ProMinent Chlorinsitu-III Assembly And Operating Instructions Manual
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ProMinent Chlorinsitu-III Assembly And Operating Instructions Manual

Chlorine electrolysis system
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Assembly and operating instructions
Chlorine electrolysis system
Chlorinsitu-III
EN
Target group: Trained user
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.
984350
Original operating instructions (2006/42/EC)
Version: BA Cl 023 09/21 EN

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  • Page 1 Assembly and operating instructions Chlorine electrolysis system Chlorinsitu-III Target group: Trained user 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 Supplemental directives General non-discriminatory approach 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.

  • Page 3: Table Of Contents

    2.2 User qualification............10 2.3 General safety information.......... 11 2.4 Intended use............... 12 Components of the system..........13 3.1 Chlorinsitu-III 100 ... 500 g/h........13 3.2 Chlorinsitu-III 600 ... 1750 g/h........15 3.3 Chlorinsitu-III 2000 ... 3500 g/h........17 Storage and transport............20 Preparation for use.............
  • Page 4 Table of contents 10.2.7 Check the amperage at the membrane cells..59 10.2.8 Monitoring the Amperage at the Membrane Cells ..............59 10.2.9 Regeneration of the Water Hardness Meter ..60 10.3 Commissioning the system after maintenance..61 10.3.1 Commissioning process......... 61 Preventative maintenance..........
  • Page 5 Table of contents 11.5.7 Checking the Temperature Sensor in the Lye Storage Tank............92 11.5.8 Checking the Level Switch in the Lye Storage Tank ..............93 11.5.9 Fitting All Components........... 93 11.5.10 Maintenance on the Fan........94 11.6 Maintenance on the Membrane Cell ......94 11.6.1 Preparation for Maintenance on the Membrane Cell ................

  • Page 6: Description Of The System

    Description of the system Description of the system The system is used for water disinfection in: Swimming pools Drinking water Waste water F&B Various process water systems etc. ‘free chlorine’ , The system is used to electrochemically produce which is referred to as the product throughout the operating instructions.
  • Page 7 Description of the system Salt quality We recommend using Chlorinsitu salt, Marina ® or Broxo-6-15 ® salt or another suitable salt specifically supplied for water softeners. The salt used must conform to one of the following standards: EN 16401, EN 973 (in tablet-form only), EN 16370.

  • Page 8: Safety And Responsibility

    Safety and responsibility Safety and responsibility 2.1 Labelling of Warning Information Introduction 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.
  • Page 9 Safety and responsibility 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.

  • Page 10: User Qualification

    Safety and responsibility 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.

  • Page 11: General Safety Information

    Safety and responsibility 2.3 General safety information WARNING! Danger from hazardous substances! Possible consequence: Fatal or very serious inju‐ ries. Please ensure when handling hazardous sub‐ stances that you have read the latest safety data sheets provided by the manufacture of the haz‐ ardous substance.

  • Page 12: Intended Use

    Safety and responsibility 2.4 Intended use The 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. All other uses or modifications are prohibited. Do not operate the system in conditions other than those described in these operating instructions.

  • Page 13: Components Of The System

    Components of the system Components of the system 3.1 Chlorinsitu-III 100 ... 500 g/h A1702 Fig. 2: Installation of the system A1701 Fig. 3: Components of the system...
  • Page 14 Components of the system Number Component Function Softener Softens the water. Removes calcium and magnesium. Brine tank Salt stock. It produces a saturated salt solution together with the softened water. Membrane cell Sodium hypochlorite is produced from a salt solution in the mem‐ brane cell in an electrochemical process.

  • Page 15: Chlorinsitu-Iii 600

    Components of the system 3.2 Chlorinsitu-III 600 ... 1750 g/h A1704 Fig. 4: Installation of the system A1703 Fig. 5: Components of the system...
  • Page 16 Components of the system Number Component Function Softener Softens the water. Removes calcium and magnesium. Brine tank Salt stock. It produces a saturated salt solution together with the softened water. Membrane cell Sodium hypochlorite is produced from a salt solution in the mem‐ brane cell in an electrochemical process.

  • Page 17: Chlorinsitu-Iii 2000

    Components of the system 3.3 Chlorinsitu-III 2000 ... 3500 g/h A1707 Fig. 6: Installation of the system A1705 Fig. 7: Components of the system (side A)
  • Page 18 Components of the system A1706 Fig. 8: Components of the system (side B)
  • Page 19 Components of the system Number Component Function Softener Softens the water. Removes calcium and magnesium. Brine tank Salt stock. It produces a saturated salt solution together with the softened water. Membrane cell Sodium hypochlorite is produced from a salt solution in the mem‐ brane cell in an electrochemical process.

