... by this with the result that the system would no longer work correctly If commissioning is not completed ensure that the membrane cell remains wet on both sides A1709 1 Fig 29 Blanking plates 1 Chlorinsitu III 100 500 g h A1710 1 Fig 30 Blanking plates 1 Chlorinsitu III 600 1750 g h Remove the blanking plates Commissioning 43 ...

Page 44: ...tion of the sample valve and the control valve for the cooling water Open the valves on the membrane cells the production tank the caustic tank and the chlorine tank 15 Enter the SMART Production parameters The manual operating display shows the SMART Production menu item Enter the diameter and height of the product tank Also enter the setpoint for the level in the product tank Enter the value for...

Page 45: ...orrosive dust Wear safety glasses Wear safety gloves Use the measuring cup and the funnel to fill the caustic tank remembering to wear gloves and safety glasses Open the cover 1 of the caustic tank and pour lye into the tank Fill the caustic tank with 33 lye 17 Use the cover to seal the caustic tank 18 Switch on the booster pump and the fan on the PLC display Please note that the booster pump is n...

Page 46: ...without lye CAUTION Danger due to lye Possible consequence Danger to health from lye Make sure that all blanking plates are removed on the membrane cell and the vacuum transmitter otherwise lye can escape and cause serious health problems Make sure that all ball valves apart from the sample valve are open otherwise lye could leak out and cause serious health problems Check that there is sufficient...

Page 47: ...manual refresh can be performed if there is sufficient negative pressure Initial check n Start a manual refresh on the display of the PLC n Check that the rinse valve and the vent valve are open n Check that the brine valve is open n Check that the brine flow corresponds to the setpoint 29 Allow the system to be switched on for around 2 hours Make sure that no malfunctions or alarms occur on the s...

Page 48: ...ar attention to the brine concentration and current if the concen tration does not correspond to the specification Check that the brine concentration in the brine tank is saturated ð Enter the valuesin the test protocol and compare the values with the valuesfrom the factory test phase 34 Sign the handover report if the value of the free chlorine is 25 g l 5 g l Commissioning of the system is thus ...

Page 49: ...oting Service Ä Chapter 2 2 User qualification on page 10 9 1 1 Vacuum system This alarm occurs if the vacuum is below 90 for more than 25 sec onds The following causes are possible n There is no process water in the brine tank n One of the O rings on the anode side is not leak tight n Leaking lines on the anode side n The vent valve has an internal leak n The product valve has an internal leak n ...

Page 50: ...chanically opened n The manual valve is closed n The cooling water supply is too low n No cooling water is being supplied n The cooling water does not flow through the heat exchanger in the production tank 9 1 3 Power Supply Unit This alarm occurs if the actual current is less than 70 of the set point The following causes are possible n There is too little brine in the membrane cell n The lye conc...

Page 51: ...ble n Lye is escaping from the caustic tank n The lines to the caustic tank are not leak tight n No process water is entering the caustic tank n Lye leaks from the system through the membranes in the membrane cell n This alarm can occur if the system is idle and does not produce for longer than one day This alarm occurs if the switch for the high liquid level in the caustic tank has been reached T...

Page 52: ... not switch off the system within 2 minutes when the fans are switched off The fans switch off when they are manually turned off or 10 minutes after production stops The following causes are possible n The sensor air flow is faulty n The sensor air flow is not correctly set up 9 1 6 Membrane cells This alarm occurs if the liquid level in the anode regeneration line is too high The following causes...

Page 53: ...e of the membrane cell 1 is too high The following causes are possible n Cooling is not working n There is too little brine in the membrane cell n The current and voltage are too high n The temperature switch is faulty n The cell cables are not correctly tightened This alarm occurs if the temperature on the anode side of the membrane cell 2 is too high The following causes are possible n Cooling i...

Page 54: ... if liquid enters the protection tray of the chlorine tank until it triggers the level switch The following causes are pos sible n The product tank has a leak n The level switch is defective n The product tank is filled with external liquids This alarm occurs if maintenance has not been performed 10 days after the Perform maintenance message has appeared 9 2 Messages n User qualification analysing...

