Jesco C 2213 Bedienungsanleitung

C 2213

Vacuum Regulator for Chlorine Gas

Operation &

Maintenance Instructions

Read these operation and maintenance instructions

before start up!

To be held for future reference.

Dosing

Conveying

Control

Liquids

Gases

Systems

EN 02

2 | Operation Manual C 2213 | Contents

Table of Contents

1 Safety ..................................................................................................................................................................... 3

1.1 General........................................................................................................................................................................................................... 3

1.2 Warnings used in this Operation & Maintenance Manual............................................................................................................................... 3

1.3 Qualiﬁcation and training of personnel........................................................................................................................................................... 3

1.4 Hazards due to non-compliance with the safety instructions ......................................................................................................................... 4

1.5 Safe operation ................................................................................................................................................................................................ 4

1.6 Safety instructions for the owner/operator...................................................................................................................................................... 4

1.7 Safety instructions for installation, maintenance and inspection..................................................................................................................... 4

1.8 Unauthorized modiﬁcation and production of spare parts .............................................................................................................................. 4

1.9 Impermissible modes of operation ................................................................................................................................................................. 4

1.10 Dosing of Chemicals.................................................................................................................................................................................... 5

1.11 Special notes for working with chlorine gas metering units and the usage of chlorine ................................................................................. 6

2 Before placing in operation................................................................................................................................... 7

2.1 Compliant use................................................................................................................................................................................................ 7

2.2 Scope of delivery............................................................................................................................................................................................ 7

2.3 Steps to take for start-up ................................................................................................................................................................................ 7

3 Functional principle of the vacuum regulator...................................................................................................... 8

3.1 Chlorine Gas .................................................................................................................................................................................................. 8

3.2 Vacuum regulator ........................................................................................................................................................................................... 8

3.3 Technical data................................................................................................................................................................................................. 9

3.4 Dimensions.................................................................................................................................................................................................... 10

4 General................................................................................................................................................................... 11

5 Installation............................................................................................................................................................. 12

5.1 Chlorine delivery............................................................................................................................................................................................ 12

5.2 Design of the piping system........................................................................................................................................................................... 15

5.3 Installation of units......................................................................................................................................................................................... 18

6 Start up .................................................................................................................................................................. 20

6.1 Leakage test.................................................................................................................................................................................................... 20

6.2 Starting the system......................................................................................................................................................................................... 20

7 Operation ............................................................................................................................................................... 21

7.1 Cylinder exchange.......................................................................................................................................................................................... 21

8 Switching off.......................................................................................................................................................... 22

9 Maintenance .......................................................................................................................................................... 23

9.1 Dismounting of the complete vacuum regulator ............................................................................................................................................. 23

9.2 Check............................................................................................................................................................................................................. 26

9.3 Adjustment of simultaneous delivery.............................................................................................................................................................. 26

9.4 Safety valve .................................................................................................................................................................................................... 29

9.5 Activated-carbon cartridge.............................................................................................................................................................................. 29

10 Troubleshooting................................................................................................................................................... 30

11 Accessories.......................................................................................................................................................... 32

12 Installation examples .......................................................................................................................................... 36

12.1 Several full-vacuum chlorinators mounted directly on the chlorine cylinders............................................................................................... 36

12.2 Manifold with one vacuum regulator for each cylinder line........................................................................................................................... 36

12.3 Schematic diagram of a complete chlorination installation........................................................................................................................... 37

13 Maintenance kits................................................................................................................................................. 38

14 Unit revision......................................................................................................................................................... 38

15 Declaration of harmlessness .............................................................................................................................. 39

16 EC Manufacturer’s Declaration........................................................................................................................... 40

17 Warranty Application........................................................................................................................................... 41

Safety | Operation Manual C 2213 | 3

1 Safety

1.1 General

This Operating & Maintenance Manual contains basic information to be noted during installation, operation

and maintenance. It is therefore essential that the Manual be read by the contractor before installing and

commissioning the pump/system, as well as by the relevant operating personnel / owner of the pump/system.

It must remain accessible at the pump/system for reference at all times. In addition to the general safety

instructions under this main heading Safety, the special safety precautions outlined in other sections must also

be observed.

1.2 Warnings used in this Operation & Maintenance Manual

This Operation & Maintenance Manual contains vital information which may endanger people, the environment

and the dosing pump/system if they are disregarded. These statements are identiﬁed by the following symbols:

DANGER!

Refers to an imminent danger.

Non-compliance can lead to death or extremely serious injury.

WARNING!