  • Page 20: Storage And Transport

    Storage and transport Storage and transport Storage Store the system in its original transport packaging in a sealed room, observing the following conditions: at a temperature of between 5 °C ... 50 °C at a relative air humidity below 85 % without condensation in a non-aggressive environment (no harmful vapours, chemi‐...

  • Page 21: Preparation For Use

    Preparation for use Preparation for use Adhere to all national and local regulations relating to the use of chlorine. The operator of the system is responsible for ensuring that the regulations are implemented. Ensure that the floor of the room has sufficient load-bearing capacity to bear the weight of the filled system.

  • Page 22: Installation And Assembly

    Route the PVCU discharge line with ⌀ 75 / ⌀ 110 mm outside. Connect the sensor air flow to the control cabinet (not needed with Chlorinsitu-III 100 ... 500 g/h). Refer to the wiring diagram for connection information.

  • Page 23: Assembly And Installation Of The System

    Installation and assembly Assembly process Tick Connect the brine tank level switch. Connect the power cable according to the voltage and current specification on the ter‐ minal strip in the control cabinet. THIS PART WAS ACCEPTED BY: NAME: SIGNATURE: Project number: System: 6.2 Assembly and installation of the system User qualification, mechanical/hydraulic installation: trained...
  • Page 24 Route this PVCU discharge line outside. The vent connector is located fully outdoors. Fit the connector in such a way that no rainwater can penetrate it. Connect the sensor air flow in the control cabinet – not needed for the Chlorinsitu-III 100 ... 500 g/h.
  • Page 25 Installation and assembly Check that the PVCU discharge line routed outside is con‐ nected. Always route the PVCU discharge line upwards. Do not allow any part of the PVCU discharge line to point downwards. Ensure that the PVCU discharge line does not have more than 8 bends.
  • Page 26 Installation and assembly Check valve Fit a check valve into the drinking water supply line (1) in compliance with national regulations. Connect the drinking water supply line to the "Water supply" PVCU connector on the system. Minimum pressure = 1.5 bar Maximum pressure = 5 bar Quality = drinking water A1716...
  • Page 27 Installation and assembly Electrically connect the pressure sensor to the terminal box of the system. Cable Terminal Black X3 - 65 White X3 - 66 Shielding Earth Description Level switch Terminal strip Liquid level too high 5LAHH45 X1-11 Electrically connect the level switch to the control cabinet. Connect a PVCU cooling water drainage line between the "Cooling water outlet"...
  • Page 28 Installation and assembly A1719 Fig. 15: PE coupling connectors A1718 Fig. 14: PE couplings for connection to the system and brine tank A1720 Fig. 16: Brine tank with hoses and coupling 1. Prepared PE coupling in the brine tank 2. Black 1.8 mm PE hose 3.
  • Page 29 Installation and assembly Connecting the brine tank level switch Connect the cables on terminal strip X1-21 The brown cable in the first row of the terminal strip The blue cable in the second row of the terminal strip. Do not remove the jumpers in the terminal strips. Electrically installing the system Connect the power cable of the system, as per the table below, to the terminal strip in the control cabinet, taking into...

  • Page 30: Operation

    Operation Operation Ä Chapter 2.2 User qualification, operation: instructed user ‘User qualification’ on page 10 The user interface Damage to the touchscreen Sharp or pointed objects can damage the plastic surface of the touchscreen. Only use your finger or a touch pen to operate the touchscreen.
  • Page 31 Operation The main menu of the user interface MAIN MENU STATUS MANUAL OPERATION OPERATING SETTINGS ALARM A1788 Fig. 19: The main menu of the user interface The main menu of the user interface represents the starting point of the menu structure of the user interface. STATUS –...
  • Page 32 Operation Menu structure of the user interface MAIN MENU PRODUCTION STATUS MANUAL PRODUCT TANK OPERATION OPERATING SETTINGS ALARM BRINE TANK MAIN MENU STATUS SCREEN for PROCESSES PRODUCTION PARAMETER 2 MANUAL OPERATION SUPPLY TANK SETTINGS OPERATING SETTINGS PRODUCTION PARAMETER 1 MAINTENANCE ALARM VACUUM SYSTEM TIME AND DATE...

  • Page 33: Navigation

    Operation Touch the (left arrow) key to move from the menu displayed one page back in the menu structure. A1790 A1790 Fig. 22: Move one page back 7.1 Navigation STATUS g/hour Serial number MAIN MENU MANUAL OPERATION STATUS STATUS MANUAL PRODUCTION OPERATION MANUAL...