Page 55: ...e middle level contact on the regenera tion pipe is reached during regeneration once the brine valve has been opened 9 2 3 Cooling Water Valve Faulty This alarm occurs if no cooling is measured when the cooling water valve has been activated ALARM Troubleshooting menu 55 ...

Page 56: ...eaning agent 1 Switch off the operating unit 2 Do not spray the operating unit directly Spray cleaning agent onto the cleaning cloth 3 Clean the operating unit Wipe by cleaning the display from the edge of the screen inwards 10 2 Maintenance 10 2 1 Introduction n User qualification maintenance trained user see Ä Chapter 2 2 User qualification on page 10 The system requires annual preventative main...

Page 57: ...aintenance kit 3 100 500 g h 1097459 Maintenance kit 1 100 500 g h 1097456 Maintenance kit 3 600 1750 g h 1097460 Maintenance kit 1 600 1750 g h 1097457 Maintenance kit 3 2000 3500 g h 1097461 Maintenance kit 1 2000 3500 g h 1097458 10 2 3 Maintenance Schedule Daily n Check whether there is sufficient salt in the brine storage tank The brine storage tank should have a minimum of 70 cm of salt n Ch...

Page 58: ...s other protection equip ment 10 2 4 Measuring the pH of the product Measuring a fresh product is crucial for a correct assessment The pH determines the stability of the product A pH between 9 12 produces a stable product A low pH can lead to a lower strength product The process water flow is measured The system issues an alarm and stops production if there is too great a deviation of the process ...

Page 59: ...e with the Chlorinsitu III 600 1750 g h and Chlorinsitu III 2000 3500 g h systems In this case you need to measure using 2 cell cables 1 Measure the amperage figure during production with a cur rent clamp on the membrane cell s 2 Compare the amperage measured with the amperage shown on the STATUS screen 3 Note the value measured in the maintenance schedule 10 2 8 Monitoring the Amperage at the Mem...

Page 60: ...e measuring cartridge with the reserve measuring cartridge 2 Regenerate soften the measuring cartridge removed A2012 I II III Fig 35 Regenerating the measuring cartridge 1 I Use the regeneration kit provided Use saturated brine for regeneration For example use salt from the brine storage tank 2 II Flush the measuring cartridge five times with brine The white part of the cartridge should move right...

Page 61: ...ted 8 Open all shut off valves with the exception of the sample valve and the cooling water control valve 9a Open the cover of the caustic tank and fill the caustic tank with the volume of lye previ ously collected Wear protective clothing when working with sodium hydroxide solution 9b Fill additional lye with the Chlorinsitu III 500 g h 10 Replace the cover on the caustic tank 11 Switch the fan o...

Page 62: ...e refresh 20 Measure the voltage at the membrane cell and monitor whether the voltage is not above 5 V DC per chamber 21 Measure and check during production that the amperage is identical to the current measured and shown on the control panel Maintenance checks and preparation for maintenance 62 ...

Page 63: ...III 600 1750 g h III Chlorinsitu III 2000 3500 g h 1 Switch production to OFF 2 Perform a manual anode refresh five times ð The system is now virtually product free 3 Switch the booster pump to OFF 4 Switch the fan to OFF 5 Switch the main switch to OFF It is mandatory that the main switch is off during maintenance work 6 Close the water tap 11 2 Maintenance on the water softener n User qualificat...

Page 64: ...58 1 2 3 4 Fig 37 Removing the softener head 1 Check the softener head 4 for leaks 2 Unscrew the screws 1 on both sides and remove the cover 3 Unscrew the screw 2 4 Unscrew the screws 3 on both sides 5 Incline the softener head backwards Remove the softener head Preventative maintenance 64 ...