Refers to a potentially hazardous situation. Non-compliance can lead to death or extremely serious injury.

CAUTION!

Refers to a potentially hazardous situation. Non-compliance can lead to minor injury or property damage.

NOTICE!

Appears in conjunction with safety instructions which may endanger the product and its operation if disre-

garded.

IMPORTANT!

Draws attention to supplementary information to make the work easier and ensure troublefree operation.

Markings which are afﬁxed directly to the product, such as

• Connectionmarkings

• Markingsforelectricalconnections

• Warningsigns

must be observed without fail and must remain fully legible at all times.

1.3 Qualiﬁcation and training of personnel

The personnel employed for installation, operation, inspection, and maintenance, must be suitably qualiﬁed

for this work. The areas of responsibility, competence and supervision of the personnel must be precisely

deﬁned by the owner. Personnel who do not have the required know-how must be duly trained and instructed.

If necessary, this training can also be provided by the manufacturer/supplier on behalf of the products owner.

In addition, the owner must also ensure that the relevant personnel are fully familiar with and have understood

the contents of the Operation & Maintenance Manual.

4 | Operation Manual C 2213 | Safety

1.4 Hazards due to non-compliance with the safety instructions

Failure to comply with the safety instructions may endanger not only people, but also the environment and the

product/system. Non-compliance with the safety instructions can lead to the loss of all entitlement to damages.

The following hazards in particular may arise:

• Failureofmajorsystemfunctions.

• Failureofspeciedmethodsformaintenanceandrepair.

• Dangertopeopleduetoelectrical,mechanicalandchemicaleffects.

• Dangertotheenvironmentduetoleakageofhazardoussubstances.

1.5 Safe operation

The safety instructions contained in this Operation & Maintenance Manual must be observed. The owner is

responsible for ensuring compliance with local safety regulations.

1.6 Safety instructions for the owner/operator

Leakages must immediately be eliminated by specialist staff in order to avoid potential hazards for persons and

environment. Statutory regulations must be observed.

Danger due to electric power must be excluded (for further details, refer to the VDE regulations and the regula-

tions of the local public utilities).

1.7 Safety instructions for installation, maintenance and inspection

The owner must ensure that all maintenance, inspection and installation work is undertaken by authorized and

duly qualiﬁed skilled personnel who have also studied the Operation & Maintenance Manual in depth.

Before carrying out installation and maintenance works, always make sure that the unit is not connected to the

system. The procedure speciﬁed in the Operation & Maintenance Manual for shutting down the system must be

observed without fail.

The device or the system and all material-conveying parts must be vented. All safety mechanisms and guards

must be reﬁtted and reactivated as soon as the work is complete.

The points set out in the section Installation and commissioning must be observed before starting the pump/

system.

1.8 Unauthorized modiﬁcation and production of spare parts

Modiﬁcations of the system are not permitted. Genuine spare parts and accessories authorized by the manu-

facturer ensure greater safety. Liability for damage or loss may be voided if non Lutz-Jesco parts are used.

1.9 Impermissible modes of operation

The operational safety of the product supplied can only be guaranteed when it is used in conformity with its

intended use as speciﬁed in our contract documents-, especially the order conﬁrmation. The limit values speci-

ﬁed in these documents must never be exceeded.

Safety | Operation Manual C 2213 | 5

1.10 Dosing of Chemicals

CAUTION!

When working on dosing systems, the accident prevention regulations applicable

on site must be observed and the speciﬁed personal protective

equipment worn.

Werecommendthefollowingprotectiveequipment:

Respirator mask Protective gloves Protective clothing Safety shoes

All people responsible for installation and maintenance of pumps, piping, hoses and accessories should wear

this protective equipment.

Before working on the dosing systems and plant, disconnect it from the mains supply and protect it against

reconnection.

Lock the main valve and if available the auxiliary valve of the chlorine gas cylinders. Before opening the main

andauxiliaryvalvesandbeforereactivatingthepowersupply,makesuretoconnectthemeteringlines.Work-

ing on the dosing plant requires special safety precautions and may only be carried out by instructed technical

personnel.

6 | Operation Manual C 2213 | Before placing in operation

1.11 Special notes for working with chlorine gas metering units and the usage of

chlorine

DANGER!

Chlorine is a hazardous material. The chemical element chlorine is a green-yellow, toxic gas with pungent

odor. It is 2.5 times heavier than air and accumulates at ground level. It is toxic when breathed in. In severe

cases chlorine may lead to death. It irritates the eyes, the respiratory system and the skin. It is very toxic for

water organisms. The reason for the toxicity of chlorine is its extraordinary reactivity. It reacts with animal and

vegetable tissue and thus destroys it.