  • Page 34: Status

    Operation 7.2 Status [STATUS] view. You can read off different parameters in the STATUS g/hour Serial number A1793 Fig. 24: [STATUS] 7.3 Manual operation You can call up and operate different parameters in the [MANUAL OPERATION] view. MANUAL OPERATION STATUS PRODUCTION MANUAL BOOSTER PUMP...

  • Page 35: Alarms

    Operation OPERATING SETTINGS OPERATING SETTINGS CUSTOMER SETTINGS DUTCH ENGLISH GERMAN FRENCH FINNISH MAINTENANCE TIME AND DATE VDHW FACTORY SETTINGS POLISH CZECH SPANISH ITALIAN SWEDISH LOGIN A3436 Fig. 26: Operating settings 7.5 Alarms You can call up and acknowledge different error messages in the [ALARMS] view.

  • Page 36: Commissioning

    Commissioning Commissioning 8.1 Check-list: Preparation for commissioning Commissioning process for Chlorin‐ User qualification, preparation for commissioning: trained quali‐ situ-III Ä Chapter 2.2 ‘User qualification’ on page 10 fied personnel Customer Project number Capacity Description Customer-specific components Tested by Start time End time Pre-commissioning Commissioning...
  • Page 37 Commissioning Preparation for commissioning Tick Check whether the line for the sensor air flow is connected. Check whether the hydrogen circuit is connected. Check whether the vent valve and the production and product tank are correctly con‐ nected. Check the drain connectors. Check the water supply.
  • Page 38 Commissioning Preparation for commissioning 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:...

  • Page 39: Check-List: Commissioning

    Remove the blanking plates on the vacuum transmitter and membrane cells. Insert the chlorine sensor into the holder (not with the Chlorinsitu-III 100-500 g/h). Open all ball valves except for the sample valve and the control valve for the cooling water.

  • Page 40: Commissioning Work

    Commissioning Step Switch on production in the display. Check whether the booster pump is running and the caustic tank stops filling. Check that all parts fitted by the customer are working correctly. Check the cooling fans for the membrane cells and the control cabinet. Manually start "Refill anode".
  • Page 41 Commissioning Check that all preparations have been completed correctly prior to starting commissioning. Commissioning is divided into two phases. Commissioning preparation is used to monitor the installation phase and should be performed prior to commissioning. INFORMATION: Only allow trained service technicians to commis‐ sion the system.
  • Page 42 Commissioning Check that there is adequate salt (EN973) in the brine tank. Check that the water supply is running correctly. Check that the brine tank is filled with softened water. The brine tank should automatically fill with softened water once you have switched on the fuses and connected the level switch in the control cabinet.
  • Page 43 If commissioning is not completed, ensure that the membrane cell remains wet on both sides. A1709 Fig. 29: Blanking plates (1) / Chlorinsitu-III 100-500 g/h A1710 Fig. 30: Blanking plates (1) / Chlorinsitu-III 600-1750 g/h...
  • Page 44 Commissioning A1711 Fig. 31: Blanking plates (1) / Chlorinsitu-III 1800-3500 g/h Remove all blanking plates (1) on the vacuum transmitter and the membrane cells. Chlorine sensor If ordered: The chlorine sensor is included in the scope of delivery of the system and is already in its holder. Remove the plastic pouch and silica gel pouch from the chlorine sensor.
  • Page 45 Commissioning CAUTION! Working with lyes Before performing the next step: Wear protective clothing and note the dangers when working with lyes. A1712 Fig. 32: Remove the cover (1) of the caustic tank Fire, naked flames and smoking are prohibited. Danger due to corrosive dust. Wear safety glasses.
  • Page 46 Commissioning Checking the direction of rotation of The fan can be switched on and off on the display of the the fan PLC. The correct direction of rotation of the fan is shown by the arrow on the fan. Perform the following steps if the booster pump and/or the fan are rotating in the wrong direction: Use the main switch to switch off the system Swap phases 2 and 3 of the main power supply...
  • Page 47 Commissioning Check that the cooling fans of the membrane cells and con‐ trol cabinet are working correctly. No cooling fan is fitted on the membrane cell of the Chlorin‐ situ-III < 600 g/h. Make sure that the cooling fan is rotating in the right direc‐ tion.
  • Page 48 Commissioning INFORMATION: Wear protective clothing and note the dan‐ gers of working with lyes before continuing with the next step. Fire, naked flames and smoking are prohibited. Danger due to corrosive dust. Wear safety glasses. Wear safety gloves. Take a sample of product from the product tank Measure the concentration of free chlorine and the pH valve in the sample from the production tank and enter the values in the test protocol...

