Lutz Jesco C 2700-V Bedienungsanleitung

Dosing

Conveying

Control

Liquids

Gases

Systems

Original Operating Instructions

BA-21210-02-V05

Vacuum Regulator for Chlorine Gas

C 2700-V

Operating Instructions

Read the Operating Instructions!

The user is responsible for installation and operation related mistakes!

Subject to technical changes.

160426

Vacuum Regulator for Chlorine Gas C 2700-V Operating Instructions

BA-21210-02-V05

Contents

1 Notes for the Reader ........................................................ 4

General non-discrimination .......................................................... 4

Explanation of the signal words .................................................... 4

Explanation of the warning signs .................................................. 4

Identification of warnings ............................................................. 4

Instruction for action identification ................................................ 4

2 Safety ............................................................................... 5

General warnings ......................................................................... 5

Information about chlorine............................................................ 5

Hazards due to non-compliance with the safety instructions......... 6

Working in a safety-conscious manner ......................................... 6

Personal protective equipment ..................................................... 6

Personnel qualification ................................................................. 6

3 Intended Use .................................................................... 7

Notes on product warranty ........................................................... 7

Intended purpose ......................................................................... 7

Device revision ............................................................................. 7

Prohibited dosing media ............................................................... 7

4 Product description ......................................................... 8

Scope of delivery .......................................................................... 8

Design and function ..................................................................... 8

Rating plate ................................................................................ 10

Technical data ........................................................................... 10

5Dimensions..................................................................... 11

Vacuum regulator with threaded connection ............................... 11

Vacuum regulator with flange connection ................................... 11

6 Installation ..................................................................... 12

Installation location .................................................................... 12

Mounting position.......................................................................12

Installing the device ...................................................................12

Completing the installation ......................................................... 15

Installation examples .................................................................. 16

7 Commissioning .............................................................. 18

Inspecting the pressure system .................................................. 18

Inspecting the vacuum system ...................................................19

Switching the system on ............................................................ 19

8Operation........................................................................ 20

Test intervals ............................................................................. 20

9Shutdown....................................................................... 21

Short-term shutdown .................................................................21

Long-term shutdown ..................................................................21

Disposal of the old device...........................................................21

10 Maintenance................................................................... 22

Maintenance intervals ................................................................22

Accessories for maintenance...................................................... 22

Preparing the system for maintenance ....................................... 22

Maintaining the inlet valve ..........................................................23

Maintaining the vacuum part ...................................................... 25

Conclusion of maintenance ........................................................27

11 Troubleshooting ............................................................. 28

12 Spare parts .................................................................... 29

Individual parts .......................................................................... 30

Complete assemblies ................................................................. 31

Maintenance sets ....................................................................... 31

13 Declaration of Incorporation ......................................... 32

14 Declaration of harmlessness ........................................ 33

15 Warranty application ..................................................... 35

16 Index .............................................................................. 37

Notes for the Reader

General non-discrimination

Vacuum Regulator for Chlorine Gas C 2700-V

Operating Instructions

BA-21210-02-V05

1 Notes for the Reader

This operating manual contains information and behaviour rules for the

safe and designated operation of the device.

Observe the following principles:

read the entire operating manual prior to commissioning the device.

ensure that everyone who works with or on the device has read the

operating manual and follows the instructions.

keep the operating manual throughout the service life of the device.

pass the operating manual on to any subsequent owner of the

device.

1.1 General non-discrimination

In these operating instructions, only the male gender is used where

grammar allows gender allocation. The purpose of this is to make the

text easy to read. Men and women are always referred to equally. We

would like to ask female readers for understanding of this text simplifi-

cation.

1.2 Explanation of the signal words

Different signal words in combination with warning signs are used in

this operating manual. Signal words illustrate the gravity of possible

injuries if the risk is ignored:

1.3 Explanation of the warning signs

Warning signs represent the type and source of a danger:

1.4 Identification of warnings

Warnings are intended to help you recognise risks and avoid negative

consequences.

This is how warnings are identified:

1.5 Instruction for action identification

This is how pre-conditions for action are identified:

Pre-condition for action which must be met before taking action.

This is how instructions for action are identified:

Separate step with no follow-up action.

1. First step in a series of steps.

2. Second step in a series of steps.

Result of the above action.

Action completed, aim achieved.

