Pressure chlorine changeover unit C 7520
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Content
1. Scope of delivery
2. Device description
3. Installation
4. Operation
5. Shutdown
6. Maintenance
7. Troubleshooting
1 Scope of delivery
The chlorine gas changeover unit C 7520 is delivered either as a
ready-to-connect unit with a mounting plate or an assembly kit for
integration in the pipe line. When unpacking, please ensure that
the installation material (included in the scope of delivery) for wall
fixing is not lost.
2 Device description
2.1 Technical data
Description
Value
Throughput Chlorine gas up to 200 kg/h
Fluid chlorine up to 1400 kg/h
Connections
depending on the
device version
Threaded connection External thread 1" NPT
Flange connection Flange DN25 / PN40 with key and slot
according to EN1092
Inputs: Groove flange (Form D)
Output: Tongue flange (Form C)
Voltage supply 100 … 240 V AC
Power consumption In standby 5 W
During changeover max. 100 W
Material in contact with the media steel, Monel, stainless steel, PTFE, silver
Pressure gauge Measuring range 0…16 bar (vacuum resistant)
Accuracy ± 2.5 %
Nominal size Ø 63 mm
Load capacity of the relay contacts max. 3 A / 250 V AC
Changeover time max. 25 s
Operating pressure 0…16 bar
Protection class IP 65
Permissible ambient temperature 0-60°C
Weight with mounting plate approx. 17 kg
Table 1: Technical data
2.2 Dimensions
All dimensions in mm
Fig. 1:
550
600
550
600
255
300
242~309
1" NPT
1" NPT
550~
1" NPT
7
Dimensions
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2.3 Control box
2.3.1 Controls
Fig. 2: Controls
No. Type Function
a
LED green: Cylinder filled
red: Cylinder empty
b
LED
c
LED green: Valve open
yellow: Motor works
red: Valve closed
d
LED
A Key 1. notify full cylinder
4LED switches to green
2. switch manually
B Key
C Key Close both valves
Table 2: Functions of the controls
2.3.2 Functions
Automatic battery changeover
Should a chlorine supply battery run empty, the pressure in the
system will fall and the contact pressure gauge will issue an
electrical contact. The control changes the motor ball valves and
ensures supply from the other supply battery. The empty supply
battery is indicated by a red LED in the cylinder symbol.
After connecting the chlorine tank, the operator presses the key in
the cylinder symbol. The LED will switch to green and if necessary,
the device can switch back to this side.
Manual changeover
Manual changeover can be performed with the press of a key.
Manual STOP
Both valves are closed with the press of a key.
nBoth LEDs in the arrow illuminate red.
nJumper JP3 must be closed.
Remote indication empty
As soon as at least of the the supply batteries has been notified as
empty, the relay deactivates and notifies an empty tank. If both
batteries are registered as empty, the alarm relay deactivates.
Close valves following a gas warning
The closure of both valves can be triggered via an electrical
contact. The relay contact of a gas warning device is connected to
terminal 27/28 to this end.
With an active input::
nclose both valves.
nThe alarm relay deactivates and triggers an alarm.
nAll LEDs flash red.
RESET
The system restarts afresh after a voltage interruption. Both valves
are closed and subject to an electrical test. The system then moves
into the standard start position: left valve open.
4
2
BA
1
C3
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2.3.3 Special operating states
Operating state
LED display: Relays empty Relay alarm
Waiting for supply
A supply battery is empty, it was subject to automatic
changeover, the operating pressure has yet to
normalise (waiting time 2 minutes)
Empty side: cylinder and arrow illuminate
red.
Active side: cylinder flashes green, arrow
illuminates green
ON OFF
All empty
Both supply batteries are empty
or the pressure gauge does not give a contact.
nA valve is closed
nA valve is open
Both cylinders: illuminate red
Valve closed: Arrow illuminates red
Open valve: Arrow illuminates green
ON ON
Gas alarm
The input contact terminal 27/28 was closed.
nBoth valves are closed
All: flash red OFF ON
Manual STOP
Key C was pressed.
nBoth valves are closed
Both arrows: illuminate red
Both cylinders: corresponding state of the
cylinder
ON/OFF OFF
Fault
Motor was switched to MAN, limit switch in the motor
has been incorrectly adjusted or electrical connection
between motor and control not OK.
