Page 1 ® WALLACE & TIERNAN CHLORINE MEMBRANE ELECTROLYSIS SYSTEM OSEC-NXT 12 - 60 INSTRUCTION MANUAL...
Page 2 ® OSEC -NXT 12-60 Note Original manual! WT.085.140.000.DA.IM.0916...
Page 3: Table Of Contents
® OSEC -NXT 12-60 Contents Contents Introduction Documentation Conventions Safety Intended use General safety instructions Handling chemicals Liability for defects Replacement of electrolysis cells Description Process System configuration Versions Required accessories PLC controller Functions Technical data Installation Scope of supply Transport and storage Ambient conditions Mechanical installation...
Page 4 ® OSEC -NXT 12-60 Contents Start up Connecting to PROFIBUS DP RS485 bus interface Operation Control and display unit Password protection Automatic mode Turning on automatic mode Turning off automatic mode Activating preparation manually Stopping preparation manually Operating messages Warning messages 5.10 Error messages 5.11...
Page 5 ® OSEC -NXT 12-60 Contents Dimension drawing Arrangement of Components Wiring diagram 10. Operating journal 11. Index...
Page 6 ® OSEC -NXT 12-60 Contents WT.085.140.000.DA.IM.0916...
Page 7: Introduction
The chapters Installation and Maintenance by service technicians are intended exclusively for Evoqua service personnel or for per- sonnel who have been trained and authorized by Evoqua. These chapters contain important information on the assembly, configu-...
Page 8: Conventions
® OSEC -NXT 12-60 Introduction Conventions Notes This operating manual contains a number of notes with different priorities, which are marked with symbols. Pictogram Note Meaning Danger! Immediate danger to life and limb! If the situation is not handled properly, death or serious injury is the result.
Page 9 ® OSEC -NXT 12-60 Introduction Pictogram Note Meaning Attention! Risk of injury! Leaks can release dangerous fluids or gasses. Use protective footwear! Note These notes assist in the operation of the chlorine membrane electroly- sis system. Main screen MENU Menu selection System Clean display Screenshots of the various controller screens are shown, with the...
Page 10 ® OSEC -NXT 12-60 Introduction WT.085.140.000.DA.IM.0916...
Page 11: Safety
® OSEC -NXT 12-60 Safety 2. Safety Intended use The chlorine membrane electrolysis system is intended exclusi- vely for the production of sodium hypochlorite solution using satu- rated brine used to disinfect water. The operational safety of the system can only be guaranteed if it is used in accordance with its intended purpose.
Page 12: General Safety Instructions
• Maintenance level 2: Evoqua service personnel or personnel who have been trai- ned and authorized by Evoqua for maintenance work. Level 2 maintenance may only be performed by such personnel Electrical work Authorized and qualified electrical technicians. All electrical work...
Page 13 ® OSEC -NXT 12-60 Safety Spare parts / components The trouble-free operation of the chlorine membrane electrolysis system can only be guaranteed, if original spare parts and compo- nents are used in the combination described in this instruction manual. Otherwise there is a danger of malfunction or damage to the chlorine membrane electrolysis system.
Page 14: Handling Chemicals
® OSEC -NXT 12-60 Safety Handling chemicals 2.3.1 General Warning! Chemical hazard! A substantial quantity of chemicals is produced in the chlorine membrane electrolysis system. For safe operation and to prevent harm to persons, be sure to follow the safety instructions and war- nings on the system and in this operating manual.
Page 15 ® OSEC -NXT 12-60 Safety The following chemicals are produced in the chlorine membrane electrolysis system: Product • Sodium hypochlorite Side products • Hydrogen Intermediate products • Sodium hydroxide • Chlorine gas • Anolyte The intermediate products are produced as part of the process and as such remain temporarily in the system.
Page 16 ® OSEC -NXT 12-60 Safety 2.3.3 Hydrogen (H Product identification • CAS No.: 1333-74-0 Properties • highly flammable • gaseous • colorless and odorless Occurrence • in the cathode chamber of the electrolysis cell • in the connection pipe between the electrolysis cell and the reactor •...
Page 17 ® OSEC -NXT 12-60 Safety 2.3.5 Chlorine gas (Cl Product identification • CAS No.: 7782-50-5 Properties • chlorine gas saturated with steam • toxic when inhaled • irritates the eyes, respiratory organs and skin • hazardous to the environment • highly-toxic to aquatic organisms •...
Page 18 Follow the instructions in the EC safety data sheets and substance data sheets. Please note If necessary, you can order a copy of the EU Safety Data Sheet for sodium hypochlorite solution from Evoqua Water Technologies. WT.085.140.000.DA.IM.0916...
Page 19: Liability For Defects
Installation, start up, shut-down, level 2 maintenance and trai- ning of operating personnel by Evoqua service personnel or by personnel that have been trained and authorized by Evo- • Return the signed original of the start up checklist to Evoqua Water Technologies • Intended use •...
Page 20: Replacement Of Electrolysis Cells
• Conclude a maintenance contract • Maintenance level 2 performed by Evoqua service personnel or by personnel trained and authorized by Evoqua for mainte- nance work Replacement of electrolysis cells PRO-RATA The electrolysis cells are subject to technical wear and are there- fore temporary parts.
Page 21: Description
® OSEC -NXT 12-60 Description 3. Description Process 3.1.1 Description of the process (See also chapter 3.1.2 "Process diagram") The chlorine membrane electrolysis system uses saturated brine, softened water and a direct current to produce sodium hypochlo- rite solution directly at the site of installation. The electrolysis cell is the core of the chlorine membrane electro- lysis system.
Page 22 ® OSEC -NXT 12-60 Description The sodium hydroxide-hydrogen mixture produced in the cathode chamber is fed to the reactor's degassing chamber, where the hydrogen is released from the sodium hydroxide. A fan dilutes the separated hydrogen with air and safely blows it out through the hydrogen vent pipe.
Page 23 ® OSEC -NXT 12-60 Description 3.1.2 Process diagram Fig. 1 Chlorine membrane electrolysis system OSEC-NXT 12- 60 with salt dissolving tank and storage tank 1 Salt dissolving tank 2 Water softener 3 Brine pump 4 Electrolysis cell 5 Chlorine separator 6 Level probe 7 Fan 8 Reactor...
Page 24: System Configuration
® OSEC -NXT 12-60 Description System configuration The chlorine membrane electrolysis system is designed as a com- pact unit, built around an electrolysis cell, with the following main system components mounted on a frame. • Electrolysis cell(s) • Water softener •...
Page 25 ® OSEC -NXT 12-60 Description 3.2.3 Brine pump Regulated by level, the brine pump supplies concentrated brine to the chlorine separator. No settings are necessary at the brine pump. 3.2.4 Chlorine separator In the chlorine separator, the chlorine gas generated in the anode chamber is separated from the anolyte and the anolyte is returned to the anode chamber, entering at the bottom of the electrolysis cell.
Page 26 ® OSEC -NXT 12-60 Description 3.2.6 Control cabinet with control and display unit Housing The control system (details in chapter 3.5 Control unit) of the chlo- rine membrane electrolysis system are housed in a sheet steel housing on the left narrow side of the mounting frame. The main switch and the control and display unit are arranged on the front side of the control cabinet.
Page 27: Versions
® OSEC -NXT 12-60 Description Versions The chlorine membrane electrolysis system is available with five different rated output capacities. Nominal performance Number of Part No. rating electrolysis cells 12 kg/d (26.5 lbs/d) Cl W3T158931 24 kg/d (53 lbs/d) Cl W3T158932 36 kg/d (79 lbs/d) Cl W3T158933 48 kg/d (106 lbs/d) Cl...
Page 28: Required Accessories
Brine that has been saturated using a salt prescribed by the ® manufacturer (e. g. Evoqua OSEC Salin salt pellets) is deposited and stored in the brine tanks. Evoqua brine tanks are designed as a cylindrical containers made of PE and are equipped with the fol- lowing parts: •...
Page 29 OSEC -NXT 12-60 Description 3.4.2 Storage tank The sodium hypochlorite solution produced is stored in the storage tank. The Evoqua storage tank is equipped with the following: • Limit value switch • Activated-carbon filter • Connections for filling, extraction and ventilation •...
Page 30: Plc Controller
® OSEC -NXT 12-60 Description PLC controller The PLC controller is used to log, display and process measure- ment data as well as to control the process. A touch panel is used as the control and display unit. The system is controlled using the buttons.