  • Page 49: Alarm] / Troubleshooting Menu

    [ALARM] / Troubleshooting menu [ALARM] / Troubleshooting menu ALARMS ALARM BOOSTER PUMP THERMAL OVERLOAD RELAY VACUUM SYSTEM MEMBRANE CELL CHLORINE TANK PRODUCTION TANK BRINE TANK POWER UNIT RESET OTHER ALARMS A1794 Fig. 33: Evaluating alarm messages [ALARM] in the [MAIN MENU] takes you to the [ALARM] Pressing [ALARM] menu you can press the various keys to call menu.

  • Page 50: Production Tank

    [ALARM] / Troubleshooting menu 9.1.2 Production tank The booster pump's thermal protec‐ This alarm occurs if the booster pump's thermal protection function tion function is activated is activated. The following causes are possible: The booster pump is operating under excessive load. One phase of the booster pump's power supply has failed.

  • Page 51: Product Tank Alarm

    [ALARM] / Troubleshooting menu 9.1.4 Product tank alarm Product tank level too high This alarm occurs when the level in the product tank reaches the switch. The following causes are possible: The level switch in the product tank is not working correctly. Product is escaping from the pump valve to the product tank into the product tank.

  • Page 52: Membrane Cells

    [ALARM] / Troubleshooting menu Water supply too high This alarm occurs if the water pressure is so high that the metering time is shorter than 2 seconds. The following causes are possible: The pressure reducing valve is faulty. The water pressure is too high. Valve to fill the caustic tank is faulty This alarm occurs if no process water is measured because the valve to fill the caustic tank has been activated.
  • Page 53 [ALARM] / Troubleshooting menu Anode filling takes too long This alarm occurs if insufficient volume of brine is taken up during regeneration. The following causes are possible: The brine valve is faulty. Insufficient or no brine in the brine tank. Insufficient or no water in the brine tank.

  • Page 54: Various Faults

    [ALARM] / Troubleshooting menu 9.1.7 Various faults Chlorine gas detector (optional) This alarm occurs if the chlorine gas detector detects chlorine gas. The following causes are possible: The anode side of the membrane cell has a leak. Product is leaking from the production tank. Water hardness analyser (optional) This alarm occurs if hard water is detected by the water hardness analyser.

  • Page 55: Brine Membrane Cell Flow Meter Faulty

    [ALARM] / Troubleshooting menu 9.2.2 Brine Membrane Cell Flow Meter Faulty This message occurs if the 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.

  • Page 56: Maintenance Checks And Preparation For Maintenance

    Maintenance checks and preparation for maintenance Maintenance checks and preparation for maintenance 10.1 Care of the operating unit User qualification, maintenance: instructed personnel Ä Chapter 2.2 ‘User qualification’ on page 10 NOTICE! Damage caused by unauthorised cleaning equip‐ ment or agents The operating unit can be damaged when cleaned using compressed air, steam cleaners, aggressive solvents or abrasive agents.

  • Page 57: Maintenance Kits

    Maintenance checks and preparation for maintenance Faults first have to be eliminated if the system is not producing due to faults or if the control points are not met. Refer to the "Troubleshooting" section for information on eliminating faults. Apart from normal tools, a number of special tools and equipment are needed to perform maintenance work: Multimeter DC current clamp...

  • Page 58: Measuring The Ph Of The Product

    Maintenance checks and preparation for maintenance [HARDNESS 2] Reagent 2, indicator, [HARDNESS 3] Reagent 3, titration solution, Procedure: Fill the volumetric flask up to the 100 ml marking with the softened water sample ð Take this water sample directly downstream of the water softener.

  • Page 59: Cooling The Control Cabinet

    Generally, a lower amperage figure leads to lower production. NOTE: There is a double cell cable 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.

  • Page 60: Regeneration Of The Water Hardness Meter

    Maintenance checks and preparation for maintenance A2011 Fig. 34: In this example, the measurement is taken on cell chamber 1. Cell chamber 1 2. Cell chamber 2 3. Cell chamber 3 4. Cell chamber 4 5. Measuring tip of the multimeter Note the voltage measured on the maintenance schedule.

  • Page 61: Commissioning The System After Maintenance

    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 Fill additional lye with the Chlorinsitu-III > 500 g/h. Replace the cover on the caustic tank.
  • Page 62 Maintenance checks and preparation for maintenance Check whether there are leaks and whether a vacuum state has been achieved. Start an anode refresh. Measure the voltage at the membrane cell and monitor whether the voltage is not above 5 V DC per chamber. Measure and check during production that the amperage is identical to the current measured and shown on the control panel.