Signal word Meaning

DANGER Refers to imminent danger. Ignoring this sign may

lead to death or the most serious injuries.

WARNING Refers to a potentially hazardous situation. Failure

to follow this instruction may lead to death or

severe injuries.

CAUTION Refers to a potentially hazardous situation. Failure

to follow this instruction may lead to minor injury

or damage to property.

NOTICE Refers to a danger which, if ignored, may lead to

risk to the machine and its function.

Warning sign Type of danger

Danger to life from chlorine poisoning

General danger zone

Danger of damage to machine or functional

influences

Warning

sign SIGNAL WORD

Description of danger.

Consequences if ignored.

The arrow signals a safety precaution to be taken to eliminate

the danger.

Safety

General warnings 5

Subject to technical changes.

160426

Vacuum Regulator for Chlorine Gas C 2700-V Operating Instructions

BA-21210-02-V05

2 Safety

2.1 General warnings

The following warnings are intended to help you to eliminate the

dangers that can arise while handling the device. Risk prevention meas-

ures always apply regardless of any specific action.

Safety instructions warning against risks arising from specific activities

or situations can be found in the respective sub-chapters.

2.2 Information about chlorine

Chlorine is a hazardous substance. The chemical element chlorine is a

greenish-yellow, toxic gas with a pungent odour, which can be detected

in the air at concentrations below 1 ppm (= 1 ml/m³).

Chlorine is 2.5 times heavier than air and accumulates at ground level.

Chlorine is extremely 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 gas content of 0.5 – 1% leads to a quick death in

mammals and humans as it attacks the respiratory tract and the pulmo-

nary alveolus (formation of hydrogen chloride or hydrochloride acid).

DANGER

Danger to life from chlorine poisoning!

Chlorine is poisonous. In severe cases, breathing in chlorine may

lead to death. It irritates the eyes, the respiratory system and the

skin.

Use sufficient personal protective equipment.

When carrying out any work on the system, use a respirator

mask with a Type B gas filter that complies with EN 14387.

Always comply with the accident prevention regulations that

apply at the place of use.

Get rid of leaks without delay. You must get rid of even very

minor leaks without delay. Together with the humidity, chlorine

forms hydrochloric acid and corrosion rapidly results in

increased leakage.

Only use chlorine-resistant seals.

Only use seals once. Reusing them leads to leaks.

DANGER

Danger to life from chlorine poisoning!

If chlorine gas escapes, a filter mask is ineffective, since it is not a

self-contained breathing apparatus.

If chlorine gas escapes, wear type 2 self-contained breathing

apparatus that complies with EN 137.

DANGER

Danger to life from chlorine poisoning!

Chlorinators without gas warning devices represent an increased

safety risk since escaping chlorine gas can either not be detected

at all or not in good time.

Install a gas warning device.

WARNING

Increased risk of accidents due to insufficient qualifica-

tion of personnel!

Chlorinators and their accessories must only be installed, operated

and maintained by personnel with sufficient qualifications. Insuffi-

cient qualification will increase the risk of accidents.

Ensure that all action is taken only by personnel with sufficient

and corresponding qualifications.

Prevent access to the system for unauthorised persons.

NOTICE

Damage to the system due to the formation of hydro-

chloric acid

Chlorine gas is highly hygroscopic. This means that humidity enters

the system at any open connection on devices or pipes, which

results in the formation of hydrochloric acid and contamination.

Damage to the devices is then inevitable.

Keep all the connections (in the vacuum system too) closed at all

times.

NOTICE

Faults due to insufficient chlorine quality

Impurities in the chlorine gas result in build-ups in devices and

valves and can chemically attack the components. This can cause

malfunctions.

Only use technically pure chlorine which satisfies the following

requirements:

- Chlorine mass content of at least 99.5%

- Max. chlorine water content of 20 mg/kg

Chlorine as per EN 937 satisfies these requirements.

Safety

Hazards due to non-compliance with the safety instructions

Vacuum Regulator for Chlorine Gas C 2700-V

Operating Instructions

BA-21210-02-V05

2.3 Hazards due to non-compliance with the safety

instructions

Failure to follow the safety instructions may endanger not only persons,

but also the environment and the device.

The specific consequences can be:

failure of major device and corresponding system functions,

failure of required maintenance and repair methods,

danger to persons,

danger to the environment caused by substances leaking from the

system.