Page 31 Evoqua RS485 bus interface The serial RS485 Bus interface is used for data transfer to the optional Process Monitoring System. In addition to this, it is also possible to connect other Evoqua devices with an RS485 bus interface. • Profibus DP interface The Profibus DP interface is a standardized interface (EN50170) for data transmission.
Page 32: Functions
® OSEC -NXT 12-60 Description Functions All of the settings and operating parameters can be read by all users, in any user group, without requiring the user to log in. Cer- tain functions are protected, requiring entry of a username and password, so that they can only be performed by certain groups.
Page 33 "Service" menu and may only be used by Evoqua service personnel or by personnel who have been trai- ned and authorized by Evoqua . This password is only available to this group of users.
Page 34: Technical Data
® OSEC -NXT 12-60 Description Technical data 3.7.1 OSEC-NXT 12 Nominal performance rating 12 kg/d (26.5 lbs/d) chlorine Number of cell blocks Electrolysis water 20 l/h (5.3 gal/h) Cooling water 200 l/h (53 gal/h) Max. cell voltage 20 V, DC Max.
Page 35 ® OSEC -NXT 12-60 Description 3.7.2 OSEC-NXT 24 Nominal performance rating 24 kg/d (53 lbs/d) chlorine Number of cell blocks Electrolysis water 40 l/h (10.6 gal/h) Cooling water 200 l/h (53 gal/h) Max. cell voltage 40 V, DC Max. electrolysis current 160 A Power consumption in operating 150 W...
Page 36 ® OSEC -NXT 12-60 Description 3.7.4 OSEC-NXT 48 Nominal performance rating 48 kg/d (106 lbs/d) chlorine Number of cell blocks Electrolysis water 80 l/h (21.2 gal/h) Cooling water 250 l/h (66 gal/h) Max. cell voltage 80 V, DC Max. electrolysis current 160 A Power consumption in operating 150 W...
Page 37 ® OSEC -NXT 12-60 Description 3.7.6 Profibus DP Hardware SIMATIC S7-300 controller CPU314C - 2DP V3.x Transmission technology RS-485 in accordance with the Profibus specifications Baud rate Max. 12 Mbit/s, autodetect Bus address Default setting 20, Adjustable from 3 - 125 Bus connection 9 pin D-Sub socket Communication...
Page 38 ® OSEC -NXT 12-60 Description WT.085.140.000.DA.IM.0916...
Page 39: Installation
® OSEC -NXT 12-60 Installation 4. Installation Scope of supply Depending on the chosen design type (for details see chapter Description, 3.3 Versions), the scope of supply includes: • Chlorine membrane electrolysis system compact design, mounted on a frame • Accessory set, comprising: •...
Page 40: Transport And Storage
Transport and storage Transport/Storage The chlorine membrane electrolysis system is correctly packaged by Evoqua Water Technologies and delivered on a palette that is suitable for vertical transport. The electrolysis cells are filled with softened water. During transport, the chlorine membrane electrolysis system must be handled with care.
Page 41 Shut-down The chlorine membrane electrolysis system may only be taken out of operation by trained and authorized personnel or by Evoqua service personnel. A shut-down is necessitated by the following: • a standstill period of the sodium hypochlorite preparation for more than four weeks •...
Page 42: Ambient Conditions
® OSEC -NXT 12-60 Installation Ambient conditions Please note Trouble-free operation of the chlorine membrane electrolysis sys- tem is only guaranteed if the environmental requirements are met. Observe the applicable local and national regulations! 4.3.1 Installation room The following requirements apply to the installation room of the chlorine membrane electrolysis system: General •...
Page 43 The following requirements apply to the brine and to the salt dis- solving tank: Brine quality • salt approved by the manufacturer of the chlorine membrane ® electrolysis system (e. g. Evoqua special salt, OSEC Salin) Brine temperature • corresponding to room temperature of the chlorine membrane electrolysis system or lower Salt dissolving tank •...
Page 44 ® OSEC -NXT 12-60 Installation 4.3.4 Interface storage tank The following requirements apply to the storage tank and to the sodium hypochlorite pipe: Material • suitable for storage of sodium hypochlorite (2,5 %) Sodium hypochlorite pipe • the sodium hypochlorite pipe must follow a downwards gradi- ent from the system to the storage tank •...
Page 45 ® OSEC -NXT 12-60 Installation • the opening must not be accessible to the public or in the direct vicinity of access areas. Minimum distance from doors, windows or other openings: 10’. Minimum distance from other air vents: 33’ • keep the openings clear and protect against ingress of debris or rainwater by means of a hood or a bend •...
Page 46: Mechanical Installation
® OSEC -NXT 12-60 Installation Mechanical installation Warning! Risk of injury or damage to the system! Only authorized specialized personnel qualified for installation and start-up may install the chlorine membrane electrolysis system. All electrical work on the chlorine membrane electrolysis system may only be performed by qualified electricians.
Page 47 ® OSEC -NXT 12-60 Installation 4.4.1 Setup Taking into account the requirements on the setup location listed in chapter 4.3.1 Installation room, set up the chlorine membrane electrolysis system and its necessary accessories, such as the salt dissolving tank and storage tank, as shown in the dimension dra- wing in chapter 7.
Page 48: Chapter 4.5 Electrical Installation
® OSEC -NXT 12-60 Installation 5 Assemble the four hinged feet using spanners. Minimum screw-in depth 0.6’. 6 Lower chlorine membrane electrolysis system to the floor. 7 Level the system using a spirit level. 8 Tighten the nuts to secure the hinged feet. 9 Mount ventilation hood.
Page 49 ® OSEC -NXT 12-60 Installation Storage tank The storage tank, optionally with a collecting basin, is a required accessory (for details see chapter Description, 3.4.2 Storage tank). When setting up the storage tank the following general points must be observed: •...
Page 50 ® OSEC -NXT 12-60 Installation 4.4.2 Installation of the connections See chapter 8. Arrangement of Components. Please note All transport plugs have to be removed! The electrolysis cells are filled with softened water during trans- port. Water may therefore escape when the connections are in- stalled! The following connections must be made in accordance with the drawings and the instructions (yellow labels) on the system:...
Page 51 ® OSEC -NXT 12-60 Installation 4.4.3 Installing air the flow monitor Install the air flow monitor immediately before the position where the hydrogen vent pipe leaves the building. The air flow monitor may only be installed in a vertical tube. Proceed as follows: Attention! Risk of injury!
Page 52: Electrical Installation
® OSEC -NXT 12-60 Installation Electrical installation Warning! Risk of injury! Only authorized and qualified electrical technicians may electrical- ly connect the chlorine membrane electrolysis system. Connect the control cabinet in accordance with the electrical terminal dia- grams and the applicable national and local regulations. 4.5.1 Checking the power supply Check that the required power supply...
Page 53 Storage tank leak monitoring sensor DC 24 V 8 VA System leak monitoring sensor DC 24 V 8 VA Dosing leak monitoring sensor DC 24 V 8 VA Please note Evoqua Water Technologies recommends that you should always use a chlorine gas leak detector!
Page 54 4.5.4 Connecting the Process Monitoring System The Evoqua visualization system is installed in the control cabinet as an option and is connected to the chlorine membrane electroly- sis system via the RS485 bus interface. Connect the Process Monitoring System locally to an analog tele- phone line with its own number.
Page 55: Completing The Acceptance Certificate
The main switch must remain sealed until start up begins! Only Evoqua service personnel or personnel who have been trained and authorized by Evoqua may open the seal on the main switch and start the chlorine membrane electrolysis system. Completing the acceptance certificate...
Page 56: Start Up
Risk of injury or damage to the system! Only Evoqua service personnel or authorized personnel who have been trained by Evoqua for installation and start-up may open the seal on the main switch and put the chlorine membrane electroly- sis system into operation..
Page 57 Details on performing the various steps of the start-up pro- cedure are given in the following chapters. The start-up checklist must be correctly completed, signed and returned to Evoqua Water Technologies (this is a precondition for the customer to be able to make claims for defects). 4.7.2...
Page 58 Installation 4.7.4 Removing the seal on the main switch Attention! Only authorized personnel who have been trained by Evoqua for installation and start-up may remove the seal on the main switch! 4.7.5 Turning the chlorine membrane electrolysis system on Proceed as follows: 1 Turn on chlorine membrane electrolysis system at main switch.