  • Page 63: Preventative Maintenance

    ON and OFF. III. A2013 Fig. 36: Close the water tap (1) Chlorinsitu-III 100 ... 500 g/h II. Chlorinsitu-III 600 ... 1750 g/h III. Chlorinsitu-III 2000 ... 3500 g/h [OFF] . Switch production to Perform a manual anode refresh five times.

  • Page 64: Maintenance On The Simplex Water Softener

    Preventative maintenance 11.2.1 Maintenance on the Simplex water softener 11.2.1.1 Removing the Softener Head A1958 Fig. 37: Removing the softener head Check the softener head (4) for leaks. Unscrew the screws (1) on both sides and remove the cover. Unscrew the screw (2). Unscrew the screws (3) on both sides.
  • Page 65 Preventative maintenance 11.2.1.2 Replacing the Drainage Nozzle and Brine Valve O-ring. A1959 Fig. 38: Replacing the drainage nozzle and brine valve O-ring. Unscrew the screws (1) and remove the protection plate. Pull the brine valve (2) out of its seat. Replace the drainage nozzle during annual maintenance.
  • Page 66 Preventative maintenance 11.2.1.3 Renewing the seals A1960 Fig. 39: Greasing and replacing the seals Remove the piston (1) out of its seat. The seals and the spacers are arranged around the piston. Replace the seals. ð Replace the seals at the latest during the three-yearly maintenance.
  • Page 67 Preventative maintenance 11.2.1.4 Cleaning the Filter Meshes on the Brine Side A1961 Fig. 40: Cleaning the filter meshes on the brine side Unscrew the two screws (1). Remove the filter meshes (2) out of their seat. Clean the filter meshes. Insert all parts (3) into the water softener head.

  • Page 68: Maintenance On The Duplex Water Softener

    Preventative maintenance 11.2.2 Maintenance on the Duplex water softener 11.2.2.1 Removing the softener head A1962 Fig. 41: Removing the softener head Check the softener head for leaks. Unscrew the screws on both sides and remove the cover (1). Loosen the display (2) on the right side and pivot the display to the left.
  • Page 69 Preventative maintenance 11.2.2.2 Replacing the Drainage Nozzle and Brine Valve O-ring A1963 Fig. 42: Replacing the drainage nozzle (5) and brine valve O-ring Remove the front panel from the softener head. The drainage pin (1). The O-ring will also come loose when you remove the drainage nozzle.
  • Page 70 Preventative maintenance 11.2.2.3 Renewing the seals A1964 Fig. 43: Renewing the seals Correct order Pay attention when dismantling the parts that you lay the parts in the correct order. This will ensure that you fit the seals and spacers in the right order. Ensure that the parts lie tightly against each other.

  • Page 71: Replacing The Water Filter

    Preventative maintenance 11.2.2.4 Cleaning the Filter Meshes on the Brine Side A1965 Fig. 44: Cleaning the filter meshes on the brine side The filter meshes are located behind the cover (1). Clean the filter meshes (2) for brine suction during annual maintenance.

  • Page 72: Checking The Float On The Level Switch

    Preventative maintenance 11.3.1 Checking the Float on the Level Switch A1967 Fig. 46: Checking the float on the level switch Unscrew the coupling on the charging hose (1). Remove the liquid level switch (2) out of its housing. Check the float (3) for dirt, damage and correct operation. Insert the liquid level switch into the brine storage tank.

  • Page 73: Cleaning The Suction Unit In The Brine Storage Tank

    Preventative maintenance 11.3.2 Cleaning the Suction Unit in the Brine Storage Tank A1968 Fig. 47: Cleaning the suction unit in the brine storage tank Unscrew the coupling on both hoses (1) on the suction unit. Remove the suction unit (2) out of its housing. Performing maintenance on both suc‐...

  • Page 74: Maintenance On The Production Tank

    Ventilate the room during maintenance. III. A1969 Fig. 48: Maintenance on the production tank 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 a tank with a minimum capacity of 20 litres to drain the production tank.
  • Page 75 Close both shut-off valves (1) under the production tank. There is only one shut-off valve in the suction side of the booster pump with the Chlorinsitu-III 600 ... 1750 g/h and Chlorinsitu-III 2000 ... 3500 g/h models. Unscrew the following threaded connectors:...

  • Page 76: Replacing The Booster Pump O-Rings

    Preventative maintenance 11.4.3 Replacing the Booster Pump O-rings A1971 Fig. 50: Replacing the booster pump O-rings Unscrew the threaded connectors on the venturi line: Threaded connector (6) under the production tank stop‐ cock Threaded connector (4) on the booster pump Threaded connector (5) under the transport pump Threaded connector (2) on the coupling on the booster pump...

