The Chemistry of this is based on the partial electrolysis of sodium chloride (Brine solution ) as it flows between direct current energized anodic and cathodic electrodes in an apparatus (named an electrolyzer ) and on successive chemical reactions which take place during electrolysis.

On passing a direct current through an aqueous solution of sodium chloride (Nacl), which is totally dissociated to Na+ and Cl.

1 )  free chlorine is generated at the anode :

2 )  hydrogen is evolved at the Cathode with the Corresponding formation of

    OH ions :

   OH ions migrate from the Cathode area and react with Na+ and Cl2 near the anode , thus producing    sodium Hypo chlorite Naocl.

3 )  This Overall chemical reaction can be expressed as follows :-

Generally the Chlorogen is supplied in Three Parts :

1) Chlorogen Machine FRP Mounted.
2) Chlorogen Rectifier.

Our all out efforts to supply you each Machine in a single vehicle thus ensuring Safety in transportation ,however sometimes due to transport in availability ,we are constrained to supply the Machine by Road Transports Operating in your City.

On Arrival at site kindly check the Machine for any external Damages and inform us immediately , do lodge a claim with transporter with a copy to us all consignments are insured by us.

The Machine inspection can be carried out to verify the following Parts.

1) Chlorogen Skid Mounted Machine Consists of .

a) One FRP Stand.
b) One - Process Tank made in FRP
c) One - Hypo Drain System .
d) One - Fresh water Inlet system

2) DC Rectifier - One with Cable From rectifier to Cell Pack

1-  Place the Machine at a suitable Place as discussed in Section V ( Location of Plant )

2-  Place the Rectifier near the machine.

3-  Connect Leads from Rectifier to Cell Pack as Shown Below.

- i.e. Negative is Taped - Blue.
4- Connect / Check Tightness of Cable Terminals from Rectifier to Cell pack.
a) + i.e. Positive Connect to anode ( Centre Bolt )
b)- i.e. Negative to Cathode. ( Left Side Bolt )

5-  Connect AC Input Supply Plug of rectifier to a 15 Amp Socket , Properly grounded. (grounding is Very Important )

COMMISSIONING.

The Chlorogen 100gm is designed to give 1100gm of chlorine in 8 hours Batch , for start up now weigh 4.5 Kg Salt.

After Adding this salt to Bucket mix it well with water and manually remove any dirt particles.

Fill up the Brine / Process Tank Upto half with water Add the Brine Solution from Bucket to Tank.

Now Fill water upto 140Ltr Mark - The Brine Solution is ready.

- Place the Lid on Top.
- Switch On AC Input to Rectifier.
- Switch On the Rectifier.
- Set the timer On the Pannel of rectifier to 8 Hours
- The Volts and Amps will start Rising.
- The Amp when set at 100 the Volts will adjust themselves between 8.0 and 10.0 - Check Solution Boiling  by Removing   the lid a little if Solution is Boiling the Process has started replace lid.
- Test the Output chlorine if the desired equipments are available , after completion of Process i.e. 8    Hours.

CAUTION.

These Machines are very ruggedly designed and maintenance is not a hasstle , the following are periodic maintenance feature :-

After every Batch
1) Wash Electrolyser with Fresh water

Every Month

1- Clean the Process Tank this is required as the salt used has dirt which settles down when salt dissolves     in water.

2- Clean Cell Pack ( Electrolyser ) Fill water upto half length of Electrolyser (Cell Pack ) add 2 Ltr of      Hydrochloric Acid Slowly pour this on water and not on Cell, Top up with water upto cell.
     so that cell is submerged leave it for 30 minutes , Drain the Solution , wash thoroughly with fresh      water.

3- Rinse the Cell with fresh water after above clean up.

EVERY THREE MONTHS

1) Check Various Valves and Pipes replace if damaged.
2) Remove Electrolyser , Dismantle and wash with water and soft cloth .

