Grundfos Selcoperm SES-10000, Selcoperm SES-20000, Selcoperm SES-5000, Selcoperm SES-15000, Selcoperm SES-7500 Installation And Operating Instructions Manual
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Selcoperm SES
Electrolysis system for 5-45 kg/h Cl2 (equivalent)
Installation and operating instructions
GRUNDFOS INSTRUCTIONS
Other languages
http://net.grundfos.com/qr/i/98647157
English (GB) Installation and operating instructions
English (GB)
Original installation and operating instructions
CONTENTS
1. General information
1.1 Documentation package
1.2 Scope of this document
1.3 Target group
1.3.1 Qualification and training
1.3.2 Obligations of the operating company
1.3.3 Obligations of the certified service persons
1.3.4 Obligations of the user
1.4 Symbols used in this document
1.5 Symbols on the product
1.6 Abbreviations
2. Safety instructions
2.1 Working with chemicals
2.1.1 Personal protective equipment
2.1.2 Sodium hypochlorite solution
2.1.3 Hydrogen gas
2.1.4 Hydrochloric acid
2.1.5 Brine
2.2 Electrical hazards
3. Storage and handling
3.1 Storage
3.2 Transport
3.3 Scope of delivery
3.4 Unpacking
4. Product description
4.1 Selcoperm electrolysis system (SES)
4.1.1 Intended use
4.1.2 Improper use
4.1.3 Safety and monitoring equipment
4.1.4 Overview of components
4.1.5 Safety concept
4.1.6 Piping and Instrumentation Diagram (PID)
4.1.7 Process description
4.2 Selcoperm electrolyser
4.2.1 Identification
4.2.2 Warranty
4.2.3 Overview of components
4.2.4 Overview hydraulics SES-5000 to SES-15000
4.2.5 Overview hydraulics SES-20000 to SES-45000
4.2.6 Signal diagram
4.3 Rectifier
4.4 DC cable set
4.5 Degassing and storage tank
4.5.1 Installation set
4.5.2 Components
4.6 Brine dosing station
4.6.1 Components
4.7 Water softener
4.8 Chiller
4.9 Heater
4.10 Brine tank
4.11 Acid cleaning station
4.11.1 Components
4.12 Gas warning system
5. Technical data
5.1 Selcoperm Electrolysis System (SES)
5.1.1 Water quality specification
5.1.2 Salt specification
5.1.3 Ambient conditions
5.2 Selcoperm electrolyser
5.2.1 General data
5.2.2 Built-in control cabinet
5.2.3 Connections
5.2.4 Setpoints
5.2.5 Approvals
5.2.6 Materials
5.2.7 Dimensions SES-5000 to SES-15000
5.2.8 Dimensions SES-20000 to SES-45000
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5.2.9 Space requirements
5.3 Rectifier
5.3.1 Technical data for air-cooled rectifier
5.3.2 Technical data for water-cooled rectifier
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5.4 DC cable set
5.5 Degassing and storage tank
5.5.1 Connections
5.6 Brine dosing station
5.7 Water softener
5.8 Chiller
5.9 Heater
5.10 Brine tank
5.11 Acid cleaning station
5.12 Gas warning system
6. Installation
6.1 Installation drawing
6.2 Installation requirements
6.2.1 Installation location
6.2.2 Foundation and space requirement
6.2.3 Water supply
6.2.4 Connective pipework
6.2.5 Selcoperm electrolyser
6.2.6 Rectifier
6.2.7 Brine dosing station
6.2.8 Water softener
6.2.9 Brine tank
6.2.10 Building ventilation
6.2.11 Drain
6.2.12 Gas warning system
6.2.13 Degassing and storage tank
6.2.14 Connection of venturi nozzle (VN) and flow sensor
(4.13)
6.3 Dismantling and reassembling the Selcoperm
electrolyser housing
6.4 Electrical connection
6.4.1 Electrical connection of the Selcoperm control cabinet
6.4.2 Electrical connection of the brine dosing station
6.4.3 Electrical connection of the degassing and storage
tank
6.4.4 Electrical connection of degassing fans (EF4.01,
EF4.02)
6.4.5 Electrical connection of rectifier (REC)
6.4.6 Earthing
7. Commissioning
7.1 Checks before commissioning
7.1.1 Water softener
7.1.2 Brine tank
7.1.3 Degassing and storage tank
7.1.4 Preparing the brine dosing station (BDS)
7.1.5 Checking the system configuration
7.2 Starting up the system initially
7.2.1 Adjusting the manual valves
7.2.2 Adjusting the total flow rate
7.2.3 Adjusting the brine dosing pumps
7.2.4 Checking and adjusting the soft water flow and the
salinity of the electrolyte
7.2.5 Checking and adjusting cell outlet level switches (1.09,
2.09, 3.09)
7.2.6 Checking and adjusting NaClO level switch (4.04)
7.3 Switching to operation mode "Automatic"
7.4 Checking the alarms
7.4.1 Degassing and storage tank
7.4.2 Selcoperm electrolyser
8. Operation
8.1 Work procedures
8.2 Control elements
8.2.1 Emergency stop
8.2.2 Main switch of Selcoperm electrolyser
8.3 Operation mode "Automatic"
8.3.1 Control modes
8.3.2 Operating states
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8.4 Operation mode "Service"
8.5 Touchscreen
8.5.1 Login to the system
8.5.2 Keyboard
8.5.3 Colours
8.5.4 Acknowledge fault messages
8.5.5 Menu structure
8.5.6 System overview
8.5.7 Overview cell lines
8.5.8 Detail single cell
8.5.9 Detail double cells
8.5.10 Settings cell line
8.5.11 Settings system
8.5.12 Overview rectifier
8.5.13 Settings rectifier
8.5.14 Overview brine pumps
8.5.15 Overview tank
8.5.16 Settings tank level
8.5.17 Overview fans
8.5.18 System menu
8.5.19 Language
8.5.20 Time / Date setting
8.5.21 User administration
8.5.22 Service menu
8.5.23 Service I/O Values
8.5.24 Service Power Supply
8.5.25 Service Cell Lines
8.5.26 Service Tank
8.5.27 Service Acid Cleaning
8.5.28 Message management
8.5.29 System configuration
8.5.30 Configuration of system capacity
8.5.31 Configuration of tank volume
8.5.32 Configuration of interface
8.5.33 Settings alarm delays
8.5.34 Settings delay-/flushing times
8.5.35 Start and stop delays
8.5.36 Settings Operating hours Counter plant
8.5.37 Settings Operating hours Counter lines
9. Maintenance
9.1 Safety instructions
9.2 Special tools
9.2.1 Test kit
9.3 Basic maintenance schedule (users)
9.3.1 Cleaning the system
9.3.2 Checking the water hardness of the softened water
9.3.3 Checking the NaClO solution
9.3.4 Checking the salinity of the electrolyte
9.4 Advanced maintenance schedule (certified service
persons)
9.4.1 Checking the system for hydrogen gas leakages
9.4.2 Retightening the DC connections
9.4.3 Replacing the gaskets in the electrolysis cells and in
the NaClO solution line
9.4.4 Dismantling and reassembling level switches (1.09,
2.09, 3.09)
9.4.5 Dismantling and reassembling level switch (4.04)
9.5 Acid cleaning
9.5.1 Interval for acid cleaning
9.5.2 Performing the acid cleaning
10. Decommissioning
10.1 Short-term decommissioning up to 4 weeks
10.1.1 Recommissioning
10.2 Decommissioning up to 6 months
10.2.1 Recommissioning
10.3 Decommissioning for more than 6 months
10.3.1 Recommissioning
10.4 Flushing the system with softened water
10.5 Draining the system
10.6 Flushing the brine dosing station
11. Fault finding
12. Spare parts
12.1 Selcoperm electrolyser
12.1.1 Hydraulic spare parts
12.1.2 Electrolysis cells, DC connection and sensors
12.1.3 O-ring sets
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12.1.4 Control cabinet
12.2 T-piece
12.3 Rectifier
12.4 Degassing and storage tank and exhaust air line
12.5 Acid cleaning station
12.6 Brine dosing station
12.7 Brine tank
12.8 Water softener
13. Disposal
Prior to installation, read this document. Installation
and operation must comply with local regulations and
accepted codes of good practice.