  • Page 77: Heat Exchanger O-Rings On The Production Tank (Only Chlorinsitu ® -Iii < 600 G/H)

    Preventative maintenance 11.4.5 Heat Exchanger O-rings on the Production Tank (only Chlorinsitu -III < 600 g/h) ® A1973 Fig. 52: Heat exchanger O-rings on the production tank Unscrew the threaded connectors on the top and bottom of the heat exchanger (1). Replace the FKM O-rings (DIN ISO 1629).

  • Page 78: Replacing The Transport Valve

    Preventative maintenance 11.4.7 Replacing the Transport Valve A1975 Fig. 54: Replacing the transport valve Loosen the threaded connectors on the transport valve (1). Remove the connector cap from the transport valve. Make sure that the arrow on the transport valve points upwards.

  • Page 79: Replacing The Seals On The Water Jet Pump

    Preventative maintenance 11.4.8 Replacing the Seals on the Water Jet Pump A1976 Fig. 55: Water jet pump seals Loosen the threaded connectors on the water jet pump and remove the water jet pump. Remove the old seals and insert new seals: Seal on the venturi side Seal on the inlet and outlet side...

  • Page 80: Cleaning The Water Jet Pump Nozzle

    Preventative maintenance 11.4.9 Cleaning the Water Jet Pump Nozzle A1977 Fig. 56: Cleaning the water jet pump nozzle Turn the nozzle (1) in a counter-clockwise direction. Remove the nozzle. Check the nozzle for dirt and wear, cleaning or replacing the nozzle if necessary.

  • Page 81: Replacing The O-Rings On The Stopcock Under The Production Tank

    Preventative maintenance 11.4.10 Replacing the O-rings on the Stopcock Under the Production Tank A1978 Fig. 57: Stopcock under the production tank. Dismantle the stopcocks under the production tank. During annual maintenance: Replace the O-rings. During three-yearly maintenance: Replace the O-rings and the stopcocks.

  • Page 82: Replacing The O-Rings On The Underside Of The Production Tank

    Preventative maintenance 11.4.11 Replacing the O-rings on the underside of the production tank WARNING! Danger from product residue in the production tank or the connecting part Possible consequence: Fatal or very serious inju‐ ries from chlorine residue. Measure: During maintenance on the production tank, wear the goggles and gloves provided.

  • Page 83: Checking The Temperature Sensor In The Production Tank

    Preventative maintenance 11.4.12 Checking the Temperature Sensor in the Production Tank A1980 Fig. 59: Checking the temperature sensor in the production tank Unscrew the white threaded connector (1). Remove the temperature sensor (2). Check the temperature sensor for oxidation and damage. Oxidation and damage may be an indication of a leak on the housing.

  • Page 84: Replacing The Seals On The Upper Side Of The Production Tank

    Preventative maintenance 11.4.13 Replacing the Seals on the Upper Side of the Production Tank A1981 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).

  • Page 85: Checking The Level Switch In The Production Tank

    Preventative maintenance 11.4.14 Checking the Level Switch in the Production Tank A1982 Fig. 61: Level switch in the production tank Unscrew the coupling of the level switch and remove the level switch. 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.

  • Page 86: Fitting All Components

    Preventative maintenance Replace the chlorine gas valve. Connect the connector cap to the chlorine gas valve. 11.4.16 Fitting All Components Fit all components of the production tank. Install the production tank in the system. Pour the collected product into the production tank. Retain a small quantity of product in the measuring cup to test the chlorine gas sensor.

  • Page 87: Preparation For Maintenance On The Lye Storage Tank

    Preventative maintenance 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.

  • Page 88: Draining The Lye Storage Tank

    Preventative maintenance 11.5.2 Draining the Lye Storage Tank You only need to drain the lye storage tank during three-yearly maintenance. Use the hose supplied with couplings and a tank with a minimum capacity of 20 litres to drain the lye storage tank.

  • Page 89: Replacing The O-Rings On The Stopcocks On The Bottom Of The Lye Storage Tank

    Preventative maintenance Fit the cathode valve into the supply line. Fit the hose (2) supplied with the appropriate coupling onto the stopcock at the bottom of the lye storage tank. Open the stopcock at the bottom of the lye storage tank and drain the contents of the lye storage tank into a bucket.

  • Page 90: Replacing The O-Rings On The Heat Exchanger (Only Chlorinsitu ® -Iii < 600 G/H)

    Preventative maintenance 11.5.5 Replacing the O-rings on the Heat Exchanger (only Chlorinsitu -III < 600 g/h) ® A1988 Fig. 68: O-ring on the heat exchanger Loosen the threaded connectors on the top and bottom of the heat exchanger. Replace the EPDM O-rings (1). Fit the threaded connectors on the top and bottom of the heat exchanger.