   In case any Scale Deposits On anode or Cathode are observed Dip Both  in a solution of dilute HCL and water (1:6) and rewash. While assembling it again check Teflon sealing Rings and Buttons if worn out or dis-shaped Replace them.

NOTE :
The duration of each shut down for Total cleaning of Electrolyser will depend on the quality of salt and water used.

WATER CHEM CORPORATION guarantees the equipment included in the Scope of supply to be of First class workmanship with best Quality of Available materials. All components Supplied will be Brand new and made using high tech manufacturing processes.

WATER CHEM CORPORATION Provides a Guarantee as to the mechanical portion of the machine for a period of 12 Calendar months from date of Installation Or 18 Months from date of despatch which ever period ends earlier.

The Wear and Tear parts like PP Pipe , Ring Seals are not covered in this guarantee, these shall not be considered as causes of free Replacement . Any damages Caused due to miscare , wear and Tear or faulty operation on the part of the owners personnel shall not be covered under Guarantee.

Any defects noted during the guarantee shall be rectified as deem fit and shall have no cause for Replacement of the machine or any part , we reserve our right to replace , repair as the deem fit by us.

Water Chem Corporation shall not be liable for any direct or indirect damage caused What so ever except for repair/ Replacement of defective parts of machine.

The Owner shall not raise any claim what so ever due to non working of the machine or any damage Caused due to non functioning of the machine.

Procedure :-

1) Collect sample solution ( Sodium hypo chlorite ) in an air-tight bottle.

NOTES / CAUTION

a) Keep sample solution away from excessive light and do not agitate the sample solution.
b) Start chlorine determination IMMEDIATELY after sampling. ( i.e. do not store sample to be analysed for chlorine ).

2) Introduce 10ml of glacial acetic acid and about 0.5 g of Pottassium Iodide (Spatula full ) crystal into a 100ml erlemeyer flask.

3) Withdraw y ml ( 5 ml in case Chlorogen - 100 ) of sample solution with bulb pipette and introduce into above Solution.

4) Swirl the flask to well mix the solution.

5) Titrate with 0.1N Sodium Thio Sulphate Solution from upto a light
Yellow Colour.

6) Add 1 ml of starch indicator solution and continue to titrate until the last drop of titrant causes the solution to turn colourless.

% active chlorine = 3.545 x N x V/y   (i;e 3.545 x N x V divided by y)

Where :

V = Volume of (N ) Na₂S₂O₃

N = Normality of Na₂S₂O₃

y = Sample amount

INSTALLATION

UNPACKING
The Power Supply is wrapped in a polythene cover and inserted in a corrugated carton of larger size with adequate padding inserts , made up of corrugated paper , on all the sides. This primary packing is packed inside a secondary packing of wooden case with adequate materials on all sides. For unpacking, ( a ) Open the wooden case , (b) Remove the carton , ( c ) Remove the Power Supply from carton , (d) Remove all paddings (e) Unwrap the polythene cover ,(f) Inspect the material for physical damage, if any , (g) Save all the packing material until inspection in completed. If damage is found notify the carriers immediately. Also notify US about it.

PREPARE FOR USE AND INSTALLATION

INITIAL INSPECTION
Inspect for any damage as soon as Power supply is unpacked. Notify the carriers if any , damage is observed.

PHYSICAL CHECK
Confirm that there are no broken knobs or connectors , that the cabinets and panel surfaces are free from dents and scratches and the meters are not scratched or cracked.

ELECTRICAL CHECK
Check the Power Supply against its electrical specs. An In-cabinet performance check will verify the proper operation of the power Supply.

INSTALLATION :
The Unit is despatched ready for floor mounting operation. It is necessary only to connect the unit to a rated source of power and it is ready for operation. Install it, where enough ventilation is available. Surrounding is neat and clean. The ambient of area around should be between 10 deg C. to 42 deg C.

Before starting the operation of the Cholorogen 10012 C.G.R., please go through the pictorial presentation of the rectifier unit.