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1. General information
1.1 Documentation package
The documentation delivered with the Selcoperm electrolysis
system comprises:
• Installation and operating instructions for Selcoperm
• Separate supplier manuals for built-in components
• Wiring diagrams (in control cabinets).
The complete documentation package must be available at the
installation location at all times.
1.2 Scope of this document
The Selcoperm electrolysis system comprises a number of
components. The core components must be purchased from
Grundfos to ensure the compliance with the Selcoperm safety
concept. These core components are:
• Selcoperm electrolyser
• Rectifier
• Brine dosing station
• Degassing and storage tank with a special installation set
including the degassing fan
• Acid cleaning station.
The Selcoperm safety concept requires a gas warning system for
hydrogen, which must meet specific requirements.
Further components required for the system are:
• Water softener
• Brine tank.
In addition, a chiller or heater can be required to achieve the
specified water inlet temperature. All mentioned components can
be purchased from Grundfos. For details see section
4.1.4 Overview of components.
This document contains detailed information on the core
components and their installation, and on general requirements
for additional components and their installation. The requirements
for components and their installation described in this document
must be adhered to, no matter if the components were purchased
from Grundfos or not. The documentation package delivered with
the Selcoperm system contains additional documents for
components, which must be observed.
English (GB)
3
1.3 Target group
English (GB)
1.3.1 Qualification and training
The persons responsible for installation, startup, operation and
maintenance must be appropriately qualified for these tasks.
Areas of responsibility, levels of authority and the supervision of
the persons must be precisely defined by the operating company.
If necessary, the persons must be trained.
Operating company
The company or person who owns the system is referred to as
"operating company" in this document. The operating company
has to coordinate the installation of the system in agreement with
Grundfos. After installation, commissioning must be done by
certified service persons.
Certified service persons
The persons responsible for commissioning, parametrisation and
advanced maintenance of the system are referred to as "certified
service persons" in this document. These persons must be
trained and certified for these tasks by Grundfos.
Users
The persons responsible for operation and basic maintenance of
the system are referred to as "users" in this document. The users
must be trained for their tasks by certified service persons.
1.3.2 Obligations of the operating company
• Observe the local safety regulations.
• Make sure that the regulations for the prevention of accidents
are observed at the installation location.
• Keep the documentation package available at the installation
location at all times.
• Prepare the installation location according to the installation
requirements specified in this document. See section
6. Installation.
• Obtain official approval for storing chemicals, if necessary.
• Make sure that the users are trained before operating the
system.
• Provide the stipulated safety equipment and personal
protective equipment.
• Make sure that the labels supplied by the manufacturer with
the system are displayed visibly at the installation location.
• Provide the passwords for the operating software only to the
persons who have received an appropriate technical training.
• Arrange regular maintenance.
1.3.3 Obligations of the certified service persons
• Read this manual thoroughly before putting the system into
operation.
• Observe the recognised health and safety regulations as well
as the accident prevention regulations.
• Wear protective equipment in accordance with national health
and safety regulations when working on the system and
handling chemicals.
• Meet the installation requirements specified in this document.
See section 6. Installation.
• Perform installation and commissioning in accordance with the
knowledge and documents received during the training at
Grundfos.
• Train the users in performing the user relevant maintenance
tasks mentioned in this document.
• Parametrise the system according to on-site requirements
during commissioning.
1.3.4 Obligations of the user
• Read this manual thoroughly before putting the Selcoperm
system into operation.
• Read all documents delivered in the documentation package
thoroughly before installation, operation, commissioning,
maintenance, service or storage of the Selcoperm system.
• Obtain instructions from Grundfos specialists on all service
work relating to the system.
• Observe the recognised regulations for health, safety and
accident prevention.
• Wear protective equipment in accordance with the national
health and safety regulations when working on the system and
handling chemicals.
• Keep secret the passwords for the operating software.
1.4 Symbols used in this document
DANGER
Indicates a hazardous situation which, if not avoided,
will result in death or serious personal injury.
WARNING
Indicates a hazardous situation which, if not avoided,
could result in death or serious personal injury.
CAUTION
Indicates a hazardous situation which, if not avoided,
could result in minor or moderate personal injury.
The text accompanying the three hazard symbols DANGER,
WARNING and CAUTION is structured in the following way:
SIGNAL WORD
Description of hazard
Consequence of ignoring the warning.
- Action to avoid the hazard.
A blue or grey circle with a white graphical symbol
indicates that an action must be taken.
A red or grey circle with a diagonal bar, possibly with
a black graphical symbol, indicates that an action
must not be taken or must be stopped.
If these instructions are not observed, it may result in
malfunction or damage to the equipment.
Tips and advice that make the work easier.
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1.5 Symbols on the product
This symbol indicates a danger of electric shock.
This symbol indicates a potentially explosive
atmosphere (ATEX zone).
This symbol indicates explosion-proof products.
All signs and symbols on the product must be observed and
maintained legible.
Observe also the manuals for built-in components.
1.6 Abbreviations
Abbrevi
ation
LEL
NaClO
PLC
Text Description
The lowest concentration
Lower
Explosive Limit
Sodium
hypochlorite
Programmable
Logic
Controller
(percentage) of a gas in air capable
of producing a flash of fire in
presence of an ignition source.
The disinfectant produced by the
Selcoperm system is a sodium
hypochlorite solution.
A PLC is a digital computer used for
automation of typical industrial
electromechanical processes.
2. Safety instructions
Non-observance of the safety instructions may have dangerous
consequences for persons, the environment and the product.
2.1 Working with chemicals
WARNING
Chemical hazard
Death or serious personal injury
- Wear the stipulated personal protective equipment
(protective clothing, goggles, respirator etc.) when
handling chemicals.
- Observe the chemical manufacturer's safety data
sheets (MSDS) and safety instructions of the used
chemicals.
Make sure, that parts in contact with the chemicals
are resistant to the chemicals under operating
conditions.
If you have questions regarding the material
resistance, please contact Grundfos.
Make sure, that leaking chemicals do not cause
personal injury or damage to property.
The installation of leak monitoring equipment and
drip trays is recommended.
2.1.1 Personal protective equipment
Due to the variety of hazardous chemicals, any information
provided in this section is only general. We recommend to follow
good practice when handling chemicals, to use personal
protective equipment such as ventilated, enclosed goggles, face
shields, chemical aprons, boots and gloves, and to install an eye
shower.
2.1.2 Sodium hypochlorite solution
The concentration of the sodium hypochlorite (NaClO) solution
produced by the Selcoperm electrolysis system is below 1 %.
CAUTION
Corrosive substance
Minor or moderate personal injury
- Sodium hypochlorite is alkaline and causes
oxidisation and bleaching. It is corrosive and can
cause damage to skin or clothing.
- Always wear protective clothing and goggles when
handling chemicals.
• If splashed onto skin, wash off with fresh water. Remove all
affected clothing.
• If the eyes are affected, rinse them immediately using an
approved eye shower or fresh running water for at least 15
minutes, keeping the eyelid open and rotating the eye. Seek
medical treatment immediately.
• If swallowed, do not induce vomiting. Keep the patient warm
and quiet and seek immediate medical help. If the patient
stops breathing, apply rescue breaths and cardiopulmonary
resuscitation as necessary, until medical help arrives.
Warning notices advising users of the possible dangers should be
prominently displayed wherever sodium hypochlorite is stored,
generated or handled.
WARNING
Chemical hazard
Death or serious personal injury
If acid is mixed with sodium hypochlorite solution,
highly hazardous chlorine gas is released.
- Keep acid away from the sodium hypochlorite
solution and the degassing and storage tank.
- Display a warning notice locally.
2.1.3 Hydrogen gas
The electrolytic process of converting brine into sodium
hypochlorite (NaClO) solution generates hydrogen gas, which is
diluted and lead to a safe external discharge point by means of
forced ventilation. The degassing and storage tank as well as all
vent piping should be regularly checked to ensure that no gas
leakages occur.
WARNING
Danger of explosion
Death or serious personal injury
- When checking the system for gas leakages, use
hydrogen detectors. Do not use a match or a
flame.
Hydrogen is an explosive gas and lighter than air. When liberated
in a room, hydrogen accumulates beneath the ceiling. Ensure
natural ventilation at a high and a low level in the room where the
electrolyser is installed.
A sign that prohibits smoking and naked flames must be
displayed in the room and at the point of discharge to the exterior.