Page 65: ... Fig 38 Replacing the drainage nozzle and brine valve O ring 1 Unscrew the screws 1 and remove the protection plate 2 Pull the brine valve 2 out of its seat 3 Replace the drainage nozzle during annual maintenance 4 Replace the brine valve O ring 3 Preventative maintenance 65 ...

Page 66: ...Greasing and replacing the seals 1 Remove the piston 1 out of its seat The seals and the spacers are arranged around the piston 2 Replace the seals ð Replace the seals at the latest during the three yearly maintenance Preventative maintenance 66 ...

Page 67: ...e Side A1961 1 2 3 Fig 40 Cleaning the filter meshes on the brine side 1 Unscrew the two screws 1 2 Remove the filter meshes 2 out of their seat 3 Clean the filter meshes 4 Insert all parts 3 into the water softener head Preventative maintenance 67 ...

Page 68: ...Fig 41 Removing the softener head 1 Check the softener head for leaks 2 Unscrew the screws on both sides and remove the cover 1 3 Loosen the display 2 on the right side and pivot the display to the left 4 Unscrew the nuts 3 5 Unscrew the bolts 4 to release the front panel Preventative maintenance 68 ...

Page 69: ...the front panel from the softener head The drainage pin 1 2 The O ring will also come loose when you remove the drainage nozzle The O ring belongs at the bottom in the drainage nozzle chamber Pull the drainage nozzle 2 out of its seat 3 Replace the drainage nozzle during annual maintenance 4 Replace the brine valve O ring 3 Preventative maintenance 69 ...

Page 70: ...cover 1 The seals and the spacers are arranged around the piston 2 There are two pistons 2 an upper piston and a lower piston 3 Remove the upper piston 3 out of its seat 4 INFORMATION The lower piston is longer with the result that it is more difficult to remove the spacers and seals from the chamber Remove the lower piston 4 out of its seat 5 Replace the seals ð Replace the seals at the latest du...

Page 71: ...ly mainte nance 11 2 3 Replacing the Water Filter I II III A1966 Fig 45 Replacing the water filter I Chlorinsitu III 100 500 g h II Chlorinsitu III 600 1750 g h III Chlorinsitu III 2000 3500 g h 1 Screw the housing of the water filter in place 2 Replacing the Water Filter 3 Screw the housing of the water filter in place 11 3 Maintenance on the Brine Storage Tank n User qualification maintenance tr...

Page 72: ...harging hose 1 2 Remove the liquid level switch 2 out of its housing 3 Check the float 3 for dirt damage and correct operation 4 Insert the liquid level switch into the brine storage tank 5 Make sure that there are O rings in the cou pling and that they are undamaged Connect the charging hose to the coupling 4 Preventative maintenance 72 ...

Page 73: ...hree yearly maintenance 5 Screw the clean new filter meshes into the housing 6 Remove the non return valve 5 7 Flush the non return valve 5 with softened water 8 Make sure that the arrow on the non return valve points upwards Remove the non return valve 5 9 Make sure that the arrow on the non return valve points upwards Make sure that there are O rings in the cou pling and that they are undamaged ...

Page 74: ... Measure During maintenance on the production tank wear the goggles and gloves provided Ventilate the room during maintenance A1969 II I III Fig 48 Maintenance on the production tank I Chlorinsitu III 100 500 g h II Chlorinsitu III 600 1750 g h III Chlorinsitu III 2000 3500 g h 1 Production tank 2 Caustic tank 11 4 2 Draining the production tank INFORMATION Use the hose supplied with couplings and...

Page 75: ...ter outlet 4 n Coupling on the suction line of the booster pump 5 3 Remove the suction line section 6 from the system Allow the section of line to drain into the collection tank 4 Connect the coupling supplied with the hose 7 to the shut off valve underneath the production tank Hang the other end of the hose into the tank min 20 litres 5 Slowly open the shut off valve underneath the production tan...

