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GRUNDFOS INSTRUCTIONS

Oxiperm® ProOCD-162

Service instructions

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English (GB) Service instructions
Original service instructions.

CONTENTSPage

1. General safety regulations 41.1 Purpose of this manual 41.2 Symbols used in this document 41.3 Authorised service personnel 41.4 Obligations of the operating company 41.5 Correct usage 41.6 Inappropriate usage 41.7 Safety and monitoring equipment 51.8 Chemicals 5

2. Product description 62.1 Application examples 72.2 Functional principle 72.3 Chlorine dioxide production process 102.4 Components of a standard system 112.5 Peripheral devices and accessories 122.6 Power supply connections and electronic connections 142.7 Display and control elements 142.8 Operation modes 162.9 Access codes 162.10 Menu structure 17

3. Transport and packaging 213.1 Unpacking 213.2 Transport damages 21

4. Installation 214.1 Installation location 214.2 Wall mounting (OCD-162-5/-10) 234.3 Floor mounting (OCD-162-30/-60) 244.4 Additional modules 264.5 External batch tank 264.6 Installing the chemical containers and suction lances 264.7 Hydraulic connections 264.8 Connecting the electronic components 284.9 Connecting the power supply cable 29

5. Commissioning 305.1 System configuration 305.2 Software settings 305.3 Commissioning procedure 345.4 Switching on the system - initial start-up 355.5 Basic setup 355.6 Setting the water flow meter 365.7 Selecting the measuring cell and measured variables 375.8 Assigning measuring range(s) 375.9 Setting the output current to an external device 395.10 Setting the chlorine dioxide controller 405.11 Setting the output current to an external dosing pump 425.12 Setting the warning relay and alarm relay 425.13 Setting the operation mode 445.14 Starting operation 455.15 Interrupting operation 455.16 Continuing operation after an interruption 465.17 Monitoring the production and dosing process 475.18 Flushing 525.19 Calibration 545.20 Error messages 575.21 Function tests 575.22 Setting the language 605.23 Saving the settings after commissioning 605.24 Switching off the system 60

6. Maintenance 616.1 Maintenance intervals 616.2 Maintenance kits for Oxiperm Pro 616.3 Maintaining the pumps 626.4 Maintaining the solenoid valve 636.5 Maintaining the multi-function valve 646.6 Maintaining the reaction tank 666.7 Maintaining the volume compensation bag and

activated carbon filter (OCD-162-5, -10) 67

6.8 Maintaining the volume compensation bag and adsorption filter (OCD-162-30, -60) 68

6.9 Completing the Maintenance work 69

7. Servicing 707.1 Preparing for servicing 70

8. Fault finding 728.1 Faults with error message 728.2 Faults without error message 76

9. Dismantling and decommissioning the system 779.1 Preparing for dismantling 779.2 Dismantling the hydraulic components 789.3 Dismantling the electrical components 789.4 Dismantling the system frame 789.5 Packing the system for transport 789.6 Final dismantling steps 789.7 Temporary storage of the dismantled system 789.8 Recommissioning after dismantling 79

10. Disposal 79

11. Technical data 8011.1 Identification 8011.2 Performance and consumption 8111.3 Temperatures and humidity 8111.4 Dimensions, weights and capacities 8111.5 Permissible chemicals 8211.6 Materials 8211.7 Dosing pumps 8211.8 Dilution water 8211.9 Main water line 8211.10 Permissible measuring cell type 8211.11 Product numbers OCD 162-5, -10 8211.12 Product numbers OCD 162-30, -60 8211.13 Electrical data 8311.14 Controller inputs 8311.15 Controller outputs 8311.16 Terminal connection plan 83

12. Spare parts 8512.1 Spare parts for OCD-162-5, -10 8512.2 Spare parts for OCD-162-30, -60 88

13. Accessories list 91

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1. General safety regulations

1.1 Purpose of this manual

These service instructions are aimed at specialist personnel responsible for installation, commissioning, maintenance, servicing, dismantling and (temporary) storage.

1.2 Symbols used in this document

Information about possible residual risks can be found:

• on warning signs located at the installation site

• at the beginning of each section in this manual

• immediately before steps associated with a residual risk.

1.3 Authorised service personnel

Only authorised service personnel trained by Grundfos are permitted to undertake installation, commissioning, maintenance, servicing, dismantling and (temporary) storage of the system. Appropriate technical expertise and familiarity with the principles of measurement and control technology are assumed.

1.3.1 Obligations of the service personnel

Service personnel are required to do the following:

• Read this manual thoroughly before commencing installation, commissioning, maintenance, service, dismantling or (temporary) storage of the Oxiperm Pro disinfection system.

• Obtain instruction from specialist personnel of Grundfos on all service work relating to the system.

• Observe the recognised health and safety and accident prevention regulations, see section 1.4 Obligations of the operating company.

• Wear protective clothing when working with the system and with chemicals, see section 1.3.3 Protective clothing.

• Keep secret the operator and service codes for the operating software.

1.3.2 Work station for service personnel

The Oxiperm Pro disinfection system is electronically controlled. Operators and service personnel operate the system via a display with control elements.

1.3.3 Protective clothing

Service personnel are obliged to wear protective clothing in accordance with the national safety regulations (Germany GUV-V D5) when working with the system and with the chemicals. The protective clothing is supplied by the operating company and stored in a dry place in the installation room.

1.4 Obligations of the operating company

Owners of the building and operators of the Oxiperm Pro disinfection system are obliged to:

• Consider this manual to be part of the product and make sure that it is kept clearly accessible in the immediate vicinity of the system for the entire service life of the system.

• Provide the installation requirements specified by the manufacturer (necessary water connections and fittings, environmental conditions, electrical connections, protective pipe for dosing line, audible or visual warning system for alarms). See section 4.1 Installation location.

• Make sure that water lines and fittings are regularly checked, serviced and maintained.

• Obtain official approval for storing chemicals, if necessary.

• Instruct operators in the operation of the system.

• Attach the labels supplied by the manufacturer at the installation site so that they are clearly visible.

• Provide the operator code for the operating software only to operators who have received appropriate technical training.

• Make sure that the regulations for the prevention of accidents are observed in the installation location (Germany GUV-V D5).

• Provide all operators and service personnel with protective clothing in accordance with the regulations for the prevention of accidents (Germany GUV-V D5): face mask, gloves, protective apron, breathing mask, if necessary.

• If the system is supplied without a dosing pump, provide an external dosing pump prior to installation. Only authorised service personnel trained by Grundfos is allowed to connect it to the Oxiperm Pro.

1.5 Correct usage

Oxiperm Pro OCD-162 is a system for the discontinuous preparation of a chlorine dioxide solution out of hydrochloric acid (9 %) and sodium chlorite (7.5 %), and the continuous dosing of this solution for water disinfection.

1.6 Inappropriate usage

Applications other than those listed in section 1.5 Correct usage are not in accordance with the intended use and are not permitted. The manufacturer, Grundfos, accepts no liability for any damage resulting from incorrect use.

A chlorine dioxide solution with an uncritical concentration of 2 g/l is generated in the reactor. Hence the Oxiperm Pro OCD-162 operates far out of the range of critical concentrations.

Danger of explosion in case of overdosage: at a concentration of more than 30 g/l the chlorine dioxide solution can explode.

Gaseous chlorine dioxide is a chemically unstable compound.At concentrations over 300 g/m3, it decomposes into chlorine and oxygen explosively without external impact.

Warning

If these safety instructions are not observed, it may result in personal injury.

CautionIf these safety instructions are not observed, it may result in malfunction or damage to the equipment.

NoteNotes or instructions that make the job easier and ensure safe operation.

Warning

Unauthorised structural modifications to the system may result in serious damage to equipment and personal injury.

It is forbidden to dismantle, modify, change the structure of, bridge, remove, bypass or disable components, including safety equipment.

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1.7 Safety and monitoring equipment

The disinfection system is fitted with the following safety and monitoring equipment:

• cover on the system frame

• two collecting trays for the two chemical containers (accessories)

• safety/multi-function valve at the dosing pump (optional)

• solenoid valve at the dilution water inlet

• volume compensation bag and activated carbon filter for ClO2 gas that escapes from the reaction tank

• alarm functions in the controller.

1.8 Chemicals

1.8.1 Chlorine dioxide concentration

In the reaction tank of the Oxiperm Pro OCD-162, diluted sodium chlorite and diluted hydrochloric acid are mixed to create a chlorine dioxide solution with a concentration of approximately 2 gram per litre of water. According to the disinfection requirement, the Oxiperm Pro OCD-162 doses the diluted chlorine dioxide solution into the main line to be disinfected.The chlorine dioxide concentration in drinking water must not exceed a maximum of 0.4 milligram per litre of water according to the German drinking water ordinance.

The following safety instructions must be observed:

1.8.2 Storing chemicals

• Chemicals must be stored in the appropriately marked original plastic containers (20 to 33 litres).

• Do not store chemicals near grease, flammable substances, oils, oxidising substances, acids or salts.

• Empty and full containers must be kept closed, especially in areas where national regulations for the prevention of accidents apply to storage (Germany GUV-V D5).

1.8.3 Procedure in case of an emergency

The general safety regulations and regulations for the procedure in case of an emergency, as specified in EN 12671 apply. Actions in case of an emergency:

• Ventilate the installation location immediately.

• Wear protective clothing (safety goggles, gloves, respirator and/or self-contained breathing apparatus, protective apron).

• Implement initial help measures

– In case of contact with the eyes, rinse immediately with plenty of water for at least 15 minutes. Consult a doctor.

– In case of contact with the skin, wash immediately with plenty of water. Remove all contaminated clothing.

– In case gas is inhaled, move the casualty to a source of fresh air. Avoid taking deep breaths. Consult a doctor (look out for a racing pulse, as vasodilating treatment may be required).

• Spillages

– In case of contact with clothing, remove the clothing immediately and wash with plenty of water.

– Chemical spillages in buildings must be washed away with water.

– Chlorine dioxide spillages can be doused with sodium thiosulphate, and washed away with water.

• Escaped gas

– Escaped gas can be rinsed away with water from a sprinkling system.

• Firefighting

– Aqueous solutions of chlorine dioxide are not directly flammable. Extinguish the surrounding fire with water, preferably using a fire sprinkler system to dilute the ambient gas. Inform the fire brigade of the installed production capacity and any harmful starting substances that are being stored (precursor substances) so that precautions can be taken regarding possible risks.

Warning

Risk of explosion when using chemicals in too high concentrations.

Only use sodium chlorite in a diluted concentration of 7.5 % by weight in accordance with EN 938.

Only use hydrochloric acid in a diluted concentration of 9.0 % by weight in accordance with EN 939.

Observe the safety data sheets from the chemicals supplier.

Warning

Risk of explosion when mixing up chemical containers or suction lances. Possible consequences are personal injury and serious damage to equipment.

Do not mix up chemical containers or suction lances.

Observe the labels on chemical containers, suction lances and pumps: red = HCl, blue = NaClO2.

Warning

Risk of burns when skin and clothing come into contact with sodium chlorite and hydrochloric acid.

Immediately wash affected skin and clothing with water.

Warning

Risk of irritation to eyes, respiratory system and skin, if chlorine dioxide is inhaled.

When changing the chemical containers, wear protective clothing in accordance with the regulations for the prevention of accidents (Germany GUV-V D5).

Warning

The temperature of the chlorine dioxide solution stored in an external batch tank may not exceed 40 °C.

Risk of outgassing at more than 40 °C.

NoteWe recommend the installation of a gas warning device.

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2. Product description

Fig. 1 Oxiperm Pro OCD-162 without cover and peripheral devices

Oxiperm Pro OCD-162 disinfection systems produce and dose chlorine dioxide for the disinfection of drinking water, process water, cooling water and wastewater.

Oxiperm Pro OCD-162 disinfection systems consist of a plastic system frame, on which the internal components are mounted. They are prepared for wall- or floor-mounting, and covered by a plastic cover.

The chemicals are supplied from two original chemical containers, which are located in two collecting trays directly under the system (OCD-162-5, -10) or in a separate tray for each container next to the system (OCD-162-30, -60). A suction lance is inserted in each container and is permanently connected to the corresponding chemical dosing pump. The suction lance cables send low-level and empty signals to the controller.

Oxiperm Pro OCD-162 is connected to two water lines:

• The drinking water line for supplying dilution water and flushing water.

• The main water line to be disinfected, into which the final chlorine dioxide solution is dosed.

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2.1 Application examples

Oxiperm Pro OCD-162 disinfection systems can be used for three different types of applications:

2.1.1 Disinfection of drinking water lines

• The flow rate of the water in drinking water lines can fluctuate greatly (peak times when water is used for bathing and cooking).

• The type and level of contamination in the water (disturbance variables) are not known or are very varied.

• Examples: drinking water lines in:

– hotels, multi-storey buildings

– schools, hospitals, nursing homes

– showers in sports facilities

– food and beverage plants

– waterworks.

2.1.2 Disinfection of industrial systems

• The water quantity in industrial systems is relatively constant.

• The type and level of contamination in the water (disturbance variables) are measured and hardly ever change.

• Examples:

– bottle cleaning plants in breweries

– industrial process water or wastewater systems

– cooling water systems.

2.1.3 Shock disinfection (with external batch tank)

• Applications requiring large quantities of disinfectant in a short time

• Example: cleaning of whirlpool baths

2.2 Functional principle

2.2.1 Production of chlorine dioxide

Chlorine dioxide solution is prepared in the reaction tank, see figure 2.

1. When a finished batch of chlorine dioxide solution flows out of the reaction tank into the batch tank, the float drops with the liquid level in the reaction tank. 60 seconds (OCD-162-5) or 70 seconds (OCD-162-10, -30, -60) after the float has dropped below level K1, the reaction tank is empty.

2. The controller starts a new production process by opening the solenoid valve. The water level in the reaction tank rises.

3. When the water in the reaction tank reaches level K1, the solenoid valve closes, and the water supply is interrupted.

4. The controller starts up the hydrochloric acid dosing pump. Hydrochloric acid flows into the reaction tank.

5. When the float reaches level K2, the controller stops the hydrochloric acid dosing pump.

6. The controller starts up the sodium chlorite dosing pump. Sodium chlorite flows into the reaction tank.

7. When the float reaches level K3, the controller stops the sodium chlorite dosing pump.

8. The reaction process begins. Reaction time: 15 minutes.

9. When the reaction time has elapsed (timer), the controller opens the solenoid valve again. The reaction tank is filled up with water to level K4.

10. The reaction tank now contains the ready-to-use chlorine dioxide solution in a concentration of approximately 2 gram per litre of water. If the batch tank is still full, the ready-to-use chlorine dioxide solution remains in the reaction tank, and the water supply is shut off.

11. When the float switch in the batch tank sends an empty signal (K5) to the controller, the solenoid valve opens again, and water flows into the reaction tank. The reaction tank overflows. Due to the hydraulic effect, the entire batch flows through a pipe in the middle of the reaction tank into the batch tank. When the level in the batch tank rises above K5, the water supply is shut off.

12. There are two different operation mode settings for internal or external batches, see section 2.8.

13. The pump doses the chlorine dioxide solution with the adjusted capacity from the batch tank to the injection unit.

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2.2.2 Flow-rate-proportional dosing

Suitable for drinking water applications:

1. The controller is set to "proportional controller".

2. A contact water meter or flow meter measures the water flow rate in the main water line, and continuously sends measured values to the controller.

3. The proportional controller calculates the required chlorine dioxide dosing volume in proportion to the water flow rate in the main line.

4. The proportional controller sends the corresponding output signals to the dosing pump.

5. The dosing pump doses the required quantity of chlorine dioxide solution from the batch tank into the main water line.

6. An optional measuring cell monitors the chlorine dioxide concentration in the main line.

2.2.3 Setpoint-controlled dosing

Suitable for industrial water applications:

1. The controller is set to "setpoint controller". A setpoint for the desired chlorine dioxide concentration in the main line is specified.

2. A measuring cell monitors the chlorine dioxide concentration in the main line, and sends actual values to the controller.

3. The setpoint controller compares the incoming actual values with the setpoint. Based on the deviation, it calculates the quantity of chlorine dioxide solution (actuating variable) required to achieve the desired concentration.

4. The setpoint controller sends output signals to the dosing pump.

5. The pump doses the corresponding quantity of chlorine dioxide solution from the batch tank into the main water line.

2.2.4 Levels K1 to K6 (OCD-162-5, -10)

Fig. 2 Reaction tank and batch tank of OCD-162-5, -10 (longitudinal cross-section)

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Pos. Description

A Manual drain

B From the overflow line of the multi-function valve

C To the dosing pump

D To the volume compensation bag

E HCl, NaClO2, H2O

F ClO2 solution

G Deaeration of the batch tank

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2.2.5 Levels K1 to K6 (OCD-162-30)

Fig. 3 Reaction tank and batch tank of OCD-162-30 (longitudinal cross-section)

2.2.6 Levels K1 to K6 (OCD-162-60)

Fig. 4 Reaction tank and batch tank of OCD-162-60 (longitudinal cross-section)

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Pos. Description

A Manual drain




E HCl, NaClO2, H2O

F ClO2 solution


K1

K2

K3

K4

K5

K6

ABC

F

OCD-162-30

D

EE E

F

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Pos. Description

A Manual drain




E HCl, NaClO2, H2O

F ClO2 solution


K1

K2

K3

K4

F

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E E EOCD-162-60

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2.3 Chlorine dioxide production process

Fig. 5 Chlorine dioxide production process

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Process stop

"Start ClO2 production" menu command

Solenoid valve opens

H2O supply

Level K1 reached, solenoid valve closes, HCl pump starts

Level K2 reached, HCl pump stops, NaClO2 pump starts

Level K3 reached, NaClO2 pump stops, timer for reaction time starts

Reaction

Time out of timer, solenoid valve opens

H2O supply

Level K4 reached

Yes

HCI supply

NaClO2 supply

No

Continuous production?

Level K1 reached, waiting time starts

ClO2 dosing

Level in batch tank rises above K5, solenoid valve closes

Waiting time has elapsed

Stop H2O

Wait until batch tank is empty

Level in batch tank drops under K5, solenoid valve opens

H2O supply, reaction tank overflowsNo

Yes

Batch tank still full?