2.4 Working in a safety-conscious manner

Besides the safety instructions specified in this operating manual,

further safety rules apply and must be followed:

accident prevention regulations

safety and operating provisions,

safety regulations on handling hazardous substances,

environmental protection provisions,

applicable standards and legislation.

2.5 Personal protective equipment

Depending on the type of work being performed, appropriate protective

equipment must be worn. Read the Accident Prevention Regulations and

the Safety Data Sheets on the dosing media to find out what protective

equipment is required.

As a minimum, the following protective equipment is recommended:

Mask Protective clothing Gloves Safety footwear

Corresponding protective equipment must be used during these tasks:

commissioning,

all work on gas-bearing sections of the system

changing the chlorine gas containers,

shutdown,

maintenance work,

disposal.

2.6 Personnel qualification

Any personnel who work with the device must have appropriate special

knowledge and skills.

Anybody who works with the device must meet the conditions below:

attendance at all the training courses offered by the owner,

personal suitability for the respective activity,

sufficient qualification for the respective activity,

training on the handling of the device.

knowledge of safety equipment and the way this equipment func-

tions,

knowledge of this operating manual, particularly of safety instruc-

tions and sections relevant for the activity,

knowledge of fundamental regulations regarding health and safety

and accident prevention.

All persons must generally have the following minimum qualification:

training as specialists to carry out work on the device unsupervised,

sufficient training that they can work on the device under the super-

vision and guidance of a trained specialist.

This operating manual distinguishes between these user groups:

2.6.1 Specialist staff

Specialist staff are able, thanks to their professional training, knowledge

and experience as well as knowledge of the respective provisions, to do

the job allocated to them and recognise and/or eliminate any possible

dangers by themselves.

2.6.2 Trained persons

Trained persons have been trained by the operator on the tasks they are

supposed to perform and on the dangers stemming from improper

behaviour.

Trained persons have attended all trainings offered by the operator.

2.6.3 Personnel tasks

In the table below you can check what qualifications are the pre-condi-

tion for the respective tasks. Only people with appropriate qualifications

are allowed to perform these tasks.

Qualification Activities

Specialist staff Assembly

Commissioning

Taking out of operation

Maintenance

Repairs

Disposal

Fault rectification

Trained persons Storage

Transportation

Operation

Intended Use

Notes on product warranty 7

Subject to technical changes.

160426

Vacuum Regulator for Chlorine Gas C 2700-V Operating Instructions

BA-21210-02-V05

3 Intended Use

3.1 Notes on product warranty

Any non-designated use of the device can compromise its function or

intended protection. This leads to invalidation of any warranty claims!

Please note that liability passes to the user in the following cases:

The device is operated in a manner which is not consistent with this

operating manual, particularly the safety instructions, handling

instructions and chapter Intended Use.

Information on the usage and ambient conditions (see "Technical

data" on page 10) is not observed.

If people operate the device who are not adequately qualified to

carry out their respective activities.

No original spare parts or accessories of Lutz-Jesco GmbH are used.

Unauthorised changes are made to the device.

The user uses different dosing media than those indicated in the

order.

Maintenance and inspection intervals are either not adhered to at all

or not as prescribed.

The device is commissioned before it or the corresponding system

has been correctly and completely installed.

Safety equipment has been bridged, removed or made inoperative in

any other way.

3.2 Intended purpose

The vacuum regulator is designated exclusively for chlorinators based

on the vacuum procedure. The vacuum regulator is only supplied with

gaseous chlorine. It reduces the existing underpressure from the chlo-

rine gas supply to a lower pressure than the atmospheric air pressure.

Only technically pure chlorine with a mass chlorine content of at least

99.5% may be used.

3.3 Device revision

This operating manual applies to the following devices:

The date of production is stated on the rating plate.

3.4 Prohibited dosing media

The device must not be used for the following media and substances:

Any gases except chlorine gas,

Liquid chlorine

Chlorine of insufficient quality.

Device Month / year of manufacture

Vacuum Regulator for Chlorine Gas

C 2700-V

07/2007 onwards

Product description

Scope of delivery

Vacuum Regulator for Chlorine Gas C 2700-V

Operating Instructions

BA-21210-02-V05

4 Product description

4.1 Scope of delivery

Carefully check the delivery prior to installation and refer to the delivery

note to ensure the delivery is complete and to check for any transport

damage. Contact the supplier and/or carrier regarding any questions

concerning the delivery and/or transport damage. Do not operate defec-

tive devices.