A gas warning system for hydrogen must be installed at the
installation location to stop the Selcoperm electrolysis system in
case of a build-up of hydrogen gas. This avoids the situation of a
user working in a potentially explosive environment.
English (GB)
5
2.1.4 Hydrochloric acid
SES-5000, -7500, -10000, 15000:
SES-20000, -30000, -45000:
English (GB)
Hydrochloric acid is used to remove deposits from the electrodes
(acid cleaning).
WARNING
Chemical hazard
Death or serious personal injury
- Wear the stipulated personal protective equipment
(protective clothing, goggles, respirator etc.) when
handling chemicals.
- Observe the chemical manufacturer's safety data
sheets (MSDS) and safety instructions of the used
chemicals.
• If splashed onto skin, wash off with fresh water. Remove all
affected clothing.
• If the eyes are affected, rinse them immediately using an
approved eye shower or fresh running water for at least 15
minutes, keeping the eyelid open and rotating the eye. Seek
medical treatment immediately.
• If swallowed, do not induce vomiting. Keep the patient warm
and quiet and seek immediate medical help. If the patient
stops breathing, apply rescue breaths and cardiopulmonary
resuscitation as necessary, until medical help arrives.
WARNING
Chemical hazard
Death or serious personal injury
If acid is mixed with sodium hypochlorite solution,
highly hazardous chlorine gas is released.
- Keep acid away from the sodium hypochlorite
solution and the degassing and storage tank.
- Display a warning notice locally.
Acid cleaning has to be performed strictly in accordance with the
instructions in this manual. See section 9.5 Acid cleaning.
2.1.5 Brine
Avoid contact with eyes. If the eyes are affected by brine
splashes, rinse them immediately with fresh running water.
3. Storage and handling
Observe the supplier documents for the components.
All supplier documents are part of the documentation
package delivered with the system.
3.1 Storage
• Observe the permissible ambient conditions. See section
5.1.3 Ambient conditions.
• The storage location must be protected from rain, humidity,
condensation, direct sunlight and dust.
• The system must be drained completely. Observe the special
requirements for the system components specified in the
supplier documents.
• Maximum storage time: 2 years from delivery.
3.2 Transport
• Wear the stipulated personal protective equipment.
• Observe the permissible ambient conditions. See section
5.1.3 Ambient conditions.
• The system must be drained completely.
• Use appropriate lifting and transporting devices.
• Make sure the freight does not sustain any point load during
transport.
• Avoid strong impact loads.
• Before lifting check the centre of gravity of the freight.
– Selcoperm electrolyser:
2.2 Electrical hazards
DANGER
Electric shock
Death or serious personal injury
- Before carrying out maintenance or repair work on
the system make sure that the system has been
satisfactorily isolated.
TM06 2240 3916
Fig. 1 Centre of gravity - top view
• If using forklifts, use forks that are long enough to cover the
entire depth of the freight.
3.3 Scope of delivery
The system is shipped in several packages:
• Selcoperm electrolyser
• Rectifier
• DC cable set
• Degassing and storage tank (if ordered) and installation set
(mandatory)
• Brine dosing station
• Accessories as ordered.
3.4 Unpacking
• Mount as soon as possible after unpacking.
• Observe the permissible ambient conditions. See section
5.1.3 Ambient conditions.
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4. Product description
4.1 Selcoperm electrolysis system (SES)
4.1.1 Intended use
The Selcoperm electrolysis system is a modular system for the
safe production of a 0.8 % sodium hypochlorite solution from a
diluted brine solution. The system is suitable for the disinfection
of drinking water and industrial process water. The intended use
of the Selcoperm system comprises the stationary operation
either in continuous or batch processing.
Typical disinfection applications for Selcoperm systems are:
• drinking water treatment,
• water treatment for industrial processes and cooling towers.
4.1.2 Improper use
Applications other than those described in section 4.1.1 Intended
use are not in accordance with the intended use and are not
permitted. The manufacturer, Grundfos, accepts no liability for
any damage resulting from incorrect use.
Unauthorised structural modifications to the system
may result in serious personal injury and damage to
equipment.
It is forbidden to dismantle, modify, change the
structure of, bridge, remove, bypass or disable
components, including safety equipment.
• The system must not be used if it is damaged.
• The system must not be used after improper repair.
• The system must not be used after unauthorised modification.
• The system must not be used in potentially explosive areas.
4.1.3 Safety and monitoring equipment
The Selcoperm electrolysis system is fitted with the following
safety and monitoring equipment:
• Emergency stop on the electrolyser control cabinet. Further
emergency stops can be installed on components or in the
room, if necessary.
• Leakage detection
• Transparent cover on electrolysis chamber
• Flow sensors, level sensor and temperature sensors
• Signal connection for gas warning system (H
• Ventilation system with flow sensor for safe hydrogen removal.
)
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4.1.4 Overview of components
E
C
H
I
1
1
2
3
4
5
G
D
F
K
I
A
B
ATEX zone 2
radius 1-2 m
English (GB)
Fig. 2 Installation scheme of a Selcoperm electrolysis system
TM06 4665 2316
Pos. Component Description
A Water softener The water softener provides the softened mains water required for the electrolysis.
Chiller and/or
B
heater
An optional chiller or heater can be used to provide the correct mains water temperature.
C Brine tank The brine tank is used for preparation and storage of brine.
Brine dosing
D
station
The brine dosing station doses the required amount of brine into the process.
The Selcoperm electrolyser comprises:
• Electrolysis cells
• Hydraulic chamber
• Control cabinet
E
Selcoperm
electrolyser
• 7" multi-colour touchscreen for operating and monitoring the whole electrolysis system.
F Rectifier
Degassing and
storage tank
with sensors
G
and degassing
fan
Gas warning
H
system
Building
I
ventilation
K DC cable set Insulated flexible copper cable for direct current connection between the Selcoperm electroyser and the rectifier.
1 Soft water line
The rectifier converts the alternating current (AC) from the power supply into the direct current (DC) needed to
run the Selcoperm electrolyser.
In the degassing and storage tank the hydrogen gas is removed from the sodium hypochlorite solution. The
degassing and storage tank must be installed as close as possible to the Selcoperm electrolyser. The level in the
tank is monitored by a level sensor. The degassing fan ensures a safe dilution and removal of hydrogen gas. The
sodium hypochlorite solution can be dosed directly from the tank to the point of application. It is also possible to
pump the sodium hypochlorite solution from the tank into separate storage tanks.
The gas warning system monitors the concentration of hydrogen gas at the installation location permanently.
Natural ventilation via ventilation holes or technical ventilation is required at the installation location. Legal
requirements and local standards must be observed.
2 Brine line
Sodium
3
hypochlorite
solution line
4 Exhaust air line
Besides the sodium hypochlorite solution this line contains hydrogen gas, which is removed in the downstream
degassing and storage tank.
Through this line the dilution air (99 %) and the hydrogen gas (1 %) are removed from the degassing and storage
tank by means of forced ventilation. The exhaust air line has to be directed with a constant upwards incline to a
safe discharge point outside the building.
5 Sodium hypochlorite solution line to the point of application
- Drain A drain for maintenance is required on site.
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4.1.5 Safety concept
This section refers to fig. 2.
A reliable safety concept for the operation of the whole system is
mandatory, because hydrogen is produced as a by-product in the
electrolysis cells.
Before even entering the degassing and storage tank (G), most of
the hydrogen is diluted by the degassing fan to 25 % of the lower
explosive limit (LEL) and led away into the atmosphere. In the
tank, the residual hydrogen is released, diluted and led away into
the atmosphere.
The whole Selcoperm electrolysis system is monitored
permanently and redundantly. Several sensors at the system,
together with hydrogen sensors at the installation location ensure
a safety shutdown of the whole system in the event of a failure.
Small amounts of hydrogen, which can escape due to a leakage,
are led away via the ventilation hole (I) at the highest point of the
room.
The safety concept is evaluated with technical report by a
third-party expert from TÜV SÜD Product Service GmbH. It
ensures safe operation without any additional explosion
protection at the installation location.