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2.4 Components of a standard system

Fig. 6 Components of a standard system (Oxiperm Pro OCD-162-5, -10)

2.4.1 External components See also the photos in sections 12.1.1 and 12.2.1.

2.4.2 Internal components

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Pos. Component

1a Water line for dilution water and flushing water

1b Dilution water extraction device with isolating valve

3Container for sodium chlorite (NaClO2, diluted concentration of 7.5 % by weight) with suction lance and collecting tray

4Container for hydrochloric acid (HCl, diluted concentration of 9 % by weight) with suction lance and collecting tray

11 Main water line to be disinfected

12 Flow meter (or contact water meter)

14 Dosing line

15Injection unit for dosing chlorine dioxide (ClO2) into the main water line

16 Hose for sample water

17 Sample-water extraction device

18Measuring cell for checking the chlorine dioxide concentration in the main water line (optional)

19 Power supply connection

Pos. Component

2 Solenoid valve for dilution water and flushing water

5 Dosing pump for sodium chlorite (NaClO2)

6 Dosing pump for hydrochloric acid (HCl)

7 Reaction tank with float switch

8Batch tank with float switch and drain cock for chlorine dioxide (ClO2)

9 Volume compensation bag for chlorine dioxide gas

10 Activated carbon filter for chlorine dioxide gas

13 Dosing pump with multi-function valve for chlorine dioxide

20Electronic controller with measured-value sensor for check measurements

21 Display of the controller

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2.5 Peripheral devices and accessories

2.5.1 Accessories for the dilution water line

• Isolating valve

• Dilution water extraction device (if necessary with double nipple and connection piece for hose).

• Hose with connection to solenoid valve.

2.5.2 Accessories for the main water line

• Contact water meter or flow meter (in case of a new water line: water flow meter providing signals, or ultrasonic flow meter).

• Tapping sleeve for the injection unit.

• Protective pipe for the dosing line, installed from the dosing pump to the injection unit.

• DIT photometer: measures the chlorine dioxide concentration after dosing.

• Sample-water filter (in case of insufficient water quality).

2.5.3 Measuring cell

• Measuring cell

• Tapping sleeve for sample-water extraction at the main line.

• Hose from the sample-water extraction device to the measuring cell.

• Hose from the measuring cell to the sample-water drain.

2.5.4 Extension modules

The standard system can be extended with:

• Measuring cell for cold and hot water (main water up to 50 °C, pressure 4 bar).

• Measuring module for cold and hot water (main water up to 70 °C, pressure 8 bar).

• The use of a bypass mixing module is recommended in order to optimise mixing and reduce the risk of corrosion and in case of fluctuations in the main water flow

Fig. 7 OCD-162-5, -10 system with measuring cell and without extension module

NoteAccessories are not included in a standard delivery.

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RedBlue

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Fig. 8 OCD-162-30, -60 system with measuring cell and without extension module

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1b 19

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Pos. Component

1a Water line for dilution water and flushing water


3Container for sodium chlorite (NaClO2, diluted concentration of 7.5 % by weight) with suction lance and collecting tray

4Container for hydrochloric acid (HCl, diluted concentration of 9 % by weight) with suction lance and collecting tray



14 Dosing line

15Injection unit for dosing chlorine dioxide (ClO2) into the main water line

16 Hose for sample water


18 Measuring cell

19 Power supply connection/main switch

23 Connection cable for measuring cell

24 Sample-water drain

25 Connection cable for cleaning motor

26 Hose for dilution water

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2.6 Power supply connections and electronic connections

The Oxiperm Pro OCD-162 is equipped with an electronic controller (see fig. 9). The controller has connections for the following:

• power supply cable to the main switch

• cable from the flow meter or contact water meter

• cable from external batch tank to level control, if applicable

• cables for measuring cell AQC-D1 or AQC-D6, if applicable:

– measuring electrode and counter-electrode

– sample-water sensor

– Pt100 temperature sensor

– pH electrode (for pH or ORP) (AQC-D1 only)

– cleaning motor (AQC-D1 only)

• cables from the measuring module, if applicable:

– measuring electrode and counter-electrode

– sample-water sensor

– Pt100 temperature sensor

• cable from the mixing module, if applicable:

– flow controller.

For additional connections, see section 4.8.

2.7 Display and control elements

Fig. 9 Display and control elements

2.7.1 Control elements

2.7.2 Display

After switching on the system, the following display appears:

Fig. 10 Starting the system

Press [OK] to access the "Main menu":

During operation, press [Esc] to access the display level:

Fig. 11 "process running" display level

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Button or LED Function

Button [Esc] Cancels command, exits menu

Button [Up]Selects the previous menu item, or sets a higher numerical value

Button [Down]Selects the next menu item, or sets a lower numerical value

Button [OK] Confirms the menu selection

Button [Cal] Calibration

Button [Man] Manual operation

LED "Alarm" Alarm (red)

LED "Caution" Warning (yellow)

LED "Cal" Calibration (yellow)

LED "Man" Manual operation (yellow)

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Main menuProcessController ClO2AlarmServiceSetupMaintenance

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54321

.........24,5 °CpH 7,35

543210,23 mg/l

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process running

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The header indicates the status. The positions are explained in the table below.

Legend

Pos. Message Description

1Headers

"process running" Chlorine dioxide production is active.

"process stop" Chlorine dioxide production has been stopped.

"process termination" Chlorine dioxide production has been terminated by a menu command or alarm.

"Flushing" Flushing is started automatically or manually.

2Relays

1Relay for solenoid valve:White number on a black background: relay active.Black number on a white background: relay not active.

2 Relay for hydrochloric acid pump: display as for 1.

3 Relay for sodium chlorite pump: display as for 1.

4 Alarm relay: display as for 1.

5 Warning relay: display as for 1.

3Symbol

Symbol for the relay of the interpulse controller.

Symbol for relay stop of the interpulse controller.

4Symbol

Symbol for continuous controller: Box with plotted line.The height of the line is proportional to the actuating variable (chlorine dioxide dosing volume).Line not visible: actuating variable = 0 %. Line fills the entire box: actuating variable = 100 %.

Symbol for stop of the continuous controller: White box with a diagonal line through it.

5Symbol

Symbol for external disturbance value input (water flow as impulse or current signal): Box with plotted triangle.The black fill is proportional to the flow (the greater the fill, the greater the flow, 0-100 %).(only visible, if proportional or combined controller is configured).

6Value

e.g. 24.5 °C Water temperature, display value is only available with connected measuring cell.

7Value

e.g. 0.23 mg/l Chlorine dioxide concentration, display value is only available with connected measuring cell.

8Value

e.g. 7.35 pH value in the sample water, display value is only available with connected measuring cell.

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2.8 Operation modes

During commissioning, the Oxiperm Pro OCD-162 system is set up according to the application. After switching on and starting up the chlorine dioxide production via the menu commands, the system runs fully automatically.

Two operation modes are available for the production of chlorine dioxide. For setting the operation mode, see section 5.13:

• "Internal batch tank" mode: Chlorine dioxide solution is generated in the internal batch tank, and dosed into the line system, until the batch tank is empty. There are two ways of refilling the batch tank:

– First method "1-20": You determine how many times the batch tank is refilled by choosing a number in the range of 1 to 20.

– Second method "0 = continuous": The batch tank is refilled continuously.

• "External batch tank" mode: Chlorine dioxide solution is generated in the internal batch tank, and dosed into an external batch tank for storage. After emptying the external batch tank, chlorine dioxide production is restarted in a continuous process.

The appropriate dosing mode for the application is set at the dosing pump and at the controller via the parameter settings. Dosing takes place automatically.

Manual operation is used for shutting down the controller (see section 5.13 Setting the operation mode) and for temporary manual control, if required (impulse dosing).

2.9 Access codes

When the system is ready for operation, the "Main menu" cannot be accessed without a code. Two different access authorisations or security levels are assigned for all submenus. Each code automatically enables the levels below it.

2.9.1 Operator code

By default, all operator menus can initially be accessed without a code. When the menu selection has been confirmed with [OK], a code request is not displayed.

Once the operator has entered his operator code ("Main menu > Setup > change code"), the code request appears before any operator submenu can be accessed. The modified operator code must only allow access for operators with appropriate technical training and experience. Access is enabled for 60 minutes after entry of the code.

2.9.2 Service code

This code is reserved for trained Grundfos service engineers. Access is enabled for 30 minutes after entry. The service code is necessary for commissioning. See section 5.4 Switching on the system - initial start-up.

2.9.3 Super user code

Some menus in the maintenance section are preset in the factory. They are only accessible with a special code (super user code). They are not described in these instructions.

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2.10 Menu structure

The submenus vary in submenus for operators (with operator code) and service engineers (with service code).

All software menus can be selected from the "Main menu" using the [Up] and [Down] buttons, and accessed using [OK]. Press [Esc] to return to the previous menu level.

2.10.1 Operator menus (part 1)

1 The "Measurement" submenu only appears, if it is enabled in the "Setup" menu.

2 The "Water flow meter" submenu only appears, if a "Water flow meter" is enabled in the "Setup" menu.

3 Depending on the type of water flow meter enabled.

4 The alarm settings are only available, if "Measurement" has been enabled. The alarm relay is activated, if previously set alarm values for chlorine dioxide are exceeded or not reached, if the maximum dosing time is exceeded, and in case of a fault.

5 Depending on the setting in the "Setup" menu.

Main menu Submenu 1 Submenu 2 Submenu 3 Submenu 4 Submenu 5

Main menu

Process

StartStart Start ClO2 production?Back

TerminateTerminate Terminate ClO2

production?Back

OperationBatches

0 = continuous1-20 (adjustable)

Ext. batch tank On/Off

Service

Process

Status Display: process statusList of events

Production ClO2

BatchesChemicals HCl/NaClO2 ResetAge of ClO2 (mm:ss)

Maintenance

FlushingStartTerminate

Measurement 1

ClO2Measured valueCalData-LogBook

Temperature °C or °F (Measured value)

pH or ORP 5Measured valueCalData-LogBook

Controller ClO2

Water flow meter 2 E.g. 5 impulses/sec. = 50 % or 10 mA = 50 % 3

Test displayProgram version

Main menu

Setup

LanguageDeutschEnglish(All listed)

Date/time

datetime

Daylight.sav.t. Begin, End, time shift (± x hours), Off

Code functionChangeDelete

Display Contrast

Alarm 4Alarm value ClO2

Alarm off

Alarm on

Alarm value 1: 0.15 mg/lUpward violation or downward viol.

Alarm value 2: 0.70 mg/lUpward violation or downward viol.

Hysteresis: 0.01

Alarm delay: 0 sec.

Dos. time monit.OffOn Max. dosing time

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Operator menus (part 2)


Calibration

Chlorine dioxideCAL meas. valueCAL result Slope: µA, mg/l

CAL cycle On/Off

pH

CAL meas. value Grundfos, DIN/NIST, others

CAL result Slope µA, mg/lasym. mV

CAL cycle On/Off

ORPCAL meas. valueCAL result Asym.mV

CAL cycle On/OffManual operation Controller ClO2 On/Off

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2.10.2 Service menus (1)

* "Proport. ctrl." and "Combined ctrl." appear, if a water flow meter has been defined under "Setup" > "Water flow meter". Otherwise "Setpoint ctrl." appears.

** Temperature correction is active, if "Measurement" is activated in "Setup". The resistance of the Pt100 temperature sensor is higher on long lines. The additional line resistance is offset with this menu function. Units see "Setup" > "Measuring range".


Main menu Setup

MeasurementAQC-D1AQC-D6Off

ClO2ClO2 + pHClO2 + ORP

Measuring range

ClO2 0.00 - 1.00 mg/l....

Temperature °C°F

0-50 °C....

pH 0.00 - 14.00 pH....

ORP 0-1000 mV....

Water flow meter

OffImpulse x l/Impulse

x m3/hCurrent

0-20 mA4-20 mAothers

RelayWarning relay on (N.C.)

off (N.O.)

Alarm relay: on (N.C.)off (N.O.)

Current output

Control0-20 mA4-20 mAothers

Measurement ClO20-20 mA4-20 mAothers

Factory settingSetup

saveactivate

Reset Factory code

Controller ClO2

Proport. ctrl. *Interpulse ctrl.

Cont. controller 0-20 mA....

Setpoint ctrl.Interpulse ctrl. P, PI, PID

Cont. controller 0-20 mA

Combined ctrl. *Interpulse ctrl. P, PI, PID

Cont. controller 0-20 mA...

Off

Main menuService

Test current Control Measurement ClO2

0 % On/Off50 % Off/On100 % Off/On

Test relay

SV H2O OffPump HCl OffPump NaCl2 OffPump ClO2 OffAlarm relay: OffWarning relay Off

Test level

Reaction tank K4, K3, K2, K1

Int. batch tank K6, K5

Ext. batch tank K13, K12, K11

Suction lance K7, K8, K9, K10

MaintenanceMaintenance rel.Temp. correction ** x °C

Manual operation Dosing flow Cont. controller or Interpulse ctrl. xx % Dosing flow

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Service menus (2)

1 Only setpoint controller or combined controller

2 Only proportional controller

3 Only PI- or PID controller

4 Only PID controller

5 Only interpulse controller

Main menu Submenu 1 Submenu 2 Submenu 3 Submenu 4 Factory setting

Main menu Controller ClO2

Set point 1 x mg/l x = 0,2

Added quantity 2x mg/l

x = 0,2

Prop.range XP 1 x % x = 30

Reset time TN 3 x s x = 60

Deriv. time TV 4 x s x = 0

Switch-on time 5 x s x = 0,5

Dosing flow x % x = 100

Controller stopN.C.

N.O.N.O.

Dosing pump

Stroke adjustm. x % x = 100

Dosing capacity x l/h

DDA 7.5-16 for OCD-162-5: 2.5 l/h

DDA 7.5-16 for OCD-162-10: 5.0 l/h

DMX 16-10 for OCD-162-30: 16.0 l/h

DDI 60-10 for OCD-162-30: 16.0 l/h

DMI 35-10 for OCD-162-60: 35.0 l/h

DDI 60-10 for OCD-162-60: 35.0 l/h

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3. Transport and packaging
3.1 Unpacking

Number of packing units: 1 box.

1. Unpack the device.

2. Unpack the cover.

3. Unpack the measuring cell, if supplied.

4. Unpack the extension modules, if supplied.

5. Retain the original packaging in order to return the device for servicing.

6. Check the device(s) for transport damage (especially hoses and cables).

3.2 Transport damages

1. Pack the device in its original packaging.

2. Inform the forwarder of the transport damage.

3. Return the device to the supplier.

4. Installation

4.1 Installation location

The operating company must ensure that all the conditions listed below for structurally and technically safe and optimum operation of the system are met prior to commencing installation.

The installation location must fulfil the following:

• It is protected from the sun, frost-proof, well-ventilated and has sufficient lighting. The Oxiperm Pro system must not be installed outdoors.

• It meets the conditions specified in section 11. Technical data regarding air temperature, humidity, permissible component temperature and dilution water quality.

• It has concrete walls and floors, which enable the OCD-162-5, -10 system to be wall-mounted (minimum wall thickness for the mounting screws 100 mm) or the OCD-162-30, -60 system to be floor-mounted.

• It has a power supply connection.

• It has access to the main water line.

• It has a connection for dilution water of drinking water quality (Germany TrinkwV 2001) with a isolating valve.

• It has a floor drain for washing away chemicals and a drain (tank) for sample water.

• It has a separate storage room for empty and full chemical containers.

• It is isolated from other areas with regard to fire protection.

• It is secured against unauthorised access, and meets the regulations for the prevention of accidents.

• It is not in permanent use by personnel. The maximum stay is two hours.

Warning

Increased risk of damage to equipment and personal injury as a result of operating faults due to transport damage.

Do not shake, crush or drop the box. Do not use a sharp or pointed blade. Open the packaging carefully.

Carefully remove the device from the box. Do not bend the hoses and cables.

NoteDo not adjust the stroke-length adjustment knob on the pump. It must not be adjusted until the pump is running.

DimensionsL x W x H[mm]

ContentsWeight gross/net[kg]

900 x 900 x 518 Oxiperm Pro with cover, hoses, screws, accessories

OCD-162-5: 30/26OCD-162-10: 32/28

766 x 558 x 1813OCD-162-30-D: 80/70OCD-162-30-P: 79/69

766 x 558 x 1813OCD-162-60-D: 100/85OCD-162-60-P: 99/84

Warning

Incorrect installation may result in serious personal injury and damage to property. Only authorised service personnel trained by Grundfos may install the system.


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4.1.1 Preparing for installation

4.1.2 Preparing the installation site

Operator’s checklist Done

• Read the installation and operating instructions for the Oxiperm Pro system, the dosing pumps, the multi-function valve, the measuring cell and the extension module, if used. Store the manuals in a dry place in the installation location.

• Measure the pressure and temperature in the dilution water line and in the main water line.

• Measure the room temperature and humidity.

• Obtain official approval for storing chemicals, if necessary.

• Purchase accessories, see section 13.

• Fit a tapping sleeve for the dilution water supply in the drinking water line.

• Fit a tapping sleeve for the injection unit in the main line.

• Install a protective pipe for the dosing line, if necessary.

• Fit a tapping sleeve for sample-water extraction at the main line, if necessary.

• Fit tapping sleeves for the measuring or mixing module, if used.

• Provide protective clothing in the room in accordance with the regulations for the prevention of accidents(Germany GUV-V D5).

• Display all warning signs provided. Display a warning sign: "No fires, naked flames or smoking".

Checklist for service engineers Done

• Check that all connections to the main line are installed.

• Check that all necessary parts have been supplied (chemical containers, hoses, cables).

• Fix the unit on the wall or on the floor. See the installation scheme (fig. 14).

• Mount the measuring cell (if used). See installation and operating instructions for the measuring cell.

• Mount the measuring or mixing module (if used).

• Connect the hydraulic components:– dilution water hose to solenoid valve– dosing line to injection unit– dosing line from external batch tank to external dosing pump (if used).

• Install the chemical containers, and attach the suction lances.

• Connect the hydraulic components to the measuring cell (if used).

• Connect the hydraulic components to the measuring or mixing module (if used).

• Route the cables through the glands into the controller.• Connect the electronic components:

– flow meter (or contact water meter)– measuring cell AQC-D1 or AQC-D6 (if used)– measuring or mixing module (if used)– higher-level control system (if used)– warning lamp or audible warning system (if used)– gas warning device (if used)– external non-switching device (if used).

• Connect the power supply cable.

• Fit the cover.

