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

A3319
3
2
1
Fig. 4: Pipework, 1, 2, 3
13. Remove the pipework (1/2/3) from under the cells.
1 - Have a vessel ready to collect water that will immediately
escape.
2 - Replace all sealing rings on the couplings.
3 - Reconnect the pipes if you do not wish to perform acid
cleaning. Do not connect the pipes if you wish to perform
acid cleaning.
A3323
Fig. 5: A light-coloured circle indicates the white flow sensor in the
outlet for 2,500 g/h.
14. Replace all sealing rings on the couplings.
Annual and 3-yearly maintenance steps when using MP1 and MP3
11

15. Reconnect the pipes if you do not wish to perform acid
cleaning. Do not connect the pipes if you wish to perform
acid cleaning.
A3324
Fig. 6: Threaded connectors of the flow sensor
16. Open both flow sensor threaded connectors in the outlet.
CAUTION!
– Pay attention to the flow sensor’s meas‐
uring cartridge, as it can fall out.
–The flow sensor carries a direction arrow.
The direction arrow must be facing
upwards.
– Fundamentally do not use any tools to
tighten the couplings or hexagonal head
screws. It is enough to tighten them
hand-tight.
Annual and 3-yearly maintenance steps when using MP1 and MP3
12

B1113
Fig. 7: Flow sensor
17. 1 - Loosen the pipework between the cells and the flow
sensor (left part at the top of the image) and remove this
pipework. The temperature sensor must remain in the
line.
2 - Replace all O-rings in the couplings.
3 - Remove the 2 hexagonal head screws from the sensor,
and replace the 2 flat seals above and below the flow
sensor - see figure below.
CAUTION! Pay attention to the flow sensor’s measuring
cartridge, as it can fall out.
Replace the measuring cartridge in the sensor every 3
years.
4 - Replace the 2 hexagonal head screws, but do not yet fit
the sensor.
B1114
Fig. 8: Threaded connectors of the flow sensor
18. Replace the water control valve every 3 years.
You can simply unclip the hoses (clip system).
Connector Label at side
Valve outlet 2
Valve inlet 1
Annual and 3-yearly maintenance steps when using MP1 and MP3
13

19. Switch on the water supply again:
1 - Slowly open the water supply valve.
2 - Slowly open the valve for softened water to release the
air.
Air is trapped in the water filter, which then migrates into
the water softener.
20. If you wish to skip acid cleaning, then skip to .
A3325
Fig. 9: Adapter kit with hose on the outlet of the cell
21. If you wish to perform acid cleaning, connect the adapter kit
with hose to the outlet of the cell.
WARNING!
Never allow the adapter hose to enter the
product tank, as hydrochloric acid and hypo‐
chlorite produce toxic chlorine gas.
– Therefore keep the lid of the product tank
closed.
Route the adapter hose into an appropriately sized empty
canister.
22. 1 - Route the suction hose of the brine metering pump into
the 5 % hydrochloric acid.
2 - Turn the rotary dial on the brine metering pump from
STOP to “100 %”.
3 - After 60 minutes, turn the rotary dial on the brine
metering pump from “100 %” to STOP.
4 - Leave the adapter hose in the canister.
ð
CAUTION!
The canister now contains hydrochloric
acid with a concentration of less than 5
%.
Switching on the water supply
Acid cleaning of the cell(s):
Annual and 3-yearly maintenance steps when using MP1 and MP3
14

23.
System capacity, g/h 625 1250 2500
Feed rate in litres/h 20 40 70
24. 1 - Route the suction hose into the bucket filled with water.
2 - Start up the brine metering pump by turning the dial from
STOP to “100 %” for 9 minutes.
As soon as the brine metering pump has started up,
press the ‘Rinse cells’ key on the system.
3 - Stop the brine metering pump after 9 minutes by turning
the rotary dial from 100 % to EXTERNAL.
25.
Tab. 2: The additional volume of rinsing water in the canister after 9 minutes is approximately:
System capacity, g/h 625 1250 2500
Rinsing water in litres 12 25 50
26. Dispose of or neutralise the hydrochloric acid needed for
rinsing.
27. Remove the adapter and refit the line from the cell to the
internal degasser (tank).
Always replace the outlet line of the cell(s) and the line to the
internal product tank.
28. Check and clean the brine tank.
You will need to clean the brine tank with clean water if there
is a lot of dirt in the brine tank or if a hard layer of ≧ 5 cm of
salt impenetrable to water has formed on the base.
29. Switch on the water supply again:
1 - Slowly open the water supply valve.
2 - Slowly open the valve for softened water to carefully
release the air.
Air is trapped in the water filter, which then migrates into
the water softener.
30. Start up the brine metering pump again:
1 - Route the suction hose of the brine metering pump into
the brine tank again.
2 - Route the suction hose of the softener into the brine tank
again.
3 - Now replace both foot valves with new foot valves.
4 - If necessary: vent the brine metering pump.
5 - Turn the rotary dial on the brine metering pump to
EXTERNAL.
Rinse the cell(s) and brine metering
pump with water:
Checking and cleaning the brine tank.
Starting up the brine metering pump
Annual and 3-yearly maintenance steps when using MP1 and MP3
15