Page 59 ® OSEC -NXT 12-60 Installation 4.7.6 Checking the pressures Check pressures and adjust if necessary: Designation Ref. Setting Operating water pressure reducing 3.5 bar valve (50.8 psi) Electrolysis water pressure reduc- 0.8 bar ing valve (11.6 psi) Please note Follow the instructions on the display. 4.7.7 Setting the cooling water flow rate Proceed as follows:...
Page 60 ® OSEC -NXT 12-60 Installation 4.7.8 Setting the electrolysis water flow rate Proceed as follows: 1 Press the "Electrolysis water On" button on the display. The button will then change to "Electrolysis water Off". 2 Set the system-specific electrolysis water flow rate using the electrolysis water ball valve (M7).
Page 61 ® OSEC -NXT 12-60 Installation 4.7.10 Measuring the operating water hardness Proceed as follows: 1 Take a water sample at the filter drain tap of the pressure reducing valve (M5). 2 Flush cuvette of the test kit provided with sample water. 3 Fill cuvette up to 5 ml marker with sample water.
Page 62 ® OSEC -NXT 12-60 Installation 4.7.12 Emptying the water-filled cathode chamber and filling with sodium hydroxide Attention! Damage to the electrolysis cell(s)! Empty the cathode chamber and refill immediately! Never empty the cathode and anode chambers at the same time! The membrane could dry out and damage the electrolysis cell! Proceed as follows: 1 Prepare sodium hydroxide and the drum pump from the stan-...
Page 63 ® OSEC -NXT 12-60 Installation 4.7.13 Checking the hydrogen vent pipe Proceed as follows: 1 Check the hydrogen vent pipe is correctly installed and check for leaks (see chapter 4.3.5, Interface hydrogen vent pipe and chapter 4.4.2, Installing the connections). 2 Check correct assembly of the air flow monitor (see chapter 4.4.3 Installing the air flow monitor).
Page 64 • Check the electrical connection to the air flow monitor • Discuss further measures with Evoqua Water Technologies Warning! Risk of injury! If the air flow monitor is not working, abort start-up. 4 Enter the result of the test in the start-up checklist.
Page 65 ® OSEC -NXT 12-60 Installation 4.7.14 Setting and testing the level switch on the the storage tank If the level switches are correctly adjusted and the storage tank is empty, the display should appear as shown on the left. Proceed as follows: Actuate each of the four level switches by hand.
Page 66 ® OSEC -NXT 12-60 Installation 4.7.16 Emptying the water-filled anode chamber and rinse with acid Attention! Damage to the electrolysis cell(s)! Empty the anode chamber and then rinse with acid immediately to prevent damage to the electrolysis cell. Proceed as follows: 1 Prepare the acid and the drum pump from the standard acces- sories.
Page 67 ® OSEC -NXT 12-60 Installation 4.7.17 Filling the anode chamber with brine Attention! Damage to the system! The anode chamber must be refilled with brine immediately after being rinsed with acid! The anode chamber may only be filled with saturated brine! Proceed as follows: 1 Press the "Brine filling On"...
Page 68 ® OSEC -NXT 12-60 Installation 4.7.18 Finishing start-up Attention! Damage to the electrolysis cell(s)! Start-up must be completed within two hours of the anode cham- ber having been filled with saturated brine to prevent damage to the electrolysis cell. Start-up is now complete. If necessary, press "BACK"...
Page 69 30 min. For further details see chapter Maintenance, 6.3.3 Che- cking the product concentration. • Replace covers • Complete and sign the start-up checklist and send to Evoqua Water Technologies (this constitutes part of the liability for defects). Measure the air flow Proceed as follows: at the vent opening 1 Measure the air current using an air flow meter, e.g.
Page 70 Training and instruction must be checked against the instruction acceptance certificate VD307. The acceptance certificate must be correctly completed, signed and returned to Evoqua Water Tech- nologies (this is a precondition for the customer to be able to make claims for defects).
Page 71: Connecting To Profibus Dp
For information, contact the PROFI- BUS User Organization, Evoqua Water Technologies GmbH or the manufacturer of the automation system you are using.
Page 72 ® OSEC -NXT 12-60 Installation Warning! Risk of injury or damage to the system! Electrical work on the chlorine membrane electrolysis system may only be performed by qualified electricians. Proceed as follows: 1 Shut-down the chlorine membrane electrolysis system, see chapter Maintenance, 6.5 Shut-down.
Page 73 ® OSEC -NXT 12-60 Installation Please note Both of the status LEDs "SF" and "BF" on the SIMATIC S7-300 will light up if the chlorine membrane electrolysis system is not con- nected to a higher level PROFIBUS DP network. This indicates that there is no communication partner (master) connected.
Page 74 ® OSEC -NXT 12-60 Installation 1 Download the driver for the GSD file SIMATIC S7-300 CPU314C - 2DP V3. 2 Insert the controller (A) and connect it to the network. A Control unit WT.085.140.000.DA.IM.0916...
Page 75 ® OSEC -NXT 12-60 Installation 3 Enter the following configuration: • 6 x 16 words, data consistency over the entire length • 1 x 13 words, data consistency over the entire length • 1 x 14 words, data consistency over the entire length A E-address: Input byte "n"...
Page 76 ® OSEC -NXT 12-60 Installation 6 x 16 words 1 x 13 words 1 x 4 words WT.085.140.000.DA.IM.0916...
Page 77 ® OSEC -NXT 12-60 Installation 4.8.4 Data exchange table The data exchange table below lists the data points provided by the chlorine membrane electrolysis system. Length Byte Format Access Description address address bytes) STRING[8] RS485 bus scan ID n + 10 STRING[4] RS485 bus scan ID n + 16...
Page 78 ® OSEC -NXT 12-60 Installation Length Byte Format Access Description address address bytes) n + 130 BOOL Warning message "Unstable mains voltage/mains failure" n + 130 BOOL Warning message "Check water softener brine flow rate" n + 130 BOOL Warning message "Storage tank empty" n + 130 BOOL Warning message "Electrolysis water check flow...
Page 79 ® OSEC -NXT 12-60 Installation Length Byte Format Access Description address address bytes) n + 133 BOOL Error message "Storage tank leak" n + 133 BOOL Error message "Storage tank overfilled" n + 133 BOOL Error message "Electrolysis water check flow meter"...
Page 80 ® OSEC -NXT 12-60 Installation Length Byte Format Access Description address address bytes) n + 135 BOOL Error message "Cooling water flow rate too low! Pressure & warning" n + 136 BOOL Error message "Salt dissolving tank filling time exeeded! Pressure & warning" n + 136 BOOL Error message "Water softener brine flow rate too...
Page 81 ® OSEC -NXT 12-60 Installation Length Byte Format Access Description address address bytes) n + 186 REAL Unused n + 190 REAL Unused n + 194 REAL Unused n + 198 REAL Unused n + 202 BOOL Digital IN, EMERGENCY STOP n + 202 BOOL Digital IN, ext.
Page 82 ® OSEC -NXT 12-60 Installation Length Byte Format Access Description address address bytes) n + 205 BOOL Unused n + 205 BOOL Unused n + 205 BOOL Unused n + 205 BOOL Unused n + 205 BOOL Digital IN, Mains monitoring n + 206 BOOL Digital OUT, Brine pump...
Page 83 ® OSEC -NXT 12-60 Installation Length Byte Format Access Description address address bytes) n + 215 BOOL User registered via HMI n + 215 BOOL User registered via PROFIBUS DP n + 215 BOOL Unused n + 215 BOOL Unused n + 215 BOOL Unused...
Page 84 ® OSEC -NXT 12-60 Installation 4.8.5 Data formats The table below lists the data formats used to transmit the process data. Data type Size Typically called Signed Value range (bits) min. max. BOOL Bit, Bool BYTE Unsigned char, byte WORD Unsigned integer, word FFFF REAL...
Page 85 ® OSEC -NXT 12-60 Installation REAL Example: 3,141593 BYTE 0 BYTE 1 BYTE 2 BYTE 3 3,141593 Sign Exponent Mantissa e e e e e e m m m m m m m m m m m m m m m m m m m m m m m 1 0 0 0 0 0 1 0 0 1 0 0...
Page 86 ® OSEC -NXT 12-60 Installation 4.8.6 Setting the PROFIBUS DP slave bus address Proceed as follows: Main screen MENU Menu selection Outputs Interface NTERFACE 1 Switch to the "Interface" screen on the chlorine membrane electrolysis system's control and display unit. The factory set- ting for the bus addresses is 20.