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4.2 Wall mounting (OCD-162-5/-10)

4.2.1 Requirements

• Minimum wall thickness (brick/concrete): 0.10 m

• Minimum room height: 2.20 m

• Mounting height: display at eye level

• Minimum distance between injection unit and measuring point: 3.00 m

• Minimum distance between top edge and ceiling: 0.19 m

• Minimum allowance on either side: 0.20 m

4.2.2 Dimensions

Fig. 12 Oxiperm Pro OCD-162-5 and OCD-162-10, with drill holes

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4.3 Floor mounting (OCD-162-30/-60)

4.3.1 Requirements

• Minimum wall thickness (brick/concrete): 0.10 m

• Minimum room height: 2.20 m

• Minimum distance between injection unit and measuring point: 3.00 m

• Minimum distance between top edge and ceiling: 0.19 m

• Minimum allowance on either side: 0.20 m

• Maximum length of suction hoses: 5.00 m

4.3.2 Dimensions

Fig. 13 Oxiperm Pro OCD-162-30 and OCD-162-60

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1800

766 568

50

660

580

A-A

320

A A

500

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4.3.3 Installation scheme

Fig. 14 Scheme for the installation of Oxiperm Pro (here OCD-162-5) with measuring cell and mixing module

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Blue Red

Pos. Component

1aWater line for supplying dilution water and flushing water (via solenoid valve in the system)


3Chemical container for NaClO2 (diluted concentration of 7.5 % by weight) with suction lance and collecting tray

4Chemical container for HCl (diluted concentration of 9 % by weight) with suction lance and collecting tray



14 Dosing line

16 Hose for sample-water extraction


18 Measuring cell

19 Power supply connection/main switch

22 Mixing module

23 Connection cable for measuring cell

24 Sample-water drain

25 Connection cable for cleaning motor

26 Hose for dilution water

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4.4 Additional modules

Additional modules such as a measuring cell or a measuring or mixing module must be fixed onto the wall. For details, see the installation and operating instructions for the respective additional module.

4.5 External batch tank

Electrical connection see section 4.8.10.

4.6 Installing the chemical containers and suction lances

1. Screw the hose (6) of the hydrochloric acid suction lance(red label) onto the hose connection of the hydrochloric acid pump (red label).

Fig. 15 Correct orientation of the float

2. Position the hydrochloric acid container in the red collecting tray on the right under the system (OCD-162-5, -10) or next to the system (OCD-162-30, -60).

3. Unscrew the cover. Immerse the suction lance (red label) in the container. Screw the cap of the suction lance onto the container.

4. Screw the hose (5) of the sodium chlorite suction lance (blue label) onto the hose connection of the sodium chlorite pump (blue label).

5. Position the sodium chlorite container in the blue collecting tray on the left under the system (OCD-162-5, -10) or next to the system (OCD-162-30, -60).

6. Unscrew the cover. Immerse the suction lance (blue label) in the container. Screw the cap of the suction lance onto the container.

4.7 Hydraulic connections

4.7.1 Oxiperm Pro OCD-162-5, -10

Fig. 16 Hydraulic connections OCD-162-05, -10

Warning

The temperature of the chlorine dioxide solution stored in an external batch tank may not exceed 40 °C.

Risk of outgassing at more than 40 °C.

Warning

Kinked hoses may result in personal injury and damage to property.

Do not kink suction hoses and cables.

Route the hoses directly down from the unit where possible. Do not lay in loops.

Warning

Do not put tensile stress on the suction hose between the suction lance and the pump.

If the suction hose is too tense, it can slide off the connection.

Danger of chemicals leaking out of the suction hose.

Warning




Warning

Risk of fire and corrosion due to incorrect storage of chemicals.

Do not store hydrochloric acid and sodium chlorite near grease, flammable or oxidising substances, oils, acids or salts.

Obtain approval for storing chemicals.

NoteThe "normally closed" symbol must be visible on top.

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NoteOCD-162-5, -10: Make sure that the chemical containers are positioned under the system.

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Pos. Description

5, 6Hoses for both suction lances on the suction side of the NaClO2 and HCl dosing pumps

8Hose at the drain cock of the batch tank(only installed for flushing and venting)

14Dosing line from the chlorine dioxide dosing pump to the injection unit at the main line, or to the injection unit at the mixing module, or to the external batch tank

26 Dilution water hose at the solenoid valve

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4.7.2 Oxiperm Pro OCD-162-30, -60

Fig. 17 Hydraulic connections OCD-162-30, -60

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62-3

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62-6

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Pos. Description

5, 6Hoses for both suction lances on the suction side of the NaClO2 and HCl dosing pumps

8Hose at the drain cock of the batch tank (only installed for flushing and venting)

14Dosing line from the dosing pump to the injection unit at the main line, or to the injection unit at the mixing module, or to the external batch tank

26 Dilution water hose at the solenoid valve

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4.7.3 Connecting the system frame

1. Close the dilution water extraction device.

2. Connect the dilution water hose to the extraction device.

3. Route the hose to the system frame.

4. Connect the hose to the solenoid valve.

5. Route the hose from the multi-function valve on the dosing pump to the injection unit (in the protective pipe provided by the customer) and connect it.

6. Connect the hose to the drain cock of the batch tank for flushing and venting only.

4.7.4 Connecting the dosing line for the external dosing pump

1. Remove the cap from the connector on the batch tank.

2. Route the dosing line from the batch tank to the external dosing pump, and connect it to the suction valve on the external dosing pump.

3. Route the overflow line from the external dosing pump back to the batch tank, and connect it.

4. Route the dosing line from the external dosing pump to the injection unit, and connect it to the injection unit.

4.7.5 Connecting the hydraulic components to the measuring cell

1. Connect the sample-water hose to the extraction device in the main line, route it to the measuring cell, and connect it.

2. Connect the sample-water hose to the measuring cell, and route it into the drain.

After dosing, the chlorine dioxide concentration, temperature and pH/ORP value of the sample water are measured in the measuring cell. The measuring cell has connections for the following:

• hose from the sample-water extraction device to the measuring cell

• hose from the measuring cell to the sample-water drain.

For more detailed information, see the installation and operating instructions for the measuring cell.

4.7.6 Measuring module connections

The measuring module is hydraulically connected to the main line. The measuring module has connections for the following:

• hose from one tapping sleeve to the measuring module

• hose from the measuring module to another tapping sleeve at the main line.

For more detailed information, see the installation and operating instructions for the measuring module.

4.7.7 Mixing module connections

The mixing module is hydraulically connected to the main line and the Oxiperm Pro system. The mixing module has connections for the following:

• dosing line from the dosing pump to the injection unit in the mixing module

• hose from one tapping sleeve to the mixing module

• hose from the mixing module to another tapping sleeve at the main line.

For more detailed information, see the installation and operating instructions for the mixing module.

4.8 Connecting the electronic components

Fig. 18 Controller with display, control elements and cable glands

Most cables are already connected to the controller on delivery. The following cables must be connected at commissioning. For connection, see also the terminal connection plan in fig. 55:

• Warning lamp or audible warning system

• Contact water meter

• Water flow meter (current input signal)

• Measuring electrode (measuring cell)

• Reference electrode (measuring cell)

• Counter-electrode (measuring cell)

• GND_Cl (measuring cell)

• Cleaning motor (measuring cell)

• Pt100 temperature sensor

• Sample-water sensor on the main line

• Fault input, for example gas warning device

• Flow monitor on mixing module or higher-level control system

• Level control of external batch tank

Warning

If protective pipes for the dosing line are installed, these may not be longer than 3 metres.

Risk of concentrated collection and dangerous escape of chlorine dioxide gas.

Warning

Incorrect installation may result in personal injury and damage to property.

Only authorised service personnel trained by Grundfos may connect an external dosing pump to the Oxiperm Pro OCD-162.

Warning

Only authorised service personnel trained by Grundfos may connect the electronic components.

Risk of shock from damaged electronic components (transport or installation damage).

Do not reach into the void behind the controller. Do not kink cables.

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4.8.1 Passing the cables through glands into the controller

1. Unfasten the two screws on the rectangular cover underneath the controller, and remove the cover.

2. Loosen the corresponding cable gland, and push through the cable.

3. Connect the cable as shown in the terminal connection plan in fig. 55.

4. Tighten the cable gland by hand.

4.8.2 Connecting the flow meter (contact water meter)

1. Route the control cable from the flow meter (contact water meter) to the controller.

2. Connect the control cable to the controller.

4.8.3 Connecting the measuring cell

Connect measuring cell AQC-D1 or AQC-D6 (if applicable):

• measuring electrode and counter-electrode (for chlorine dioxide)

• sample-water sensor

• Pt100 temperature sensor

• pH electrode (for pH or ORP) (AQC-D1 only)

• cleaning motor (AQC-D1 only).

4.8.4 Connecting the measuring module

Connect measuring module to measuring cell AQC-D1 or AQC-D6 (if applicable):

• measuring electrode and counter-electrode(for chlorine dioxide)

• sample-water sensor

• Pt100 temperature sensor.

4.8.5 Connecting the mixing module

If a mixing module is used:

• connect the cable from the flow monitor (terminals 49/50).

4.8.6 Connecting a higher-level control system

If a higher-level control system is used, and no mixing module is connected:

• connect the cable from the higher-level control system to terminals 49/50.

The higher-level control system can also be used to switch off the Oxiperm Pro controller and the dosing pump.

4.8.7 Connecting a warning lamp or audible warning system

If a warning lamp or an audible warning system is used:

• connect the cable from the warning lamp or audible warning system to the collective relay for error messages.

• Alarm relay

– Terminals 25 and 29 N.C. (normally closed)

– Terminals 25 and 27 N.O. (normally open).

• Warning relay

– Terminals 26 and 30 N.C. (normally closed)

– Terminals 26 and 28 N.O. (normally open).

In case of power failure, the warning lamp lights up, if it is connected with the normally closed contact.

4.8.8 Connecting the gas warning device

If a gas warning device is used:

• connect the cable from the gas warning device.

4.8.9 Connecting external non-switching devices

Two external devices can be supplied with power supply voltage.

• Select free cable glands, and connect to the terminals 14/16/18 and 20/22/24. See section 11.16 Terminal connection plan.

4.8.10 Connecting an external batch tank

If an external batch tank is used:

• Connect level sensors from external batch tank to terminals 45, 46, 47 and 48.

– Terminal 45: min. level

– Terminal 46: max. level

– Terminal 47: max. -max. level (batch tank is overfull)

– Terminal 48: ground

4.9 Connecting the power supply cable

Prerequisites for the main switch:

• Operating voltage min. 230 V AC

• Operating current min. 4 A AC

• 2-pole interruption.

Position the main switch as close as possible to the OCD-162 system. Connect the protective earth with terminal 6, see section 11.16 Terminal connection plan.

1. Check that the voltage corresponds to the value specified on the nameplate.

2. Route the power supply cable up at the side between the controller and the reaction tank.

3. Route the power supply cable as far as the main switch.

4. Connect the power supply cable to the main switch.

5. Switch off the main switch.

Warning

Incorrect electrical connections may result in serious personal injury and damage to property.

Electrical connections may only be carried out by authorised service personnel trained by Grundfos.

Switch off the power supply before starting work.

Carry out power supply connection according to the local regulations.

Provide for an all-pole separator.

Warning

Risk of gas poisoning due to escape of gas from a damaged volume compensation bag.

Do not route the power supply cable through the void behind the controller.

Route it up at the side between the controller and the reaction tank.

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5. Commissioning

5.1 System configuration

5.2 Software settings

The software settings depend on the application. There are three different application groups.

5.2.1 Drinking water applications

According to the German drinking water standard (TrinkwV), the chlorine dioxide concentration in drinking water lines should not exceed 0.4 mg/l.

• Set a value between 0.1 and 0.4 mg/l

• Dosing is controlled proportionally to the flow.

These applications are controlled proportionally to the flow. The signal from the flow meter is sent to the controller as disturbance variable ("x-in"). The dosing flow corresponds to the signal from the controller to the dosing pump ("y-out: %").

Dosing coefficient

The controller of the Oxiperm Pro calculates the dosing coefficient automatically using the values set by the service engineer.

Pump with mechanical stroke adjustment

In case of a small chlorine dioxide dosing volume, there is a risk of formation of chlorine dioxide clouds. In order to reduce the formation of chlorine dioxide clouds, the stroke length can be mechanically reduced at the dosing pump. When reducing the stroke length, the reduced stroke length value has to be entered into the stroke adjustment in percent: "Main menu > Controller ClO2 > Dosing pump > Stroke adjustm.", see section 2.10.2.

Fig. 19 Distribution of dosing volume by various stroke-lengths

Warning

Only authorised service personnel trained by Grundfos may commission the Oxiperm Pro system.

Before commissioning, check the hoses, connections and pumps for leaks. Check the system for installation faults.

Risk of burns due to the escape of chemicals from faulty seals, valves, hose connections and lines.

Note

Risk of corrosion damage to the main water line and damage to property due to malfunctions resulting from insufficient quality of the dilution water.

Pressure, temperature and drinking water quality must comply with the system specifications.

Check the dilution water before and during commissioning.


Checklist Yes No

1. Which application group does the system belong to? Which controller type should be used?

– Drinking water applications - proportional controller

– Industrial water applications - setpoint controller

– Industrial water applications with water flow meter - combined controller

– Applications with external batch tank (shock disinfection) - without controller.

2. Does the main line have the following connected (required for drinking water applications, shock disinfection, and for industrial water applications with combined controller):

– contact water meter

– flow meter.

3. Does the main line have the following connected (required for industrial water applications, optional for drinking water applications):

– measuring cell for check measurements.

4. Which variables have to be measured:

– ClO2 (select measuring cell AQC-D6/AQC-D1)

– ClO2 + pH (select measuring cell AQC-D1)

– ClO2 + ORP (select measuring cell AQC-D1).

5. Does the Oxiperm Pro have the following connected:

– measuring module

– mixing module.

6. Does the Oxiperm Pro have the following connected:

– external dosing pump

– recorder

– warning lamp or audible warning system

– higher-level control system.

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NoteOnly adjust the stroke-length adjustment knob when the dosing pump is running.

100

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Stroke length [%] Stroke adjustment = 100 %

=> uneven dosing of ClO2

Stroke adjustment < 100 % => even dosing of ClO2

Time [s]

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* Only for proportional controllers and combined controllers.

Checklist Your notes OK

• Service code for operating software

• Commissioning date

• Commissioning time

• Language

• Factory settings– Retain all factory settings

– Save changes

• Flow meter impulse rate (xxx l/imp) *

• Maximum flow Qmax. (m3/h) *

• Flow meter current *– 0-20 mA

– 4-20 mA or other

• Measured values in the measuring cell, if used– ClO2 + pH

– ClO2+ ORP, or ClO2

• Measuring ranges, see section 5.8 Assigning measuring range(s)– For ClO2 concentration in sample water

– For temperature of sample water

– For pH or ORP in sample water

• Output current to external device (if used)

– Controller settings for drinking water applications: controller type Proportional controller

– Interpulse controller or continuous controller?

• Dosing coefficient (calculated) *

• Dosing capacity in percent (calculated)

– Stroke length setting in percent

– Target concentration in mg/l (g/m3)

– Internal batch tank mode and external batch tank mode

– For other control parameters, see section 5.10.3 Parameterising the controller.

• Output current to external dosing pump (if used)

• Alarm relay

– Alarm value 1

– Alarm value 2

– Hysteresis

– Alarm delay

– Dosing time monitoring

– Batch tank empty signal

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5.2.2 Industrial water applications

In industrial water applications, the chlorine dioxide concentration in the main line can be set to a value higher than 0.4 mg/l.

• Dosing is controlled proportionally to the flow

• Dosing is controlled by comparing setpoint and actual value.

Industrial water applications with or without flow meter are controlled by means of setpoints (target concentration). A measuring cell monitors the chlorine dioxide concentration in the main line, and sends actual values to the controller.

The controller compares the incoming actual values with the setpoint. Based on the deviation, it calculates the quantity of chlorine dioxide solution (actuating variable) required to achieve the desired concentration.

* Only for combined controllers.





• Language

• Factory settings

– Retain all factory settings

– Save changes

• Flow meter current, if used *

• Measured values in the measuring cell, if used

– ClO2 + pH

– ClO2 + ORP, or ClO2

• Measuring ranges, see section 5.8 Assigning measuring range(s)

– For ClO2 concentration in sample water



• Output current to external device (if used)

– Controller type for industrial water applications without flow meter Setpoint controller

– Controller type for industrial water applications with flow meter Combined controller

– Interpulse controller or continuous controller?

– P, PI or PID?

• Dosing capacity in percent

– Stroke length setting in percent

– Target concentration in mg/l (g/m3)

– Setpoint

– Internal batch tank mode and external batch tank mode

– For other control parameters, see section 5.10.3 Parameterising the controller

• Output current to external dosing pump, if used

• Alarm relay

– Alarm value 1

– Alarm value 2

– Hysteresis

– Alarm delay

– Dosing time monitoring

– Batch tank empty signal

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5.2.3 Applications with external batch tank (shock disinfection)

Applications with external batch tank are possible with or without flow meter. In these applications, an external batch tank is filled. Dosing is not made with the Oxiperm Pro.

The production of chlorine dioxide continues, until the external batch tank is full. If the maximum filling level of the batch tank (K12) is attained, the dosing pump is switched off. The chlorine dioxide production in the reaction tank is stopped.

If the minimum level (K11) of the batch tank is attained, the chlorine dioxide dosing pump starts running, and the process is re-started.





• Language

• Factory settings

– Retain all factory settings

– Save changes

• Measured values in the measuring cell, if used

– ClO2 + pH

– ClO2+ ORP, or ClO2

• Measuring ranges, see section 5.8 Assigning measuring range(s)

– For ClO2 concentration in sample water



– External batch mode

• Alarm relay

– Alarm value 1

– Alarm value 2

– Hysteresis

– Alarm delay

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5.3 Commissioning procedure

Carry out initial commissioning according to this checklist.

Checklist Section OK

• Read this manual.

• Check the installation visually (hoses, lines, connections).

• Set the flow meter, if applicable. 5.6

• If a measuring cell is connected, set the measurement, the measured variables, the measuring ranges. 5.7

• If an external device is connected, set the current output for the external device. 5.9

• Set the controller (not for shock disinfection). 5.10

• If an external dosing pump is connected, set the current output for the external dosing pump. 5.11

• Set the warning relay and alarm relay. 5.12

• Set the mode 5.13

– Internal batch tank mode and external batch tank mode.

• Vent the chemical dosing pumps manually. 5.13

• Start up operation: 5.14.1

– Start chlorine dioxide production.

– Manually vent dosing pump (not for shock disinfection). 5.12.2

• Set the stroke-length adjustment knob (not for shock disinfection). 5.12.3

• Stop operation: 5.15

– Terminate chlorine dioxide production.

– Terminate the dosing process.

• Restart operation. 5.16

• Monitor the system:– Display the measured value for chlorine dioxide, water temperature, pH or ORP.