All: flash red OFF ON
Jumper error
The jumpers on the control were set to an impermissible combination.
All: Flashing clockwise. OFF OFF
Table 3: Signals with special operating states
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2.3.4 Terminal connection
Fig. 3:
Com
Off
On
Com
Off
On
POWER IN Motor 2 Motor 1 Alarm empty
feedback M2 feedback M1
JP1
JP2
JP3
JP5
JP4
Vaccum
Press.
123456789
1011121314
151617
181920
212223242526272829
30
NN'LL'PEPEPENclose
openPEN
close
open
close
open
GND
close
open
GND
GasW.
GND
Mano.
GND
Terminal connection
Terminal
Description Function
1+2 N Voltage supply input
3+4 L
5+6 PE
7 PE Voltage supply for motor 2
(ball valve right)
8 N
9 Close
10 Open
11 PE Voltage supply for motor 1
(ball valve left)
12 N
13 Close
14 Open
15 Com Relay output "alarm"
max. 3 A / 250 VAC
NC (15-17 closed with power failure)
16 Off
17 On
18 Com Relay output "empty"
max. 3 A / 250 VAC
NC (18-20 closed with power failure)
19 Off
20 On
Table 4: Terminal connection
Processor
Jumper
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Terminal
Description Function
21 close Position switch in motor 2
(ball valve right)
22 open
23 GND
24 close Position switch in motor 1
(ball valve left)
25 open
26 GND
27 GasW. Gas warning device input
closed = alarm
28 GND
29 Mano. Contact pressure gauge switch
closed = chlorine shortage
30 GND
Table 4: Terminal connection
2.3.5 Jumper settings
The jumpers were set voltage-free The change becomes active
once the voltage supply has been switched on.
Jumper Name Position Function
JP 1 fast closed Both motors activate at the same time.
open
(state of delivery)
The reserve battery valve opens only after
the valve of the active battery has closed.
JP 3 pressure closed
(state of delivery)
The software of a positive pressure
changeover unit is activated.
JP1 and JP5 must be open.
open The software of a vacuum changeover
unit is activated.
JP 5 rest
evacuation
closed Residual emptying activated
open
(delivery state)
Residual emptying deactivated
Table 5: Jumper
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3 Installation
The pre-fitted chlorine gas changeover unit is fitted to the wall with
the screws and washers included in the scope of delivery.
Devices without a wall plate are supported by the pipe line. The
pipe line requires adequate support.
The location of installation must be easily-accessible to operating
personnel in order to allow manual activation of the changeover
unit where necessary. The changeover unit should not be subject to
direct sunlight or any other similar bright direct light. This could
obscure the operating displays.
3.1 Hydraulic Installation
Caution!
Changeover is only suitable for use in a chlorinator system in
positive pressure. The changeover unit is resistant against pure, dry
chlorine (fluid or gaseous).
Caution!
The connections must be made carefully. Chlorine can also enter
the atmosphere of the operation room from small leaks. It will
combine with the air moisture to generate a corrosive air. The
automatic chlorine cylinder changeover may only be operated with
two connected chlorine gas batteries. If only one chlorine gas
battery is connected, the non-utilised side be must be closed
tightly.
Perform the leak test with ammonia.
3.2 Power connections
The electrical installation must be performed by a qualified
electrician.
Ensure that the mains voltage corresponds with the values on the
rating plate. Fuse the mains supply line in accordance with local
specifications.
The changeover unit is ready for operation immediately after
connection of the supply voltage. The motors need only be
connected with devices without a mounting plate. The plugs are
already fitted to the cables and are marked.
