ProMinent CHLORINSITU IIa 625 Technical specifications

Chlorine electrolysis system
CHLORINSITU® IIa 625 ... 2500 g/h
Maintenance instructions
A2933
Target group: technical personnel.
These maintenance instructions are only valid in conjunction with the installation and operating instructions for the CHLOR‐
INSITU® IIa 625 - 2500.
EN
Original operating instructions (2006/42/EC)999734 Version: BA CI 021 05/21 EN
Please carefully read these operating instructions before use. · Do not discard.
The operator shall be liable for any damage caused by installation or operating errors.
The latest version of the operating instructions are available on our homepage.

Table of contents
1Safety.................................................................................... 3
2Maintenance of the Chlorinsitu® IIa 625 ... 2500 g/h............. 4
2.1 Warning information...................................................... 4
2.2 Recommendation for the pre-maintenance weeks....... 4
2.3 Maintenance intervals................................................... 4
2.4 You will need the following for maintenance................. 4
2.4.1 Protective clothing..................................................... 4
2.4.2 Contents of the capacity-specific “Maintenance
Pack 1” (annual maintenance):.................................. 5
2.4.3 Contents of the capacity-specific “Maintenance
Pack 3” (3-yearly maintenance):................................ 5
2.4.4 Hydrochloric acid 5 %................................................ 5
2.4.5 Collecting vessel........................................................ 5
2.4.6 10-litre bucket............................................................ 5
2.4.7 Canister..................................................................... 6
2.4.8 Service passwords..................................................... 6
2.5 Before undertaking maintenance work: Check and
note the following.......................................................... 6
2.6 How often is acid cleaning needed?............................. 6
3 Annual and 3-yearly maintenance steps when using MP1
and MP3................................................................................ 7
4 Maintenance check-list....................................................... 18
Table of contents
2

1 Safety
WARNING!
Danger from hazardous substances!
Possible consequence: Fatal or very serious inju‐
ries.
Please ensure when handling hazardous sub‐
stances that you have read the latest safety data
sheets provided by the manufacture of the haz‐
ardous substance. The actions required are
described in the safety data sheet. Check the
safety data sheet regularly and replace, if neces‐
sary, as the hazard potential of a substance can be
re-evaluated at any time based on new findings.
The system operator is responsible for ensuring
that these safety data sheets are available and that
they are kept up to date, as well as for producing
an associated hazard assessment for the worksta‐
tions affected.
nMaintenance may only be carried out by authorised technical
personnel.
nThese maintenance instructions are only valid in conjunction
with the “Installation and operating instructions for the chlorine
electrolysis system CHLORINSITU® IIa”.
Safety
3

2 Maintenance of the Chlorinsitu® IIa 625 ... 2500 g/h
2.1 Warning information
WARNING!
Danger from hazardous substances!
Possible consequence: Fatal or very serious inju‐
ries.
Please ensure when handling hazardous sub‐
stances that you have read the latest safety data
sheets provided by the manufacture of the haz‐
ardous substance. The actions required are
described in the safety data sheet. Check the
safety data sheet regularly and replace, if neces‐
sary, as the hazard potential of a substance can be
re-evaluated at any time based on new findings.
The system operator is responsible for ensuring
that these safety data sheets are available and that
they are kept up to date, as well as for producing
an associated hazard assessment for the worksta‐
tions affected.
WARNING!
You are working with chemicals here:
– Sodium hypochlorite 0.9% (NaOCl)
–Hydrochloric acid 5% (HCI)
– Salt (NaCl)
Therefore:
– Never mix NaOCI with HCI as this produces
toxic gas.
– Pay attention to the material safety data
sheets.
– Wear effective personal protective equipment.
2.2 Recommendation for the pre-maintenance weeks
In the weeks leading up to maintenance, preferably fill only as
much salt into the brine storage tank as you will need during the
final weeks before maintenance.
2.3 Maintenance intervals
nannually
ncarry out an additional maintenance every 3 years
2.4 You will need the following for maintenance
2.4.1 Protective clothing
Protective clothing:
nsafety goggles,
ngloves,
Maintenance of the Chlorinsitu® IIa 625 ... 2500 g/h
4

nappropriate clothing and shoes,
nrefer to the material safety data sheet.
2.4.2 Contents of the capacity-specific “Maintenance Pack 1” (annual maintenance):
Maintenance Pack 1 = MP1
1 - Test kit for softened water < 0.1 °dH,
2 - Water filter (optional),
3 - 3 filter mats for the fan,
4 - Spare parts kit: brine metering, complete,
5 - Various flat seals, for example sensor drain,
6 - Various sealing rings, 3-part PVC couplings.
7 - Injection / check valve for brine
8 - Foot valves, brine tank
2.4.3 Contents of the capacity-specific “Maintenance Pack 3” (3-yearly maintenance):
Maintenance Pack 3 = MP3
1 - Contents as per “Maintenance Pack 1”, but in addition:
2 - Control valve for water metering
3 - Measuring cartridge, sensor, drain (625 and 1,250 g/h)
4 - Maintenance kit for the softener (optional)
2.4.3.1 Contents of the Chlorinsitu® lla service kit
1 - Measuring cylinder 1000 ml to calibrate the dosing rate of the
brine metering pump.
2 - Adapter kit for acid cleaning and calibration of the dosing rate
of the brine metering pump.
3 - Wrench (spanner) for maintenance of the softener (optional).
2.4.4 Hydrochloric acid 5 %
Tab. 1: Required quantity of hydrochloric acid:
Type / System capacity, g/h 625 1250 2500
Volume in litres 20 40 70
2.4.5 Collecting vessel
A collecting vessel to collect the water while the pipework is open.
2.4.6 10-litre bucket
10-litre bucket for water and brine.
Maintenance of the Chlorinsitu® IIa 625 ... 2500 g/h
5

