These Operating Instructions are intended for studying the EAS and contain the description, the design and the principle of operation, as well as the performance specification and other data required for a proper operation of the EAS.

  ATTENTION! Before starting the assemblage of the EAS forming part of the line for preparing the preservation agent, closely study these Instructions. If any questions arise, please, call the manufacturer.

  2.1. Purpose and application.

  The electrical activator of water is purposed for producing Electrochemical Activated Solutions (EAS) used in siloing green feeds with the view of replacing expensive, deficient and imported preparations.

  2.2. Outline of design

  2.2.1. The EAS forms part of the line for preparing the preservation agent.

  2.2.2. The activated water line (Fig. 1) consists of an EAS 1, a control unit 2, connecting electrical cables 3, connection hoses 4, a supply pump 5 of a pumping capacity of no less than 2 m³/h and of a volume capacity of 6 with 0.65% … 1.5% sodium chloride solution (depending on the local water hardness) provided with a metal gauze for trapping mechanical inclusions, valves 7, 8, 9, 12, accumulative vessels 10 and 11, concentrated NaCl solution vessels 13; a valved pipeline 8 intended for an active intermixing; a water supply pipeline 14.

Fig. 1. The activated water line diagram recommended.

Manufacturer's delivery 1. Activator; 2. Control unit; 3. Connecting electrical cables; 4. Connection hoses; 5. Feed pump; 9,12. Regulating valves.
Customer's delivery 6. Vessel (3-5 m3); 7,8. Valves; 10,11. Accumulative vessels (neutral material: stainless steel, aluminum, glass fiber laminate); 13. Concentrated solution vessel (200-300 l); 14.Water supply pipeline

  2.2.3. The EAS (Fig. 2) is a compact easily dismountable unit. A body 1 is installed on a support 3. A fitting 5 is intended for connecting with the supply pump. The activator is provided with shutoff valves 7 and 11 for adjusting the production rates of the catholyte and the anolyte according to 1/6 … 1/8; a bowl 8, studs 9 for connecting with the control unit, a fitting 10 having a plug fitting for draining off the solution before dismounting or laying up the activator; a control unit 12, connecting cables 13, a pump 14 and connection cables 15.

Fig. 2. EAS.

Salt solution supply 1. Body; 2. Support; 5. Fitting; 6. Ringbolt; 7. Regulating valve; 8. Hydrogen-separating bowl; 9. Current-carrying stud; 10. Draining fitting; 11. Regulation valve; 12. Control unit; 13. Connecting electrical cables; 14. Pump; 15. Connection hoses; 16. Regulation valve

  2.2.4. The internal design of the EAS is shown (Fig. 3).

  The EAS consists of two electrodes: a graphite anode 1 and a metal cathode 2. The anode and the cathode are separated with a semi-impermeable membrane 3 made of linen canvas. The cathode 2 is a cylinder course having two flanges. The anode 1 is installed on a base 4. The contact studs 5 tightly screwed into the anode 1 concurrently serve for fastening a cover 6. On the base 4 and the cover 6 there are recesses intended for fastening the membrane 3 with threads 7. In the base 4 a fitting 8 intended for supplying the feed solution and a branch pipe 9 having a plug 10 are installed. The branch pipe 9 having a plug 10 is intended for draining off the feed solution before dismounting the activator or placing it for a long storage. The cathode 2 is attached to the base 4 by means of studs 11 and nuts 12. On the cover 6 a distribution unit is installed. The distribution unit consists of a hydrogen-separating bowl 13, valves 14, 22 and a fitting 15. The hydrogen-separating bowl 13 is intended for leading out the evolved hydrogen to the atmosphere and taking the catholyte. The valves 14, 22 are intended for adjusting the production rate by the anolyte and the catholyte. The fitting 15 is intended for taking the anolyte. Gaskets 16, 17, 18 and a rubber ring 19 are intended for ensuring impermeability. The distribution unit is attached to the cover 6 by means of studs 20 and nuts 21.

  2.3. Technical data

  Table 1

  Note: The amount of the concentrated NaCl solution added depends on the mechanical properties and the hardness of the local water.

  ATTENTION! The valves 14 and 22 are intended for adjusting the production rate by the catholyte and the anolyte - 1/6 … 1/8.

  3.1. General provisions.

  3.1.1. To service and repair the electrical equipment of the line, only the staff trained in the technique of working, acquainted with the properties of the solutions and gases produced, having an admittance group by PTE and PTB no lower than III, and having passed the annual attestation should be admitted. The age of the maintenance staff should be no less than 18 years.