Page 76: ... the O rings in the couplings during annual mainte nance 4 Check the booster pump couplings for leak tightness and wear If the couplings on the pump housing are not tight it may be necessary to readjust the couplings 5 Replace the couplings including the nipples and O rings 6 Fit all the components and tighten the threaded connectors on the couplings 11 4 4 O rings on the Three part Coupling at th...

Page 77: ...he FKM O rings DIN ISO 1629 3 Tighten the threaded connectors 4 Insert the line into the system 11 4 6 Replacing the O rings on the Transport Stopcock 1 A1974 Fig 53 Replacing the O rings on the transport stopcock 1 Remove the transport stopcock 1 2 Replace the O rings 3 Replace the O rings and the transport stopcock 4 Insert the transport stopcock into the line Annual maintenance Three yearly mai...

Page 78: ... Loosen the threaded connectors on the transport valve 1 2 Remove the connector cap from the transport valve Make sure that the arrow on the transport valve points upwards 3 Replace the transport valve 4 Re fit the connector cap onto the new transport valve Preventative maintenance 78 ...

Page 79: ...976 1 Fig 55 Water jet pump seals 1 Loosen the threaded connectors on the water jet pump and remove the water jet pump 2 Remove the old seals and insert new seals n Seal on the venturi side n Seal on the inlet and outlet side Preventative maintenance 79 ...

Page 80: ...lockwise direction 2 Remove the nozzle 3 Check the nozzle for dirt and wear cleaning or replacing the nozzle if necessary Make sure that the nozzle in the housing is fitted tightly A dirty or insufficiently tightened nozzle will result in too weak a vacuum 4 Insert the nozzle into the water jet pump Preventative maintenance 80 ...

Page 81: ...uction Tank A1978 1 Fig 57 Stopcock under the production tank 1 Dismantle the stopcocks under the production tank 2 Replace the O rings 3 Replace the O rings and the stopcocks During annual maintenance During three yearly maintenance Preventative maintenance 81 ...

Page 82: ... during maintenance A1979 1 Fig 58 Replacing the O rings on the underside of the production tank 1 Unscrew the threaded connectors of the connecting part 1 between the production tank and the caustic tank 2 Replace the FKM O rings DIN ISO 1629 on both sides of the connecting part 3 Loosen the couplings under the production tank 4 Replace the coupling O rings under the production tank 5 Fit the cou...

Page 83: ... Checking the temperature sensor in the production tank 1 Unscrew the white threaded connector 1 2 Remove the temperature sensor 2 3 Check the temperature sensor for oxidation and damage Oxidation and damage may be an indication of a leak on the housing Preventative maintenance 83 ...

Page 84: ...ction Tank A1981 1 Fig 60 Replacing the seals on the upper side of the production tank 1 Replace the seals on the upper side of the production tank 1 Seal design n Chlorinsitu III 600 g h flat seals n Chlorinsitu III 600 g h O rings Preventative maintenance 84 ...

Page 85: ...Replace the level switch during three yearly maintenance Check the two floats for dirt and damage and clean or replace the level switch if necessary 11 4 15 Replacing the Chlorine Gas Valve A1983 1 Fig 62 Replacing the chlorine gas valve 1 1 Loosen the threaded connectors on the chlorine gas valve 1 2 Remove the connector cap for the chlorine gas valve Preventative maintenance 85 ...

Page 86: ...on tank 2 Install the production tank in the system 3 Pour the collected product into the production tank Retain a small quantity of product in the measuring cup to test the chlorine gas sensor 11 5 Maintenance on the Lye Storage Tank n User qualification maintenance trained user see Ä Chapter 2 2 User qualification on page 10 Preventative maintenance 86 ...

Page 87: ...om lye Measure During maintenance on the production tank wear the goggles and gloves provided Ventilate the room during maintenance A1969 II I III Fig 63 Maintenance on the Lye Storage Tank I Chlorinsitu III 100 500 g h II Chlorinsitu III 600 1750 g h III Chlorinsitu III 2000 3500 g h 1 Production tank 2 Lye storage tank Preventative maintenance 87 ...