2.4.7 Canister
Only with acid cleaning: appropriate number and size of canisters
to dispose of the diluted hydrochloric acid.
2.4.8 Service passwords
Your sales partner will provide you with the service password.
2.5 Before undertaking maintenance work: Check and note the following
1. Check the content of the alarm sequence of events in the
‘Service’ menu. If required: Delete the alarm messages.
2. Note down the value of the “Production hours” counter in the
‘Service’ menu.
3. Carry out a visual inspection of the unit including checking for
any leaks.
4. Carry out a visual check of the discharge line for diluted
hydrogen and the outlet into the outdoor air.
5. Allow the system to produce for a minimum of 5 minutes.
Then raise the level switch in the product storage tank and
note the following:
1 - The time elapsed since the last start. A minimum of 5
minutes.
2 - Does the system stop as soon as the operator opens
the door of the control cabinet?
3 - Take a sample of the softened water – the hardness
should be < 0.05°dH.
4 - Cell voltage
5 - Cell current
6 - Cell temperature at the inlet
7 - Cell temperature at the outlet
8 - Flow at the input
9 - Flow at the output
10 - Which salt is used? Does it comply with the specifica‐
tion?
6. Is the liquid level of the brine storage tank normal?
1 - The liquid level should be below the overflow point.
2 - Does the valve close after filling?
3 - Is the liquid level high enough (> 20 cm)?
2.6 How often is acid cleaning needed?
The cells need to be cleaned with acid annually.
It is possibly sufficient to clean them with acid every 3 years if you
are using good-quality salt or the equipment is run for relatively few
production hours each year. Raised cell voltage is the first effect to
indicate that the cells need to be cleaned.
Maintenance of the Chlorinsitu® IIa 625 ... 2500 g/h
6

3 Annual and 3-yearly maintenance steps when using MP1 and
MP3
1. Use the
[START/STOP] key in the main menu to stop the
system.
2. Rinsing the suction side:
1 - Remove both foot valves from the brine tank.
2 - Insert both suction hoses into a 10-litre bucket filled with
water and rinse the suction hoses.
3 - Replace both foot valves.
4 - Put both foot valves back into the bucket.
5 - Turn the rotary switch of the brine pump from
EXTERNAL to “100 %” operating mode to rinse the brine
out of the system.
6 - Vent the brine pump, if you need to.
3. In the
‘Maintenance’ menu, press the [right arrow key] and
select ‘Rinse’ :
rinse Acid cleaning
Brine pump
Service
B1107
ðThe cell is rinsed with water for 10 minutes: no chlorine is
produced and no brine is metered. The brine pump works
as the brine pump is still in manual “100 %” operating
mode.
Annual and 3-yearly maintenance steps when using MP1 and MP3
7

4. Maintain the optional chlorine metering pump:
WARNING!
The chlorine metering pump and the hoses
are filled with NaOCI.
– Take precautionary measures as per the
material safety data sheet.
1 - De-pressurise the chlorine metering hose.
2 - If necessary, empty the product tank in advance and fill
with water.
WARNING! Never mix the product with an acid as
this will produce chlorine gas.
3 - Set the chlorine metering pump to manual
‘100 %’ oper‐
ating mode; the pump and hoses will fill up with water.
4 - You can remove the pump from the tank to work more
easily on the liquid end.
5 - Carry out maintenance as per the operating instructions
for the metering pump.
Replace the diaphragm and the valves etc.
6 - Replace the foot valve in the product tank.
7 - Vent the chlorine metering pump and check that it is
working properly.
8 - Wipe away any NaOCI that has escaped, rinse and
clean the surfaces with water.
5. Move the rotary switch of the brine metering pump to STOP.
ðThe pump and hoses are filled with water instead of with
NaOCI.
6. Switch off the external power supply as soon as cell rinsing
has ended.
The cell(s), pipes, sensors etc. are now filled with water
instead of with brine or NaOCI.
Maintaining the optional chlorine
metering pump
Annual and 3-yearly maintenance steps when using MP1 and MP3
8

A3317
1
Fig. 1: Water softener test valve (1)
7. Disconnect the water supply. Open and close the water soft‐
ener test valve (1) several times to bring the system to
atmospheric pressure.
B1111
Fig. 2: Water filter
8. Replace the optional water filter.
B1190
9. Annually: clean the venturi pipe at the top.
Every 3 years: replace the piston, seal and washer set.
Replacing the water filter
Maintain the softener in line with its
operating instructions:
Annual and 3-yearly maintenance steps when using MP1 and MP3
9

10. Connect up the power supply, but do not yet connect up the
water supply.
A3318
1
Fig. 3: Disconnect the brine pipework (1) from the inlet of the cells.
11. Disconnect the brine pipework (1) from the inlet of the cells.
Have a vessel ready to collect any water that escapes.
You can remove the 4x6 mm water hose from the water con‐
trol valve (clip-on attachment).
1 - Replace the O-ring on the 3-part coupling of the cell
inlet.
2 - Replace the brine injection valve.
3 - Carry out maintenance on the brine metering pump as
per the operating instructions for the brine metering
pump.
You can remove the brine metering pump from the
internal product tank to work more easily on the liquid
end.
Replace the diaphragm and the valves etc.
INFORMATION! Once you have completed points 2 and 3,
first calibrate brine metering, as otherwise you will have to
dismantle the brine injection valve again.
12. Reconnect the brine supply line if you wish to carry out acid
cleaning.
Annual and 3-yearly maintenance steps when using MP1 and MP3
10