  3.1.2. The non-attested staff, when servicing the activated water line, has a right to only switch on and off the switching equipment.

  3.1.3. Before starting the work all the participants should get familiarized with the circuit and erection diagram, learn the arrangement of the diagram circuits and elements, paying special attention to the location of the switch from the direction of the mains supply.

  3.1.4. The category of the room with respect to the fire safety and the explosion hazard is "D". The class with respect to PUE is В-1б, and the class with respect to the electrical hazard is with a higher level.

  3.1.5. In accordance with CH-245-71 and CH and П2.04.05-86, considering the gas evolution amount, the anolyte and the catholyte drain points should be provided with exhaust ventilation and general ventilation of a factor of no less than 3 or with good aeration.

  3.1.6. The activator and the power supply cabinet as part of the line are to be installed under a shed and should have an insulating platform.

  3.1.7. It is necessary to provide for separately branching the anolyte, the catholyte and the gas evolved in the catholyte

  3.1.8. The anolyte (the preservation agent) is an acid solution having pH not exceeding 2.5, containing chlorine. The chlorine is a gas of yellow-green color having a strong odor.

  3.1.9. The catholyte is an alkaline solution having pH of no less than 10 producing a biologically active effect

  3.1.10. The hydrogen is a colorless and odorless gas. With a compact unventilated room (see item 3.1.5.) and a high concentration in the air an explosive mixture can be formed.

  Provision is to be made for safely branching the hydrogen to the atmosphere by increasing the hydrogen-separation bowl branch-pipe height, if the activator is installed in a closed room

  3.1.11. The work on collecting the anolyte and the catholyte and on maintaining the water activation line is to be executed with wearing protective glasses.

  3.1.12. Indoors, when the line is operated, no smoking is to be allowed, and no open flame is to be applied.

  3.1.13. During the operation the electric cabinet doors should be closed.

  3.1.14. Upon completing the working season the feed pump vessel, the pump and the activator must be thoroughly cleaned and rinsed 3-4 times with water

  3.2. When mounting and assembling:

  3.2.1. The slinging is to be carried out by the places designated with "Slinging place" according to GOST 14192-04.

  3.2.2. The circuit assembling should be executed when the system is de-energized, with the knife switch or the switch from the direction of the mains supply switched off.

  3.2.3. The vessel for the feed solution, the control unit and the pump motor should be set to zero and earthed.

  3.2.4. No mechanical impacts, and no over-tightening the bolted joints in the parts made of a dielectric are allowable.

  3.3. When testing, running-in and operating:

  3.3.1. The energization is executed only after the circuit is checked by the chief. Before energizing and de-energizing, a signal or a warning in voice "Attention! I am energizing the system" which annunciate all the personnel working on the line are to be given.

  3.3.2. The voltage absence is checked on the apparatus in the circuits only by means of voltage detectors.

  3.3.3. No ingress of moisture is admitted onto the electrical equipment and devices.

  3.3.4. The activator, the control unit and the feed pump should be con-trolled from an insulating support.

  3.3.5. The presence of unauthorized persons and, in particular, children at the workplace is prohibited.

  3.4. When maintaining:

  3.4.1. It is flatly prohibited to execute any work on the maintenance when the electrical activator and the feed pump are energized.

  4.1. The EAS controls are located directly on the EAS (Figs. 1, 2).

  4.2. The control unit controls and devices are located on the front panel of the electrical equipment cabinet. On the underside of the electrical equipment cabinet door a plate is attached where an electrical drawing containing the control and automation elements is represented.

  5.1. The EAS, the control unit, the vessel for the feed pump are installed under a shed.

  5.2. The EAS and the control unit are to be installed upright. Any deviation of the activator from the vertical position by over 5 degrees is prohibited.

  ATTENTION! The valve 9 (Fig. 1) should be located above the receiving vessel mouth by no less than 200 mm. To provide for a free discharge of the catholyte and the anolyte, it is necessary to eliminate any bending of the hoses.

  5.3. For convenience in servicing the EAS, the control unit, the feed pump, the feed solution vessel and the concentrated NaCl solution vessel are to be installed in immediate proximity to each other.

  5.4. The hoses for collecting the anolyte and the catholyte are to be in-stalled, and the feed pump is to be connected by the hose with the activa-tor, and the pump is to be connected by the hose with the solution vessel. The solution and the preservation agent vessels should be made in a corrosion-proof version. It is allowed to use the concentrated solution vessel 13 and the initial solution vessel 6 (Fig. 1) made of ferrous metal.