Hydrogen (H
) characteristics
2
Parameter Value Note
Vapour density under
standard conditions
0.0899 kg/m
3
(0 °C, 1013 mbar)
Relative vapour density
(air = 1)
Lower explosive limit
Upper explosive limit
0.0695
4.0 % by
volume in air
77 % by
volume in air
Significantly lighter
than air
4.65 % by volume in
oxygen
93.9 % by volume in
oxygen
Ignition temperature 560 °C
Temperature class T1
Explosion group IIC
Max. H
in electrolysis process
generation rate
2
3
0.6 m
/kg chlorine equivalent
Conformity with ATEX directive
The ATEX directive covers devices that can be used in a
potentially explosive atmosphere and/or may contain a potentially
explosive atmosphere. However, the ATEX directive is only
applicable, if the device has a potential source of ignition in its
internal zoned area.
The Selcoperm system has internal zoned areas, but the ignition
sources inside the system have been eliminated by design. The
Selcoperm system is not intended for operation in a potentially
explosive atmosphere. Therefore, the Selcoperm system is not
subject to the ATEX directive and must not be ATEX marked. A
declaration of conformity in accordance with the directive is not
applicable.
The following guidelines and standards have been applied:
• Machinery Directive 2006/42/EC
• EN ISO 12100 for the risk analysis
• DIN EN 1127-1 and DIN EN 13463-1 for the identification of
explosion hazards and ignition sources
• (EX-RL) BGR 104, TRBS2152 and DIN EN 60079-10-1 for
zoning and security measures
Furthermore, the explosion safety is ensured by several
measures.
Explosion protection by avoiding the explosive zones:
• Preventing or limiting inside the unit
– Redundant level sensors to ensure liquid filled parts
• Preventing or limiting to the facility
– All connections are designed as permanently technically
sealed according to DIN EN 1127-1:2011 Appendix B and
TRBS 2152 Part2 2.4.3
– Design with flange, glue or weld connection
– Organisational measures by 100 % FAT leakage test,
leakage sensors and permanently monitoring of H
by H
sensors and safe shutdown
2
leakage
2
• Reduction of the zones through ventilation
– Exhaust gas is diluted with air down to 1 % by volume.
Correct air flow is monitored redundantly and leads to safe
shutdown in case of failure.
Dilution air to
2
reach less than 1
% by volume H
(25 % of LEL)
2
SES type
Capacity level
equivalent)
(Cl
2
[g/h] [m
Max. H
generation
rate
3
/h] [m3/h]
SES-5000 5000 3.0 300
SES-7500 7500 4.5 450
SES-10000 10000 6.0 600
SES-15000 15000 9.0 900
SES-20000 20000 12.0 1200
SES-30000 30000 18.0 1800
SES-45000 45000 27.0 2700
Explosion Protection by avoiding ignition sources
• An ignition source analysis and earthing concept was carried
out for the system. All ignition sources inside the system were
eliminated by design. During operation, cells and piping of the
system are filled with liquid. No electrical or moving
mechanical components are implemented. Sensors that affect
an explosive area are used as ATEX sensor.
Safety Facts
• Unique safety concept, evaluated with technical report by a
third-party expert from TÜV SÜD Product Service GmbH
• Technically permanently sealed components and thus no zone
in the installation room
• Ignition sources inside the system eliminated by design
• Artificial ventilation to dilute H
by-product inside the system
2
– Redundant monitoring of the ventilation system (fan & flow)
– Pressureless system; no valves after the cells; dangerous
pressure build-up is impossible.
– High quality standard: Every Selcoperm electrolyser is
checked for 100 % performance and tightness at the factory
– Direct pipe-to-product degassing tank with level switches
(cell outlet & tank inlet) to ensure filled lines and electrode
fluid level. No gas accumulation.
– Alarm and safe automatic shutdown of the installation in
case of an error, e.g. drop of flow for dilution
– Redundant safety including a gas detection system
combined with ventilation inside the building
Acceptance test by TÜV is possible for a complete system
installed on site.
English (GB)
9
Labelling recommendations
1
2
3
English (GB)
A warning sign must be placed on the outside of the degassing
and storage tank near the manhole. The purpose of the sign is to
warn people of an explosive atmosphere, so that they can take
the necessary precautions.
We recommend that the sign is accompanied by a written notice,
e.g. "Permanently technically sealed system, during process
zone 2 inside, outside no external zones".
Fig. 3 Label for degassing and storage tank
An additional sign must be placed near the exhaust air outlet of
the building to inform people of the zone radius.
Radius of Zone 2 around exhaust air
SES type
outlet (fig. 4, pos. 1)
[m]
SES-5000
SES-7500
1.0
SES-10000
SES-15000
SES-20000
SES-30000
SES-45000
1.5
2.0
Area classification
TM06 2215 3615
Fig. 4 Area classification
Pos. Description
1 Exhaust-air outlet to atmosphere: Zone 2
2 Inside degassing and storage tank: Zone 2
3 Installation room: no Zone
TM06 2216 2316
10
4.1.6 Piping and Instrumentation Diagram (PID)
V0. 08
V0. 10
V0. 01 V0 .02
V0. 06
V0. 09
FIAHL
0.02
SV
0.05
LSA H
0.01
TIAHL
0.03
V0. 04
V0. 07
V1. 01
TIAH
1.02
TIAH
1.01
TIAH
1.03
TIAH
1.04
FIAHL
1.10
DP0.10
LSA L
1.09
DP0. 11
FSAL
0.26
LSA L
4.04
TIAHL
1.11
FSAL
0.16
E4.05
TP
VN
EF 4.01
EF 4.02
LSA H
4.03
LIS AHL
4.10
LSA HH
4.12
V1. 02
A
5.01
AAH
5.00
TIAH
2.02
TIAH
2.01
TIAH
2.03
TIAH
2.04
LSA L
2.09
TIAH
3.02
C3.2
TIAH
3.01
TIAH
3.03
TIAH
3.04
LSA L
3.09
V2. 02
V3. 02
V2. 01
FIAHL
2.10
V3. 01
FIAHL
3.10
-
+
C
C3
C2
C1
3.1
C2.2
-
+
C2.1
C1.2
-
+
C1.1
-
+
V0. 05
FISAHL
4.13
GND1
GND2GND3
B
T
A
V
X
Z
C
U
H
Y
W
D
DST H2S
CTR
REC
SES
BDS
F
L
G
J
S
E
R
QK
Fluid line
Electrical line
Electrical signal line
Interface customer (white) | Grundfos (black)
English (GB)
Fig. 5 Piping and Instrumentation Diagram (PID). Example of a system with electrolyser SES-45000
TM06 2213 3615
11
English (GB)
Pos. Description Instrument type Pos. Description
0.01 Level switch in collecting tray LSAH BDS Brine dosing station
0.02 Water inlet flow sensor FIAHL C1 Cell line 1
0.03 NaClO outlet temperature sensor TIAHL C1.1 Electrolysis cell 1
0.05 Water inlet solenoid valve SV C1.2 Electrolysis cell 2
0.16 Dosing monitor brine pump 1 FSAL C2 Cell line 2
0.26 Dosing monitor brine pump 2 FSAL C2.1 Electrolysis cell 3
1.01 Temperature sensor (DC+) TIAH C2.2 Electrolysis cell 4
1.02 Temperature sensor (DC-) TIAH C3 Cell line 3
1.03 Temperature sensor (DC+) TIAH C3.1 Electrolysis cell 5
1.04 Temperature sensor (DC-) TIAH C3.2 Electrolysis cell 6
1.09 Cell outlet level switch LSAL CTR Control cabinet of Selcoperm electrolyser
1.10 Cell inlet flow sensor FIAHL DP0.10 Brine dosing pump 1
1.11 Cell inlet temperature sensor TIAHL DP0.11 Brine dosing pump 2 (optional)
2.01 Temperature sensor (DC+) TIAH DST Degassing and storage tank assembly
2.02 Temperature sensor (DC-) TIAH E4.05 Degassing and storage tank
2.03 Temperature sensor (DC+) TIAH EF4.01 Degassing fan 1
2.04 Temperature sensor (DC-) TIAH EF4.02 Degassing fan 2 (optional)
2.09 Cell outlet level switch LSAL H2S Gas warning system
2.10 Cell inlet flow sensor FIAHL GND1 Earth connection rectifier
3.01 Temperature sensor (DC+) TIAH GND2 Earth connection Selcoperm electrolyser
3.02 Temperature sensor (DC-) TIAH GND3 Earth connection electrolyte
3.03 Temperature sensor (DC+) TIAH REC Rectifier