5.17.1

– Display the dosing flow, controller type, control parameters (not for shock disinfection). 5.17.2

– Display the current flow of the water flow meter, if applicable. 5.17.3

– Display process status. 5.17.4

– Display event list. 5.17.5

– Display chlorine dioxide batches. 5.17.6

– Display maintenance date. 5.17.7

– Display or reset chemical consumption. 5.17.8

• Display the residence time. 5.17.9

• Flush the system, if necessary. 5.18

• Vent the system, if necessary. 5.13

• Calibrate. 5.19

• Test the system: 5.21

– Check visually for leaks. 5.21.1

– Test power supply. 5.21.2

– Test current outputs (not for shock disinfection). 5.21.3

– Test relays. 5.21.5

– Test level (float switch and suction lances). 5.21.6

– Test warning lamp and warning system, if applicable 4.8.7

– Test display. 5.21.7

– Test emergency stop. 5.21.8

– Test manual operation (not for shock disinfection). 5.21.10

• Set the operator language, if necessary. 5.22

• Save the settings. 5.23

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5.4 Switching on the system - initial start-up

1. Open the dilution water supply.

2. Switch on the main switch for power supply.

3. Select the language > [OK].For details, see section 5.22 Setting the language.

4. You are prompted to enter the factory-set service code:

Fig. 20 Service code

5. Enter the factory-set service code (----) > [OK].

Fig. 21 Start-up display

6. Press [OK] to confirm. The "Main menu" appears. The system is ready for use.

* The "Controller ClO2" submenu only appears, if the controller has been defined under "Setup" > "Controller ClO2".

5.5 Basic setup

All software menus can be selected from the "Main menu" using the [Up] and [Down] buttons, and accessed using [OK]. Press [Esc] to return to the previous menu level.

The menu structures for the submenu levels are illustrated by means of a graphic. The white fields can be edited by the operator, the grey fields only by service engineers.

1. "Main menu" > "Setup" > [OK].

Fig. 22 Structure of the "Setup" menu

* The "Measuring range" submenu only appears, if a measuring cell and a measured variable have been selected in the "Measurement" submenu.

** The submenu "Controller ClO2" only appears, if a measuring cell is selected in the "Measurement" submenu, or a water meter is selected in the "Water flow meter" submenu.

5.5.1 Setting the language

1. "Main menu > Setup" > [OK].

2. "Language" > [OK].

3. Select the operator language > [OK] > [Esc].

5.5.2 Setting the time


2. "Date/time" > [OK].

3. "time" > [OK].

4. Press the [Up] or [Down] button to set the commissioning time, confirm with [OK].

The settings are saved.

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TM

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Main menuProcessController ClO2 *

AlarmServiceSetupMaintenance

0000

SERVICE CODE

54321

process stop

TM

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Main menu

Setup

Language

Measurement

Measuring range

Water flow meter

Relay

Controller ClO2

Date/time

Code function

Display

Factory setting

Current output

*

**

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5.5.3 Setting the date


2. "Date/time" > [OK].

3. "date" > [OK]. The current date is displayed.

4. Press [OK] to confirm, or use the [Up] or [Down] button to set the commissioning date. Confirm with [OK].

5.5.4 Setting or cancelling daylight saving time


2. "Daylight.sav.t."> [OK].

3. Use the [Up] or [Down] button to make your settings.

5.5.5 Changing the display contrast


2. "Display" > [OK].

The display contrast is shown in percent.

3. Press [Up] to increase the contrast, press [Down] to reduce the contrast. Confirm with [OK].

The settings are saved.

5.6 Setting the water flow meter

If a contact water meter or a flow meter is connected to the main line, switch to the "Water flow meter" menu and define the disturbance variable (water flow).

5.6.1 Parameterising the contact water meter

1. "Main menu > Setup" > [OK]

2. "Water flow meter" > [OK].

3. Enter the service code > [OK].

The factory setting is "Off".

Entering impulse rate and maximum flow

4. Press [Up] to select the "Impulse" submenu, confirm with [OK]. Enter the impulse rate in litres per impulse and the maximum flow in m3/h.

5. "Impulse" > [OK].

6. Enter the impulse rate of the installed water flow meter, confirm with [OK]. (Setting range:1-999 L/IMP).

7. Enter the maximum flow, confirm with [OK].Setting range: 1-100 m3/h.

5.6.2 Parameterising the flow meter

If a flow meter is connected to the main line, switch to the "Water flow meter" menu and define which flow (0 % or 100 %) corresponds to which current signal (0-20 mA) of the flow meter.

1. "Main menu > Setup" > [OK]



The factory setting is "Off".Switching on the flow meter, and setting the current range

4. Press [Up] to select the "Current" submenu, confirm with [OK]. Here you specify the range for the flow meter current signal, corresponding to a flow of 0 to 100 %.

5. "Current" > [OK].

The factory setting is 0-20 mA.

6. Select the range, confirm with [OK]. If you select "others", the following submenu appears:

7. Set "begin meas range" > [OK].

8. Set "end meas range" > [OK]. If the current moves outside the specified range, an alarm signal is generated, see also section 5.17.3.

9. Enter the maximum flow, confirm with [OK].

NoteIn the operating software, the term "Water flow meter" is used for the flow meter and the contact water meter.

Water flow meterImpulseCurrentOff

Note

For proportional or combined controllers:

If the water flow meter is switched off while the controller is activated, disturbance variable-based control is switched off at the same time. This is indicated by the Off display in the"Setup > Controller ClO2" submenu.

The same applies to dosing time monitoring, if it is switched on.

Warning

The water flow meter has to be dimensioned so that more than 3 impulses/minute are emitted!

max.count frequ.1 L/IMP

max. flow10 m3/h

Water flow meterImpulseCurrentOff

Water flow meter0-20 mA

4-20 mA

others

Note

If you select 0-20 mA, the current with 0 % water is 0 mA, and the current with 100 % water is 20 mA.

If you select 4-20 mA, the current with 0 % water is 4 mA, and the current with 100 % water is 20 mA.

Water flow meter5 mA

begin meas range

Note

If you select "others", the current set for the beginning of the measuring range flows with 0 % water, and the current set for the end of the measuring range flows with 100 % water.


end meas range

max. flow10 m3/h

Factory setting Range [m3/h] Resolution

10 m3/h 1-100 1

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5.7 Selecting the measuring cell and measured variables

This section is only relevant, if a measuring cell is connected. The measured variables that can be set depend on the type of measuring cell:

• AQC-D6: ClO2 concentration

• AQC-D1: ClO2 concentration and pH, or ClO2 concentration and ORP (pH and ORP are optional).

5.7.1 Selecting the measuring cell and switching on measurement

In this menu, you select the type of measuring cell. "Measurement" is switched on automatically.


2. "Measurement" > [OK].

3. Enter the service code, confirm with [OK].

4. Specify the connected measuring cell.

– AQC-D1 measures the ClO2 concentration and pH or ORP (see section 5.8).

– AQC-D6 measures the ClO2 concentration(see section 5.7.2).

5. Select the measuring cell, confirm with [OK]. If you select AQC-D1 in "Setup > Measurement", the following submenu appears:

The factory setting for AQC-D1 is ClO2.

5.7.2 Measuring cell AQC-D1

If AQC-D1 is selected:

1. Select "ClO2 + ORP" (or "ClO2 + ORP or ClO2"), confirm with [OK]. The "Temp. comp." submenu is displayed:

Switching on temperature compensation

The factory setting is "Off".

2. Press [Up] to select "On", confirm with [OK].

Monitoring the cleaning motor of the measuring cell

3. Select "monitoring on", confirm with [OK]. If you select "monitoring off", no error message appears, if the cleaning motor stops running.

5.7.3 Measuring cell AQC-D6

If AQC-D6 is selected in the "Setup > Measurement" menu:

1. Select "ClO2", confirm with [OK].

AQC-D6 measures only ClO2.

5.8 Assigning measuring range(s)

In this menu, you set the measuring ranges for the chlorine dioxide concentration, water temperature, pH or ORP.


2. "Measuring range" > [OK].


– "Temperature" and "pH/ORP" only appear, if AQC-D1 has been selected in the "Measurement" menu. "pH/ORP" only appears, if "ClO2" + "pH" or "ClO2" + "ORP" has been selected.

4. Select and set all planned measuring ranges in succession. For the settings, see section 5.2.

Note

The submenus "Setup > Measuring range" are only displayed, if a measuring cell is connected, and has been selected in the operating software in "Setup > Measurement".

measuring cellAQC-D1

AQC-D6

Off

MeasurementClO2ClO2 + pH

ClO2 + ORP

Temp. comp.OnOff

Note

Temperature compensation for chlorine dioxide and pH is switched on. This means, the temperature of the sample water will not influence the measured values of chlorine dioxide and pH.

Temperature compensation is not available, if ORP is selected.

cleaning motormonitoring onmonitoring off

Note

The cleaning motor is monitored indirectly.

If the measured value drops by 50 % within 8 seconds, the controller receives information that the cleaning motor has stopped running. The error message "Fault of cleaning motor" is displayed.

The water sensor and the Pt100 temperature sensor are activated.

MeasurementClO2

NoteThis section is only relevant, if a measuring cell is connected and has been selected in the "Setup > Measurement" menu.

Measuring rangeClO2TemperaturepH/ORP

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5.8.1 Setting the chlorine dioxide measuring range

1. Select the ClO2 measuring range, confirm with [OK].

If you select "others", the following submenu appears:

2. Press [Up] or [Down] to set the end of the measuring range, confirm with [OK]. Enter your setpoint within the selected measuring range, see section 5.10.3.

5.8.2 Setting the temperature measuring range

1. Select "Main menu > Setup", confirm with [OK].


3. "Temperature" > [OK].

4. Select the unit > [OK].

5. Select the temperature measuring range > [OK].

5.8.3 Setting the pH measuring range

If "Setup > ClO2 + ORP > Measurement" is selected, the pH measuring range is displayed.



3. "pH" > [OK].

4. Select pH measuring range, confirm with [OK].

If "others" is selected, the following message appears:

5. Set "begin meas range", confirm with [OK].

6. Set "end meas range", confirm with [OK]. The display reverts to "Measuring range".

5.8.4 Setting the ORP measuring range

If "Setup > ClO2 + ORP > Measurement" is selected, the ORP measuring range is displayed.



3. ORP > [OK].

4. Select ORP measuring range, confirm with [OK].

If "others" is selected, the following message appears:


6. Set "end meas range", confirm with [OK]. The display reverts to "Measuring range"

ClO20.00 - 0.50 mg/l

0.00 - 1.00 mg/l

0.00 - 2.00 mg/l

0.00 - 5.00 mg/l

0.0 - 10.0 mg/l

others

Factory setting Resolution

0.00 - 1.00 mg/l 0.01

Range [mg/l] Resolution

0.00 - 0.05 to 0.00 - 5.00 0.01

0.0 to 10.0 and "others" 0.1

ClO21.00 mg/l

end meas range

Temperature° C......CELSIUS

° F.......FAHRENHEIT

Temperature0.0 - 50.0 °C

0.0 - 100.0 °C

-5.0 - 120.0 °C


0-50 °C 0.1

pH

pH 0.00 - 14.00

pH 2.00 - 12.00

pH 5.00 - 9.00

others


0.00 - 14.00 0.01

pH

0.00 pH

begin meas range

pH

14.00 pH

end meas range

ORP-1500 - 1500 mV

0-1000 mV

others


0-1000 mV 1

ORP- 1500 mV

begin meas range

ORP1500 mV

end meas range

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5.8.5 Setting the temperature correction

Only set this menu, if a measuring cell is connected, and measuring ranges have been defined under "Measuring range".

With long lines, the actual line resistance of the Pt100 temperature sensor will change. In this menu, you set a reference temperature to compensate for the line resistance.

1. "Main menu" > "Maintenance" > [OK].

2. "Temp. correction" > [OK].

The factory setting is 25 °C. The unit (°C or °F) and setting range depend on the settings in the "Setup > Measuring range" menu.

5.9 Setting the output current to an external device

It is possible to set the range for the output current to a connected external device, for example a recorder.


2. "Current output" > [OK].


For a detailed description of the "Control" menu, see section 5.11.

4. ClO2 > [OK].


5. Select the planned value, confirm with [OK]. If you select "others", you have to set the beginning and the end of the measuring range with [Up] and [Down].


7. Set "end meas range", confirm with [OK].

The specified range for the output current is assigned to the corresponding chlorine dioxide concentration. The display reverts to "Current output".

Temp. correction25 °C

reference-temp.

Current outputControlClO2

Measurement0-20 mA

4-20 mA

others

Chlorine dioxide0.00 mg/l = 0 mA

begin meas range

Chlorine dioxide20.00 mg/l = 20 mA

end meas range

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5.10 Setting the chlorine dioxide controller

Not for applications with external batch tank.

Fig. 23 Structure of the "Controller ClO2" menu

5.10.1 Selecting the controller


2. "Controller ClO2" > [OK].

The factory setting is "Off"

3. Select the controller, confirm with [OK].

5.10.2 Configuring the controller

1. Configure the selected controller as"Interpulse ctrl." or "Cont. controller".

The factory setting is "Interpulse ctrl."If "Setpoint ctrl." or "Combined ctrl." is selected, the following display appears:

The factory setting is "P".

2. Assign a control character "P", or "PI" (or "PID") to the selected setpoint controller or combined controller.

5.10.3 Parameterising the controller

Fig. 24 Structure of the menu for parameterising (for example proportional and interpulse controller)

1. Select "Main menu > Controller ClO2", confirm with [OK]. The parameters for the selected controller are displayed.

2. Press [Up] or [Down] to select the parameter > [OK].

3. Set the planned value with [Up] or [Down], confirm with [OK].

4. Note the value in the following table.

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Setup

Controller ClO2

Setpoint ctrl. Proport. ctrl. Combined ctrl. Off

Cont. controller

Interpulse ctrl. Cont. controller

Interpulse ctrl. Cont. controller

Interpulse ctrl.

P PI PID PI PIDP

Note

Drinking water applications are controlled in proportion to the flow with the proportional controller.

Industrial water applications without flow meter are controlled by means of setpoints with the setpoint controller.

Industrial water applications with flow meter are controlled with the combined controller.

Controller ClO2Setpoint ctrl.Proport. ctrl.Combined ctrl.Off

Note

"Setpoint ctrl." only appears, if "Measurement" is switched on.

"Proport. ctrl." only appears, if "Water flow meter" is switched on, see section 5.6.

"Combined ctrl." only appears, if "Measurement" and "Water flow meter" are switched on.

Proport. ctrl.Interpulse ctrl.Cont. controller

ctrl. charact.P

PI

PID

TM

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56

09

08

Main menu

Added quantity ctrl. stop ext.

Stroke adjustm.

Switch-on time Dosing flow Dosing pump

Controller ClO2

Dosing capacity

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Controller parameter, depending on the selected controller

* The setting range for the setpoint corresponds to the specified measuring range, see section 5.8.

Added quantityInput of the desired chlorine dioxide quantity, depending on the application, see section 5.2.

Switch-on timeUsed for interpulse controllers. The minimum switch-on time must be kept as short as possible. Example: The dosing pump executes 120 strokes per minute. The lowest reasonable switch-on time is 1 stroke, so the minimum switch-on time is0.5 seconds.

Set pointThe controller compares the actual value of the chlorine dioxide concentration in the sample water with the specified setpoint (target concentration mg/l), and calculates the deviation (difference between actual value and setpoint). The controller uses the deviation to determine the actuating variable (Y-OUT), which sets the dosing flow for the dosing pump.

Dosing flowInput of the required maximum dosing rate in percent of the maximum dosing capacity. The maximum dosing capacity is set in the "Dosing pump > Dosing capacity" menu.

ctrl. stop ext.The setting for "ctrl. stop ext." must match the assignment for an external device that sends a signal to stop the controller, for example a flow monitor. Make the appropriate settings in the "ctrl. stop ext." menu:

• N.O. (normally open)

• N.C. (normally closed).

In "ctrl. stop ext." the controller symbol in the display is struck through, and the message "controller stop external" is displayed. This message can be confirmed with [Esc]. The controller remains switched off, and the symbol on the display is still struck through.

Prop.range XPUsed with the control characters P, PI and PID.

With P, the actuating variable (dosing volume) is proportional to the system deviation (difference between actual value and setpoint). Set the range (0.1 to 3000 %) in this menu.

Reset time TNUsed with the control characters PI and PID.

The step-response from the PI controller is composed of two parts: the actuating variable (corresponding to XP) and the rate at which it increases.

TN indicates the slope of the line and hence the rate, at which the control signal increases. The higher the value of TN, the slower the rate at which the control signal increases over time. If TN is infinite, we have pure P character.

Deriv. time TVUsed with control character PID.

The derivative action time TV is the characteristic parameter of a D controller. It is a measure of the weighting of the rate of change of the measured variable.

Dosing pump > Stroke adjustm.For DDA (digital) dosing pumps, the value is 100 %.

For DMX 221 (mechanical) dosing pumps, the stroke adjustment value (stroke length in percent) has to be set.

Reduce the stroke length at the mechanical dosing pump, if the flow is relatively low. The pump then executes more strokes with a smaller dosing volume, the dosing rate remains the same. The chlorine dioxide is dispersed more evenly and does not produce any clouds in the main line. The stroke adjustment value set in this menu is used to calculate the requested stroke frequency, see section 2.10.2.

Dosing pump > Dosing capacityInput of the maximum dosing capacity of the pump. The maximum dosing capacity depends on the type of pump, and on the size of the Oxiperm Pro system. Normally the factory setting does not have to be changed.

Parameter Range Resolution Factory setting Your value

Added quantity 0.00 - 1.00 mg/l 0.01 mg/l 0.20 mg/l

Switch-on time 0.1 - 10.0 s 0.1 s 0.5 s

Set point * 0.20 mg/l

Dosing flow 0-100 % 1 % 100 %

ctrl. stop ext. N.C./N.O. N.O.

Prop.range XP 0.1 - 3000.0 % 0.1 % 30 %

Reset time TN 1-3000 s 1 s 60 s

Deriv. time TV 0-1000 s 1 s 0 s

Dosing pump > Stroke adjustm. 0-100 % 1 % 100 %

Dosing pump > Dosing capacity

DDA 7.5-16/OCD-162-5

0-40 l/h 0.1 l/h

2.3 l/h

DDA 7.5-16/OCD-162-10 5.0 l/h

DMX 35-10/OCD-162-30 18.0 l/h

DDI 60-10/OCD-162-30 18.0 l/h

DMX 35-10/OCD-162-60 35.0 l/h

DDI 60-10/OCD-162-60 36.0 l/h

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5.11 Setting the output current to an external dosing pump

In this menu, you set the range for the output current from the controller to the external dosing pump, if the continuous controller is selected.

Once you have selected and parameterised the controller:


2. "Current output" > [OK].


4. Select "Control", confirm with [OK]. Set the output current to the external dosing pump.


5. Select the planned value, confirm with [OK].

If you select "others", the following submenu appears:

The factory setting is 0 mA.