Page 88: ...I 2000 g h 2 stopcocks n With Chlorinsitu III 2000 g h 3 stopcocks 2 Close the cathode valve 2 on the membrane cell 3 Remove the supply cable to the membrane cell out of the system and allow the supply line to slowly drain into the col lection tank 4 Open the cathode valve and allow the membrane cell to slowly drain into the collection tank 1 2 A1985 Fig 65 Draining the lye storage tank 5 Unscrew ...

Page 89: ... the Stopcocks on the Bottom of the Lye Storage Tank A1986 1 Fig 66 Replacing the O rings on the stopcocks on the bottom of the lye storage tank Replace the EPDM O rings 1 on the stopcocks on the bottom of the lye storage tank 11 5 4 Replacing the O rings on the Couplings on the Bottom of the Lye Storage Tank A1987 1 Fig 67 Couplings on the bottom of the lye storage tank During three yearly mainte...

Page 90: ...itu III 600 g h A1988 Fig 68 O ring on the heat exchanger 1 Loosen the threaded connectors on the top and bottom of the heat exchanger 2 Replace the EPDM O rings 1 3 Fit the threaded connectors on the top and bottom of the heat exchanger Preventative maintenance 90 ...

Page 91: ...rage Tank A1989 1 Fig 69 Replacing the seals on the upper side of the lye storage tank 1 Replace the seals on the upper side of the lye storage tank 1 Seal design n Chlorinsitu III 600 g h flat seals n Chlorinsitu III 600 g h O rings Preventative maintenance 91 ...

Page 92: ...Checking the temperature sensor in the lye storage tank 1 Unscrew the white threaded connector 1 2 Remove the temperature sensor 2 3 Check the temperature sensor for oxidation and damage Oxidation and damage may be an indication of a leak on the housing Preventative maintenance 92 ...

Page 93: ... level switch and remove the level switch 2 Replace the level switch during three yearly maintenance Check the two floats for dirt and damage and clean or replace the level switch if necessary 11 5 9 Fitting All Components 1 Fit all components of the lye storage tank 2 Install the lye storage tank in the system Preventative maintenance 93 ...

Page 94: ... fan 3 5 Carefully rinse the fan 4 with water 6 Fit the fan 7 Fit the connecting section 8 Unscrew the adjustment screw and remove the air flow sensor 5 out of the supply pipe 9 Clean the air flow sensor 10 Fit the air flow sensor 11 6 Maintenance on the Membrane Cell n User qualification maintenance trained user see Ä Chapter 2 2 User qualification on page 10 Maintenance on the Air Flow Sensor Pr...

Page 95: ...0 500 g h membrane cell This example showed a Chlorinsitu III 100 500 g h membrane cell The same provisions apply to the Chlorinsitu III 600 3500 g h 11 6 2 Replacing the O rings on the Anode Side of the Membrane Cell A1993 1 2 3 Fig 73 O rings on the anode side 1 Close the refresh tap 1 2 Close the brine tap 2 3 Tighten the threaded connector on the membrane cell 4 Manually open the bleed valve 3...

Page 96: ... the brine valve and the O rings 5 Fit the connector cap on the brine valve 11 6 4 Replace the O rings on the brine valve A1995 1 Fig 75 O rings on the brine tap 1 During every maintenance Replace the FKM O rings DIN ISO 1629 11 7 Maintenance on the Anode Pipe n User qualification maintenance trained user see Ä Chapter 2 2 User qualification on page 10 Annual maintenance Three yearly maintenance P...

Page 97: ...1 7 2 The PVDF Float and Stop Pipe A1996 2 1 Fig 76 The PVDF float 1 Tighten the coupling under the anode 2 Remove the PVDF float and the stop pipe from the anode pipe 3 Clean the PVDF float 4 Check the PVDF float for leaks 5 Clean the stop pipe 6 Replace the PVDF float Make sure that the reed switch for low level is correctly adjusted to the PVDF float pipe 7 Replace the stop pipe During annual m...