3.04 Temperature sensor (DC-) TIAH SES Selcoperm electrolyser
3.09 Cell outlet level switch LSAL TP T-piece
3.10 Cell inlet flow sensor FIAHL V0.01 Water inlet valve
4.03 Level switch LSAH V0.02 Pressure reducing valve
4.04 NaClO solution line level switch LSAL V0.04 Non-return valve
4.10 Degassing tank level sensor LISAHL V0.05 Static mixer
4.12 Degassing tank overflow switch LSAHH V0.06 Electrolyte sample valve
4.13 Exhaust air flow sensor FISAHL V0.07 Acid inlet and outlet valve
5.00 Gas warning system controller AAH V0.08 Drain outlet valve
5.01 Hydrogen (H
5.02 Hydrogen (H
) sensor 1 A V0.09 NaClO sample valve
2
) sensor 2 A V0.10 Brine inlet valve
2
V1.01 Cell inlet adjusting valve
V1.02 3-way ball valve
V2.01 Cell inlet adjusting valve
V2.02 3-way ball valve
V3.01 Cell inlet adjusting valve
V3.02 3-way ball valve
VN Venturi nozzle
12
Connections SES type
Pos. Description Connection type 5000 7500 10000 15000 20000 30000 45000
A Soft water inlet Union connection DN 25 DN 25 DN 25 DN 25 DN 40 DN 40 DN 40
B Brine inlet Union connection DN 20 DN 20 DN 20 DN 20 DN 25 DN 25 DN 25
C Acid cleaning inlet and outlet Union connection DN 20 DN 20 DN 20 DN 20 DN 20 DN 20 DN 20
D Tank manhole
E Tank air inlet Socket flange DN 150 DN 150 DN 150 DN 200 DN 200 DN 200 DN 300
F Tank drain Union connection DN 50 DN 50 DN 50 DN 50 DN 50
G Tank NaClO solution inlet Loose flange DN 80 DN 80 DN 80 DN 100 DN 125 DN 125 DN 125
H Tank overflow switch Loose flange DN 25
J T-piece inlet Loose flange DN 50 DN 50 DN 50 DN 65 DN 80 DN 100 DN 100
K Venturi nozzle inlet Socket flange DN 125 DN 150 DN 150 DN 200 DN 250 DN 300 DN 300
L Tank level sensor Internal thread 1/2"
Q Venturi nozzle outlet Socket flange DN 125 DN 150 DN 150 DN 200 DN 250 DN 300 DN 300
R T-piece outlet NaClO Loose flange DN 80 DN 80 DN 80 DN 100 DN 125 DN 125 DN 125
S T-piece outlet gas Loose flange DN 80 DN 80 DN 80 DN 100 DN 125 DN 125 DN 125
T Exhaust air outlet to atmosphere Ventilation grid DN 125 DN 150 DN 150 DN 200 DN 250 DN 300 DN 300
U Tank NaClO solution outlet Union connection DN 32 DN 32 DN 50 DN 50 DN 50
V NaClO solution outlet Loose flange DN 50 DN 50 DN 50 DN 65 DN 80 DN 100 DN 100
W Tank exhaust air outlet Socket flange
X NaClO sample outlet Hose connection DN 8
Y Electrolyte sample outlet Hose connection DN 8
Z Drain outlet Union connection DN 25
Loose flange with blind
flange
DN 150 DN 150 DN 250 DN 250 DN 300 DN 400 DN 400
DN 100
d125
DN 80
flange
DN 80
flange
DN 150 DN 150 DN 200 DN 250 DN 300 DN 300
DN 80
flange
DN 80
flange
English (GB)
13
4.1.7 Process description
English (GB)
This section refers to fig. 5.
General information
The number of electrolysis cells in a Selcoperm electrolyser
depends on the SES type:
SES type Cells inlcuded
SES-5000, SES-7500 C1.1
SES-10000, SES-15000 C1.1, C1.2
SES-20000, SES-30000 C1.1, C1.2, C2.1, C2.2
SES-45000 all cells as shown in fig. 5
Figure 5 shows the PID of the largest system which includes an
electrolyser type SES-45000 with 6 electrolysis cells. The
functional principal described here also applies to smaller
systems with less electrolysis cells.
The soft water for the Selcoperm electrolyser is connected to soft
water inlet (A). The soft water enters the system via shut-off valve
(V0.01) and passes through pressure reducing valve (V0.02) to
ensure a regulated pressure in the system.
The brine supplied by brine dosing station (BDS) is connected to
brine inlet (B) and passes shut-off valve (V0.10). The brine dosing
station (BDS) is usually equipped with 2 brine pumps (DP0.10)
and (DP0.11). Only 1 brine pump is used for production while the
other pump is in standby mode. The system can be configured to
alternate between the 2 pumps each time production is started or
in case the used pump fails. For simplification the following
description only refers to brine pump (DP0.10).
The degassing and storage tank (DST) can optionally be
equipped with a second standby degassing fan (EF4.02). The
system can be configured to alternate between the 2 degassing
fans each time production is started or in case the used fan fails.
For simplification the following description only refers to
degassing fan (EF4.01), which is included in each system as a
standard.
Production process
When the system starts production, degassing fan (EF4.01) on
degassing and storage tank (E4.05) is switched on. Once the
exhaust air flow sensor (4.13) measures the correct flow rate,
solenoid valve (0.05) opens and brine pump (DP0.10) is started.
The soft water passes flow sensor (0.02) and is mixed with the
brine in static mixer (V0.05). The resulting electrolyte passes flow
sensors (1.10, 2.10, 3.10) and adjusting valves (V1.01, V2.01,
V3.01) before it enters the electrolysis cells via 3-way valves
(V1.02, V2.02, V3.02). The level switches (1.09, 2.09, 3.09)
signal to the PLC that the electrolysis cells are filled. As soon as
level switch (4.04) signals to the PLC that the NaClO (sodium
hypochlorite) solution line is filled, the rectifier (REC) switches on
the DC power supply for the cells (C1.1, C1.2, C2.1, C2.2, C3.1,
C3.2) to start the electrolysis. The temperature switches (1.01 -
1.04, 2.01 - 2.04, 3.01 - 3.04) monitor the temperature of the DC
connections on the cells.
The temperature sensor (0.03) monitors the temperature of the
NaClO solution before it passes outlet (V). The NaClO solution
contains a certain amount of hydrogen gas, which is produced as
a by-product in electrolysis. It is led through a horizontal or
slightly upwards inclining line into the degassing and storage tank
(E4.05). Before entering the tank, the NaClO solution passes the
T-piece (TP) to separate the hydrogen gas. The separated
hydrogen gas is immediately diluted with air from degassing fan
(EF4.01) to 25 % of the LEL. The exhaust air is led away through
exhaust air outlet (T) to a safe external discharge point. The
correct air flow in the exhaust air line is monitored by air flow
sensor (4.13). In addition, the frequency converter of the
degassing fan is used to monitor the fan speed.
When the NaClO solution reaches the stop-fill level in the tank
measured by level sensor (4.10), the process is stopped. First,
the DC power supply from the rectifier (REC) to the electrolysis
cells is switched off. Solenoid valve (0.05) stays open, and brine
pump (DP0.10) keeps running to flush the lines and cells with
electrolyte for a few minutes.
After flushing is completed, brine pump (DP0.10) stops and
solenoid valve (0.05) closes. The flow of electrolyte through the
electrolysis cells stops. The degassing fan (EF4.01) stops after a
few minutes. The system switches into "Standby" mode.
Additional monitoring equipment
The gas warning system (H2S) with two hydrogen sensors (5.01,
5.02) measures the concentration of hydrogen at the installation
location. If hydrogen is detected, the gas warning controller (5.00)
sends a signal to the PLC in the control cabinet (CTR) of the
Selcoperm electrolyser to shut down the system.
The level switch (0.01) detects liquid in the Selcoperm
electrolyser housing.
The level switch (4.03) detects liquid in the collecting tray of tank
(E4.05).
Dosing of produced NaClO solution
The NaClO solution can be dosed directly from tank (E4.05) via
solution outlet (U) to the point of application. It is also possible to
pump the NaClO solution from tank (E4.05) into separate storage
tanks.