Page 87: Rs485 Bus Interface
® OSEC -NXT 12-60 Installation RS485 bus interface 4.9.1 Version The standard serial RS485 bus interface in the chlorine membrane electrolysis system is used for data transmission to a PC, web server or an external plant control. The interface is designed as a symmetrical two-wire bus line according to EIA RS 485 (DIN 66259 Part 4 and ISO 8482);...
Page 88 ® OSEC -NXT 12-60 Installation 4.9.3 Interface connection The RS485 bus interface in the chlorine membrane electrolysis system is connected to the following two terminals: Bus line A Terminal A Bus line B Terminal B Please note The RS485 bus interfaces of the chlorine membrane electrolysis system are galvanically isolated.
Page 89 ® OSEC -NXT 12-60 Installation 4.9.5 Bus design Potentially non-isolated RS485 bus design RS485 slave RS485 slave RS485 master (Addr. 00) (Addr. 01 - 31) + 5 V G N D The earth bus or earth electrode conductor >= 6 mm² must be laid parallel to the bus cable.
Page 90 ® OSEC -NXT 12-60 Installation 4.9.6 Specification of the bus interface Synchronization mode: Asynchronou Transmission rate: 19200 baud Data format (asynchronous): Start bit: 1 Bit Data bit: 8 Bit Parity bit: even Stop bit: 1 Bit Signal polarity: Differential voltage interface Logical "1"...
Page 91 ® OSEC -NXT 12-60 Installation 4.9.8 Description of the frame bytes Synchronisation bytes (SYN) The synchronisation bytes are used to synchronise user units to each other. Start byte (SB) Marks the start of the frame. The value depends on the type of frame: •...
Page 92 ® OSEC -NXT 12-60 Installation Additional check byte information (Bit 4 - 7): Bit (7654) Function 1000 Min. variable value 0100 Max. variable value 0010 Default variable value 0001 Additional variable information If a bit is not set in bit 5 - 7, the actual value is written or read. Otherwise, the slave sends the corresponding additional information.
Page 93 ® OSEC -NXT 12-60 Installation 4.9.9 Request frame The request frame is necessary to read data or additional information from a slave. Format of the request frame: Byte Name: Byte Name: Assignment: Synchronization bytes Start byte 10H Slave address Destination address Check byte Number byte Frame check...
Page 94 ® OSEC -NXT 12-60 Installation Example: Requesting the contents of destination address 02H from slave 07H: 4.9.10 Set frame The set frame is necessary to write data to a slave. Set frame forma: Byte Name SYN SB Byte: Name: Assignment: Synchronisation bytes Start byte 68H Slave address...
Page 95 ® OSEC -NXT 12-60 Installation Please note To set parameters via the RS485 bus interface, such as setpoints, it is absolutely necessary to set the interface password (ZA = 02) to the value 904 (decimal) or 0388 (hexadecimal) beforehand. 4.9.11 Answer frame The answer frame is transmitted by the slave as a result of a master request frame.
Page 96 ® OSEC -NXT 12-60 Installation Answer to the example request frame 4.9.12 Positive and negative confirmation The “positive confirmation" is transmitted by the slave if a master set frame has been executed validly. A “negative confirmation" is sent by the slave if a set frame or a request frame could not be executed validly.
Page 97 ® OSEC -NXT 12-60 Installation 4.9.13 Address reference list Length Byte Format Range Unit Status Description Addr. Address (Byte) ASCII[8] Kennung RS485 Bus-scan ASCII[4] Kennung RS485 Bus-scan ASCII[10] Typbezeichnung Anlage ASCII[8] Software Artikelnummer ASCII[6] Software Version ASCII[6] Software Datum, MM/YY ASCII[16] Seriennummmer Anlage ASCII[16]...
Page 98 ® OSEC -NXT 12-60 Installation Length Byte Format Range Unit Status Description Addr. Address (Byte) 130.4 CHAR WARNmeldung "Kühlwasser Durchfluss prüfen" 130.5 WARNmeldung "Netzausfall kürzer 4 Stunden!" 130.6 WARNmeldung "Netzausfall länger 4 Stunden!" 130.7 WARNmeldung "Monatliche Wartung!" 131.0 CHAR WARNmeldung "Jährliche Wartung! Kundendienst erfor- derlich"...
Page 99 ® OSEC -NXT 12-60 Installation Length Byte Format Range Unit Status Description Addr. Address (Byte) 134.3 CHAR Störmeldung "Elektrolysewasser Durchfluss zu hoch" 134.4 Störmeldung "Produktbehälter Niveausonden Plausibilität" 134.5 Störmeldung "NOT-STOP" 134.6 Störmeldung "Externe Enthärtung / Härtekontrolle Stör- ung" 134.7 Störmeldung "Salzlösebehälter Befüllzeit überschritten" 135.0 CHAR Störmeldung "Sicherheits-Absperrarmatur öffnet nicht!
Page 100 ® OSEC -NXT 12-60 Installation Length Byte Format Range Unit Status Description Addr. Address (Byte) 137.7 CHAR frei FLOAT 0... Bereitung gesamt [h] 999999,9 FLOAT 0... Bereitung Durchschnitt [h] 999999,9 FLOAT 0...0,999 Bereitungszyklen 999999 FLOAT 0... Betriebsstunden gesamt [h] 999999,9 FLOAT 0...999,9 Zellenspannung [V]...
Page 101 ® OSEC -NXT 12-60 Installation Length Byte Format Range Unit Status Description Addr. Address (Byte) 203.6 CHAR Digital IN, Produktbehälter übervoll 203.7 Digital IN, Produktbehälter max 204.0 CHAR Digital IN, Produktbehälter min 204.1 Digital IN, Produktbehälter leer 204.2 Digital IN, Salzlösebehälter Niveau 204.3 Digital IN, Soledurchfluss 204.4...
Page 102 ® OSEC -NXT 12-60 Installation Length Byte Format Range Unit Status Description Addr. Address (Byte) 208.0 CHAR frei 208.1 frei 208.2 frei 208.3 frei 208.4 frei 208.5 frei 208.6 frei 208.7 frei CHAR frei CHAR frei CHAR frei CHAR frei CHAR frei 214.0...
Page 103 ® OSEC -NXT 12-60 Installation Length Byte Format Range Unit Status Description Addr. Address (Byte) CHAR Hand Enthärtung Regeneration über RS485 auslösen CHAR Hand Enthärtung Regeneration über RS485 auslösen CHAR Hand Sole füllen über RS485 ein,- ausschalten CHAR Hand Sole füllen über RS485 ein,- ausschalten CHAR Hand Kühlwaser über RS485 ein-, ausschalten CHAR...
Page 104 ® OSEC -NXT 12-60 Installation WT.085.140.000.DA.IM.0916...
Page 105: Operation
® OSEC -NXT 12-60 Operation 5. Operation Control and display unit 5.1.1 General Fig. 1 Siemens SIMATIC Touch Panel A Display with Touch Screen The Touch Screen is the standard input device on the control unit. All of the control objects required to control the unit are displayed on the Touch Screen when the control unit is switched on.
Page 106 ® OSEC -NXT 12-60 Operation 5.1.2 Main screen When the chlorine membrane electrolysis system is switched on, the Touch Screen displays the main screen: Fig. 2 Main screen showing an error message A System type B Log in/Log out button (see chapter 5.2.2) C Display menu D Mode display (Manual or Automatic) (see chapter 5.3) E Error display showing the number of faults...
Page 107: Password Protection
® OSEC -NXT 12-60 Operation Password protection 5.2.1 General All of the settings and operating parameters can be read by all users, in any user group, without requiring the user to log in. Cer- tain functions are protected, requiring entry of a username and password, so that they can only be performed by certain groups.
Page 108 ® OSEC -NXT 12-60 Operation Main screen Log in 4 Press OK to confirm. The display then returns to the previous AIN SCREEN menu and the "Log in" button changes into a "Log out" button. The required functions are now accessible. Please note Once you have logged in, all of the other functions available to that user level are accessible too.
Page 109: Automatic Mode
® OSEC -NXT 12-60 Operation Automatic mode Main screen Mode Change operating mode? Yes NO The chlorine membrane electrolysis system is running in auto- AIN SCREEN matic mode. Automatic preparation is turned on and off by pres- sing the "Mode" button (see chapters 5.6 Activating manual preparation and chapter 5.7 Stopping preparation manually for details).