  5.5. The EAS is to be cabled together with the control unit, the polarity be-ing observed.

  ATTENTION! When connecting the cable with the studs 5 (Fig. 3) no rotat-ing the studs is allowed, and two double-pin spanner wrenches are to be used.

  5.6. The control unit and the pump are to be connected up to the electrical supply network. The rotating sense of the pump motor is to be checked up. The cabinet is to be set to zero and earthed.

  5.7. The reliability of the bolt joints is to be checked up, and the bolt joints are to be tightened, if necessary.

  6.1. EAS line starting (Fig. 1)

  6.1.1. Filling the vessel 6 with water is to be effected by means of a pres-surized water source by the feeding water pipeline 14.

  6.1.2. The NaCl salt is to be bulked into the concentrated solution vessel 13 (for 1/3), poured over with water and thoroughly agitated. At a temperature of 18-22°C a 33% NaCl solution is produced. To reduce the membrane clogging, clean salt should be applied.

  6.1.3. The pump drive is to be switched on. The production rates by the anolyte - 1 m3/h and by the catholyte ? 120-200 l/h (see Table 1) are to be set up by the valves 7, 8, 9 and 12. Valve 7 - line production rate; the valve 8 - intermixing; the valves 9, 12 - the catholyte to anolyte ratio 1/6-1/8.

  6.1.4. The control unit is to be switched on. Gradually, subject to the solu-tion vessel volume, the concentrated NaCl solution is to be added from the vessel 13 to the vessel 6.

  ATTENTION! The amperemeter readings are to be watched. The current will gradually rise.

  Inertial system, the current rises when the solution reaches the activator.

  By adding the concentrated NaCl solution, the current is to be raised up to 500-550 A (as the concentrated solution is consumed, water and salt are to be added into the vessel 13, and, at regular intervals, stirred).

  The catholyte pH which must be pH=12 is to be checked with litmus paper. Then, from the anolyte branch pipe the preservation agent goes out. The evolution of hydrogen in a form of a light transparent-white cloudlet, coming from the upper branch pipe of the bowl, and a strong odor of chlorine, coming from the anolyte branch pipe, are evidence of the fact that the anolyte (the preservation agent) produced meet the parameters; this should be confirmed by the analysis.

  The installation is taken out to the running conditions.

  The vessel 11 needs to be hermetically sealed (polyethylene film).

  6.1.5. When the production rate is increased by the valve 7 the current is dropping, and when the production rate is decreased by the valve 7 the current is growing.

  As the clean water comes from the feeding water pipeline 14 into the vessel 6, the current will gradually fall. The preservation agent having the parameters required, with the production rate of 1m3/h, is produced at a current up to 450 A. When the 450 A current is attained, a gradual adding of the concentrated NaCl solution from the vessel 13 into the vessel 6 and a raising of the current up to 550 A are required. This provides for a continuous process for producing the preservation agent.

  ATTENTION! If the inspection amperemeter is installed on the tall side of the transformer, 600 A of the load are in line with 22 A; 550 A-20 A; 450 A-16.5 A.

  6.1.6. The production rate is to be checked up every day before starting the work.

  The anolyte and the catholyte hoses are to be thrown over into a volumetric vessel, and the start and the finish of the filling-up are to be fixed by the stop watch. The production rate is to be determined according to Table 2 depending on the volumetric vessel chosen.

  For example:

  1. When filling up a volumetric vessel of 3 l in capacity with the catholyte the filling-up is fixed for 54 s. According to Table 1, it is clear that the production rate amounts to 0.2 m³/h.

  2. When filling up a volumetric vessel of 8 l in capacity with the anolyte the filling-up is fixed for 23 s. According to Table 1, it is clear that then the production rate is between 1.2 and 1.3 m³/h.

  After checking up the production rate, the stable reading of the amperemeter and the hydrogen evolution from the bowl, the electrical activator is to be switched off and the analyzing of the samples is to be started. The analyzing of the samples is set forth in Section 7 of these Instructions.

  With the positive results obtained from the analyses, the collection of the anolyte and the catholyte is to be started. The results are considered to be positive if pH by the catholyte is no less than 10, and pH by the anolyte is no more than 2.5, and the active chlorine content is no less than 170 mg/l.

  6.1.7. Line stop.

  Upon completing the work or exhausting the feed solution, the rectifier, the pump, the power supply automation are to be switched off.