6. Make the setting: 0 % corresponds to X mA.

The factory setting is 20 mA.

7. Make the setting: 100 % corresponds to X mA.

The specified output current (input current for the external dosing pump) is assigned to the corresponding dosing flow (0-100 %).

5.12 Setting the warning relay and alarm relay

Fig. 25 Structure of the "Alarm" menu

(1) "alarm" is only visible, if "Measurement" or a controller is activated, see "Setup".

(2) "Alarm value ClO2" is only visible, if "Measurement" is activated.

(3) "Dos. time monit." is only visible, if a controller is activated.

Current outputControlClO2

Control0-20 mA

4-20 mA

others

Control0 % = 0 mA

Dosing flow

Control100 % = 20 mA

Dosing flow

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Alarm

Alarm value ClO2 Dos. time monit.

On On Off

Alarm value 1 Hysteresis Alarm delay

Upward violation

downward viol.

Max. dosing time

Alarm value 2

Off

(1)

(2) (3)

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5.12.1 Configuring the warning relay

The warning relay is activated whenever an alarm is signalled, and remains active until the alarm is confirmed (collective warning relay).


2. "Relay" > [OK].


4. "Warning relay" > [OK].

The factory setting for the electrically isolated output of the warning relay is "off (N.O.)", normally open.

5. Select "on (N.C.)", confirm with [OK]. The setting is "normally closed". If a power failure occurs, the relay signals a fault (fail safe).

5.12.2 Configuring the alarm relay

In this menu, you set the electrically isolated output for the collective warning relay:

1. "Main menu >Setup" > [OK].

2. "Relay" > [OK].


4. "alarm relay" > [OK].

The factory setting is "off (N.O.)"5. Select "on (N.C.)", confirm with [OK]. The setting is "normally

closed". If a power failure occurs, the relay signals a fault(fail safe).

5.12.3 Setting the alarm values

In this menu, you set the upper and lower switching point for the alarm:

1. "Main menu > Alarm" > [OK].

2. "Alarm value ClO2" > [OK].

The factory setting is "Alarm off".3. "Alarm on" > [OK].

Setting the lower switching point for the alarm"Alarm value 1"

1. "Alarm value 1" > [OK].

The factory setting is 0.15 mg/l.

2. Factory setting > [Esc], or enter another value > [OK].

The factory setting is "downward viol.."If the alarm is to be triggered by a downward violation:

3. "downward viol." > [OK]. If an alarm is triggered when the specified value is undershot, the following message appears: "alarm val 2 ClO2 undershot".– Rectify the cause of the downward violation.

– Confirm the alarm message.

If the alarm is to be triggered by an upward violation:

4. "Upward violation" > [OK]. If an alarm is triggered when the specified value is exceeded, the following message appears: "alarm val 1 ClO2 exceeded".

– Rectify the cause of the upward violation.


Setting the upper switching point for the alarm"Alarm value 2"

1. "Main menu > alarm" > [OK].


3. "Alarm on" > [OK].

4. "Alarm value 2" > [OK].


5. Factory setting > [Esc], or enter another value > [OK].

The factory setting is "downward viol."If the alarm is to be triggered by an upward violation:

6. "Upward violation" > [OK]. If an alarm is triggered when the specified value is exceeded, the following message appears: "alarm val 2 ClO2 exceeded".

– Rectify the cause of the upward violation.


If the alarm is to be triggered by a downward violation:

7. "downward viol." > [OK]. If an alarm is triggered when the specified value is undershot, the following message appears: "alarm val 2 ClO2 undershot".– Rectify the cause of the downward violation.


fail safeon (N.C.)off (N.O.)

fail safeon (N.C.)off (N.O.)

AlarmAlarm value ClO2Dos. time monit.

Alarm value ClO2Alarm onAlarm off

Alarm value ClO2Alarm value 1Alarm value 2HysteresisAlarm delay

Alarm value 10.15 mg/l

eff. directionUpward violationdownward viol.

Alarm value ClO2Alarm value 1Alarm value 2HysteresisAlarm delay

Alarm value 20.70 mg/l

eff. directionUpward violationdownward viol.

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5.12.4 Setting the hysteresis

The hysteresis indicates the tolerance of the alarm value (alarm value ± 0.5 x hysteresis). In this menu, you set the hysteresis for the two alarm values:




4. "Hysteresis" > [OK].


5. "Factory setting" > [Esc], or enter another value > [OK] > [Esc]. The "Hysteresis" function is effective for both alarm value settings.

5.12.5 Setting the alarm delay




4. "Alarm delay" > [OK].

The factory setting is 0 seconds. The setting range is 0-999 seconds.

5. "Factory setting" > [Esc], or enter another value > [OK] > [Esc]. The alarm relay is switched on at the end of the specified time.

6. Press [Esc] > [Esc].

5.12.6 Switching on dosing time monitoring


1. "Main menu > alarm" > [OK].

2. "Dos. time monit." > [OK].

The factory setting is "Off".3. Select "On" to switch on dosing time monitoring, confirm with

[OK].

The factory setting is 600 minutes. The setting range is 0-600 minutes.

4. "Factory setting" > [Esc] or enter another value > [OK] > [Esc]. The alarm is triggered, if the controller sets the predefined maximum dosing flow (Y-OUT = X %) for the dosing pump for longer than the specified time.

5.13 Setting the operation mode

Fig. 26 Structure of the "Process" menu

5.13.1 Adjusting the process (how many batches)

To specify whether just one batch or several batches of chlorine dioxide is to be prepared, or whether the production process should run continuously, proceed as follows:

1. "Main menu > Process" > [OK].

"Operation" > [OK]. The factory setting is "Int. batch tank"

"Int. batch tank" > [OK], the factory setting is confirmed.

The system produces the chosen number of batches. The setting "0 = continuous" means continuous production.

2. Or "Ext. batch tank" > [OK]. The system is now set to "Ext. batch tank" operation.

In the operation modes "0 = continuous" or "Ext. batch tank", a new production process is started when the batch tank is empty.

In the operation mode "Batches", the chlorine dioxide production stops when the reaction tank is empty.

Hysteresis0.01 mg/l

Alarm delay0 sec

AlarmAlarm value ClO2Dos. time monit.

Dos. time monit.OnOff

Max. dosing time600 minutes

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ProcessStartTerminateOperation

OperationInt. batch tankExt. batch tank

Int. batch tankX Batches0 = continuous

Main menu

Process

Start Terminate Operation

Int. batch tank Ext. batch tank

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5.14 Starting operation

5.14.1 Starting chlorine dioxide production


2. "Start" > [OK].

3. "Back" > [OK], the command is cancelled.

4. "Start" > [OK], the command is executed.

5. Press [OK], chlorine dioxide production starts.

Fig. 27 Display level during operation

The measured values for temperature, chlorine dioxide concentration and pH or ORP are only displayed, if "Measurement" is enabled in "Setup". In the example, the symbols for continuous controller and water meter are also visible, because they are switched on.

5.14.2 Manually venting the dosing pump

Conditions for venting:

• The batch tank must contain chlorine dioxide solution.

• The dosing pump must be operated in "manual" mode.

If the dosing pump is running:

1. Hold the green knob and the black knob on the multi-function valve. Turn the green knob slightly clockwise as far as the stop (the movement is barely noticeable). For details, see installation and operating instructions for the multi-function valve.

2. Repeat the procedure, if necessary.

The dosing pump is vented.

Turning the knob opens the pressure loading valve at the multi-function valve to the overflow line. The chlorine dioxide solution, possibly containing air bubbles, flows back to the batch tank.

5.15 Interrupting operation

5.15.1 Terminating chlorine dioxide production


2. "Terminate" > [OK].

3. "Back" > [OK], the command is cancelled.

4. "Terminate" > [OK], chlorine dioxide production is terminated.

5. Press [OK]. The chemical dosing pumps are stopped. The reaction tank is filled with water up to level K4, in order to dilute the undefined content of the reaction tank.

Fig. 28 Display level process stop

5.15.2 Terminating the dosing process

• Switch off the controller in normal operation. The dosing pump stops.

• It is not recommended to switch off the controller in "Setup", because all the controller parameters will be lost for resuming the dosing process.

• For switching off the controller in manual operation,see 5.21.9.

5.15.3 Resuming the dosing process

• Switch on the controller in normal operation. Reset all the controller parameters, see sections 5.10.1, 5.10.2 and 5.10.3.

• "activate" the controller in manual operation, see 5.21.10.


StartStartBack

StartStart ClO2 production?

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Warning

Risk of personal injury and damage to equipment and due to incorrect handling of chemicals.

Before commencing work, put on protective clothing.

Note

The dosing pump can be vented manually with the multi-function valve.

Only actuate the green knob on the multi-function valve when the dosing pump is running.

.........24,5 °C 543210,23 mg/l

process running


ProcessTerminateBack

process stopTerminate ClO2 production?

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Note

The chemical reaction in the reaction tank continues. The dosing pump continues running, until the chlorine dioxide solution is emptied from the batch tank.

For continuing operation after terminating chlorine dioxide production, see 5.16.1.

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5.16 Continuing operation after an interruption

5.16.1 Continuing operation after terminating chlorine dioxide production

During commissioning and in normal operation: Start chlorine dioxide production:

– "Main menu > Process" > [OK].

– "Start" > [OK].

– "Start" > [OK].

The undefined content of the reaction tank is flushed into the batch tank, and the warning message "check ClO2 batch" appears. The batch should be disposed, see section 5.18.2.

After that, the process and dosing proceed in normal operation.

5.16.2 Continuing operation after removing a fault

Confirm the alarm message. Continue operation as described in section 5.16.1.

5.16.3 Continuing operation after changing a chemical container

The Oxiperm Pro system automatically continues operation.

5.16.4 Continuing operation after a power supply interruption

As soon as the power is restored, the Oxiperm Pro system is switched on again automatically.

If the reaction tank is full, the liquid is in an undefined state. It can contain too much hydrochloric acid or too little NaClO2.The controller uses the float switch in the reaction tank to determine whether the reaction tank is empty or full, and continues operation accordingly:

• The reaction tank is part-filled or full, the batch tank is empty:

– If the reaction tank is part-filled, it is filled up with water. The undefined liquid is drained into the batch tank, and the following alarm message is displayed: "check ClO2 batch".

– Drain the batch tank manually. For details, see section 5.18.2. If it is not emptied manually, the undefined liquid will be dosed.

– The dosing pump is switched off when the batch tank is empty.

• The reaction tank is empty, the batch tank is part-filled or full:

– In continuous ClO2 production or operation with external batch tank a new production process will be started. For details, see section 2.8.

• The reaction tank is part-filled or full, the batch is tank part-filled or full:

– The remaining batch is dosed into the batch tank.

– The reaction tank is filled up with water. The undefined liquid remains in the reaction tank, until the batch tank is empty. Water is supplied to make the reaction tank overflow, and the alarm message "check ClO2 batch" is displayed.

– Drain the batch tank manually. If it is not drained manually, the undefined solution will be dosed.

– In continuous chlorine dioxide production, a new production process is started after the reaction tank is empty.

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5.17 Monitoring the production and dosing process

Fig. 29 Structure of the "Service" menu for service engineers

(1) Only visible, if "Measurement" is activated.

(2) Only visible, if "Controller ClO2" is activated.

(3) Only visible, if "Water flow meter" is activated.

(4) Different submenus, according to the selected measuring cell and measured variable.

(5) Not visible for applications with external batch tank.

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Measured value

Main menu

Service

Process

Status List of events Production ClO2 Flushing

Status Chemicals Maintenance

Start Terminate

HCl/NaClO2Measurement

ClO2 pH ORP Temperature

CalData-LogBook

Controller ClO2

Water flow meter

Test relay

Test level

Test display

Age of ClO2

Program version

Temp. comp.

(1)

(2)

(5)

(4)

(3)

(5)

(4) (4)

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5.17.1 Current measured values for ClO2, water temperature and pH/ORP

1. "Main menu > Service" > [OK].


ClO2 measured value

1. "ClO2" > [OK].

2. Press [Down] to select "Measured value", confirm with [OK].

The current ClO2 measured value is displayed:

– ClO2 concentration [mg/l],

– current from measuring cell [µA]),

– set measuring range [mg/l)].

Calibration logbook for ClO2

1. Press [Up] to select "CalData-LogBook", confirm with [OK].

2. ClO2 > [OK]. The last 10 calibration data records are listed in chronological order in "CalData-LogBook". Data record 1 is the one that was last saved.

3. Press [OK] to display the previous data record.

pH value



3. pH > [OK].


The current pH measured value is displayed:

– pH measured value,

– voltage [mV],

– set measuring range [pH].

Calibration logbook for pH

1. Press [Up] to select "CalData-LogBook", confirm with [OK].

2. pH > [OK]. The last 10 calibration data records are listed in chronological order. Data record 1 is the one that was last saved.

3. Press [OK] to display the previous data record. Press [Up] or [Down] to display all lines with calibration data.

.

Note

The measured values in this menu are only displayed, if "Measurement" has been enabled.

If the AQC-D6 measuring cell has been selected, only the ClO2 measured value is displayed.

If the AQC-D1 measuring cell has been selected, the ClO2 and the pH/ORP measured values are displayed.

MeasurementClO2TemperaturepH/ORP

Measurement ClO2CalData-LogBookMeasured value

Measurement ClO20.00 mg/l

0.000 µA

0.0 - 1.0 mg/l

MeasurementClO2TemperaturepH

CalData-LogBooknumber 1

date 2008-09-14

time 7:54

Slope: 20.2

MeasurementClO2TemperaturepH

Measurement pH

CalData-LogBookMeasured value

Measurement pH

7.20 pH

-30 mV

0.00 - 14.00 pH

Measurement

ClO2

pH


date 2008-09-23

time 09:01

Slope: -54.2

Asym. 11.31

buffer 1 4.01

buffer 2 7.00

Cal temp. 25.0

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ORP value



3. "ORP" > [OK].


The current ORP measured value is displayed:

– ORP measured value: voltage in [mV],

– set measuring range in [mV].

5. Press [Esc].

Calibration logbook for ORP

1. Press [Up] to select "CalData-LogBook" > [OK].

2. "ORP" > [OK]. The last 10 calibration data records are listed in chronological order in the "CalData-LogBook". Data record 1 is the one that was last saved.

3. Press [OK] to display the previous data record.

Temperature of the sample water



3. "Temperature" > [OK].

4. "Measured value" > [OK].

The current measured value is displayed:

– temperature [°C],

– set measuring range.

If the measuring range is exceeded or not reached, a fault has occurred (for example temperature sensor cable breakage).

5.17.2 Current control parameters


Parameters for the setpoint controller


2. "Controller ClO2" > [OK].MeasurementClO2ORP

MeasurementORPCalData-LogBookMeasured value

MeasurementORP-1400 mV

-1500 . . .1500 mV

MeasurementClO2

ORP


date 2008-09-23

time 08:54

offset: -4.49

Temperature23 °C

0.0 - 50.0 °C

Controller ClO2y-out: %:..............75 %

setpt: mg/l:...... 0.40 mg/l

Setpoint ctrl.XP:............................. 83 %

TN:........................ 300 sec.

(TV)

Dosing capacity:........ 100 %

Menu Description Visible for

y-out: % Controller output signal to the dosing pump

setpt: mg/l Setpoint in mg/l

Setpoint ctrl. Controller type

XP

Proportional band: When selecting the P controller range, the actuating variable (dosing volume) is proportional to the system deviation (difference between actual value and setpoint)

TN Reset timeP, PI controller, PID

(TV) Derivative action time PID controller

Qmax: %

Maximum dosing flow (0-100 %) (the value entered in the "Controller ClO2" menu under "Dosing flow")

minOn: s Minimum on-timeInterpulse controller

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Parameters for the proportional controller



5.17.3 Current input value for water flow meter




Contact water meter

The display shows:

• The rate of impulses from the contact water meter in impulses per second.

• The percentage of the entered maximum flow (for example 40 m3/h => 54 % * 40 m3/h = 21.6 m3/h).For details, see 5.6.1.

If the defined input values are exceeded or not reached, a fault has occurred (for example at the water flow meter).

Flow meter

The display shows:

• The current in mA corresponding to the flow.

• The percentage of the entered flow (for example Qmax. = 40 m3/h => 54 % = 21.6 m3/h). For details, see 5.6.2.

5.17.4 Process status

Examples:


2. "Process" > [OK].

3. "Status" > [OK].

Examples of status messages:

5.17.5 List of events

The list of events is useful for fault finding. Faults and messages are stored chronologically in the list of events.

1. "Main menu > Service > Process" > [OK].

2. "List of events" > [OK]. Record number 1 is the most recently stored, record number 20 is the oldest. The oldest record is deleted when a new one is stored.

– Press [Down] to scroll through the list. For details of possible events, see the tables with alarm messages in section 8. Fault finding.

Controller ClO2y-out: %:.............. 75 %

addit.: mg/l:....... 0.40 mg/l

Proport. ctrl.Qmax: %:........... 100 %

minOn: s:........ 1.0 sec.

dos.coeff.:...................... 1.0

Menu Description Visible for

y-out: % Controller output signal to the dosing pump.

addit.: mg/l 0.20 mg/l

Proport. ctrl. Controller type

Qmax: %

Maximum dosing flow (0-100 %) (the value entered in the "Controller ClO2" menu under "Dosing flow")

minOn: s Minimum on-timeInterpulse controller

dos.coeff.: Dosing coefficient, calculated by the controller

Water flow meter1.20 imp./sec.

54 %


54 %

process statusHCl supply running

Status message Description

H2O supply 1 running Start of ClO2 production, dilution water 1, relay 1

HCl supply running Pump HCl, relay 2

NaClO2 supply running Pump NaClO2:, relay 3

Reaction time Timer running, showing the remaining reaction time

H2O supply 2 running Dilution water 2, relay 1

Filling int. batch tank After dilution water 3, relay 1

system waiting Waiting until the batch tank is empty

process stop An alarm message has caused the process to stop

process terminationAn alarm message or menu command has caused the process to be terminated

List of eventsnumber........................ 1/99

process termination

2008-07-22.................11:45

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5.17.6 Number of ClO2 batches

1. "Main menu > Service > [OK].

2. "Production ClO2" > [OK].

3. "Batches" > [OK].

After 9999 batches, the display is reset to 0.

5.17.7 Maintenance date



3. "Maintenance" > [OK].

5.17.8 Resetting the chemical consumption after changing containers

The controller calculates the chemical consumption and displays it in litres. It starts automatically at 0.000 litres.

Displaying the chemical consumption

1. Main menu > Service" > [OK].



4. "Chemicals" > [OK].