Page 110 ® OSEC -NXT 12-60 Operation Main screen "i" (info) operating messages PERATING MESSAGES "P " To display details of which phase the system is currently in as well REPARATION START UP as the date and time, press the "i" (Info) button. Main screen "i"...
Page 111: Turning On Automatic Mode
® OSEC -NXT 12-60 Operation Turning on automatic mode Main screen Mode Change operating mode? Yes Once start up has been completed, or once any faults that caused AIN SCREEN automatic preparation to stop have been corrected, the chlorine membrane electrolysis system enters the "Preparation off" opera- ting state.
Page 112 ® OSEC -NXT 12-60 Operation Main screen If the chlorine membrane electrolysis system is in the "Preparation AIN SCREEN active!" operating state, it first goes through the run-out process before then switching automatic mode off. The system switches to the "Preparation off" operating state. The mode "MANUAL"...
Page 113: Activating Preparation Manually
® OSEC -NXT 12-60 Operation Activating preparation manually Preparation of sodium hypochlorite can also be activated manually when the system is in automatic mode if: • The chlorine membrane electrolysis system is in the "Prepara- tion standby" operating state. • The fill level in the storage tank is below "Storage tank max.".
Page 114: Stopping Preparation Manually
® OSEC -NXT 12-60 Operation Stopping preparation manually Preparation of sodium hypochlorite can also be stopped manually when the system is in automatic mode if: • The chlorine membrane electrolysis system is in the "Prepara- tion active!" operating state. • The fill level in the storage tank is above "Storage tank max.".
Page 115: Operating Messages
® OSEC -NXT 12-60 Operation Operating messages 5.8.1 General There are six different operating operating messages that can be displayed by the chlorine membrane electrolysis system. The operating states: • Preparation off • Preparation standby • Preparation active! Other operating messages include: •...
Page 116 ® OSEC -NXT 12-60 Operation 5.8.2 Preparation off Main screen The chlorine membrane electrolysis system is in the "Preparation AIN SCREEN off" operating state. The system is ready to operate. • Automatic mode is off. • All of the control system's control functions are active. •...
Page 117 ® OSEC -NXT 12-60 Operation 5.8.3 Preparation standby Main screen The chlorine membrane electrolysis system is in the "Preparation AIN SCREEN standby" operating state. • Automatic mode is active. • All of the control system's control functions are active. • The protection potential is switched on.
Page 118 ® OSEC -NXT 12-60 Operation Please note Components and hose connections that are mechanically or elec- trically operated are labeled on the system with abbreviations (e.g. M3). To facilitate their identification, these abbreviations are re- peated at relevant points in the operating instructions and on the drawings.
Page 119 ® OSEC -NXT 12-60 Operation Main screen "i" (info) operating messages PERATING MESSAGES "P " Once electrolysis power is reached, the chlorine membrane electroly- REPARATION RUNNING sis system switches to the product preparation state and prepares sodium hypochlorite until the "Storage tank max." level is reached in the storage tank.
Page 120 ® OSEC -NXT 12-60 Operation Please note In the "Preparation active!" operating state it is possible to stop preparation of sodium hypochlorite manually. The stop preparation button is displayed for this purpose. See chapter 5.7 Stopping pre- paration manually for details. Main screen Stop preparation AIN SCREEN...
Page 121 ® OSEC -NXT 12-60 Operation 5.8.5 Water softener regenerating Main screen Automatic regeneration is usage-based and depends on the water AIN SCREEN hardness. The automatic regeneration of the water softener is active in every operating state. If regeneration is running, this is indicated on the display.
Page 122 ® OSEC -NXT 12-60 Operation 5.8.7 Manual mode active! Main screen The manual functions are only active in "MANUAL" mode when the AIN SCREEN system is in the "Preparation off" state. They can be used to enable the required function temporarily. The manual functions are password protected.
Page 123: Warning Messages
® OSEC -NXT 12-60 Operation Warning messages 5.9.1 General Main screen The chlorine membrane electrolysis system is capable of displaying AIN SCREEN twelve different warning messages. The last warning message repor- ted by the system is displayed asa text message on the main screen, together with the time stamp and the state and the "i"...
Page 124 5.9.3 Perform annual maintenance! Service required Main screen Once a year, annual maintenance must be carried out by Evoqua AIN SCREEN service personnel or by personnel trained and authorized by Evo- qua for maintenance work. This is indicated on the display. This warning message will be displayed for the first time after six months, and then every twelve months thereafter.This warning...
Page 125 ® OSEC -NXT 12-60 Operation 5.9.5 Operating water pressure too low Main screen If the actual operating water pressure drops below the setpoint AIN SCREEN (see the information label on the chlorine membrane electrolysis system) the warning "Operating water pressure too low" is dis- played.
Page 126 ® OSEC -NXT 12-60 Operation 5.9.7 Electrolysis water check flow rate Main screen If the actual electrolysis water flow rate differs from the setpoint AIN SCREEN (see the sign on the chlorine membrane electrolysis system), the warning "Electrolysis water check flow rate" is displayed. This may be because of: •...
Page 127 ® OSEC -NXT 12-60 Operation 5.9.8 Cooling water check flow rate Main screen If the actual cooling water flow rate differs from the setpoint (see AIN SCREEN the sign on the chlorine membrane electrolysis system), the war- ning "Cooling water check flow rate" is displayed. This may be because of: •...
Page 128 ® OSEC -NXT 12-60 Operation 5.9.9 Water softener check brine flow rate Main screen If the actual brine flow rate in the water softener differs from the AIN SCREEN setpoint the warning "Water softener check brine flow" is dis- played. This may be because of: •...
Page 129 Please note If you know that the power supply is going to be interrupted for four hours or more, the chlorine membrane electrolysis system must be shut down by trained and authorized personnel or by Evoqua ser- vice personnel.
Page 130 ® OSEC -NXT 12-60 Operation 5.9.12 Unstable mains voltage/mains failure Main screen If the power supply fails (see chapter Installation, 4.5.1 Checking AIN SCREEN the power supply), the warning "Unstable mains voltage/mains fai- lure" is displayed. This may be because of: •...
Page 131: Error Messages
® OSEC -NXT 12-60 Operation 5.10 Error messages If the system develops a fault, a corresponding error message is displayed, irrespective of the current operating state or what else is currently being displayed by the system. Every error message has to be acknowledged individually by pressing the button.
Page 132 ® OSEC -NXT 12-60 Operation Main screen "i" (info) Error messages The "i" (Info) button allows you to view the error messages that RROR MESSAGES have been displayed by the system, including the date, time and status details ("come", "ack" and "gone"), at any time. The arrow keys are used to navigate around the display.
Page 133: Reading The Cell Voltage And Electrolysis Current
® OSEC -NXT 12-60 Operation 5.11 Reading the cell voltage and electrolysis current Main screen The current cell voltage and electrolysis current can be seen on AIN SCREEN the main screen at all times. They are displayed both as a bar and as a number to the right of the bar.
Page 134: Menus
® OSEC -NXT 12-60 Operation 5.12 Menus 5.12.1 Menu selection Main screen MENU Pressing the "MENU" button on the basic display opens the "Menu ENU SELECTION selection" screen. You can select from a total of five menus: • Outputs • Diagnostics •...
Page 135: Relay Assignment
The control system provides two potential-free alarm relays for UTPUTS operating messages, warning messages or error messages as well as interfaces to the bus systems Evoqua RS485 bus and PROFIBUS DP. In the "Outputs" menu you can assign various messages to the alarm relays and the interfaces to certain addresses.
Page 136 ® OSEC -NXT 12-60 Operation Main screen MENU Menu selection Outputs Alarm relay 1/2 Assignment RELAY ASSIGNMENT • Selection warning messages Main screen MENU Menu selection Outputs Alarm relay 1/2 Assignment RELAY ASSIGNMENT • Selection error messages Main screen MENU Menu selection Outputs Alarm relay 1/2 Assignment...
Page 137 ® OSEC -NXT 12-60 Operation Main screen MENU Menu selection Outputs Alarm relay 1/2 Assignment RELAY ASSIGNMENT • Selection error messages Main screen MENU Menu selection Outputs Alarm relay 1/2 Assignment RELAY ASSIGNMENT • Selection error messages Main screen MENU Menu selection Outputs Alarm relay 1/2 Assignment...
Page 138 ® OSEC -NXT 12-60 Operation Main screen MENU Menu selection Outputs Alarm relay 1/2 Assignment RELAY ASSIGNMENT • Selection error messages Main screen MENU Menu selection Outputs Alarm relay 1/2 Assignment RELAY ASSIGNMENT • Selection error messages • Selection SMS Please note The "EMERGENCY STOP"...