Air with a chlorine content of 0.5-1% leads to a quick death of mammals and humans, because the respiratory

tract and the pulmonary alveolus are attacked (formation of hydrogen chloride or hydrochlorid acid).

DANGER!

Breathing in air with a chlorine content of 0.01% for hours may lead to mortal intoxications. Already a chlorine

content of only 0.001% (10 ppm) severely attacks the lungs. 0.0001% (1 ppm) of chlorine in breathing air

irritates the respiratory systems and is easily detected due to its odour. It is not hazardous in this case. The

threshold limit value is at 0.5 ppm.

In order to avoid hazardous incidents, make sure to do a maintenance of the chlorine gas metering units at

leastonceayear.Insomecases,regionalregulationsmayrequireshorterintervalsofmaintenance.Workingon

the system requires special safety precautions and may only be carried out by instructed technical personnel.

The operating personnel must be instructed and must know all operating instructions and regional regulations.

These must be available on site. The devices/system must be checked daily and after each maintenance or

repair work for leak tightness.

DANGER!

Leakages may cause a chlorine gas escape. Breathing in chlorine gas may lead to death! Make sure to im-

mediately eliminate any leakage. For all work on gas-conveying system parts, make sure to wear a functioning

respirator mask with ﬁlter and and to evacuate all chlorine from the system. This is also important when chang-

ing the chlorine cylinders. In the case of an escape of chlorine gas, use a self-contained breathing apparatus.

Only use sealings once, a second usage is not allowed and leads to leakage.

Before starting work on chlorine gas metering systems the cylinder valves must be closed. All chlorine leading

pipes must be evacuated using the ejector.

Liquid chlorine must never enter chlorinators not being explicitly authorized for liquid chlorine.

In case that the pressure gauge at the vacuum regulator still indicates a pressure, the pressure has to be

discharged using the ejector.

Before startup of the chlorination installation all connections must be carried out properly and tightened using

the suitable tools. The tightness of the whole installation must be tested using ammonia vapor (ammonium

hydroxide solution).

Chlorine gas is highly hygroscopic. Therefore humidity penetrates the system at every open connection of the

units or pipes resulting in the formation of hydrochloric acid thus inevitably causing damage of the units. In

such cases, damages of the devices are inevitable. Therefore all connections (at the vacuum units and vacuum

pipes as well) must be closed at any time.

If chlorinators must be used with other gases than chlorine gas, the chemical resistance of the unit must be

checked after consulting the manufacturer.

Functional principle of the vacuum regulator | Operation Manual C 2213 | 7

2 Before placing in operation

2.1 Compliant use

The product is especially designed for the following purpose: Metering of chlorine gas from a pressure tank to

a line under vaccuum.

The operational safety of the delivered unit can only be guaranteed when it is used in conformity with its

intended use. Other usage and modiﬁcations will determine the immediate cancellation of the warranty and any

other manufacturer’s liability.

2.2 Scope of delivery

IMPORTANT!

Please unpack the product and ordered accessories carefully in order not to miss small parts. Immediately

compare the scope of delivery to the delivery note. If there are any discrepancies, contact your local distributor.

Carefully check the delivery before installation and refer to the delivery note to ensure the delivery is complete

and to check for any transport damages. Contact the supplier and/or carrier regarding any questions concern-

ing the delivery and/or transport damages.

Do not operate any defective devices.

The following belong within the scope of delivery:

• Full-vacuumchlorinatorC2213

• Wallmountingkit(optional)

• mountingset(optional)

• Operation&MaintenanceInstructions

2.3 Steps to take for start-up

The following steps are recommended by the manufacturer in order to install the product successfully:

• Readingtheoperationmanual

• Mountthedevice

• Startup

8 | Operation Manual C 2213 | Functional principle of the vacuum regulator

3 Functional principle of the vacuum regulator

10 9 7 8

1 3 6 5

Vakuum

Fig. 1:Cross section C 2213

3.1 Chlorine Gas

Chlorine gas is important for the disinfection of potable and swimming pool water but also represents a source

of danger as far as handling, transportation and storage are concerned. Therefore the vacuum principle has

been used in chlorination installations already for decades. According to this principle, the pressure of the chlo-

rine gas is reduced to vacuum, and only then, if the vacuum is sufﬁcient, will chlorine gas ﬂow to the metering

point. The main safety aspect is that the escape of chlorine gas is actually avoided. Even in the case of a line

rupture chlorine gas cannot escape but only ambient air can be primed.