Sampling
A sample of the NaClO solution can be taken from sample outlet
(X) via sample valve (V0.09). A sample of the electrolyte entering
the electrolysis cells can be taken at sample outlet (Y) via sample
valve (V0.06).
Draining
After the system has been flushed and switched off, it can be
drained via drain outlet (Z) using drain outlet valve (V0.08) and
3-way valves (V1.02, V2.02, V3.02).
Acid cleaning
For acid cleaning of the electrodes within the electrolysis cells, an
external acid cleaning station can be connected to (C). Acid
cleaning must be done according to section 9.5 Acid cleaning.
Operation and supervision
All components and safety functions are monitored and operated
via a multi-colour touchscreen on the Selcoperm electrolyser
(SES). If a fault occurs, the system stops and a message is
displayed on the touchscreen.
14
4.2 Selcoperm electrolyser
8
Selcoperm SES-15000
98720681
S/N: 00000001
15 kg/h, 380-415 V, 50 Hz
3 kW
98720681P11153300000001
1
7
11
2
3
4
5
6
9
10
Made in Germany
Grundfos Water Treatment GmbH - Reetzstr. 85 - D-76327 Pfinztal
Full guarantee (system)
Time-dependent
guarantee (electrodes)
Yea rs
1
2
3
4
11
5
6
Z
B
A
V
V
6
4.2.1 Identification
Nameplate
Fig. 6 Nameplate
4.2.2 Warranty
The Selcoperm range is fully guaranteed for a period of two
calendar years from installation and commissioning, provided
optimum operating conditions are as detailed in this manual. The
maximum period for full guarantee is 36 months from delivery.
The electrodes are guaranteed time-dependent a further three
years. Grundfos will replace or refurbish the electrodes during
this period at cost of parts, less a percentage that is equal to the
expected life not obtained from the electrodes. If this option is
taken, warranty conditions current at the time of replacement will
apply. See fig. 7.
TM06 2212 1516
English (GB)
Pos. Description
1 Type designation
2 Product number
3 Serial number
4 Capacity level Cl
(equivalent)
2
5 Max. power rating of control cabinet
6 Country of origin
7 Frequency of control cabinet
8 Supply voltage of control cabinet
Fig. 7 Warranty
A guarantee claim in accordance with our general terms of sale
and delivery is only valid, if the following requirements are
fulfilled:
• The system is used in accordance with the information within
this manual.
• The system is not dismantled or incorrectly handled.
• The maintenance is carried out by certified service persons.
9 Code for year and week of production
10 Marks of approval
11 Address of manufacturer
4.2.3 Overview of components
The Selcoperm electrolyser is the core piece of the Selcoperm electrolysis system.
TM06 2221 3615
Fig. 8 Overview components SES-5000 to SES-15000
TM06 2222 5115
15
English (GB)
1
2
2
3
4
11
5
6
Z
A
B
V
V
6
6
Fig. 9 Overview components SES-20000 to SES-45000
Pos. Description
1 Chemically resistant PEHD frame with collecting tray
2 Easily removable powder-coated housing
3
4
5
6 Top or bottom connection for direct current cables from the rectifier
11
A Soft water inlet
B Brine inlet
V NaClO solution outlet
Z Drain outlet
Horizontal electrolysis cells with transparent PVC pipe for easy process monitoring and visual electrode check. Several sensors
monitor the level and temperature of the liquid as well as the voltage and temperature of all direct-current (DC) connections.
Lockable hydraulic chamber with shut-off valves and adjusting valves, temperature sensors, flow sensors and leakage sensors,
sample valves for brine and sodium hypochlorite solution, and a connection for acid cleaning.
Lockable control cabinet with multi-colour touchscreen, emergency stop and main switch. The control cabinet monitors and/or
controls the following components and functions:
• Rectifier
• Brine dosing station
• Sensors and valves of the Selcoperm electrolyser
• Level sensors and flow sensors of the degassing and storage tank and the sodium hypochlorite solution line
• Degassing fans (duty/standby) of the degassing and storage tank
• Potential-free contact for start signal of dosing pumps or transfer pumps downstream the degassing and storage tank
• Gas warning system
• Several potential-free alarm contacts
• Acid cleaning station
• Remote maintenance (optional)
7" multi-colour touchscreen for operating and monitoring of the whole electrolysis system. Several languages can be selected.
The system can be operated in two operation modes:
• automatic mode
• service mode
The system can also be remotely controlled and monitored via PROFINET.
TM06 4671 5115
16
4.2.4 Overview hydraulics SES-5000 to SES-15000
V0.09
1
X
V0.05
1.10
1.11
V0.10
0.05
0.01
0.02 V0.04 V1.01 V0.02 V0.01 C V0.07 V0.08 Y Z A
1.09
0.03
V
1.03 1.02
1.04
1
1.01
B
V1.02
V0.06
GND3
C1.1
C1.2
English (GB)
Fig. 10 Overview hydraulics SES-5000 to SES-15000
Pos. Description Pos. Description
0.01 Level switch in collecting tray GND3 Earth connection of electrolyte
0.02 Water inlet flow sensor V NaClO solution outlet
0.03 NaClO outlet temperature sensor V0.01 Water inlet valve
0.05 Water inlet solenoid valve V0.02 Pressure reducing valve
1 Protection against accidental contact V0.04 Non-return valve
1.01 Temperature sensor (DC+) V0.05 Static mixer
1.02 Temperature sensor (DC-) V0.06 Electrolyte sample valve
1.03 Temperature sensor (DC+) V0.07 Acid inlet and outlet valve
1.04 Temperature sensor (DC-) V0.08 Drain outlet valve
1.09 Cell outlet level switch V0.09 NaClO sample valve
1.10 Cell inlet flow sensor V0.10 Brine inlet valve
1.11 Cell inlet temperature sensor V1.01 Cell inlet adjusting valve
A Soft water inlet V1.02 3-way ball valve
B Brine inlet X NaClO sample outlet
C Acid cleaning inlet and outlet Y Electrolyte sample outlet
C1.1 Electrolysis cell 1 Z Drain outlet
C1.2 Electrolysis cell 2*
* Only available in SES-10000 and SES-15000.