Page 139: Relay Function
® OSEC -NXT 12-60 Operation Main screen MENU Menu selection Outputs Alarm relay 1/2 Function Both of the alarm relays, 1 and 2, require an NC (normally closed) RELAY FUNCTION or NO (normally open) switching function. If a time delay is needed before the switching function is triggered, you can also specify a delay of between 0 and 3600 seconds.
Page 140: Operating Data
® OSEC -NXT 12-60 Operation 5.12.3 "Diagnostics" menu Main screen MENU Menu selection Diagnostics In the "Diagnostics" menu, all of the operating parameters and set- IAGNOSTICS tings can be viewed without needing to enter a user name or pass- word. The "Diagnostics"...
Page 141 ® OSEC -NXT 12-60 Operation Main screen MENU Menu selection Diagnostics Operating data "FWD" • Electrolysis water PERATING DATA Current electrolysis water flow rate. The specific flow rate that is required is system-specific. See the information label on the chlo- rine membrane electrolysis system.
Page 142 ® OSEC -NXT 12-60 Operation Main screen MENU Menu selection Diagnostics Operating data "FWD" • Date of last monthly maintenance PERATING DATA • Date of last annual maintenance Main screen MENU Menu selection Diagnostics Warning message log All of the warnings are stored in the "Warning message log" and ARNING MESSAGE LOG can be viewed at any time, irrespective of the current operating state.
Page 143 ® OSEC -NXT 12-60 Operation Main screen MENU Menu selection Diagnostics Error message log All of the errors are stored in the "Error message archive" and can RROR MESSAGE LOG be viewed at any time, irrespective of the current operating state. The display is structured as follows: •...
Page 144: Digital Inputs
® OSEC -NXT 12-60 Operation Main screen MENU Menu selection Diagnostics Digital inputs I n the "Digital inputs" menu you can view the current status of the digi- IGITAL INPUTS tal inputs for diagnostic purposes. A white signal status box means that the potential on the digital input is zero, a black signal status box means that the potential on the digital input is not zero.
Page 145: Digital Outputs
® OSEC -NXT 12-60 Operation Main screen MENU Menu selection Diagnostics Digital outputs In the "Digital outputs" menu you can view the current status of the IGITAL OUTPUTS digital outputs for diagnostic purposes. A white signal status box means that the digital output is set to zero, a black signal status box means that the potential on the digi- tal output is set to one.
Page 146: Analog Inputs
® OSEC -NXT 12-60 Operation Main screen MENU Menu selection Diagnostics Analog inputs In the "Analog inputs" menu service personnel can view the cur- NALOG INPUTS rent values and states of the analog inputs for the cell voltage and the electrolysis current, the operating water pressure and the ambient temperature for diagnostic purposes.
Page 147 ® OSEC -NXT 12-60 Operation 5.12.4 "Service" menu Main screen MENU Menu selection Service The "Service" menu is primarily intended for use by service per- ERVICE sonnel (password level 3). All of the settings and operating para- meters can, however, be read by all users, in any user group, without requiring the user to log in.
Page 148 There are certain tasks that the ope- rator is required to perform on a daily, weekly or monthly basis. Once a year, annual maintenance must be carried out by Evoqua service personnel or by personnel trained and authorized by Evo- qua for maintenance work.
Page 149 3 service personnel. Attention! Risk of injury and damage to the system! These settings may only be changed by Evoqua service personnel or by personnel trained and authorized by Evoqua after consulting the manufacturer.
Page 150: Brine Pump
® OSEC -NXT 12-60 Operation Main screen MENU Menu selection Service Brine pump The "Brine pump" menu is used to configure the brine pump. RINE PUMP These settings are configured at the factory and are system-spe- cific. They are therefore password protected and only accessible to level 3 service personnel.
Page 151 ® OSEC -NXT 12-60 Operation 5.12.5 "System" menu Main screen MENU Menu selection System IIn the "System" menu you can configure the control and display YSTEM unit. The "System" menu has the following submenus: • Clean display • Display contrast - / + •...
Page 152 ® OSEC -NXT 12-60 Operation Main screen MENU Menu selection System Change display language The factory default setting is German. If necessary, the language can YSTEM be changed. The languages available are: • German • English • French Proceed as follows: 1 Press the "Change display language"...
Page 153: Manual Functions
® OSEC -NXT 12-60 Operation 5.12.6 "Manual functions" menu Please note The "Manual functions" button is only displayed on the "Menu se- lection" screen when the system is in "MANUAL" mode. It is not displayed when the system is in Automatic mode. Main screen MENU Menu selection...
Page 154 ® OSEC -NXT 12-60 Operation Main screen MENU Menu selection Manual functions Electrolysis water On Electrolysis water can be turned on manually either for diagnostic ANUAL FUNCTIONS purposes or when performing maintenance, for instance to set the flow rate or to calibrate the electrolysis water flow meter. Proceed as follows: 1 Press the "Electrolysis water On"...
Page 155 ® OSEC -NXT 12-60 Operation Main screen MENU Menu selection Manual functions Brine filling On The brine pump can be turned on manually, either for diagnostic ANUAL FUNCTIONS purposes or when performing maintenance. Proceed as follows: 1 Press the "Brine filling On" button. 2 The brine pump supplies brine to the chlorine separator.
Page 156 ® OSEC -NXT 12-60 Operation Main screen MENU Menu selection Manual functions Water softener Regenerating the water softener Automatic regeneration of the water softener is usage-based and ANUAL WATER SOFTENING depends on the water hardness. Regeneration of the water softe- ner can also be started manually.
Page 157 ® OSEC -NXT 12-60 Operation Main screen MENU Menu selection Manual functions Water softener Test Inlet Testing the water softener water inlet solenoid valve (E5). ANUAL WATER SOFTENING Proceed as follows: 1 Press and hold the "Test Inlet" button. This is a key function. If the water softener water inlet solenoid valve (E5) is working correctly it will open and the LED on the valve will switch on.
Page 158 ® OSEC -NXT 12-60 Operation Main screen MENU Menu selection Manual functions Water softener Test Injector Testing the injector. This tests the: ANUAL WATER SOFTENING • Water softener injector solenoid valve (E6) • Water softener flushing solenoid valve (E8) • Injector •...
Page 159: Maintenance By The Operator
Performed by trained and instructed operators. • Maintenance level 2 Performed by Evoqua service personnel or by personnel trai- ned and authorized by Evoqua for maintenance work. The liability for defects is only valid if maintenance work is perfor- med as specified.
Page 160 ® OSEC -NXT 12-60 Operation weekly Required work chapter • Replenish salt in the salt dissolving tank. 5.13.2 • Check the electrolysis current and cell vol- tage and enter the readings in the operating journal. 5.11 • Check the preparation and total operating hours and enter in the operating journal.
Page 161 Warning! If you find any leaks or damage to the chlorine membrane electro- lysis system, switch off automatic preparation immediately by pressing the "Mode" button and contact Evoqua customer services immediately. Please note Components and hose connections that are mechanically or elec- trically operated are labeled on the system with abbreviations (e.g.
Page 162 Attention! To ensure fault-free, safe operation, use only the salt prescribed by the manufacturer (e. g. Evoqua OSEC® Salin) and completely softened water produced by the chlorine membrane electrolysis system. The minimum fill level is 16“ above the top of the sieve tray.
Page 163 (0 - 0.25° dH)! If the color of the sample turns red, repeat the test. If the color of the sample is red again, con- tact Evoqua customer services immediately! 6 Check the result and enter in the operating journal.
Page 164 ® OSEC -NXT 12-60 Operation 5.13.4 Measuring the operating water hardness As part of the monthly maintenance, the water hardness of the operating water supplied to the system needs to be checked and entered on the control and display unit. The operating water hard- ness can be measured and entered in any operating state.
Page 165 ® OSEC -NXT 12-60 Operation 5.13.5 Calibrating the electrolysis water flow meter As part of the monthly maintenance it is necessary to check the electrolysis water flow meter measurements and it may be neces- sary to recalibrate it. Proceed as follows: 1 Check the electrolysis water flow rate and adjust using the dosing ball valve (M7) if necessary.
Page 166 ® OSEC -NXT 12-60 Operation 5.13.6 Checking and cleaning the filter See chapter 8. Arrangement of components. As part of the monthly maintenance procedure, check the filters one after another and clean them if necessary: • Soft water filter • Cathode inlet filter •...