3.2 Vacuum regulator

The full-vacuum chlorinator used as pressure reducing valve is of central importance for the safety in vacuum

installations. For this reason the C 2213 version has been designed in accordance with the latest ﬁndings.

The device combines several functions in one housing:

Vacuum regulation

In the initial position the ball ①(see ﬁg. 3.1) rests on the valve seat ②. It is pressed onto the seat by the lock-

ing spring ③and the chlorine cylinder pressure and closes the system. After switching on the ejector (water-

jet pump), a vacuum is generated. The vacuum applies a force to the working diaphragm ⑦of the full-vacuum

chlorinator, which is directed to the right. This force is transferred to the valve ball ①by the valve rod ⑧so

that chlorine gas enters the vacuum system. If the vacuum breaks down, the valve ball falls back immediately

onto the valve seat and stops the chlorine gas supply.

Simultaneously extraction

The constant volume of chlorine gas delivered per hour from one chlorine cylinder must not exceed 1 % of the

original contents. Consequently the maximum rate for e.g. a 65 kg cylinder is 650g Cl2/h.

Functional principle of the vacuum regulator | Operation Manual C 2213 | 9

In most cases, a chlorine delivery from a chlorine cylinder is not sufﬁcient, because more than 650 g/h shall be

metered. In such cases, chlorine gas is delivered by several cylinders at the same time in a so-called battery

operation. In order to make sure that the cylinders are emptied uniformly, all full-vacuum chlorinators must

start working at the same vacuum. For this purpose the C 2213 chlorinators are ﬁtted with an opening pres-

sure adjusting device. The adjusting screw ⑩is used to set the effect of forces between springs ⑨and ③.

As a result, it is ensured that the opening pressure is the same for all chlorinators and that the chlorine gas is

delivered almost simultaneously from all connected cylinders.

Simultaneously delivery works with rate of approximately 200 g/h and more. In order not to remain under this

rate, make sure that the number of connected cylinders is not larger than necessary.

Flow limiter

If some cylinders of a battery are already emptied and the full metering capacity is required, the delivery rate of

the partly ﬁlled cylinders becomes inadmissibly high, thus causing icing of the cylinders. This will be prevent of

the in the vacuum connector integrated ﬂow limiter ⑪. It allows for a maximum delivery rate of 1000g/h.

If the full-vacuum chlorinator is mounted on chlorine barrels or in the case of sufﬁcient chlorine supply from

other sources, the device enables rates of up to 10 kg/h. For this purpose, the ﬂow limiter can easily be

removed.

(As a standard the ﬂow limiter is an integrated part of the delivery).

Residual pressure preservation

Whileemptyingthechlorinecylinder,thecylinderpressuredecreasesuntilitistoolowtoremovetheball④

against the spring ⑥from the valve seat ⑤. A residual pressure of approx. 0.1 bar remains in the cylinder.

Thus humidity cannot enter the cylinder during replacement. The humidity of the entering air would cause

the chlorine cylinder to corrode internally so that the chlorine gas could be contaminated. Consequently, the

residual pressure preservation helps to extend the operational life of the chlorine cylinder.

Pressure gauge

The C 2213 chlorinator is equipped with a pressure gauge for the indication of the cylinder pressure. It is a

diaphragm pressure gauge with a splash-proof measuring mechanism in a plastic housing. The diaphragm of

the manometer is coated with a silver ﬁlm as a protection against the chlorine gas. In order not to damage it by

dirt particles the chlorine gas is directed through an integrated ﬁlter ⑫before reaching the pressure gauge.

The measuring range of the manometer of -1...0...15 bar was chosen in order to allow a supervision of the

residual pressure maintenance.

3.3 Technical data

materials chlorine-resistant materials such as nickel-plated brass, Hastelloy, PVC, FPM

max. capacity with ﬂow

limiter

ca. 1 kg Cl2/h

without ﬂow limiter 10 kg Cl2/h

operating vacuum 110 mbar (for 200 g/h)

display accuracy +/- 6% of ﬁnal scale reading

weight 2300 g

pressure stage PN16

pressure connection unionnutW1“,G5/8,G3/4,1.030“-14NGO,Yoke

dosing connector PEtubingd8/12,12/16

Tab.: 1: Technical data C 2213

10 | Operation Manual C 2213 | General

3.4 Dimensions

Ø108

142~

218~

169~

Fig. 2: Dimension C 2213

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