Page 98: ... 3 Replace the O rings 4 Replace the refresh valve and O rings 5 Fit the connector cap on the refresh valve 11 7 4 Replace the O rings on the Refresh Tap A1998 1 Fig 78 O rings on the refresh tap 1 1 Replace the O rings 2 Replace the refresh tap and O rings Annual maintenance Three yearly maintenance Annual maintenance Three yearly maintenance Preventative maintenance 98 ...

Page 99: ...de pipe 4 Replace the O rings 5 Replace the O ring on the lower measuring pipe connector 3 6 Replace the O ring on the lower anode pipe connector 2 7 Replace the O ring on the stop pipe 4 8 Open the coupling 1 on the upper side of the measuring pipe 9 Replace the O ring 10 Check the upper stop for oxidation 11 Replace the upper stop Annual maintenance Three yearly maintenance Preventative maintena...

Page 100: ...nsequence Fatal or very serious inju ries from product residue Measure Wear the goggles and gloves provided during maintenance on the product tank Ventilate the room during maintenance INFORMATION The standard scope of delivery includes the level switch The product tank the dry running level switch and the product suction unit are optional This maintenance manual describes the maintenance of the l...

Page 101: ...float for dirt and damage 6 Replace the low flow liquid level switch 11 8 5 Checking the Level Switch A2003 1 Fig 82 Checking the level switch 1 1 Open the level switch coupling 2 Check the float for dirt and damage 3 Replace the level switch Checking the too high liquid level switch During annual maintenance During three yearly maintenance Checking the low flow liquid level switch During annual m...

Page 102: ...e suction unit A2004 1 Fig 83 Checking the chlorine suction unit 1 Remove the product suction unit from the product tank 2 Check the product suction unit for dirt and damage ð Clean or replace if necessary Checking the low flow level switch During annual maintenance During three yearly maintenance Preventative maintenance 102 ...

Page 103: ... 1 2 3 Fig 84 Sealing rings on the product suction unit 1 Dismantle the threaded connector 1 on the check valve 2 Replace the O ring 2 3 Dismantle the float 3 from the check valve 4 Replace the seal on the float 5 Fit the threaded connector 1 into the check valve 11 9 Maintenance on the Control Cabinet n User qualification maintenance trained user see Ä Chapter 2 2 User qualification on page 10 Pr...

Page 104: ... contacts 1 Check all relay contacts for discolouration and oxidation and clean if necessary 2 Check all connectors for discolouration and tighten if neces sary 3 Check all components for discolouration and oxidation and clean if necessary Preventative maintenance 104 ...

Page 105: ... filter 11 10 Maintenance on the chlorine gas detector n User qualification maintenance trained user Ä Chapter 2 2 User qualification on page 10 Replace the chlorine gas sensor during annual maintenance The process for installing and adjusting the chlorine gas sensor is described in the instructions for the chlorine gas detector which is supplied with the maintenance package During three yearly ma...

Page 106: ...the new chlorine gas sensor into the correct position in the holder 11 10 2 Testing the Chlorine Gas Sensor A2010 1 2 Fig 88 Testing the chlorine gas sensor 1 Hold a measuring cup 2 containing a small amount of chlorine product under the chlorine gas sensor 1 2 Check whether the alarm is triggered when chlorine gas is detected and the Chlorinsitu III system switches to fault mode ð Should no fault...

Page 107: ...fication repair Service see Ä Chapter 2 2 User qualification on page 10 The system can only be repaired by the manufacturer or the authorised Service department Please get in touch with your local Service contact Repair 107 ...

Page 108: ...bers to order these maintenance kits Tab 5 Maintenance kits Maintenance kit Order number Maintenance kit 3 100 500 g h 1097459 Maintenance kit 1 100 500 g h 1097456 Maintenance kit 3 600 1750 g h 1097460 Maintenance kit 1 600 1750 g h 1097457 Maintenance kit 3 2000 3500 g h 1097461 Maintenance kit 1 2000 3500 g h 1097458 Maintenance kits Spare parts 108 ...