Page 167 ® OSEC -NXT 12-60 Operation Operating water pressure 1 Close the ball valve of the water inlet (M1). reducing valve filter (M3) 2 Open and empty pressure reducing valve filter drain tap (M5). 3 Close the drain tap filter of the pressure reducing valve (M5) . 4 Dismantle the filter, clean if necessary, and reassemble.
Page 168: Faults
Injury or damage to the system! If you find any leaks or damage to the chlorine membrane electro- lysis system, switch off automatic preparation immediately by pressing the "Mode" button and contact Evoqua customer services immediately. Attention! Damage to the system! Only in emergencies turn off the main switch! Otherwise, important safety functions are deactivated.
Page 169 ® OSEC -NXT 12-60 Operation Main screen The last error message reported by the system is displayed as a AIN SCREEN text message on the main screen, together with the time stamp and the state and the "i" (Info) button flashes. The text message, the symbol and the flashing "i"...
Page 170 ® OSEC -NXT 12-60 Operation 5.14.1 Faults without interruption of the preparation process Error message caused by Remedy • "Min." and "Max." fill level • The switching functions of the Siphon device message displayed simulta- level probes in the lifting tank level probes neously should be checked by an electri-...
Page 171 Faults that cause preparation to stop (AUTOMATIC "Preparation standby") Error message caused by Remedy • Limit value exceeded • Notify Evoqua customer service (electrical resistance too immediately Cell voltage high, electrolysis process too high not working properly) • Below limit value •...
Page 172 • Salt dissolving tank level switch Check level! faulty • Check the warning message log • Contact Evoqua customer ser- vice if necessary • Limit value for the filling time • Check level! Salt dissolving tank of the salt dissolving tank •...
Page 173 OSEC -NXT 12-60 Operation Error message caused by Remedy • Rectifier is faulty • Notify Evoqua customer service immediately Rectifier • Check the warning message log not ready • Rectifier not ready due to: • Have the power supply required...
Page 174 Dosing leak • Perform visual inspection of the pipes to check for leaks • Notify Evoqua customer service • Signal from the leak sensor • Perform visual inspection to of the chlorine membrane check for leaks...
Page 175: Emergency Stop
Signal from the gas alert • Put on protective clothing device due to increased chlo- • Bring any bystanders to safety Chlorine gas alarm rine concentration in the air. • Create a fresh air supply • Notify Evoqua customer service immediately.
Page 176 Risk of injury or damage to the system! If the system needs to be shut down for longer than four weeks, it must be shut-down by trained and authorized personnel or by Evoqua ser- vice personnel. For further details see chapter Maintenance, 6.5 Shut-down.
Page 177: Maintenance By A Service Technician
Once a year, level 2 maintenance must be carried out by Evoqua service personnel or by personnel that have been trai- ned and authorized by Evoqua for maintenance work. This is first required six months after the system is commissioned.
Page 178 6.3 Detailed maintenance work. The maintenance checklist must be properly completed and sig- ned and then returned to Evoqua Water Technologies (required for any defect liability claims). Starting the system up again Once the maintenance has been completed, the chlorine memb- rane electrolysis system can be started up again as described in chapter 6.6 Starting the system up again.
Page 179: Maintenance Parts Sets
® OSEC -NXT 12-60 Maintenance by a service technician Maintenance parts sets The parts required for performing annual maintenance are inclu- ded in the maintenance parts sets. The following maintenance parts sets are available: Part No. Designation W3T164984 Maintenance parts set, 1 year (or for the first time after 6 months) W3T164985 Maintenance parts set, 2 years...
Page 180 ® OSEC -NXT 12-60 Maintenance by a service technician 6.2.1 Maintenance parts set for 1 year The item numbers in the table refer to the drawings in chapter 6.3.8 Replacing wear parts. Maintenance parts set W3T164984, 1 year Item Quantity Part No.
Page 181 ® OSEC -NXT 12-60 Maintenance by a service technician 6.2.2 Maintenance parts set for 2 years The item numbers in the table refer to the drawings in chapter 6.3.8 Replacing wear parts. Maintenance parts set W3T164985, 2 years Item Quantity Part No.
Page 182 ® OSEC -NXT 12-60 Maintenance by a service technician 6.2.3 Maintenance parts set for 5 years The item numbers in the table refer to the drawings in chapter 6.3.8 Replacing wear parts. Maintenance parts set W3T164986, 5 years Item Quantity Part No.
Page 183 ® OSEC -NXT 12-60 Maintenance by a service technician 6.2.4 Pump head service set The brine pump has a two year maintenance interval. The prescri- bed maintenance schedule is given in the table in chapter 6.2.6 Using the maintenance part sets. For details on maintenance of the brine pump, see chapter 6.3.9 Brine pump maintenance.
Page 184 ® OSEC -NXT 12-60 Maintenance by a service technician 6.2.6 Using the maintenance part sets Since the various wear parts wear at different rates, the following maintenance parts sets need to be used, depending on the main- tenance interval and the size of the chlorine membrane electroly- sis system: Mainte- nance...
Page 185: Detailed Maintenance Work
® OSEC -NXT 12-60 Maintenance by a service technician Detailed maintenance work 6.3.1 Measuring individual cell voltage The chlorine membrane electrolysis system is in Automatic mode, operating state "Preparation active!". Proceed as follows: 1 Measure the voltage of the individual electrolysis cell via their electrical connections using the multimeter and probes, and while the system is preparing the product.
Page 186 ® OSEC -NXT 12-60 Maintenance by a service technician 6.3.3 Checking the product concentration Attention! Chemical hazard! Sodium hypochlorite is a strong oxidant. Avoid all skin contact! Al- ways wear protective clothing! After skin contact, rinse thoroughly with lots of water! The chlorine membrane electrolysis system is in Automatic mode, operating state "Preparation active!".
Page 187 ® OSEC -NXT 12-60 Maintenance by a service technician 6.3.5 Checking the salt dissolving tank level probe The chlorine membrane electrolysis system is in manual mode, operating state "Preparation off". Proceed as follows: 1 Lift the cover of the salt dissolving tank. 2 Lift the level probe out of the guide tube.
Page 188 ® OSEC -NXT 12-60 Maintenance by a service technician 6.3.6 Emptying and rinsing the cathode chamber Attention! Damage to the electrolysis cell(s)! Never empty the cathode and anode chambers at the same time! The membrane could dry out and damage the electrolysis cell! The chlorine membrane electrolysis system is in manual mode, operating state "Preparation off".
Page 189 ® OSEC -NXT 12-60 Maintenance by a service technician 6.3.7 Emptying and rinsing the anode chamber. Warning! Chemical hazard! There is chlorine gas in the anolyte circuit. Leaks may release chlorine gas. Chlorine gas is toxic when inhaled and may cause loss of consciousness Use gas mask! Attention! Damage to the electrolysis cell(s)!
Page 190: Replacing Wear Parts
® OSEC -NXT 12-60 Maintenance by a service technician Main screen MENU Menu selection Manual functions Electrolysis water On ANUAL FUNCTIONS 10 Switch to the "Manual functions" screen and press the "Elec- trolysis water On" button. Open the electrolysis water solenoid valve (E2) and the water softener water inlet solenoid valve (E5).
Page 191: Item Quantity Part No
® OSEC -NXT 12-60 Maintenance by a service technician 1 year maintenance The following wear parts, contained in maintenance parts set W3T164984, need to be replaced as shown in the drawings below when performing the 1 year maintenance. Item Quantity Part No.
Page 192: W3T169064 Sieve Tube
® OSEC -NXT 12-60 Maintenance by a service technician 2 year maintenance The following wear parts, contained in maintenance parts set W3T164985, need to be replaced as shown in the drawings below when performing the 2 year maintenance. Item Quantity Part No.
Page 193 ® OSEC -NXT 12-60 Maintenance by a service technician 5 year maintenance The following wear parts, contained in maintenance parts set W3T164986, need to be replaced as shown in the drawings below when performing the 5 year maintenance. Item Quantity Part No.
Page 194 ® OSEC -NXT 12-60 Maintenance by a service technician Fig. 1 Wear parts to be replaced Fig. 2 Wear parts to be replaced WT.085.140.000.DA.IM.0916...