  6.1.8. Discharging the solution remainder from the vessel.

  The solution is discharged at the end of the season or in a case of an absolute necessity. For this purpose, it is essential to preliminarily remove the hose 4 (Fig. 1) from the activator fitting and switch on the feed pump 5.

  6.1.9. Discharging the solution remainder from the EAS.

  The solution is discharged from the activator in a case of an absolute necessity or for dismounting the activator.

  6.1.10. Rinsing the feed solution vessel and the activator vessel.

  The rinsing is effected with clean water. The valves 7 and 9 are to be opened in full, the feed pump 5 (Fig. 1) is to be switched on. After the water starts to go through the anolyte branch pipe, the valve 12 is to be opened. The operations 6.1.8 and 6.1.9 are to be repeated.

  6.2. The EAS can work in all the zones of the country.

  6.3. Transportation rules.

  6.3.1. When transporting the EAS, a carriage of a carrying capacity of no less than 500 kg is to be used.

  6.3.2. The EAS can be transported by any mode of transport.

  The requirements for the transportation should comply with the following documents: "General rules on transportation of goods by motor transport" approved by the Ministry of Transport of RSFSR dated 30.07.2004; "Rules on transportation of goods" approved by the Ministry of Inland Water Transport dated 14.08.2004, No. 144.

  When transporting, the safety of the installation and the loading pieces from damage and losses is to be secured

  6.3.3. The load-carrying capacity of the loading mechanisms should be no less than 500 kg.

  6.3.4. When lifting the load, the slinging places designated in accordance with GOST 14192-04 are to be used.

  7.1. Analyzing of samples.

  7.1.1. The anolyte sample volume for determining the active chlorine con-tent should not be less than 200 ml.

  7.1.2. The activated water samples are not to be preserved. The determination should be conducted immediately after taking the sample.

  7.2. The main point of the method.

  The method is based on oxidizing the iodine with active chlorine up to the iodine which is titrated with sodium thiocyanate.

  7.3. Apparatus, materials, reagents.

  Laboratory measuring glassware according to GOST 1770-04 of volume capacities: volumetric flasks - 100 and 1000 ml; droppers having scale divisions 5, 10, 25 ml; a cone flask having a ground-in plug - 250 ml according to GOST 23932-04E.

  Potassium iodine (KJ) according to GOST 4232-04, chemically pure, in crystals.

  Distilled water according to GOST 6709-04.

  Chloroform (trichloromethane) according to GOST 20015-04.

  Sulfuric acid (H₂SO₄) according to GOST 4204-04.

  Salicylic acid according to GOST 624-04.

  Soluble starch according to GOST 10163-04.

  Sodium sulfate (sodium thiosulfate) (Na₂S₂O₃x5H₂O) according to GOST 244-04.

  Crystalline sodium carbonate (Na₂SO₃) according to GOST 84-046.

  All the reagents used in the anolyte should be qualified as "Pure For Analyzing" (PFA).

  7.4. Preparation for analyzing.

  7.4.1. Preparation of 0.1 H solution of sodium sulfate. Solve 25 g of sodium thiosulfate Na₂S₂O₃x5H₂O in green boiled and cooled distilled water, add 0.2 g of sodium carbonate Na₂SO₃ and bring the volume up to one liter.

  7.4.2. Preparation of 10% sulfuric acid H₂SO₄ solution. Pour some distilled water into a volumetric flask of 1 l in capacity, then pour in 61 ml of concentrated sulfuric acid H2SO4 and bring the volume up to 1 l.

  7.4.3. Preparation of 10% solution of potassium iodine (KJ). Introduce 100 g of potassium iodine KJ into a volumetric flask of 1 l in capacity and, gradually agitating, add the distilled water in small portions to bring the volume up to 1 l.

  7.4.4. Preparation of 0.5% starch.

  Mix up 0.5 g of the soluble starch with a small amount of the distilled water, bring in 100 ml of the boiling distilled water and boil for several minutes. After cooling, the preservation is performed, adding several drops of chloroform or 0.1 g of salicylic acid.

  7.5. Analyzing

  7.5.1. Take 25-30 ml of the solution (EAS) to be analyzed into a cone flask equipped with a ground-in plug, add 5 ml of 10% potassium iodine KJ, add 10 ml of the 10% sulfuric acid (H₂SO₄) solution. Hold 5 minutes and titrate 0.1H of the 10% sulfuric acid (H₂SO₄) solution. Hold 5 minutes and titrate 0.1H with the sodium thiosulfate solution until a light-yellow color is produced. The titration is conducted on a white background. Then add 1 ml of the 0.5 starch solution, resulting in producing a blue color of the solution. Continue the titration by the 0.1H sodium thiosulfate solution until the blue color disappears.