5. HCl> [OK].

6. Press [Esc].

7. NaClO2 > [OK].

Resetting the chemical consumption

1. Production ClO2 > [OK].

2. Chemicals > [OK].

3. Reset > [OK].

4. HCl > [OK]. The counter is reset to 0.

5. NaClO2 > [OK]. The counter is reset to 0.

5.17.9 Indicating the "Age of ClO2" in the reaction tank and in batch tank

1. "Main menu > Service > [OK].


3. "Age of ClO2" > [OK]. The factory setting for both is 00:00 (minutes and seconds).

4. Press [Esc].

5.17.10 Program version

1. "Main menu > Service > Program version" > [OK].

2. View program version > [Esc]

5.17.11 Test menus

For description of the other "Service" test menus, see the following sections:

5.21 Function tests:

5.21.3 Testing the current output "Control"5.21.5 Testing the relays

5.21.6 Testing the level

5.21.7 Testing the display.

Production ClO2

25

Batches

MaintenanceLAST

2012-07-25

NEXT

2013-07-25

ChemicalsHClNaClO2Reset

HCl0.000 L

since 2012-04-29

ResetHClNaClO2

Production ClO2BatchesChemicalsMaintenanceAge of ClO2

Age of ClO2Reaction tank03:16

Int. batch tank00:00

Program versionOxiperm Pro 162

5 g/h

V 0.20.020090426

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5.18 Flushing

The Oxiperm Pro system has two flushing functions:

• Automatic flushing, see section 5.16.4.

• Flushing with the "Flushing" menu command, described in this section.

The Oxiperm Pro system must be flushed with the "Flushing" menu command in the following situations:

• prior to an extended shutdown of the system

• prior to maintenance and servicing work.

The entire system is flushed with water to remove any traces of chemicals in the suction hoses, pumps and reaction tank. Dilution water is used for flushing. Before flushing, the suction lances have to be removed from the chemical containers, and placed in individual 10-litre buckets with drinking water so that they take up the water. Each pump is flushed for four minutes.

Before flushing, the batch tank must be manually drained via the drain cock.

• Only start flushing when the chlorine dioxide production is not running. Otherwise the "Flushing" menu is not visible. The flushing process can be stopped anytime with [Esc].

5.18.1 Preparing to flush

1. Before starting to flush, have ready the following items:

– Empty10-litre plastic buckets (1 bucket for OCD-162-5, -10, -30, and 2 buckets for OCD-162-60)

– PE hose, 11 x 8 mm, for the drain cock on the batch tank

– Chlorine dioxide breakdown substance (sodium thiosulfate Na2S2O3 x 5 H2O): 20 g for OCD-162-5, 40 g forOCD-162-10, 120 g for OCD-162-30, 240 g for OCD-162-60

– Two 10-litre buckets filled with water

– The original screw caps for the chemical containers.

5.18.2 Manually draining the batch tank

1. Place the two 10-litre buckets filled with water to the right and left of the chemical containers.

2. Untwist the screw cap on the suction lance of the sodium chlorite container. Remove the suction lance, and place it in one of the buckets of water.

3. Screw the original cover onto the sodium chlorite container.

4. Untwist the screw cap on the suction lance of the hydrochloric acid container. Remove the suction lance, and place it in the other bucket of water.

5. Screw the original cover onto the hydrochloric acid container.

6. Fill the empty bucket with 1 litre of water and 20 g (OCD-162-5), 40 g (OCD-162-10) or 120 g (OCD-162-30) of chlorine dioxide breakdown substance, and place it to the left of the Oxiperm Pro. For the OCD-162-60, fill two empty buckets, each with 1 litre of water and 120 g of chlorine dioxide breakdown substance, and place them to the left of the Oxiperm Pro.

7. Remove the cover from the Oxiperm Pro.

8. Connect one end of the hose (PVC) to the drain cock of the batch tank, and place the other end in the bucket. Open the drain cock.

9. Empty the contents of the batch tank (OCD-162-5 around 1 litre, OCD-162-10 around 1.8 litres, OCD-162-30 around 6.5 litres, OCD-162-60 around 13.0 litres) into the bucket(s).

10. When the batch tank is empty, close the drain cock.

5.18.3 Starting flushing



3. "Flushing" > [OK].

Start flushing:

4. "Start" > [OK].

5. Press [OK].

6. Press [OK], if the suction lances are in the water.

7. Press [OK], if the batch tank is empty, see section 5.18.2 Manually draining the batch tank.

8. Press [OK], if the drain cock is closed.

9. Flushing starts. The flushing process automatically runs twice.

Warning

Risk of poisoning from chlorine dioxide gas.

Do not mix sodium chlorite and hydrochloric acid.

Do not put suction lances in the same bucket.

Do not insert suction lances in the wrong container.


Warning

Risk of serious personal injury and damage to equipment due to incorrect handling of chemicals.

Before starting work, put on protective clothing (gloves, face mask, protective apron)(Germany GUV-V D5).

Warning

Risk of burns from drips when removing the suction lance from the chemical container.

Do not allow drips to fall on the skin, clothing, shoes or ground.

Rinse away any drips on the container or in the collecting tray with water immediately.

FlushingStart system flushing?

FlushingPut suct. lance into water [OK]

FlushingDrain int. batch tank [OK]

FlushingClose drain cock [OK]

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Fig. 30 Flushing process

10. Flushing process

– Dilution water is filled up in the reaction tank until the level reaches K1.

– The hydrochloric acid pump runs for two minutes.

– The sodium chlorite pump runs for two minutes.

– Dilution water is filled up in the reaction tank until the level reaches K4, and it overflows into the batch tank. The following message is displayed:

At the end of flushing, the following message is displayed:

11. If the reaction tank is empty, the flushing process is repeated. After two flushing processes, the following message is displayed:

12. Confirm with [OK].

5.18.4 Working with the system after flushing

1. Remove the hose from the drain cock, and place it in the bucket.

2. Pour the contents of the bucket down the drain.

3. Clean the hose and bucket, and drain thoroughly with water.

4. Unscrew the original cover of the sodium chlorite container.

5. Remove the sodium chlorite suction lance from the bucket of water, and insert it in the sodium chlorite container. Screw the suction lance cap onto the container. Retain the original cover.

6. Unscrew the original cover of the hydrochloric acid container.

7. Remove the hydrochloric acid suction lance from the bucket of water, and insert it in the hydrochloric acid container. Screw the suction lance cap onto the container. Retain the original cover.

8. Fit the cover back on the Oxiperm Pro.

5.18.5 Terminating flushing

The flushing process can be terminated any time:

1. Main menu > Service > Process > Flushing > [OK].

2. Terminate > [OK].

Terminate flushing:

3. Terminate > [OK].

Restart flushing:

4. start again > [OK].

5.18.6 Responding to flushing faults

It can take five minutes to rinse the pumps. If the following error message appears after five minutes, proceed as follows:

1. There may be a problem with the pumps.

2. Once the fault has been removed, press [Esc] or [OK] to confirm.

3. Restart flushing.

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H2OPump HCl:

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2 min.

Drain int. batch tank [OK]

End

StartH2O

Please wait!

FlushingSystem flushing is running

FlushingPlease wait!

FlushingSystem flushing is finished [Esc]

FlushingStartTerminate

Flushingstart again

Terminate

Flushing

flushing error

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5.19 Calibration

Fig. 31 Structure of the "Calibration" menu

5.19.1 Calibrating the chlorine dioxide measured value

To calibrate the chlorine dioxide measured value, a reference measurement must be taken. This can be made with the Grundfos DIT photometer and the usual reagents.

The determined reference value is entered by correcting the current measured value in the display.

The controller reads in the new measured value. It assigns the current signal [µA] from calibration, coming in at the current input of the measuring cell, to the new measured value.

Check, if the measured value of the electrode is constant:

1. "Service > Measurement > ClO2 > Measured value"

– Current chlorine dioxide concentration at the measuring cell– Current signal of the measuring cell– Measuring range.

If the measured value remains constant:

2. Determine the chlorine dioxide value by means of a reference measurement, and note it down.

3. Press [Cal].

4. "Chlorine dioxide" > [OK].

5. "CAL meas. value" > [OK].

6. Set the determined reference value in mg/l with [Up] or [Down], confirm with [OK]. The controller assigns the reference value to the current signal.

7. "CAL cycle" > [OK].

The slope is the straight line between the measured value and the zero point. The unit is µA per ppm (ppm = parts per million = mg/l in water).

The slope can be presented graphically:

Fig. 32 Reference value measured with e.g. the DIT photometer

From now on, the controller uses this value as the basis for calculations. Chlorine dioxide calibration is completed.

Reading the slope in the calibration logbook

1. "Service > Measurement " > [OK].

2. "ClO2" > [OK].

3. "CalData-LogBook" > [OK]. Entry number 1 is the latest entry, entry number 2 is the previous one, etc.

Enabling and disabling the display of the chlorine dioxide calibration interval

1. "Calibration > ClO2 > CAL cycle" > [OK].

2. (Interval) Off > [OK] or (Interval) On > [OK].

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Calibration

CAL cycle

pH

On Off On Off

Slope:µA/mg/l

CAL meas. value

CAL result Asym. mV

ORPClO2

On Off

CAL cycle

CAL meas. value

CAL result

CAL cycle

CAL meas. value

CAL result

GRUNDFOS

DIN/NIST

others

Slope: µA/mg/l

Asym. mV

Note

Perform calibration only with constant measured values from the measuring cell. For details, see installation and operating instructions for the measuring cell.

Prior to calibration, check the measured value of the electrode of the measuring cell ("Main menu > Service > Measurement > ClO2 > Measured value").

Measurement ClO2

0.21 mg/l

5.800 µA

0.0 - 0.5 mg/l

CalibrationChlorine dioxidepH/ORP

Chlorine dioxideCAL meas. valueCAL resultCAL cycle

CAL meas. value0.05 mg/l

I-cell: 5.2 µA

CAL cycleSlope:22.0 µA/ppm

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CalData-LogBooknumber..............................1date...................2007-07-31

time.............................12:34

Slope:...................... 22.0 µA

μA

mg/l

5,2

0,05

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5.19.2 Performing (two-point) pH calibration

The electrode sends the voltage [mV] that corresponds to the pH value to the controller. Two different buffer solutions can be used to calibrate the pH measured value.

1. Prepare two glass jars with the buffer solutions.

2. Prepare an empty 10-litre plastic bucket.

3. Measure the temperature of the buffer solution.

4. Press [Cal].

5. pH > [OK].

6. "CAL meas. value" > [OK].

7. Select one of the three buffer types with [Up] or [Down].

8. GRUNDFOS > [OK].

9. Set the measured temperature of the buffer solution with [Up] or [Down], confirm with [OK].

10. Shut off the water supply of the measuring cell.

11. Unscrew the pH electrode from the measuring cell. Use the bucket to catch any water that flows out.

12. Immerse the pH electrode in the glass jar containing the second buffer solution (for example 4.01 pH).

13. Select the buffer value of the buffer solution in which the electrode is immersed (for example 4.01 pH). The voltage [mV] at the electrode in the second buffer solution(for example 4.01 pH) is measured, and assigned to thepH value.

14. Remove the pH electrode from the buffer solution, and rinse with water.

15. Immerse the pH electrode in the glass jar containing the second buffer solution (for example 7.00 pH).

16. Select the buffer value of the buffer solution in which the electrode is immersed (for example 7.00 pH). The voltage [mV] at the electrode in the second buffer solution (for example 7.00 pH) is measured, and assigned to the pH value.

The slope is the straight line between both measured values. The unit is mV/pH.

The slope can be presented graphically:

Fig. 33 Performing the two-point pH calibration

17. CAL result > [OK]. The result is displayed as the slope of the straight line, and the asymmetry (the asymmetry is the deviation from the zero point at pH 7). In this example, one pH unit corresponds to -57.88 mV.

18. Remove the pH electrode from the buffer solution, and rinse with water.

19. Screw the pH electrode back into the measuring cell.The current pH value of the water in the main line is updated in the display level.

20. Open the water supply of the measuring cell.

21. Dispose of the buffer solution. Do not pour it back into the bottle.

22. Pour the contents of the bucket down the drain. pH calibration is completed.

For alternative method, see the operating and installation instructions for the respective measuring cell.

Enabling and disabling the display of the pH calibration interval

1. Calibration > pH > CAL cycle > [OK].


CalibrationChlorine dioxidepH/ORP

pH

CAL meas. valueCAL resultCAL cycle

CAL meas. valueGRUNDFOS

DIN/NIST

others

Buffer type Buffer values

GRUNDFOS 4.01, 7.00, 9.18

DIN/NIST 4.01, 6.86, 9.18

othersThe lower and upper buffer values can be freely adjusted (difference of at least 1 pH) within the set pH measuring range.

buffer temp.25 °C

buffer value4.01 pH

7.00 pH

9.18 pH

buffer value4.01 pH

7.00 pH

9.18 pH

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CAL resultSlope:-57.88 mV/pH

Asym.-0.6 mV

mV

pH7

-0.6 mV

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5.19.3 Performing ORP calibration

The electrode sends the voltage [mV] that corresponds to the ORP value to the controller. It indicates the voltage of all ions in the water (summation parameter).

1. Prepare a glass jar with ORP buffer solution with a known mV value.

2. Prepare an empty 10-litre plastic bucket.

3. Press [Cal].

4. ORP > [OK].

5. "Measured value" > [OK].

6. Turn off the measuring cell water supply.

7. Unscrew the ORP electrode from the measuring cell. Use the bucket to catch any water that flows out.

8. Immerse the ORP electrode in the glass jar containing the ORP buffer solution.

9. In the display, set the mV value of the ORP buffer solution, confirm with [OK]. The mV value of the ORP buffer solution is measured.

10. "CAL result" > [OK]. The "ORP offset value is displayed as the result (for example -2 mV). This is the deviation between the entered mV value and the measured mV value of the buffer solution. The controller corrects the measured ORP value in the water of the main line by the offset value.

11. Remove the ORP electrode from the buffer solution, and rinse with water.

12. Screw the ORP electrode back into the measuring cell.

13. Open the water supply of the measuring cell.

14. Dispose of the buffer solution. Do not pour it back into the bottle.

15. Pour the contents of the bucket down the drain. ORP calibration is completed.

For alternative method, see the operating and installation instructions for the respective measuring cell.

Enabling and disabling the display of the ORP calibration interval

1. Calibration > ORP > CAL cycle > [OK].


5.19.4 Calibration faults

1. If, for example, 4.0 pH is selected in the display, but the electrode is immersed in a 7.00 buffer solution, the following error message is displayed: "wrong buffer"– Press [Esc] to terminate calibration, and repeat the process

correctly.

2. If the slope or asymmetry is outside the norm, the following error message is displayed: "slope error", "error asym. pot.". This is caused by an old electrode or buffer solution. Check the expiry date.

– Press [Esc] to terminate calibration, replace the electrode, and repeat calibration.

3. If the electrode does not send a stable measuring signal to the controller within 120 seconds, the following error message is displayed: "calibration time exceeded". This is caused by an old electrode.

– Press [Esc] to terminate calibration, replace the electrode, and repeat calibration.

CalibrationChlorine dioxideORP

ORPCAL meas. valueCAL resultCAL cycle

CAL meas. value225 mV

CAL resultORP offset-2 mV

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5.20 Error messages

See sections 7.1 Preparing for servicing and 8. Fault finding.

5.21 Function tests

1. Remove the cover from the Oxiperm Pro.

2. Carry out function tests and checks in accordance with the checklist and descriptions.

5.21.1 Performing visual checks

1. Check the drain cock, the dilution water hose and the connection to the solenoid valve for leaks.

2. Check all hoses and hose connections on the pumps for leaks, including the suction hoses to the suction lances.

5.21.2 Testing the power supply

1. Check the fuses, the main switch and the power supply cable.

2. Check all cables and electrical connections.

3. Check the cable to the measuring cell or measuring module, if applicable.

4. Check the cable to the mixing module, if applicable.

Simulating a power failure

1. Switch off the main switch with the system running.

2. Switch on the main switch again, see section 5.16.4.

5.21.3 Testing the current output "Control"1. "Main menu > Service" > [OK].

2. "Test current" > [OK].

3. Enter the service code.

4. "Control" > [OK].

5. Press [Down] to select the second current value > [OK]. The current output is automatically set to 50 % and the display line shows the status ON.

6. Press [Down] to select the third current value > [OK]. The current output is automatically set to 100 % and the display line shows the status ON.

5.21.4 Testing current output "Measurement ClO2"


2. "Test current" > [OK].


4. Press [Down] to select current output "Measurement ClO2" > [OK].

5. Continue as in step 5. or 6. of section 5.21.3. Press [Esc] > [Esc] to go back to the "Service" menu. The current output test is finished, when you exit the menu.

6. Use a multimeter to measure the actual current at the two current outputs. The value specified in the test must match the value that is actually measured. Otherwise, there is a fault on a current output.

7. Replace the controller, if necessary. See section 7.1.4.

5.21.5 Testing the relays

This test is carried out with the system running. The display shows, which relay is switched on at a given moment. All the relays are listed together with their names.


2. "Test relay" > [OK].

3. Enter the service code. "SV H2O:" means: Solenoid valve for water supply.

4. Press [OK] to switch on, and press [OK] again to switch off.If one of the relays does not switch on, the connected component or the relay is faulty.

5. Check the connected component and relay.

6. Replace the controller, if necessary.

Checklist Done

1. Check the hoses and connections for leaks.

2. Test the power supply.

3. Test the current outputs, see 5.21.3.

– current output 1

– current output 2.

4. Test the relays, see 5.21.5.

5. Test the levels, see 5.21.6.

– float switch in reaction tank

– float switch in batch tank

– suction lances.

6. Test warning lamp or warning system, if applicable.

7. Test the display (with LEDs), see 5.21.7.

8. Terminate chlorine dioxide production, see 5.21.8.

9. Stop chlorine dioxide dosing, see 5.21.9.

10. Test manual operation, see 5.21.10.

Test currentControlMeasurement ClO2

Control0 %:............................ On50 %:...........................Off100 %:........................ Off

Test currentControlMeasurement ClO2

Measurement ClO20 %:........................... On50 %:......................... Off100 %:....................... Off

Test relaySV H2O:............... OffPump HCl:............ OffPump NaClO2:..... Offpump ClO2:.......... OffAlarm relay:.......... OffWarning relay:....... Off

Note

The relays of the solenoid valve and the dosing pumps are semiconductor relays.

Therefore the switching procedure is not audible, unlike both of the mechanical relays for alarm and warning.

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5.21.6 Testing the level

This test is carried out with the system running. The correct functioning of the float switches and suction lances is checked. During the test, the display shows which contact the float has reached in the reaction tank, batch tank or suction lance. This contact is indicated on the display by X.