TM06 2242 4915
17
4.2.5 Overview hydraulics SES-20000 to SES-45000
V0.043.10 V3.01 V2.01 V0.10 V1.01 V3.02 V2.02
V1.02
X
V0.09
1.02
X
3.02
1.03
2.02
3.03
2.03
2.10 1.10 / 1.11V0.05GND3
A
B
Z
1
3.04
2
2.04
1.093.092.09 0.03
V
1.04
2.01
1.01
3.01
V0.06 Y 0.05 V0.01 0.02 0.01 V0.02 V0.08 V0.07 C
C1.1
C3
C2
C1
C3.1
C1.2
C2.1
C3.2
C2.2
English (GB)
Fig. 11 Overview hydraulics SES-20000 to SES-45000
18
TM06 2241 4516
Pos. Description Pos. Description
0.01 Level switch in collecting tray C1 Cell line 1
0.02 Water inlet flow sensor C1.1 Electrolysis cell 1
0.03 NaClO outlet temperature sensor C1.2 Electrolysis cell 2
0.05 Water inlet solenoid valve C2 Cell line 2
1 Protection against accidental contact C2.1 Electrolysis cell 3
1.01 Temperature sensor (DC+) C2.2 Electrolysis cell 4
1.02 Temperature sensor (DC-) C3 Cell line 3*
1.03 Temperature sensor (DC+) C3.1 Electrolysis cell 5*
1.04 Temperature sensor (DC-) C3.2 Electrolysis cell 6*
1.09 Cell outlet level switch GND3 Earth connection of electrolyte
1.10 Cell inlet flow sensor V NaClO solution outlet
1.11 Cell inlet temperature sensor V0.01 Water inlet valve
2 Protection against accidental contact V0.02 Pressure reducing valve
2.01 Temperature sensor (DC+) V0.04 Non-return valve
2.02 Temperature sensor (DC-) V0.05 Static mixer
2.03 Temperature sensor (DC+) V0.06 Electrolyte sample valve
2.04 Temperature sensor (DC-) V0.07 Acid inlet and outlet valve
2.09 Cell outlet level switch V0.08 Drain outlet valve
2.10 Cell inlet flow sensor V0.09 NaClO sample valve
3.01 Temperature sensor (DC+) V0.10 Brine inlet valve
3.02 Temperature sensor (DC-) V1.01 Cell inlet adjusting valve
3.03 Temperature sensor (DC+) V1.02 3-way ball valve
3.04 Temperature sensor (DC-) V2.01 Cell inlet adjusting valve
3.09 Cell outlet level switch V2.02 3-way ball valve
3.10 Cell inlet flow sensor V3.01 Cell inlet adjusting valve
A Soft water inlet V3.02 3-way ball valve
B Brine inlet X NaClO sample outlet
C Acid cleaning inlet and outlet Y Electrolyte sample outlet
Z Drain outlet
* Only available in SES-45000
English (GB)
19
4.2.6 Signal diagram
tcatnoc eerf laitnetoP
Alarm 2xNC
Selcoperm SES-5000 - 45000
Control Cabinet
Brine dosing staƟon
DP0.10 DP0.11
RecƟĮer
Acid
cleaning
staƟon
AAH5.00
Gas warning system controller
Main
control
Degassing and storage tank
EF 4.01
VenƟůaƟon Fan
Duty
EF 4.02
VenƟůaƟon Fan
Standby
FIAHL 4.13
Exhaust air Ňow
sensor
LSAHH 4.12
Degassing tank
overŇow switch
4-20mA
Flow rate signal
LISAHL 4.10
Dega ssing t ank
level sensor
LSAL 4.04
NaClO soluƟon
line level sw itch
4-20mA
Tank level
Namur
Level switch
LSAH 4.03
Level switch in
retenƟon
PotenƟal free contact
Leakage fault si gnal NC
24V DC
Power Supply
14V DC
Power Supply
24V DC
Power Supply
Selcoperm electroyser
LSAH 0.01
Level switch in
collecƟng tray
FIAHL 0.02
Water inlet Ňow
sensor
24V DC
Power supply
PotenƟal free contact
Leakage fault signal NC
TIAHL 0.0 3
NaClO outlet
temper at ure se nsor
SV 0.05
Water inlet
solenoid valve
TC
Te mper ature s igna l
24V DC
Power supply*
TIAH 1.0 1-x.04
Temper ature
sensor (DC+/-)
LSAL x.09
Cell outlet level
switch
Level switch
FIAHL x.10
Cell inlet Ňow
sensor
24V DC
Power Supply
TIAHL 1.1 1
Cell inlet
temper at u re se nsor
3 phases + PE
Power supply*
24V DC
Power Supply
4-20mA
Flow rate
230 V AC
Power supply*
PotenƟal free contact
Fault signal
ProĮnet
Current, Voltage, ...
230 V AC
Power supply*
4-20mA
Flow rate
230 V AC
Power supply*
PotenƟal free contact
Fault signal
PotenƟal free contact
Emerg ency stop 2xNC
PotenƟal free contact
Emerg ency stop 2xNC
Wa tc h do g
380 /400/ 415V A C 50 /60H z (3 phase s + N +PE)
Power supply BY COSTUMER
GSM OP TION AL
Remote mai nten anc e by GRU NDFO S
ProĮnet
2.)
PotenƟal free contact
Emerg ency sto p 2x NC
PotenƟal free contac t
Emerg ency sto p 2x NC
2.) Signals (PotenƟal free or ProĮnet)
- Standby
- Run
- Fault
- Water request
- Release NaClO dosing pump
- Release NaClO transfer pump
5V DC
Power supply
0,5-3,5 V DC
Flow rate signal
5V DC
Power supply
0,5-3,5 V DC
Flow rate signal
5V DC
Power supply
0,5-3,5 V DC
Flow rate signal
PotenƟal free contact
Remote on/oī
PotenƟal free contac t
2.)
Alarm 2xNC
TC
Temper ature s ign al
Namur
Level switch
14V DC
Power Supply
PotenƟal free contact
Emerg ency sto p 2 xNC
380 /400/ 415V A C 3 phase s + P E, 50 Hz
Power supply BY COSTUMER
A5.01
Hydrogen (H
2
)
sensor 1
A5.02
Hydrogen (H
2
)
sensor 2
* permanent power supply
Emergency s top does not lead to de-energised component
PotenƟal free contact
Start / Stop
PotenƟal free contact
Fault signal
3 phases + PE
Power supply*
PotenƟal free contact
Start / Stop
PotenƟal free contact
Fault signal
PotenƟal free contac t
External alarm inpu t
English (GB)
Fig. 12 Signal diagram
20
TM06 2217 3615
4.3 Rectifier
5
8
1
4
2
1
11
6
3
The rectifier converts the alternating current (AC) from the power
supply into the direct current (DC) needed to run the Selcoperm
electrolyser. In case of a failure, the rectifier shuts down. The
communication between the Selcoperm electrolyser and the
rectifier is designed redundantly (Profinet and hardwired) for the
safety shutdown functions.
4.4 DC cable set
The DC cable set contains the flexible insulated copper cable for
direct current connection between the Selcoperm electroyser and
the rectifier. The standard cable length must not exceed 10 m.
Longer cables are available on request.
4.5 Degassing and storage tank
The degassing and storage tank is a mandatory component of the
Selcoperm electrolysis system. In systems with several
electrolysers, one tank for each electrolyser must be installed.
The minimum volume of the tank depends on the capacity level of
the Selcoperm electrolyser.
The sodium hypochlorite solution can be dosed directly from the
tank to the point of application. In this case, the volume of the
tank must be selected according to the demand of sodium
hypochlorite solution of the individual application. It is also
possible to pump the sodium hypochlorite solution from the
degassing and storage tank into separate storage tanks provided
by the customer.
One degassing fan is installed on the tank by default. To avoid a
system shutdown due to a defective fan, an additional standby
fan can be installed.
4.5.1 Installation set
A special installation set is pre-installed on the degassing and
storage tank. The use of this installation set is mandatory to
ensure the compliance with the certified safety concept of the
Selcoperm electrolysis system.
4.5.2 Components
14
13
12
10 9
Fig. 13 Degassing and storage tank with installation set
Pos. Description
1 NaClO solution inlet G
2 Air inlet E
3 Blind flange
4 Exhaust air outlet W
5 Manhole D
6 NaClO solution outlet U
7Drain F
8 Degassing fan
9 Level sensor 4.10 yes
10 Manual valve
11 Level sensor connection L
12 Manual valve
13 Overflow switch 4.12 yes
14 Overflow switch connection H
Air flow sensor for exhaust air line
with connection flange
Leakage sensor
(for installation with collecting tray)
A collecting tray is not within the scope of delivery.
7
Pos. in
EF4.01
EF4.02
installation
PID
4.13 yes
4.03 yes
Part of
set
yes
English (GB)
6
TM06 2218 3615
21
4.6 Brine dosing station
5
12
4
3
6
English (GB)
The brine is dosed with digital dosing pumps. To ensure reliable
brine dosing, the dosing station comprises a duty pump and a
standby pump. Pulsation dampers ensure low pulsation. As the
counterpressure of the Selcoperm electrolyser is too low, the
brine dosing station contains a pressure loading valve. Pressure
relief valves ensure safe operation in case the pressure limit is
exceeded.
The dosing station is controlled via the touchscreen on the
Selcoperm electrolyser. A Flow Monitor is installed on each pump
to monitor the dosing process. Errors in the dosing process are
displayed on the touchscreen of the Selcoperm electrolyser.
The Selcoperm electrolyser provides the brine dosing station with
the supply voltage and the control current.
4.6.1 Components
Fig. 14 Brine dosing station
Pos. Description
1 Dosing cabinet with sliding doors
2 Pressure pulsation damper
3 Pressure loading valve PLV
4 Pressure relief valve PRV
5 Digital dosing pumps (duty/standby) with Flow Monitor
Suction pulsation damper with scale for calibration and
6
manual vacuum pump for priming
4.7 Water softener
The water softener provides the softened mains water required
for the electrolysis.
The water softener is equipped with a dual head and two
cylinders to ensure a constant soft-water supply even during
regeneration. A stand-alone brine tank provides the brine needed
for regeneration. A pipe installation set, a bypass valve and a
filter with manual backwash function are delivered with each
water softener.
The water softener can be delivered pre-assembled on a skid or
without skid.