  ATTENTION! The titration and holding of the sample titrated must not be held under direct solar radiation.

  7.6. Analysis of results

  The content of the summable active chlorine in mg/l is calculated by the formula:

x = (V x 3.55 x 1000)/y

  where: V is the summary volume of the 0.1H sodium thiosulfate solution (Na₂S₂O₃) spent for both the titration procedures; Y is the analyzed sample (EAS) volume; and 3.55 is the active chlorine amount which is in line with the 0.1H sodium thiosulfate solution (Na₂S₂O₃).

  To provide for a normal operation of the EAS as part of the line, as well as for the safety and the durability, a proper maintenance and observation of the safety of the assemblies and parts must be conducted.

  8.1. Maintenance types and rate.

  Table 3

  The EAS, after finishing the work, is to be stored in a non-knocked-down form, then the drying of the graphite electrode takes place.

  8.2. Use of set of spare parts and accessories.

  The parts which are members of the set of spare parts and accessories are to be installed in the following order:

  8.2.1. Replacement of membrane 3 (Fig. 3):

  - Disconnect the electric cables.

  Note: When disconnecting the electric cables the rotation of the contact studs 5 is prohibited. Use two double-pin spanner wrenches.

  Remove the hoses from the fitting 15 and the bowl-distributor.

  Screw off the plug 10 and pour out the feed solution remainder.

  Screw off the nuts 21 and remove the distributor.

  Screw off the nuts 12.

  Screw three M12x40 bolts and, by alternately rotating the bolts, achieve the cathode swinging with respect to the cover 6 and remove the cathode.

  Remove the threads 7 (from two sides of the membrane).

  Remove the failing membrane.

  Clean the internal surfaces from the sludge formed in the process of the work when the openings in the electric cathode 1 and the cover 6 must be cleaned.

  Install a new membrane 3, fastening it with the threads 7.

  ATTENTION! The openings in the cover 6 must not be overlapped. Eliminate the excess of the material. When installing the membrane no corrugation is allowed.

  The assemblage is made in a reverse sequence, and an autosealer is to be applied to the rubber ring 19 of the upper cover 6. The drying time is no less than 2 hours.

  9.1. Store the electrical activator before mounting in a closed area according to the GOST 7751-04 requirement. The storage conditions З(ЖЗ) according to GOST 15150-04.

  9.2. The selection of the means of a temporary anticorrosive protection and conservation for the period of storage and transportation is to be made according to GOST 9.014-04, storage category B3-1; the tools and the spare parts are to be conserved, packed into a box and handed over to the storehouse pursuant to the list of contents.

  9.3. Preparation of the EAS for storing

  9.3.1. The operations set forth in item 8.2.1 are to be performed.

  9.3.2. The membrane and the wet components are to be died up.

  9.3.3. When a visual examination is carried out, a decision about replacing the membrane is to be made.

  9.3.4. The assemblage of the EAS is to be made in a reverse sequence according to item 8.2.1.

  9.3.5. All the openings through which any atmospheric precipitation may fall into the internal cavities should be tightly closed with the covers.

  9.3.6. The places where the coating is broken are to be restored.

  9.3.7. The hoses, electrical equipment, devices and electric cables are to be handed over to the storehouse.

  ATTENTION! You can manufacture a membrane of linen canvas (for example, tarpaulin) yourself. However, in view of the fact that the material may shrink, the canvas must be preliminarily soaked in boiling water, held for 1.5 h, rinsed in cold water, dried up, and only after that a membrane can be cut out and laced according to a pattern available.

  Table 4

  11.1. The electric circuit works in the following way (See Appendix 1).

  11.1.1. Switch on the QF entrance circuit-breaker.

  11.1.2. The lamp signaling unit HL is lighted up, signalizing about energizing the control board, 380/220 V, 50 Hz.

  11.1.3. Switch on the pump drive pressing down the SB1п button.

  11.1.4. The lamp signaling unit HL1 is lighted up, signalizing about the pump running.

  11.1.5. Switch on the EAS pressing down the SB2п button; at the same time, the rectifying unit cooling fan is switched on. The SB2п button is to be held down until the fan is driven up to speed.

  11.1.6. The lamp signaling unit HL2 is lighted up, signalizing about the activator running.

  11.1.7. The line is switched off in a reverse sequence: SB2c, SB1c, QF.

  Table 2