Page 109: ...air To do so remove all traces of hazardous substances Refer to the Material Safety Data Sheet for your feed chemical A current Declaration of Decontamination is available to download on the ProMinent website In accordance with the European Directive 2012 19 EU on waste electrical and electronic equipment this device features the symbol showing a waste bin with a line through it The device must no...

Page 110: ...h 63 A 3 x 400 V AC 16 05 kW 3000 g h 63 A 3 x 400 V AC 19 05 kW 3500 g h 80 A 3 x 400 V AC 22 05 kW Tab 7 Electrical data 100 1000 g h Capacity g h 100 200 300 400 500 600 750 1000 Capacity kg 24 h 2 2 4 4 6 6 8 8 11 13 2 16 5 22 Power consumption net kVA 1 1 1 5 1 9 2 3 2 7 3 1 3 7 4 7 Power consumption gross kVA 1 65 2 25 2 85 3 45 4 05 4 65 5 55 7 05 Main fuse A 3 x 16 3 x 20 3 x 25 Tab 8 Elec...

Page 111: ...50 Salt kg 24 h 5 10 15 20 25 30 35 50 60 Dilution air m3 h 8 16 24 32 40 47 59 79 99 Product concentration 20 25 g l Ambient temperature 10 35 C Maximum ambient air humidity 85 Connectors Raw water feed 20 mm Brine for softener 20 mm Brine for membrane cell 20 mm Filling the brine tank 20 mm Product outlet 20 mm Bleeding diluted hydrogen 63 mm 110 mm Bleeding production tank 20 mm Waste water duc...

Page 112: ...50 175 Dilution air m3 h 119 138 158 198 237 277 Product concentration 20 25 g l Ambient temperature 10 35 C Maximum ambient air humidity 85 Connectors Raw water feed 20 mm Brine for softener 20 mm Brine for membrane cell 20 mm Filling the brine tank 20 mm Product outlet 20 mm Bleeding diluted hydrogen 110 mm 125 mm Waste water duct 50 mm Cooling output 20 mm Remarks Maximum water hardness 15 dH m...

Page 113: ...5 Fig 89 Flow diagram for Chlorinsitu III 100 500 g h A1956 Fig 90 Flow diagram for Chlorinsitu III 600 1750 g h Flow diagram for Chlorinsitu III 100 500 g h Flow diagram for Chlorinsitu III 600 1750 g h Technical data 113 ...

Page 114: ...A1957 Fig 91 Flow diagram for Chlorinsitu III 2000 3500 g h Flow diagram for Chlorinsitu III 2000 3500 g h Technical data 114 ...

Page 115: ...tu III Serial number see nameplate on the unit Relevant EC Directives EC Machinery Directive 2006 42 EC to 19 04 2016 EC EMC Directive 2004 108 EC from 20 04 2016 EC EMC Directive 2014 108 EC Compliance with the protection targets of the Low Voltage Directive 2006 95 EC according to Appendix I No 1 5 1 of the Machinery Directive 2006 42 EC to 19 04 2016 Explosion Safety Directive ATEX 94 9 EC from...

Page 116: ...114 G General non discriminatory approach 2 I Information in the event of an emergency 11 Installation of the system 13 15 17 Intended use 12 L Life phases of the system 12 Links to elements or sections of these instruc tions or other applicable documents 2 M Magnesium 7 More symbols 2 N Non discriminatory approach 2 P Personal protective equipment 11 Protective equipment 11 R Relevant EC directiv...

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Page 120: ...cherpenzeel Netherlands Telephone 31 0 33 2778600 Fax 31 0 33 2778399 Email info vdhwater nl Internet www vdhwater nl DTP and design ProMinent GmbH Im Schuhmachergewann 5 11 69123 Heidelberg Germany Telephone 49 6221 842 0 Fax 49 6221 842 419 Email info prominent com Internet www prominent com ...

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