Fig. 15 Water softener
4.8 Chiller
If the required soft water temperature cannot be met, a chiller can
be used to cool the soft water down. The chiller is placed between
the water softener and the Selcoperm electrolyser. The softened
water entering the chiller must comply with the recommended soft
water quality. See section 5.1 Selcoperm Electrolysis System
(SES). The chiller must be designed according to the local
system requirements and must be controlled via a separate
control panel.
TM06 2223 3615
4.9 Heater
If the required soft water temperature cannot be met, a heater
can be used to warm the soft water up. The heater is placed
between the water softener and the Selcoperm electrolyser. The
softened water entering the heater must comply with the
recommended soft water quality. See section 5.1 Selcoperm
Electrolysis System (SES). The heater must be designed
according to the local system requirements and must be
controlled via a separate control panel.
4.10 Brine tank
The brine tank is used for preparation and storage of brine.
TM06 2224 3615
4.11 Acid cleaning station
The acid cleaning station is pre-assembled on a trolley for acid
cleaning of the electrodes. Acid cleaning shouldn’t be required
more often than every two years during maintenance, unless
there is a softening fault, or the quality of the used water or salt is
poor.
The Selcoperm electrolyser provides the acid cleaning station
with the supply voltage by means of a special plug. The acid
cleaning station is controlled via the touchscreen on the
Selcoperm electrolyser.
22
4.11.1 Components
3
411
2
1
9
10
8
7
6
5
5.1.2 Salt specification
Use food-grade granular/pellet salt (98.5 % NaCl) according to
EN 14805 type 2 with following minimum requirements:
Fig. 16 Acid cleaning station
Pos. Description
1 Collecting tray
2 Trolley
3 Acid tank, 300 l
4 Return flow line
5 Special plug for connection to Selcoperm electrolyser
6 3-way ball valve
7 Dosing pump
8 Connection to Selcoperm electrolyser with manual valve
9 3-way ball valve
10 Drain valve
11 Pressure loading valve
Parameter Symbol
Iron Fe 10.0
Manganese Mn 10.0
Bromide Br 100.0
Calcium Ca 100.0
Magnesium Mg 100.0
5.1.3 Ambient conditions
Permissible ambient temperatures (min./max.)
Transport* -10 / +50 °C
TM06 2226 2216
Storage* +0 / +40 °C
Operation +5 / +40 °C
Operation (rectifier) +10 / +40 °C
Max. relative humidity (non-condensing) 90 %
Max. relative humidity (non-condensing) for
rectifier
Max. altitude above sea level 2000 m
* System must be drained. For storage temperatures below +5
°C, the whole system including water softener, lines and
external components must not contain any water.
Exposition to direct sunlight can cause colour
changes, material deformations and cracks.
Do not expose the system to direct sunlight.
Max. mass fraction
for dry salt [mg/kg]
English (GB)
75 %
4.12 Gas warning system
As a part of the safety concept, a gas warning system for
hydrogen gas (H
The Selcoperm electrolyser provides a two-channel safety input
to shut down the whole system in case of gas leakage.
) must be installed at the installation location.
2
5. Technical data
The values stated in the technical data must be
adhered to.
5.1 Selcoperm Electrolysis System (SES)
The following data apply to the core components of the
Selcoperm electrolysis system and cover all capacity levels.
5.1.1 Water quality specification
Make sure that the water supply conforms to the required
standard of drinking water given in the specification below. Ask
your local water supplier for the specific values.
Parameters
Colour [mg/l Pt/Co] 20
pH value 6.5 - 10.0
Iron Fe [μg/l] 200
Manganese Mn [μg/l] 20
Fluoride F [mg/l] 2
Turbidity [NTU] 4
Max. particle size [μm] 100
Value (maximum unless stated
otherwise)
Because of the embrittlement of plastics at low
temperatures, the transport must not be done if the
temperature falls below the specified value for
transport, otherwise plastic parts can be damaged.
Freezing and boiling liquids can cause damage.
Observe the freezing and boiling points of the used
liquids. The freezing and boiling point of a liquid
varies depending on the pressure.
23
5.2 Selcoperm electrolyser
English (GB)
5.2.1 General data
Sodium hypochlorite concentration 0.8 %
Max. salt consumption 3.5 kg NaCl per kg of Cl
Max. power consumption (DC/AC)* 4.6 / 5.4 kWh per kg of Cl
Soft water consumption 125 litres per kg of Cl
Soft water inlet pressure 3-5 bar (depending on the capacity level)
Soft water temperature
Soft water quality for operation Drinking water quality, softened to: 1 °dH / 17.8 ppm CaCO
Max. pressure inside electrolyser, NaClO
solution line and degassing and storage tank
* System with air-cooled rectifier, excluding optional chiller and heater
The Selcoperm electrolyser is available in seven capacity levels.
(equivalent)
2
(equivalent)
2
(equivalent)
2
10-20 °C (for higher or lower temperatures an external chiller or heater is
required)
and less
3
1 bar
Weight
[kg]
SES type
Capacity level Cl
(equivalent)
[g/h]
2
Total soft water flow
[l/h]
Empty Filled
SES-5000 5000 633 660 685
SES-7500 7500 944 680 715
SES-10000 10000 1266 700 750
SES-15000 15000 1887 780 845
SES-20000 20000 2532 1170 1270
SES-30000 30000 3776 1250 1380
SES-45000 45000 5660 1350 1550
5.2.2 Built-in control cabinet
Supply voltage: 380-415 V, 50-60 Hz (3 phases + N + PE)
Enclosure class: IP54
Electrical safety class: I
Pollution degree: 2
SES type
Current
[A]
Max. power rating
[kW]
Max. fuse rating
[A]
SES-5000 5.5 1.5 32
SES-7500 5.5 1.5 32
SES-10000 5.5 1.5 32
SES-15000 9 3 32
SES-20000 9 3 32
SES-30000 13.5 5.2 32
SES-45000 13.5 5.2 32
5.2.3 Connections
Details on connections can be found in section 4.1.6 Piping and
Instrumentation Diagram (PID).
24
5.2.4 Setpoints
The following table shows typical values expected upon commissioning. Please note that these values may need to be adjusted due to
salt and water quality on site.
No. Setpoint SES- 5000 7500 10000 15000 20000 30000 45000
1 Capacity [g/h] 5000 7500 10000 15000 20000 30000 45000
2 Water inlet pressure (into unit) [bar] 3-4 3-4 3-4 3.5-5 3-4 4-5 4-5
Adjusted water pressure (at pressure
3
reducing valve V0.02)
4 Soft water flow [l/h] 570 +15 850 +15 1140 +20 1700 +25 2280 +40 3400 +50 5100 +75
5 Brine flow* [l/h] 63 94 126 187 252 376 560
6 Max. capacity brine pump [l/h] 100 130 150 250 350 450 650
7 Total sodium hypochlorite solution flow [l/h] 633 944 1266 1887 2532 3776 5660
8 Water temperature [°C] 10-20 10-20 10-20 10-20 10-20 10-20 10-20
9 Conductivity of electrolyte [mS/cm] 44-46 44-46 44-46 44-46 44-46 44-46 44-46
10 Amperage [A] 780 780 780 780 780 780 780
11 Voltage** [V] 27-32 42-49 54-63 84-94 54-63 84-94 84-94
12 Sodium hypochlorite solution strength [g/l] 8 8 8 8 8 8 8
13 Exhaust air flow [m
14 Specific gravity of electrolyte [g/ml]
* The brine flow can be different, depending on the saturated brine concentration. It is important to adjust the right salinity.
** The voltage can be different, depending on the water temperature and the brine temperature.
5.2.5 Approvals
The Selcoperm system is certified according to CE and EAC.
5.2.6 Materials
[bar] 1.5 - 2 1.5 - 2 2 - 2.5 3.5 - 4 2.5 - 3 3 - 3.5 3.5 - 4
3
/h] 300 450 600 900 1200 1800 2700
1.02 -
1.022
1.02 -
1.022
1.02 -
1.022
1.02 -
1.022
1.02 -
1.022
1.02 -
1.022
1.02 -
1.022
English (GB)
System frame PE-HD
Housing cover Powder coated steel
Electrolysis chamber cover Polycarbonate
Electrolysis cell tube PVC-U clear
Electrolyser parts PVC-U grey
Electrodes Titanium / Titanium coated
Electrical connections Copper
Internal pipes / fittings PVC-U grey
Seals EPDM
Pump dosing heads PVC-U grey
25
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