The device is assembled ready-to-install. All the openings are closed by

transportation locks.

The scope of delivery includes:

Vacuum regulator with inlet valve and integrated safety valve.

Pressure gauge (optional)

Flange connection on chlorine gas input including screws and seal

(optional)

5-m tube with mounting material as blow-off line

Ammonia solution for leakage test

Operating manual

4.2 Design and function

4.2.1 Design of a vacuum chlorinator

Fig. 4-1: Design of a vacuum chlorinator

The chlorine gas is under overpressure when it comes from the chlorine

barrels. The vacuum regulator (1) only allows the chlorine to flow if

there is a suctioning vacuum at the device’s output. Therefore, if a line

behind the vacuum regulator breaks, there is no need to fear a chlorine

leak.

The dosing device comprises a flow meter (2) with manual control

valve, and also often an electrically actuated control valve (3) and a

pressure regulator (4).

The injector (6) creates the vacuum based on the Venturi effect and

mixes the chlorine gas in the motive water flow. If the water does not

move, chlorination is stopped immediately. Then the non-return valve

(5) prevents water from penetrating into the dosing devices.

4.2.2 Structure of the device

Fig. 4-2: Structure of the device

Item Description

1 Input

2 Pressure gauge (optional)

3 Safety valve output

4Plug

5 Output

Product description

Design and function 9

Subject to technical changes.

160426

Vacuum Regulator for Chlorine Gas C 2700-V Operating Instructions

BA-21210-02-V05

4.2.3 Function description

Fig. 4-3: Vacuum Regulator for Chlorine Gas C 2700-V - cross-sectional view

Pressurised chlorine gas flows from the chlorine barrel to the vacuum

regulator. The vacuum regulator comprises the inlet valve (1) and the

membrane chamber (3). In the inlet valve the chlorine gas is under

overpressure, in the membrane chamber there is a vacuum.

The PVC output of the vacuum regulator is connected to the injector. A

sufficient vacuum draws the diaphragm disc (4) upwards and pushes

the valve cone (2) downward against the spring force. The inlet valve (1)

opens and the amount of chlorine required flows into the membrane

chamber (3). If the vacuum is not sufficient, the spring closes the

system again. This results in a constant vacuum in the piping down-

stream of the vacuum regulator.

A constant vacuum ensures maximum system safety: In the event of a

leak, ambient air is drawn into the tube without enabling a dangerous

amount of chlorine gas to escape into the atmosphere.

If the valve cone (2) does not close properly due to heavy soiling, slight

overpressure builds up in the membrane chamber (3). In the event of

such faults, the safety valve (5) in the diaphragm disc opens and vents

the system vents to a neutralisation system, e.g., a chlorine eliminator

or an activated carbon cartridge.

Atmosphere

Chlorine (vacuum)

Chlorine (overpressure)

Product description

Rating plate

Vacuum Regulator for Chlorine Gas C 2700-V

Operating Instructions

BA-21210-02-V05

4.3 Rating plate

The rating plate contains information on the safety and functional

method of the product. The rating plate must be kept legible for the

duration of the service life of the product.

Fig. 4-4: Rating plate

4.4 Technical data

Item Meaning

1 Product designation

2 Part number

3 Serial number

4 Materials

5 Month of manufacture

6 Year of manufacture

Description Value

Throughput up to 200 kg/hr

Inlet pressure 1.5 – 16 bar

Operating vacuum -50 mbar

Response pressure of the safety valve 500 mbar

Pressure gauge (optional) 0 – 16 bar / Ø 63 mm

Materials Inlet valve Brass (chemically nickel-

plated), Monel, Hastelloy

Vacuum housing PVC

Seals FPM, PTFE

Weight with flange and pressure

gauge

approx. 8 kg

Ambient temperature 10 – 50°C

(no direct sunlight)

Lutz-Jesco GmbH 30900 Wedemark

Am Bostelberge 19 Germany

Chlorine Gas Vacuum Regulator C 2700-V

12/2008

P/N: 1234567890

S/N: 102A12345 Made in Germany

*102A12345678*

Material: PVC/FPM/Monel/Ms58

4 5 6

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