No. Motor
1 Left valve
2 Right valve
Table 6: Number of the motors
Where required, the relay contacts for remote indication of the
operating state can be connected. The assignment and function of
the individual terminals can be taken from the terminal connection
plan.
Every motor is equipped with an additional position switch for the
remote indication of the operating state. It sends the positions
OPEN and CLOSED. The terminal connection is pressed directly
onto the motor.
Superfluous cable screw connections on the control must be sealed
in order to maintain the protection class.
3.3 Adjusting the contact pressure gauge
The factory settings of the pressure gauge switching contact have
been set to c. 4 bar. The system could require calibration of the
switching points. The front plate of the pressure gauge must be
unscrewed to perform this task. The switching point is then
adjusted by moving the red mark within the range 1 to 6 bar.
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M
A
B
a
b
c
d
e
f
g
hr
n
o
i
j
k
l
m
Fig. 5: Installation example
A Room for the chlorine supply
1 Chlorine barrel
2 Chlorine barrel scale
3 Manifold
4 Changeover valve
5 Chlorine gas filter
6 Pressure reducing valve
7 Moisture eliminator with heating collar
8 Vacuum regulator
14 Gas sensor
15 Entrance port of the chlorine eliminator
B Dosing device room
9 Dosing device
10 Motive water pump
11 Injector with non-return valve
12 Gas warning device
13 Horn
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4 Operation
4.1 Normal mode
Automatic changeover
Should a chlorine supply battery run empty, the pressure in the
system will fall and the contact pressure gauge will issue an
electrical contact. The control changes the motor ball valves and
ensures supply from the other supply battery. The empty supply
battery is indicated by a red LED in the cylinder symbol.
Waiting time
After changeover, the control undergoes a waiting time of c. 2
minutes, during which time the operating pressure has the
opportunity to normalise. This waiting time is shown by the flashing
of the green cylinder symbol.
RESET for a full chlorine tank
After connecting the full chlorine tank, the operator presses the key
in the cylinder symbol. The LED will switch to green and if necessary,
the device can automatically switch back to this side.
Further control functions are described in Chapter 2.3.2.
4.2 Manual mode
The motor valve can be activated by hand if necessary (e.g. following
a current output). To this end, the changeover lever on the motor is
set to manual. The hand grip can then be turned freely. Automatic
changeover is now no longer possible. Make sure to return to
automatic operation. Turn the hand grip slightly when changing over
to automatic operation until it locks in.
Label on the motor Motor operating mode
MAN Manual mode
AUTO Automatic operation
Table 7: Motor operating mode
5 Shutdown
Chlorine gas is hygroscopic and together with the moisture, forms
hydrochloric acid, which destroys the dosing device. As a result,
all connections must be closed carefully upon shutdown of the
chlorine gas dosing system.
All pipes and valves must be flushed with dry air or nitrogen.
We recommend storage of the device in a heated dry room after
long operation interruptions.
When dismantling the device, the lines must be sealed airtight for
the reasons outlined above.
Look out for condensate in the lines during reactivation. It may be
necessary to blow them out with dry air or nitrogen.
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6 Maintenance
6.1 Maintenance intervals
To avoid hazardous incidents, chlorinators must be regularly
maintained. We recommend the following maintenance intervals:
Interval Maintenance
After 1 year Minor maintenance:
nLeak test
nFunctional control
After 3 years Major maintenance:
nReplace all seals
After 5 years nReplace the pressure gauge
Table 8: Maintenance intervals
6.2 Minor maintenance
The device exterior is cleaned and checked for any corrosion
damage.
Checking for leaks
Even the smallest leakages of chlorine will attract moisture and
result in the formation of hydrochloric acid. The leakage rate
increases quickly due to corrosion. As a result, every leak must be
remedied immediately.
Leaks are to be located with ammonia solution. Move an open
cylinder with ammonia along the installation whilst the system is
filled with chlorine pressure. Leakages become visible because the
ammonia vapour for combines with the chlorine to form a white
dust. In particular, pay attention to the following points:
nAll locations on which corrosion is visible.
nThread and flange connections
nControl rods of the ball valves
If necessary, the gland screws of the ball valves can be tightened. A
description is available in the ball valve instructions.