  • Page 91: Replacing The Seals On The Upper Side Of The Lye Storage Tank

    Preventative maintenance 11.5.6 Replacing the Seals on the Upper Side of the Lye Storage Tank A1989 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).

  • Page 92: Checking The Temperature Sensor In The Lye Storage Tank

    Preventative maintenance 11.5.7 Checking the Temperature Sensor in the Lye Storage Tank A1990 Fig. 70: Checking the temperature sensor in the lye storage tank Unscrew the white threaded connector (1). Remove the temperature sensor (2). Check the temperature sensor for oxidation and damage. Oxidation and damage may be an indication of a leak on the housing.

  • Page 93: Checking The Level Switch In The Lye Storage Tank

    Preventative maintenance 11.5.8 Checking the Level Switch in the Lye Storage Tank A1982 Fig. 71: Level switch in the lye storage tank Unscrew the coupling of the level switch and remove the level switch. Replace the level switch during three-yearly maintenance.

  • Page 94: Maintenance On The Fan

    Preventative maintenance 11.5.10 Maintenance on the Fan 1. 2. A1991 Fig. 72: Maintenance on the fan Loosen the hose clamps (1) on the side of the lye storage tank. Loosen the screw on the fan flange. Remove the connecting section (2). Remove the fan (3).

  • Page 95: Preparation For Maintenance On The Membrane Cell

    Preventative maintenance 11.6.1 Preparation for Maintenance on the Membrane Cell WARNING! Danger from chemical residue Possible consequence: Fatal or very serious inju‐ ries from chemical residue Measure: During maintenance wear the goggles and gloves provided. Ventilate the room during maintenance. Chlorinsitu -III 100 ...

  • Page 96: Replacing The O-Rings On The Brine Valve

    Preventative maintenance 11.6.3 Replacing the O-rings on the Brine Valve A1994 Fig. 74: O-rings on the brine valve (1) Loosen the threaded connectors on the brine valve (1). Remove the connector cap from the brine valve. Annual maintenance: Replace the O-rings. Three-yearly maintenance: Replace the brine valve and the O-rings.

  • Page 97: Preparation For Maintenance On The Anode Pipe

    Preventative maintenance 11.7.1 Preparation for Maintenance on the Anode Pipe WARNING! Danger from chemical residue Possible consequence: Fatal or very serious inju‐ ries from chemical residue Measure: During maintenance wear the goggles and gloves provided. Ventilate the room during maintenance. 11.7.2 The PVDF Float and Stop Pipe A1996...

  • Page 98: Replacing The Refresh Valve

    Preventative maintenance 11.7.3 Replacing the Refresh Valve A1997 Fig. 77: Refresh valve (1) Loosen the threaded connectors on the refresh valve (1). Remove the connector cap from the refresh valve. Annual maintenance: Replace the O-rings. Three-yearly maintenance: Replace the refresh valve and O-rings. Fit the connector cap on the refresh valve.

  • Page 99: Replace The O-Rings On The Anode Pipe

    Preventative maintenance 11.7.5 Replace the O-rings on the Anode Pipe A2001 Fig. 79: O-rings on the anode pipe Open the vacuum ejector coupling (6). Replace the O-rings. Open the coupling (5) on the upper side of the anode pipe. Replace the O-rings. Replace the O-ring on the lower measuring pipe connector (3).

  • Page 100: Replacing The O-Rings On The Bleed Valve

    Preventative maintenance 11.7.6 Replacing the O-rings on the Bleed Valve A2002 Fig. 80: O-rings on the bleed valve Loosen the threaded connector (1) on the bleed valve. Dismantle the connector cap on the bleed valve. Annual maintenance: Replace the O-rings on the bleed valve Three-yearly maintenance: Replace the bleed valve.

  • Page 101: Checking The Lid On The Product Tank

    Preventative maintenance 11.8.3 Checking the lid on the product tank Check whether the lid is properly closed and undamaged. 11.8.4 Checking the Liquid Level Switch A2003 Fig. 81: Checking the liquid level switch (1) Checking the "too high" liquid level Open the liquid level switch coupling.

  • Page 102: Checking The Chlorine Suction Unit

    Preventative maintenance Checking the "low flow" level switch Open the level switch coupling. During annual maintenance: Check the float for dirt and damage. During three-yearly maintenance: Replace the level switch. 11.8.6 Checking the chlorine suction unit A2004 Fig. 83: Checking the chlorine suction unit Remove the product suction unit from the product tank.