2. "Test level" > [OK].

Testing the float switch in the reaction tank

The chlorine dioxide production must be running for this test.

3. "Reaction tank" > [OK].

The "X" indicates which contact the float has reached. With the production process running, contacts K1 to K4 must be marked in succession in the "Reaction tank" menu. If this is not the case, replace the faulty float in the reaction tank, and repeat the test. For details, see section 7.1.5.

Fig. 34 Contacts at the reaction tank

Testing the float switch in the batch tank

Carry out this test, when a batch is ready in the reaction tank.



3. "Int. batch tank" > [OK].

Fig. 35 Batch tank levels

If the batch tank is empty, the contact K5 must be marked in the menu. If the batch tank is full, no contact is marked. The float is between K5 and K6. If the batch tank is overfull, K6 is marked (alarm). If this is not the case, replace the faulty float in the batch tank, and repeat the test, see section 7.1.6.

Test levelReaction tankInt. batch tankExt. batch tankSuction lance

Reaction tankK4:....................................--

K3:................................... X

K2:................................... --

K1:....................................--

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Component Contact Contact input

Reaction tank

K1 Water supply 1

K2 HCI supply

K3 NaClO2 supply

K4 Water supply 2

Batch tankK5 empty signal int. batch tankK6 Maximum level of batch tank

Suction lance

K7 Low level HCl

K8 HCI empty signal

K9 Low level NaClO2

K10 NaClO2 empty signal

External batch tank

K11 Min. level

K12 Max. level

K13Max. -max. levelbatch tank is overfull - alarm

K1

K2

K3

K4

Int. batch tankK6:................................... x

K5:................................... --

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K5

K6

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Testing the float switch in the external batch tank



3. "Ext. batch tank" > [OK].

Fig. 36 Contacts at the external batch tank

If the external batch tank is filled to a minimum, the contact K11 must be marked in the menu. If the external batch tank is full, contact K12 is marked. If no contact is marked, the float is between the contacts K11 and K12, or between K12 and K13. If the external batch tank is overfull, K13 is marked (alarm).

If this is not the case, replace the faulty float in the external batch tank, and repeat the test.

Testing the suction lances

1. On the display, open the "Test level" > "Suction lance" menu



3. "Suction lance" > [OK]. If both chemical containers are full, K7 (HCl) and K9 (NaClO2) are marked.

Fig. 37 Contacts at the suction lance

4. Untwist the screw cap from the suction lance in the HCl container. Carefully pull the suction lance about half way out of the container. The mark at contact K7 disappears from the display, and the red alarm LED starts flashing after 10 seconds.

5. Carefully pull the suction lance all the way out of the container, and immediately insert it into the drip pipe in the collecting tray. Contact K8 is marked in the display, and the red alarm LED starts flashing after 10 seconds.

6. If the contact is not marked, the HCl suction lance is faulty. Replace the faulty HCl suction lance, see section 7.1.2.

7. If the contacts were marked correctly, place the suction lance back into the HCl container and fasten the cover. Confirm the error message.

8. Repeat the test with the suction lance in the NaClO2 container. The contacts K9 and K10 are tested.

9. Exit the "Test level" menu with [Esc].

5.21.7 Testing the display


2. "Test display" > [OK].

The test function is started. The display goes completely dark, so that each pixel can be checked. In addition, all LEDs are switched on. They light up orange, and the red alarm LED flashes.After about 5 seconds, the display returns to the "Test display" submenu.

5.21.8 Terminating chlorine dioxide production


2. "Terminate" > [OK].

3. "Terminate" > [OK]. The production of chlorine dioxide is stopped, see section 5.15.1.

Ext. batch tankK13:.................................. -

K12:.................................. x

K11:.................................. -

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Warning

Put on protective clothing before starting work.




Do not allow sodium chlorite and hydrochloric acid to come into contact.

Risk of gas poisoning from chlorine dioxide gas.

Suction lanceK7:................................... x

K8:.................................. --

K9:................................... x

K10:................................ --

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K11

K12

K13

Red

Blue

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5.21.9 Stopping chlorine dioxide dosing

The controller can be reset in the "Setup > Controller ClO2" menu. This is not recommended, because all the controller parameters will have to be reset, when it is restarted.

Switching off the controller in manual operation

1. Press [Man].

– If the controller is switched off in "Setup", the message "Check settings!" is displayed. You cannot access manual operation.

– If the controller is switched on in "Setup", the "Man" LED lights up, and "Manual operation" is ready for use.


The factory setting is ON.

3. "Off" > [OK]. The display automatically reverts to "Manual operation". The controller is switched off, and the dosing pump shuts off. To switch off manual operation, see section 5.21.10.

Stopping the controller via the higher-level control system

The controller and the dosing pump can be stopped via an external device, for example a higher-level control system, which is connected to terminals 49/50 of the controller, see section 11.16.

Switching off the system at the main switch

The Oxiperm Pro OCD-162 system can be switched off at the main switch. This terminates the production and dosing process. For restart, see section 5.16.4.

5.21.10 Testing manual operation


Manual operation is used for temporary manual control of the chlorine dioxide dosing pumps, for example for impulse dosing. In manual operation, the controller can also be switched off in order to stop the dosing pump.

Switching on manual operation

1. Press [Man]. If the controller is switched off in "Setup", the message "Check settings!" is displayed. The controller must be configured before manual operation can be tested.

Setting the dosing flow in manual operation

In manual operation you can set the dosing flow for temporary (impulse) dosing.

1. "Dosing flow" > [OK].


Opening this menu deactivates the controller, but the controller settings are retained. The actuating variable is set to 0, and the following display appears:

3. Press [Up] or [Down] to change the dosing flow (0-100 %).

4. [OK] transmits the adjusted value to the dosing pump, which operates at the adjusted dosing capacity until further notice.

5. [ESC] returns the display to "Manual operation". The dosing pump continues operating at the adjusted dosing capacity.

Switching off manual operation

• Press [Man] again. The controller is activated again. The "Man" LED goes out. Then the display switches to display mode.

5.22 Setting the language


2. "Language" > [OK].

3. Select the operator language > [OK] > [Esc].

5.23 Saving the settings after commissioning

5.23.1 Saving changes to factory settings


2. "Factory setting" > [OK].


4. "Setup" > [OK].

5. "save" > [OK].

The display automatically reverts to "Factory setting". Your changes to the factory settings are saved. If the settings are changed again later, you can reactivate your original settings in the following menu:

1. "Setup" > [OK].

2. "activate" > [OK] > [Esc]. The original settings are reactivated.

5.23.2 Resetting to the factory settings


2. "Factory setting" > [OK].


4. "Reset" > [OK].

5. Enter the reset code (6742).

All settings are restored to the factory settings.

5.24 Switching off the system

1. See section 5.15.1 Terminating chlorine dioxide production.

2. See section 5.18 Flushing.

3. Switch off the Oxiperm Pro at the main switch.

4. Close the dilution water supply.

For restart, see section 5.16 Continuing operation after an interruption.

Manual operationController ClO2Dosing flow

Controller ClO2OnOff


NoteFor impulse dosing in manual operation, set the stroke-length adjustment knob to 100 %, if necessary. After manual operation, reset it again.

Cont. controllerX %Dosing flow


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6. Maintenance
Fig. 38 Structure of the "Maintenance" menu

6.1 Maintenance intervals

The Oxiperm Pro OCD-162 disinfection system must be serviced once a year. The current and next maintenance date are displayed in the operating software. The first maintenance date is one year after commissioning. Display the maintenance date:




4. Maintenance > [OK] > [Esc].

6.2 Maintenance kits for Oxiperm Pro

6.2.1 OCD-162-5

6.2.2 OCD-162-10

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Warning

Incorrect maintenance may result in personal injury and damage to property.

Only authorised service personnel trained by Grundfos may carry out maintenance work.

Switch off the system, and disconnect it from the power supply before carrying out maintenance work and repairs.

Warning

Risk of gas poisoning due to the escape of gas from a damaged volume compensation bag.

Do not reach into the void behind the controller.

Check the system for installation faults before starting maintenance.

Warning


Flush the system before starting maintenance work. Check the hoses for leaks.

Warning

Risk of faults due to failure to carry out maintenance work or due to delays in maintenance work may result in significant personal injury and damage to property.

Always abide by the specified maintenance intervals.

Note

The Oxiperm Pro is unpressurised.

Only the dosing pump, dosing line and injection unit on the main water line are under pressure (maximum 10 bar).

Note

The "Dosing flow", "Reaction time", "Chlorine dioxide" and "Water sensor" menus are preset in the factory and can only be accessed with a special code. They are not described in this manual.

Warning

Incorrect handling of chemicals may result in serious personal injury and damage to property.

Before starting work, put on protective clothing (gloves, face mask, protective apron).

Main menu

Maintenance

Maintenance rel.

Temp. correction

Dosing flow

Reaction time

Chlorine dioxide

Water sensor

Maintenance done

Maintenance kit Product No.

Dosing pump DDE 6-10 (230 V/115 V) 97751181

Dosing pump DDA 7.5-16 (230 V/115 V) 97751181

Solenoid valve (230 V/115 V) 95702990

Reaction tank 95702992

Multi-function valve 95702993

Activated carbon filter and volume compensation bag

95702994

Complete kit with dosing pump DDA 7.5-16 98153636

Complete kit without dosing pump 98153651



Dosing pump DDA 7.5-16 (230 V/115 V) 97751181




2 activated carbon filters and 2 volume compensation bags

95705995

Complete kit with dosing pump DDA 7.5-16 98153962


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6.2.3 OCD-162-30

6.2.4 OCD-162-60

6.3 Maintaining the pumps

6.3.1 Chemical dosing pumps

1. Flush the system, see section 5.18 Flushing.

2. Have ready the suitable maintenance kit.

3. See the installation and operating instructions for the pumps.

Fig. 39 Dosing head DDE: exploded view



Dosing pump DDI (230 V/115 V) 95715695

Dosing pump DMX (230 V/115 V) 95715694


Pair of non-return valves (0.8 bar, installed in the suction lance)

98165354



Adsorption cylinder and volume compensation bag

95717914

Complete kit with dosing pump DMX 98162637

Complete kit with dosing pump DDI 98162644



Dosing pump DMX (230 V/115 V) 95715693

Dosing pump DDI (230 V/115 V) 95715695


Pair of non-return valves (0.8 bar, installed in the suction lance)

98165354



Adsorption cylinder and 2 volume compensation bags

95717918

Complete kit with dosing pump DMX 95717919

Complete kit with dosing pump DDI 95717920


OCD-162 Maintenance kit No.

-05, -10 97751181 (DDE 6-10)

-30 97751217 (DDE 15-4)

Pos. Spare parts for maintenance kits No. 97751479 and 97751497

1 Discharge valve with compression spring

2 Suction valve

7 Screws

9 Ventilation cartridge

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OCD- Maintenance kit No. Including

162-60 95722514 (DMX 221)Dosing diaphragm, profiled gasket, grooved ring, sealing diaphragm

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6.3.2 Chlorine dioxide dosing pumps

See the installation and operating instructions for dosing pumps.

6.3.3 Replacing a chemical container

Chemical containers should be replaced:

• As soon as possible after the low level signal is displayed.

• Immediately after the empty signal is displayed.

1. Untwist the screw cap from the suction lance in the chemical container.

2. Carefully pull the suction lance out of the container, and immediately insert it into the drip pipe in the collecting tray.

3. If any drips fall onto the container or ground, dilute with water and rinse away immediately.

4. Remove the empty chemical container. Screw the original cover onto the container for storage prior to disposal.

5. Prepare a full chemical container.

6. Unscrew the original cover, and retain it.

7. Insert the suction lance into the full container, and fasten the screw cap again. As soon as the suction lance is inserted, the chlorine dioxide production starts up again. The alarm message is confirmed automatically.

8. Reset the chemical consumption counter to 0. For details, see section 5.17.8.

6.4 Maintaining the solenoid valve

Fig. 40 Solenoid valve (OCD-162-5)

6.4.1 Preparation

1. Have ready the suitable maintenance kit:

– for OCD-162-5, -10

– for OCD-162-30, -60

2. Have ready a 10-litre bucket (OCD-162-5, -10) or a 25-litre container (OCD-162-30, -60), see section 5.15.1.

3. Close the dilution water extraction device, see section 2.4.1.

4. Unscrew the hose connection at the bottom of the solenoid valve, and let the water flow into the bucket or container.

5. Unscrew the hose connection from the top of the solenoid valve.

Oxiperm Pro Pump type Maintenance kit No.

OCD-162-5-P/G, -P/HDDA 7.5-16 97751181

OCD-162-10-P/G, -P/H

OCD-162-30-D/G, -D/H DMX 16-10 95715694

OCD-162-60-D/G, -D/H DMX 35-10 95715693

OCD-162-30-P/G, -P/HDDI 60-10 95715695

OCD-162-60-P/G, -P/H

NoteOCD-162-5, -10: Make sure that the chemical containers are positioned under the system.

Warning




Warning


Risk of poisoning from chlorine dioxide gas.

Put on protective clothing before starting maintenance work.

Do not allow sodium chlorite and hydrochloric acid to come into contact.



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Product No. Pos. Spare part

95702990

2 2 O-rings

4 1 O-ring

11 Cap

1071 Strainer

Product No. Spare part

95717912

2 O-rings

2 O-rings

Strainer

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6.4.2 Changing O-rings, cap and strainer (OCD-162-5, -10)

1. Unfasten the two screws on the enclosure, and remove the enclosure (V) with the cable connection socket (K) from the system.

2. Unfasten the screw on the cable connection socket, remove the cable connection socket from the plug, and place the valve on a working surface.

3. Remove the four screws from the enclosure, and pull the upper section up and off.

4. Take out the tappet (S) and guide (F).

5. Remove the cap, and fit a new cap (11).

6. Remove the O-ring, and fit a new O-ring (4).

7. Place the tappet and guide.

8. Place the upper section of the enclosure.

9. Fasten the four screws on the enclosure.

10. Change the O-rings (2) in the connector on the enclosure.

11. Screw down the cable connection socket again.

12. Screw the enclosure back onto the system.

13. Fit a new strainer (1071).

14. Attach and screw down the bottom hose connection.

15. Open the dilution water extraction device.

16. After two minutes, check the top end of the hose connection for leaks.

17. If it is tight, screw down the top hose connection again.

6.4.3 Changing O-rings and strainer (OCD-162-30, -60)

1. Replace the O-rings from the top and bottom hose connection by new ones.

2. Replace the O-rings from both cable connection sockets by new ones.

3. Fit a new strainer.

4. Attach and screw down the bottom hose connection.




6.4.4 Final maintenance steps

1. Pour the contents of the bucket down the drain. Dispose of the old O-rings, cap (OCD-162-5, -10) and strainer.

2. Start chlorine dioxide production, see section 5.16.1.

Fig. 41 Solenoid valve (OCD-162-5, -10), exploded view

6.5 Maintaining the multi-function valve

6.5.1 Functions of the multi-function valve

The multi-function valve is directly installed on the discharge side of the pump. It is designed as a pressure retention valve and pressure relief valve.

Fig. 42 Multi-function valve on the dosing pump

6.5.2 Preparing for maintenance

1. Put on protective clothing.

2. Flush the system, see section 5.18. After flushing, the batch tank is empty. There is water in the hoses and pumps. Only the dosing line contains chlorine dioxide solution.

3. Have ready an empty bucket.

4. Have ready the following maintenance kit:

6.5.3 Draining the dosing line

1. Grasp the green knob and the black knob. Turn them both clockwise as far as the stop, and hold them in this position. The pressure retention valve and pressure relief valve open. Chlorine dioxide solution flows out of the dosing line back into the batch tank.

2. Hold both knobs in position, until the flow of chlorine dioxide solution into the batch tank has stopped. Release both knobs. They return automatically to their original position, and the valves close again.

3. Attach the hose to the drain cock on the batch tank, and pass it into the bucket. Open the drain cock, manually drain the batch tank, and close the drain cock again.

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Pos. Description

V Enclosure with top and bottom hose connection

K Upper section with cable connector

F Guide

S Tappet

2

1071

2F

11S

K

4x

V

4

NoteRead the installation and operating instructions for the multi-function valve before starting work.

Warning

Risk of burns due to the escape of chlorine dioxide from the dismantled dosing line.

Risk of gas poisoning due to the escape of chlorine dioxide from the dismantled gas hose.

Flush the system before dismantling the multi-function valve. Drain the dosing line before unscrewing it.

Put on protective clothing.

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95702993

2 2 diaphragms

14 O-ring

17 2 O-rings

NoteA non-return valve must be installed at the dosing point. Otherwise the entire contents of the dosing line can flow back.

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6.5.4 Removing and dismantling the multi-function valve

1. Unfasten the screw connection together with the dosing line. Allow residual chlorine dioxide solution to flow into the bucket.

2. Unfasten the screw connection together with the overflow line to the batch tank. Allow residual chlorine dioxide solution to flow into the bucket.

3. Unfasten the lower screw connection (fig. 43, pos. A) at the dosing head. Allow chlorine dioxide solution to flow into the bucket. The connection nipple with union nut is released.

4. On the side of the green knob, unfasten the four screws in the valve body. Both knobs can be detached from the body.

Changing the O-ring in the screw connection to the dosing head

1. Insert a 6 mm Allen key into the connection nipple (with union nut) for the dosing head. Unscrew the connection nipple from the valve body.

2. Remove the old O-ring, and fit a new O-ring (14).

3. Screw the connection nipple and union nut back into the valve body.

Changing the diaphragm and O-ring on the green knob

1. Remove the covering cap from the green knob.

2. A white plastic pin with a split end can be seen inside. Use a pair of needle-nose pliers to squeeze the two halves together, and press them towards the knob to release the tension.

– The membrane, compression spring, washer and green knob are released.

3. Remove the old membrane. Fit the new membrane together with the compression spring and washer.

4. Reassemble the green knob.

5. Remove the old O-rings. Fit a new O-ring (17) to the connector on the enclosure.

Fig. 43 Multi-function valve, exploded view

Changing the diaphragm and O-ring on the black knob

1. Remove the covering cap from the black knob.

2. A white plastic pin with a split end can be seen inside. Use a pair of needle-nose pliers to squeeze the two halves together, and press them towards the knob to release the tension.

– The membrane, compression spring and washer are released.