In this presentation, efforts have been made to familiarise you with different parts of the rectifier unit. You are requested to identify the parts and go through in detail about its function. It is very important for the operator to know about the operating switches, knobs and indicators, in order to operate the system in a proper manner. In the following lines, a step to step operating instruction has been given for easy understanding of the procedure.

Step One :- Install the Rectifier according to the guidelines provided in the manual. Select a suitable electrical outlet of 15 amps. Check for loose or sparking electrical connection. Put the plug into the Socket firmly. Adjust the Rectifier unit in such a manner that the mains wire remains loose.

Step Two :- After being sure about the electrical connection, put the mains On/Off Switch /M.C.B (Part No.1 in the Diagram of 10012 CGR) in the right direction to on the UNIT.

Result :- The A.C. ON. L.E.D. will begin to below Red. The Buzzer will be ON and a continuous chriping sound will be generated. The exhaust fans fitted inside the Rectifier unit will start :

Step Three:- The next step is to put on the Timer On/Off Switch (Indicated as Part No.2 in the Diagram).

Result :- The Timer (Indicated as Part No.3 in the Diagram) will be activated. The digits will start to glow.

Step Four :- Now, please examine the display of timer. It should indicate Zero's. There is a thumb wheel selector on the timer. Please insure that the thumb wheel selector is set to 480 minutes. After adjusting the thumb wheel switches to 480 minutes, the Timer Reset Switch is to be pushed. The Timer Reset Switch has been indicated as Part No.4 in the Diagram.

Step Five:- Next Step is to look at the Digital Panel Meters, indicated as Part 6 & 7 in the Diagram. Part 6 is Digital Volt meter which displays the output D.C. Voltage. Part No.7 is Digital Amp. Meter which displays the output current.

Step Six:- At this stage, the operator will notice the Over Current/Reset Indicator L.E.D., which will glow red and the Buzzing sound will be there. Now the operator is required to push the Reset Switch to ON. The Reset Switch has been indicated as Part No.5 in the Diagram. It has been referred as process start & over current Reset Switch also.

Result :- The Buzzing sound will stop, The indicator L.E.D. to indicate D.C. Voltage output will start to glow Green. The Digital volt meter will begin to display the output D.C. Voltage. The Digital Ampere meter will show the output occurrent in Amp.

Step Seven :- Please make adjustments with the help of Part No.9 as shown in the diagram, that is Ampere and Volt Adjuster. By turning the knob to clockwise, the output D.C. Voltage and Ampere can be increased. The operator is required to adjust the knob in such a manner that Digital Volt Meter shows 9.5 Volts. + .5 volts. Now the Digital Ampere meter will display approx. 100 Amps. + 6 Amps.

As soon as this is done, the operators job to start the rectifier unit is finished. The Rectifier starts to deliver required voltage and current to the electrodes. This will continue up to 480 minutes. As soon as the Timer unit displays 480 minutes of the operation completed, the Rectifier unit will automatically trip and stop the output to the Electrodes.

Things to do. If the Rectifier Unit Not Works

The Rectifier Unit will not operate if the input A.C. Voltage will be 250 Volts or higher. In this case, the over voltage indicator L.E.D. will glow Red. Under these circumstances, one is required to adjust the input voltage at 220 V. A.C. For this a voltage stabilizer of 5 K.V. capacity can be used.

The output current exceeds to 110 Amps, the Rectifier will trip and a buzzing sound will be there. The indicator L.E.D. for indicating over current/over/Oad/Reset will start to Glow. To start the unit the operator will have to adjust the Part No.9 Amp. and Volt. Adjuster knob to anti clockwise. This will decrease the output volt and Amp. Now Push the Reset Switch (Part No.5) to start the operation.

If the Input A.C. Voltage drops below to 150 Volts., or less the Rectifier unit will stop to function.

Another problem to be encountered may be from Timer. Please, ensure that the Timer has been adjusted in a proper manner.

If the mains ON/Off Switch/M.C.B. trips as soon as it is put to ON, please contact the technical service department of Electroset Aqua Purifiers Ltd., Delhi.