31. Prepare for calibration of the brine metering pump:
1 - If you have not yet done so: Replace the brine injection
valve.
2 - If you have not yet done so: Carry out maintenance on
the brine metering pump as per the operating instruc‐
tions for the brine metering pump.
3 - Route the liquid coming from the brine valve into the
measuring cylinder.
4 - Turn the rotary dial on the brine metering pump to
100 %. If necessary: remove the pump’s vent valve and
the vent hose.
5 - Allow the pump to run for at least 2 minutes to allow
brine to enter the line.
6 - Turn the rotary dial on the brine metering pump to
EXTERNAL.
7 - Note the liquid level in the measuring cylinder.
32. Calibrate the brine metering pump.
1 - In the
‘Maintenance’ menu, use the [right arrow key] to
press the [key] with the metering pump.
2 - Follow the instructions on the display.
3 - The bring pump is calibrated once the volume measured
has been entered in the display.
4 - Turn the rotary dial on the brine metering pump to
EXTERNAL.
5 - Reconnect the inlet line for the brine to the cell.
6 - If necessary: wipe away any brine that has escaped or
rinse it away with water.
33. Replace the 3 filter mats for the fans.
34. In the
‘Settings’ menu, press the [Fill cell] key to fill the cells
with brine and water for approximately 5 minutes.
35. Press the
[START/STOP] key and let the unit run for a min‐
imum of 5 minutes.
ðA power supply error can occur (
‘Voltage too high’ or
‘Current strength too low’ ). Simply reset the alarm and
restart the unit.
A third attempted start should be successful.
36. In the
‘Maintenance è Total production’ menu, press
[Reset production hours] .
Calibrating the brine metering pump
Calibrating the brine metering pump:
Replacing the 3 filter mats
Filling the cell(s) with brine
Restarting NaOCI production
Resetting
‘Production hours’
Annual and 3-yearly maintenance steps when using MP1 and MP3
16

37. Note down the data for the cells.
Allow the system to produce continuously for a minimum of 5
minutes. That suffices for an initial test. Complete warm-up of
the cells would need 30 minutes.
Note down the following:
1 - Time elapsed since the last start (a minimum of 5
minutes)
2 - Cell voltage
3 - Cell current
4 - Cell temperature at the inlet
5 - Cell temperature at the outlet
6 - Flow at the input
7 - Flow at the output
8 - Take a sample of the softened water – the hardness
should be < 0.05°dH.
38. Use the orange screw lid to seal the product tank.
Noting the cell data
Annual and 3-yearly maintenance steps when using MP1 and MP3
17

4 Maintenance check-list
CIIa serial number:
CIIa capacity:
Commissioning date:
Maintenance interval: nannually
nevery 3 years
nevery 5 years
Performed by:
Date:
Remarks:
No. Re: OK
1 Pre-maintenance performance values:
Cell current [A]:
Cell voltage [V]:
Temperature at cell input [°C]:
Temperature at cell output [°C]:
Cell flow on [l/h]:
Cell flow off [l/h]:
Production hours [hours]:
Days until next maintenance [days]:
Water hardness < 0.05 °dH? [yes / no]:
2 Alarm messages to be noted?
3 Visual check and visual leaks to be noted?
4 Does the salt used comply with the specification?
5 Safety in relation to hydrogen:
Visual check of the extract air pipe for diluted hydrogen
Visual check of the outlet point for diluted hydrogen to the outside
Maintenance check-list
18

No. Re: OK
Room air suction opening free (> 225 cm2)?
Does the unit stop after the cabinet door is opened?
6 Replace the water filter.
7 Change or clean the air intake filter.
8 At least every 3 years: Cleaning of the cell(s) with acid is recommended but is not nec‐
essary in each case.
9 Maintain the lye metering pump.
10 Replace the lye injection valve.
11 Calibrate the lye metering pump.
12 If fitted: maintain the chlorine metering pump.
13 Annually: replace the foot valve in the internal chlorine tank – recommended.
14 Replace sealing rings in the three-part couplings:
Do not use any tools to tighten the three-part couplings.
nat the inputs and outputs of the cells
ndownstream of the far right / last cell
n32 mm pipe on the internal chlorine tank
15 Replace around the outlet sensor:
nO-rings on the three-part coupling upstream and downstream of the sensor
nFlat seal upstream and downstream of the sensor. Manually tighten rotary sensor
16 Salt tank:
nCheck for hard salt crust on the base.
nCheck for dirt on the base.
nClean the tank if needed.
nReplace both foot valves.
17 Has the test kit for the water hardness not yet run out?
18 Every 3 years: Replace the measuring turbine cartridge of the outlet sensor.
19 Every 3 years: Replace the control valve for water metering.
20 Every 3 years: Maintain the water softener.
Replace the plunger, seals and washers and clean the nozzle.
21 Every 5 years: Replace the housing fan.
22 Every 5 years: Replace the cells - recommended.
23 Every 5 years: Replace the float switch of the chlorine tank, recommended.
24 Reset the maintenance counter to 365 days.
Maintenance check-list
19

No. Re: OK
25 Post-maintenance performance values:
Cell current [A]
Cell voltage [V]
Temperature at cell input [°C]
Temperature at cell output [°C]
Cell flow on [l/h]
Cell flow off [l/h]
Production hours [hours]
Days until next maintenance [days]
Water hardness < 0.05 °dH? [yes / no]
26 Check the orange screw lid of the internal storage tank. The screw lid must be fully
closed.
Maintenance check-list
20