Page 195 ® OSEC -NXT 12-60 Maintenance by a service technician 6.3.9 Brine pump maintenance Please note The brine pump has a two year maintenance interval. The prescri- bed maintenance schedule is given in the table in chapter 6.2.6 Using the maintenance part sets. Drain and rinse the chlorine membrane electrolysis system and switch off at the main switch.
Page 196 ® OSEC -NXT 12-60 Maintenance by a service technician 6.3.10 Cleaning the water softener injector Drain and rinse the chlorine membrane electrolysis system and switch off at the main switch. Proceed as follows: 1 Release the pipe clamps on the injector line. 2 Dismantle the injector line as shown in the drawing.
Page 197 ® OSEC -NXT 12-60 Maintenance by a service technician 6.3.11 Replacing the hydrogen vent hose on the hydrogen vent pipe Drain and rinse the chlorine membrane electrolysis system and switch off at the main switch. Proceed as follows: 1 Cut the new hydrogen vent hose to the required length. 2 Release the hose clamps with a screwdriver.
Page 198 ® OSEC -NXT 12-60 Maintenance by a service technician 6.3.13 Replacing the rectifier Please note The rectifier has a three year maintenance interval. The prescribed maintenance schedule is given in the table in chapter 6.2.6 Using the maintenance part sets. Drain and rinse the chlorine membrane electrolysis system and switch off at the main switch.
Page 199 ® OSEC -NXT 12-60 Maintenance by a service technician 6.3.14 Replacing the paddle switch out of the air flow monitor Drain and rinse the chlorine membrane electrolysis system and switch off at the main switch. Proceed as follows: 1 Prepare the paddle switch. 2 Remove the old paddle switch from the system.
Page 200: Replacing The Electrolysis Cell
For replacment of the electrolysis cell we provide as a spare part: Part No. Designation System W3T188264 Spare electrolysis cell OSEC-NXT 12-60 Proceed as follows: The chlorine membrane electrolysis system is in manual mode, operating state "Preparation off". 1 Prepare the following tools: •...
Page 201 ® OSEC -NXT 12-60 Maintenance by a service technician 9 Empty the water from the replacement cell. 10 Remove the old electrolysis cell from the chlorine membrane electrolysis system. 11 Replace the elbow unions from the cathode inlet on both of the electrolysis cells by unscrewing the union nuts on the cell con- nection to the elbow unions.
Page 202 ® OSEC -NXT 12-60 Maintenance by a service technician 21 Wait 15 minutes and then drain the acid from the anode cham- ber. 22 Turn on the chlorine membrane electrolysis system at the main switch. Main screen MENU Menu selection Manual functions Brine filling On 23 Refill the anode chamber with brine immediately.
Page 203: Shut-Down
Shut-down If the chlorine membrane electrolysis system needs to be shut down for longer than four weeks, it must be shut down by trained and authorized personnel or by Evoqua service personnel. Attention! Damage to the electrolysis cell(s)! If the system is switched off and disconnected from the power supply for a prolonged period (>...
Page 204 ® OSEC -NXT 12-60 Maintenance by a service technician 6.5.2 Shut-down the system on the control and display unit The chlorine membrane electrolysis system is empty and rinsed and in MANUAL mode, operating state "Preparation off". Main screen MENU Menu selection Service Shut-down Proceed as follows:...
Page 205: Starting The System Up Again
® OSEC -NXT 12-60 Maintenance by a service technician Starting the system up again Affected Required work parts chapter System in Ensure the system requirements general given in the chapter Start-up are met Turn the system on at the main switch 4.7.5 Start the system...
Page 206 ® OSEC -NXT 12-60 Maintenance by a service technician WT.085.140.000.DA.IM.0916...
Page 207: Dimension Drawing
® OSEC -NXT 12-60 Dimension drawing 7. Dimension drawing...
Page 208 ® OSEC -NXT 12-60 Dimension drawing WT.085.140.000.DA.IM.0916...
Page 209: Arrangement Of Components
® OSEC -NXT 12-60 Arrangement of Components 8. Arrangement of Components A4 M12 M9 M10...
Page 211: Component Parts List
® OSEC -NXT 12-60 Component Parts List Group Designation Labels Mechanically Operating water ball valve activated com- Cooling water ball valve ponents Operating water pressure reducing valve Electrolysis water pressure reducing valve Pressure reducing valve filter drain tap Cooling water membrane valve Electrolysis water dosing ball valve Soft water sample ball valve Separator screw-in closable outlet...
Page 212 ® OSEC -NXT 12-60 WT.085.140.000.DA.IM.0916...
Page 213: Wiring Diagram
® OSEC -NXT 12-60 Wiring diagram 9. Wiring diagram...
Page 214 ® OSEC -NXT 12-60 Wiring diagram WT.085.140.000.DA.IM.0916...
Page 215 ® OSEC -NXT 12-60 Wiring diagram...
Page 216 ® OSEC -NXT 12-60 Wiring diagram WT.085.140.000.DA.IM.0916...
Page 217 ® OSEC -NXT 12-60 Wiring diagram...
Page 218 ® OSEC -NXT 12-60 Wiring diagram WT.085.140.000.DA.IM.0916...
Page 219 ® OSEC -NXT 12-60 Wiring diagram...
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Page 247: 10.Operating Journal
® OSEC -NXT 12-60 Operating journal 10.Operating journal...
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Page 249: 11.Index
® OSEC -NXT 12-60 Index 11.Index Fault 176 Brine pump 19, 23, 24, 25, 30, 150 Abbreviations 46, 56, 118, 161, 211 Errors 173 Accessories 28, 39 Fault 173 Accessory set 39 Maintenance 195 Accident 18 Manual brine pump 155 Additional tools 177 Buttons 106 Adjust date/time 152...
Page 250 ® OSEC -NXT 12-60 Index Electrical 52 Electrolysis cell 24 Electrical installation 52 Hose connections 211 Electrolysis 149 Mechanical 29, 50 Electrolysis cell 19, 21, 23, 24 Sodium hypochlorite storage tank 29 Pro-Rata 20 Control and display unit 105 Replacing 20 Control cabinet 13, 24, 26, 42 Electrolysis current 30, 31, 34, 35, 36 Electrical installation 52...
Page 251 ® OSEC -NXT 12-60 Index Main switch 19, 26, 55, 58, 168 Mains connection 34, 35, 36 Handling chemicals 14 Maintenance 11, 19, 47, 142, 148 Heat emission 42 Additional tools 45 Heat exchanger 23, 24, 25 Annual 124 Hinged feet 39, 41, 47 Checklist 178 Hose connections 46, 49, 211 Customer services 177...
Page 252 ® OSEC -NXT 12-60 Index Measuring the cell current 185 Cooling water 176 Measuring the water hardness 60, 61 Flow meter 176 Mechanical installation 46 Potentially isolated RS485 bus system 89 Membrane 20, 188, 189 Potentially non-isolated RS485 bus system 89 Menu selection 134 Power consumption 34 Menus 134...
Page 253 ® OSEC -NXT 12-60 Index Replacement of electrolysis cell 20 Service Parameter reset 149 Replacing the electrolysis cell 200 Setting the electrolysis water flow rate 60 Replacing wear parts 190 Setup 47 Replenish Shut-down 41, 111, 176, 203 Salt 162 Shutdown period 20, 41, 176, 203 Request frame 93 Signage 14, 39...
Page 254 ® OSEC -NXT 12-60 Index Empty 52, 53, 124 Leak 174 Unpacking 40 Level switch 49, 65 Using the maintenance part sets 184 Overfilled 52, 53, 174 Setup 49 Supply 40 Synchronisation bytes 91 Ventilation hood 39, 41, 48 System 151 System adjust date/time 152 System calibrate operator display 152 System change display language 152...
Page 255 -NXT 12-60 ® Wallace & Tiernan Products worldwide Australia Canada China +61 3 8720 6597 +1 905 944 2800 +86 10 57076305 info.au@evoqua.com canadainfo@evoqua.com sales.cn@evoqua.com France Germany Singapore +33 1 41 15 92 20 +49 8221 9040 +65 6830 7165 wtfra@evoqua.com wtger@evoqua.com...
Page 256 All information presented herein is believed reliable and in accordance with accepted engineering practices. Evoqua makes no warranties as to the completeness of this information. Users are responsible for evaluating individual product suitability for specific applications. Evoqua assumes no liability whatsoever for any special, indirect or consequential damages arising from the sale, resale or misuse of its products.

Evoqua OSEC-NXT 12-60 Instruction Manual

Osec -Nxt 12-60

Chapter 4.5 Electrical Installation

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