Functional control
Operate the changeover unit in normal operation.
nBoth chlorine supply batteries are connected
nTank valves are opened
nOne side of the changeover unit opened
nInjector switched on
Connect the tank valves of the active chlorine supply battery. The
pressure on the pressure gauge falls and when the switching point
has been reached, the ball valves change their switch position.
Open the tank valves and press the key in the cylinder symbol. The
LED switched to green.
Connect the tank valves of the other supply battery. The device
must switch back to the other supply side.
6.3 Major maintenance
Replace all seals on the ball valves. A description is available in the
ball valve instructions.
Proceed in the same fashion as in the small maintenance.
6.4 Replace the pressure gauge
1. Disconnect the pressure gauge cable from the control.
Unscrew the pressure gauge from the connecting piece. This
requires some force, as it is stuck in.
2. Clean the internal thread on T-piece.
3. Glue in the new pressure gauge and allow the glue to harden
for 24 hours. Lay the cable to the control and connect it. Pull all
the cable screw connections to the control.
4. Adjust the contactor on the pressure gauge to the same value
that was set on the pressure gauge.
5. Then perform a leak check and a function test as described
under "minor maintenance".
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7 Troubleshooting
Problem Possible cause Remedy
The changeover unit does not change
even though the battery connected is
empty and a full battery has been
connected to the other side.
After connecting the new chlorine
tank, the RESET key in the cylinder
symbol was not pressed.
The RESET key in the cylinder symbol must be
pressed after changing the cylinder. The LED
changes from red to green.
The voltage supply has been
interrupted. All LEDs are off.
Reactivate the voltage supply.
The changeover unit changes during
normal operation, even though the
chlorine tank is still full.
The maximum supply volume from
the battery was exceeded. Possible
causes:
nInsufficient chlorine tanks
connected
nNot all tank valves were opened.
nShort-term strongly increased
extraction due to shock
chlorination
nConnect sufficient chlorine tanks and open
the valves.
nRemove simultaneously from both tank
batteries for a shock chlorination.
Switch the motors on MAN previously.
The switching point on the contact
pressure gauge has been adjusted
incorrectly.
See 3.3 "Adjusting the contact pressure gauge".
The valves are not activated subsequently, rather simultaneously.
The jumpers in the control have not
been connected correctly.
Adjust the jumpers to the delivery state. See
chapter 2.3.5.
All LEDs flash red. A motor has been switched to
manual mode
Set both motors to AUTO Start a manual
changeover by pressing the key in the cylinder
symbol.
A cable connection between the
motor and control has been
interrupted, the position switch in the
motor has been adjusted incorrectly
or a motor is defective.
Check whether the plugs on the motors are
loose. If you do not experience any success:
inform Lutz-Jesco service.
The gas warning device contact
(terminal 27/28) is closed.
Locate and redress the cause.
The control shows an unusual illumination or flashing pattern.
A particular operating state is given. See tables in chapter 2.3.3.
Table 9: Troubleshooting
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8 Spare parts
Fig. 4: General view
Position Qty. Description Info Order-No.
1 1 Baseplate PP, 600x600 mm 35790
1 Mounting kit for plate A4 34439
2 2 Servomotor 85 - 240 V, AC/DC, 90° 88820
1 Cam switches adjusting tools W00037
2 Replacement ball valve Innengewinde 1" NPT 22300059
Flansche DN 25 / PN 40 22300060
3 1 Contact pressure gauge Ø63, G1/4 axial 24087653
Ø100, G1/2 unten 24087342
4 1 Control unit complete 100 - 240 V, 50 - 60 Hz 22400012
1 Processor (programmed) 79583
IC-gripper (for processor exchange) 79804
Maintenance set for C7520
(after 3 years)
2x maintenance set ball valve
from 08 / 2014 onwards 41218
Table 10: Spare parts
2
1
2
4
3
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