  • Page 103: Replacing The Sealing Rings On The Product Suction Unit

    Preventative maintenance 11.8.7 Replacing the sealing rings on the product suction unit INFORMATION!: The maintenance package includes two versions of sealing rings for check valves. This means that there is always a spare sealing ring and O-ring. A2005 Fig. 84: Sealing rings on the product suction unit Dismantle the threaded connector (1) on the check valve.

  • Page 104: Checking The Relay Contacts

    Preventative maintenance 11.9.1 Checking the Relay Contacts A2006 Fig. 85: Checking the relay contacts Check all relay contacts for discolouration and oxidation and clean if necessary. Check all connectors for discolouration and tighten, if neces‐ sary. Check all components for discolouration and oxidation and clean if necessary.

  • Page 105: Cleaning The Filters

    Preventative maintenance 11.9.2 Cleaning the Filters A2007 Fig. 86: Cleaning the filters Frequency The frequency of cleaning depends on the contam‐ ination level of the filters and on the installation location. Clean the filter by tapping or blowing. During three-yearly maintenance: Replace the filter.

  • Page 106: Renewing The Chlorine Gas Sensor

    Preventative maintenance 11.10.1 Renewing the chlorine gas sensor During annual maintenance: A2009 Fig. 87: Renewing the chlorine gas sensor Remove the sensor from its holder (1). Remove the protective cap (2) from the new chlorine gas sensor. Observe the instructions for the chlorine gas detector. Enter the resistance value (4) of the new chlorine gas sensor [nA/ppm] into the chlorine gas detector.

  • Page 107: Repair

    Repair Repair Ä Chapter 2.2 ‘User User qualification, repair: Service, see 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.

  • Page 108: Spare Parts

    Spare parts Spare parts 13.1 Maintenance kits Maintenance kits The manufacturer of the system has a "1-year" maintenance kit and a "3-year" maintenance kit. Use the following order numbers to order these maintenance kits. Tab. 5: Maintenance kits Maintenance kit Order number Maintenance kit 3, 100 ...

  • Page 109: Disposal Of Used Parts

    Refer to the Material Safety Data Sheet for your feed chemical. A current Declaration of Decontamination is available to download on the ProMinent website. Sign indicating EU collection system 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.

  • Page 110: Electrical Data

    Electrical data Electrical data Tab. 6: Electrical data Capacity Main fuse Voltage Capacity 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...

  • Page 111: Technical Data

    Technical data Technical data Tab. 9: 100 ... 1250 g/h Capacity 1000 1250 kg/24 13.2 16.5 27.5 Dimensions 1250x600x1550 1650x600x2000 Space requirement 1850x1500 2250x1500 Transport weight Brine tank Litres 130 Recommended product Litres 200 1200 1500 tank Process data Number of cell chambers Water needed* Process water Cooling water 20 °C**...
  • Page 112 Technical data Tab. 10: 1500 ... 3500 g/h Capacity 1500 1750 2000 2500 3000 3500 kg/24 h 33 38.5 Dimensions 1650x600x2000 1750x1200x2000 Space requirement 2250x1500 2350x2400 Transport weight 1150 Brine tank Litres Recommended product tank Litres 1700 2000 2200 3000 3300 4000 Process data...

  • Page 113: Flow Chart

    Flow chart Flow diagram for Chlorinsitu-III 100 ... 500 g/h A1955 Fig. 89: Flow diagram for Chlorinsitu-III 100 ... 500 g/h Flow diagram for Chlorinsitu-III 600 ... 1750 g/h A1956 Fig. 90: Flow diagram for Chlorinsitu-III 600 ... 1750 g/h...
  • Page 114 Technical data Flow diagram for Chlorinsitu-III 2000 ... 3500 g/h A1957 Fig. 91: Flow diagram for Chlorinsitu-III 2000 ... 3500 g/h...

  • Page 115: Ec Declaration Of Conformity For Machinery

    EC directives: Designation of the product: Chlorinsitu-III Serial number: see nameplate on the unit Relevant EC Directives: EC Machinery Directive (2006/42/EC) to 19.04.2016;...

  • Page 116: Index

    Warning information ..... . . 8 Flow diagram for Chlorinsitu-III 100 ... 500 g/h . 113 Water quality ......7 Flow diagram for Chlorinsitu-III 600 ...
  • Page 120 Netherlands Telephone: ++31 (0)33-2778600 Fax: ++31 (0)33-2778399 Email: info@vdhwater.nl Internet: www.vdhwater.nl 984350, 5, en_GB 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 © 2021...

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