3. Remove the old membrane. Fit the new membrane together with the compression spring and washer.

4. Reassemble the black knob.

6.5.5 Reassembling the multi-function valve

Fig. 44 Multi-function valve, exploded view

1. Fit the black knob (1) to the valve body on the side marked with "P" (pressure).

2. Fit the green knob (6) to the valve body on the side marked with "S" (safety).

3. Insert the four screws back into the valve body, and tighten the nuts.

4. Screw the union nut back onto the dosing head.

5. Screw down the screw connection together with the overflow line.

6. Screw down the screw connection together with the dosing line.

7. Use the green knob for manually venting the dosing pump.

8. After 48 hours of operation, re-tighten the four screws on the enclosure (torque 2 Nm).

9. Correct the overflow pressure later, if necessary, see 6.2.

6.5.6 Final maintenance steps

1. Pour the contents of the bucket down the drain, and rinse with plenty of water.

2. Dispose of the old O-rings and membranes.

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Pos. Description

AScrew connection for the dosing head (connection nipple and union nut)

2 2 diaphragms

14 O-ring

17 2 O-rings

2

14 A

2

17

17

NE P

O

NEP

O

TM

03

66

59

45

06

P S

2 41 6

3

5

Black Green

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6.6 Maintaining the reaction tank

Fig. 45 Reaction tank and batch tank of OCD-162-5, -10


1. Flush the system, see section 5.18. After flushing, the reaction tank and batch tank are empty.

2. Have ready the suitable maintenance kit:

– for OCD-162-5/-10

– for OCD-162-30/-60

6.6.2 Changing the O-rings on float switch and drain cock

Connections on the top of the reaction tank

Fig. 46 OCD-162-5, -10: Connections on the reaction tank

Fig. 47 OCD-162-30: Connections on the reaction tank

Fig. 48 OCD-162-60: Connections on the reaction tank

1. Unfasten the float switch connection on top of the reaction tank, and pull out the float switch.

2. Remove the O-ring (fig. 49 or 50).

3. Unfasten the float switch connection at the bottom of the batch tank, and pull out the float switch.

4. Remove the O-ring.

5. Pull out the drain cock, and remove the O-ring.

Warning

Risk of burns due to the escape of chemicals from hoses, reaction tank, batch tank and dismantled dosing line.


Wear gloves, protective apron and breathing mask.

Check that the reaction tank and batch tank are empty before dismantling the reaction tank. Flush the system before dismantling the reaction tank.

TM

03

69

48

45

06


95702992

27 O-ring on float switch in batch tank

29 O-ring on float switch in reaction tank

80 O-ring on drain cock


95717913

27 O-ring on float switch in batch tank

29 O-ring on float switch in reaction tank

80 O-ring on drain cock

Note

When the gas hose is unscrewed, chlorine dioxide gas can escape.


Do not hold your face over the reaction tank.

TM

03

69

49

45

06

TM

04

09

57

17

09

TM

04

09

58

17

09

HCl

H O

NaClO

2

HClH O

NaClO

2

2

2

OCD-162-5, -10

Gas

Gas

NaClO

H 2O

2

HCl

HClH O2

NaClO2

OCD-162-30

Gas

Gas

NaClO2

H 2O

HCl

HClH O

NaClO2

2

OCD-162-60

Gas

Gas

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Removing the float switch

Fig. 49 OCD-162-5, -10 and OCD-162-30: Removing the float switch from the reaction tank, and removing the float switch and drain cock from the batch tank

Fig. 50 OCD-162-60: Removing the float switch from the reaction tank

6. Screw the float switch with the new O-ring back into the reaction tank.

7. Screw the float switch with the new O-ring back into the batch tank.

8. Screw the drain cock with the new O-ring back into position.

6.7 Maintaining the volume compensation bag and activated carbon filter (OCD-162-5, -10)


Have ready the suitable maintenance kit with activated carbon filter and volume compensation bag.

For OCD-162-5

For OCD-162-10

6.7.2 Changing the volume compensation bag

The volume compensation bag of the OCD-162-5 and -10 is situated in the system frame, behind the controller.

1. Unfasten the top screw connection on the activated carbon filter. The hose can now be moved.

2. Hold the volume compensation bag by the T-piece, and carefully pull it out from the void behind the controller.

3. Loosen but do not remove the screwed joint on the volume compensation bag.

4. Pull the hose out of the screwed joint, and remove the volume compensation bag.

5. Unpack the new volume compensation bag, loosen but do not remove the screwed joint.

6. Push the hose into the screwed joint as far as the stop, and carefully tighten the screwed joint by hand.

7. Hold the volume compensation bag by the T-piece, and carefully push it into the void behind the controller.

8. Replace the top screw connection on the activated carbon filter.

TM

04

85

35

13

12

TM

04

09

59

17

09

8027

29

OCD-162-5, -1027

80

9

27

OCD-162-30

9

27

9

27OCD-162-60

Warning

Risk of burns due to the escape of chemicals when the hoses are disconnected.



Do not hold your face over the volume compensation bag or activated carbon filter.


95702994

1 1 activated carbon filter

41 O-ring at the bottom of the activated carbon filter

52 valves, at the bottom and at the side of the activated carbon filter

- 1 volume compensation bag


95705995

1 2 activated carbon filters

41 O-ring at the bottom of the activated carbon filter

52 valves, at the bottom and at the side of the activated carbon filter

- 2 volume compensation bags

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Fig. 51 Maintaining the activated carbon filter

6.7.3 Removing the activated carbon filter

1. Unscrew the top screw connection (7) from the activated carbon filter (1).

2. Remove the activated carbon filter with valve support (2) from the two retaining clamps.

3. Dispose of the activated carbon filter in a professional way.

6.7.4 Changing the lower O-ring

1. Detach the valve support (2) from the bottom screw connection (3).

2. Unfasten the bottom screw connection (3) and retain it for the new filter.


6.7.5 Changing the valves in the valve support

1. Unfasten the connection piece (6) for the top valve from the valve support. Unscrew and remove the valve, and screw in a new valve (5). Fasten the connection piece again.

2. Unfasten the bottom valve from the valve support. Unscrew and remove the valve, and screw in a new valve (5).

6.7.6 Fitting a new activated carbon filter

1. Screw the bottom screw connection (3) into the new activated carbon filter and change the PTFE sealing tape, if necessary.

2. Position the valve support (2) on top of the screw connection.

3. Insert the activated carbon filter with valve support back into the filter support, and fasten the two clamps again.

4. Screw the top screw connection (7) onto the new activated carbon filter.

6.8 Maintaining the volume compensation bag and adsorption filter (OCD-162-30, -60)


Have ready the suitable maintenance kit for the adsorption filter and volume compensation bag.

For OCD-162-30

For OCD-162-60

6.8.2 Changing the volume compensation bag

The volume compensation bag of the OCD-162-30 as well as both volume compensation bags of the OCD-162-60 are situated in the system frame, below the chlorine dioxide dosing pump.

Fig. 52 Changing the volume compensation bag

1. Secure the screw-in part at the volume compensation bag with a 17 mm open-ended spanner and loosen the union nut.

2. Replace the volume compensation bag by a new one. Insert the connection hose into the screw-in part until the stop.

3. In order to avoid damages of the volume compensation bag, secure the screw-in part with a 17 mm open-ended spanner and fasten the union nut entirely by hand.

TM

03

69

56

45

06

Pos. Description

1 Activated carbon filter

2 Valve support

3 Bottom screw connection

4 O-ring

5 Valve

6 Connection piece

7 Top screw connection

7

1

6

3

4

5

5

2

7

1

6

3

4

5

5

2

Warning

Risk of burns due to the escape of chemicals when the hoses are disconnected.



Do not hold your face over the volume compensation bag or adsorption filter.


95717914

9 2 valves

12 O-ring

16 Refill pack of adsorbent (2.3 kg)

- 1 volume compensation bag


95717918

9 2 valves

12 O-ring

16 Refill pack of adsorbent (2.3 kg)

- 2 volume compensation bags

TM

04

09

60

17

09

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6.8.3 Changing the adsorption filter granulate

Fig. 53 OCD-162-30, -60

1. Unscrew the top screw connection (2) from the adsorption filter (17).

2. Loosen the adsorption filter retaining clamp by pulling it downwards.

3. Move the adsorption filter slightly upwards, and remove it in direction to the front.

4. Turn the adsorption filter by 180°, and unscrew the union nut with pressure disc.

5. Empty the adsorption cylinder and dispose of the adsorbent in a professional way.

6. Fill in new adsorbent, and screw on the union nut with pressure disc again.

7. Insert the refilled adsorption filter. Introduce the bottom screw connection (11) into the valve support (10).

8. Lock the adsorption filter with the retaining clamp.

9. Screw the top screw connection (2) onto the refilled adsorption filter.

Changing the lower O-ring

1. Detach the valve support (10) from the bottom screw connection (11).


Changing the valves in the valve support

1. Unfasten the connection piece (8) for the top valve from the valve support. Unscrew and remove the valve, and screw in a new valve (9). Fasten the connection piece again.

2. Unfasten the bottom valve from the valve support. Unscrew and remove the valve, and screw in a new valve (9).

Final maintenance steps

– Dispose of the old O-rings, valves and old adsorbent in a professional way.

6.9 Completing the maintenance work

After completion of the maintenance work, confirm the maintenance in the operating software:

1. "Main menu> Maintenance" > [OK].

2. "Maintenance rel." > [OK]."

3. "Maintenance done" > [OK] > [Esc].

TM

04

09

61

17

09

Pos. Description

2 Top screw connection

7 Union nut

8 Connection piece

9 Valve

10 Valve support

11 Bottom screw connection

12 O-ring at the bottom of the adsorption filter body

13 Pressure disc

16 Refill pack of adsorbent

17 Adsorption filter body

12

11

9

16

7

10

9

13

17

8

8

11

12

9

9

10

2

17

2

Warning

Check the tightness of all seals, valves, hose connections and chemical lines.

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7. Servicing

7.1 Preparing for servicing

1. Check the system status:

– An error message is displayed, see section 2.7 and 8.

– The warning or alarm LED flashes up.

– The warning or alarm relay is active.

– If chlorine dioxide production has been terminated automatically, the message "process stop" or "process term." is displayed.

– If the controller has been stopped by an external device, the message "controller stop external" is displayed. The controller symbol in the display is struck through.

2. Carry out fault status diagnostics:

– Check the operation mode, see 5.13.

– Open the monitoring menus, see section 5.17. Make a note of the displayed values.

– See section 2.2 Functional principle.

3. Eliminate the fault:

– Flush if possible, see section 5.18.

– See section 5.24 Switching off the system.

– Implement the measures suggested in the tables of section 8.

– Use measuring and testing instruments.

– Use spare parts as specified in section 12.

– Use the test functions in the operating software,see section 5.21.

4. Prepare the system for operation, see section 5.16.

7.1.1 Replacing the solenoid valve

See section 6.4 Maintaining the solenoid valve.

1. Prepare a 10-litre bucket (OCD-162-5, -10) or 25-litre container (OCD-162-30, -60), see section 5.15.1.

2. Close the dilution water extraction device, see section 2.4.1.

3. Unscrew the hose connection at the bottom of the solenoid valve, and let the water flow into the bucket or container.

4. Unscrew the hose connection from the top of the solenoid valve.

5. Unfasten the two screws on the enclosure, and remove the enclosure with the cable connection socket from the system.

6. Unfasten the screw on the cable connection socket, remove the cable connection socket from the plug, and remove the solenoid valve.

7. Take the new solenoid valve, position it on the cable connection socket and screw into place.

8. Screw the valve enclosure back onto the frame.

9. Remove the old strainer and old O-ring from the bottom of the hose connection. Insert the new strainer and the new O-ring.

10. Screw the hose connection back into place.




14. Pour the contents of the bucket down the drain. Dispose of the old O-ring and strainer.

7.1.2 Replacing a suction lance

1. Untwist the screw cap from the suction lance in the chemical container.

2. Carefully pull the suction lance out of the container, and immediately insert it into the drip pipe in the collecting tray.

3. If any drips fall onto the container or ground, dilute with water and rinse away immediately.

4. Unscrew the signal cable from the controller(hydrochloric acid - terminals 31, 32 and 33) (sodium chlorite - terminals 34, 35 and 36).

5. Unscrew the suction hose from the pump.

6. Screw the suction hose of the new suction lance onto the pump.

7. Insert the new suction lance into the chemical container, and fasten the screw cap.

8. Connect the signal cable to the controller (hydrochloric acid - terminals 31, 32 and 33) (sodium chlorite - terminals 34, 35 and 36).

Warning

Incorrect servicing may result in personal injury and damage to property.

Only authorised service personnel trained by Grundfos may carry out servicing.

Switch off the system, and disconnect it from the power supply before carrying out servicing.

Warning

Risk of gas poisoning due to escape of gas from a damaged volume compensation bag.

Do not reach into the void behind the controller.

Check the system for installation faults before starting servicing.

Warning


Flush the system before starting servicing. Check the hoses for leaks.

Warning

Risk of burns due to the escape of chemicals from leaky valves, seals, connections or diaphragms.

Check the pumps for leaks during servicing.

Note

For details on servicing the pumps, see the installation and operating instructions for the pumps.

For details on servicing the measuring cell, see the installation and operating instructions for the measuring cell.

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7.1.3 Replacing the multi-function valve

See section 6.5. The batch tank must be empty before the multi-function valve is replaced.

Preparing for replacement

1. Read the installation and operating instructions for the multi-function valve.


3. Have ready an empty bucket.

4. Flush the system, see section 5.18.

5. Drain the discharge-side dosing line, see sections 6.5.3.

Replacing the multi-function valve

1. Unfasten the screw connection between the multi-function valve and the discharge side of the dosing pump.

2. Carefully detach the multi-function valve from the dosing pump, and hold it over the bucket together with the lines. Unscrew the screw connection on the overflow line and the screw connection on the dosing line. Allow any residual chlorine dioxide solution to drain into the bucket, and remove the two lines.

3. Screw the new multi-function valve onto the discharge side of the dosing pump.

4. Screw down the overflow line and dosing line.

5. Manually vent the dosing pump, see section 5.14.2.

Final replacement steps

1. Pour the contents of the bucket down the drain, and rinse with plenty of water.

2. Dispose of the old valve.

3. See section 5.16.1 Continuing operation after terminating chlorine dioxide production.

7.1.4 Replacing the electronic controller

The controller is fastened to the frame with three screws. One screw is at the back in the top centre, two screws are on the bottom right and left in a void next to the cable connections.

Preparing for replacement

1. See section 5.15.1 Terminating chlorine dioxide production.

2. Switch off the main switch.

3. Unfasten the cover of the controller (under the operating panel) with a screwdriver.

4. Unfasten all cables from their connections and pull them out of the glands.

5. Unscrew the two screws on the bottom right and left.

6. Lift the controller off the screw in the top centre.

7. Hook the new controller onto the screw in the top centre. Fasten the bottom right and left screws again.

8. Reconnect the cables as described, see section 4.8.

9. Screw the cover back into place.

10. Switch on the main switch again.

11. If necessary, make a new set-up.

12. Continue operation, see section 5.16.

7.1.5 Replacing the float switch in the reaction tank

1. Maintaining the reaction tank, see section 6.6

2. Preparing for maintenance, see section 6.6.1

3. Unscrew the cables from the controller (terminals 40, 41, 42, 43 and 44).

4. Unfasten and pull out the float switch of the reaction tank.

5. Insert the new float switch and O-ring, and screw into place.

7.1.6 Replacing the float switch in the batch tank

1. See section 6.6 and 6.6.1.

2. Unscrew the cables (terminals 37, 38, 39) from the controller.

3. Unfasten and pull out the float switch of the batch tank.

4. Insert the new float switch and O-ring, and screw into place.

7.1.7 Replacing the reaction tank and the batch tank

1. See section 6.6 Maintaining the reaction tank and 6.6.1.

2. Unscrew the hose connections for water, hydrochloric acid, sodium chlorite and gas at the top of the reaction tank, and remove the hoses.

3. Unfasten and pull out the float switch at the bottom of the batch tank.

4. Remove the O-ring.

5. Unscrew and pull out the drain cock, and remove the O-ring.

6. Remove the reaction tank and the batch tank from the retaining clamps.

7. Attach the drain cock to the new batch tank.

8. Position the float switch at the top of the reaction tank, and screw into place.

9. Position the float switch at the bottom of the batch tank, and screw into place.

10. Fasten the connections and the gas hose to the reaction tank.

11. Attach the overflow line connection to the bottom of the batch tank.

12. Attach the connection for the dosing pump supply line.

13. Dispose of the old reaction tank in a professional way.

7.1.8 Replacing chemical dosing pumps

See the installation and operating instructions for the respective dosing pump: DDE or DMX 221.

7.1.9 Replacing the dosing pump

See the installation and operating instructions for the respective dosing pump: DDA 7.5-16, DMX 221 or DDI 222.

Warning

Danger of death from electric shock.

Shut down the system and switch off the main switch before removing the controller.

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8. Fault findingActivated relays can be deactivated with the [Esc] button. An exception is the warning relay, which is activated by the signal "batch tank empty". The warning relay is only deactivated, if the fault is removed.

For trouble-free operation of the Oxiperm Pro system, eliminate the cause of the faults.

8.1 Faults with error message

Error message, reaction of Oxiperm Pro

Cause Remedy

1. Low-level signal HCl or NaClO2:– ClO2 production proceeds.– Warning relay activated.

a) HCl or NaClO2 container is almost empty. Change the HCl or NaClO2 container. Oxiperm Pro OCD-162-05, -10: the chemical containers must be positioned under the system.

b) The float on the suction lance has a wrong orientation.

Turn the float upside down, see section 4.6, fig. 15.

2. Empty signal HCl or NaClO2:– ClO2 production stops, and

continues after elimination of the fault.

– Alarm relay activated.

HCl or NaClO2 container is empty.

Change the HCl or NaClO2 container. Oxiperm Pro OCD-162-05, -10: the chemical containers must be positioned under the system.

3. "check ClO2 batch":– ClO2 production proceeds.– Warning relay activated.

Warning message, undefined contents in the batch tank after power supply failure.

Drain the batch tank manually, and dispose of the content.

4. "level int. batch tank":– ClO2 production is terminated.– Alarm relay activated.

Too much water is flowing into the batch tank. The ClO2 solution in the batch tank is too diluted.

Stop the system.

a) Solenoid valve is leaking. Check the solenoid valve.Clean or replace the filter in the solenoid valve.

b) Faulty float switch in the reaction tank, or too much HCl and/or too much NaClO2 is flowing into the batch tank.

Replace the float switch in the reaction tank.

5. Max. -max. level external batch tank:

– Alarm relay activated.

Faulty float switch in the external batch tank, or external batch tank is overfull.

Replace the float switch in the external batch tank.

6. "Timeout H2O supply 1":– ClO2 production is terminated.– Alarm relay activated.

During the first addition of water (after process start), the level in the reaction tank has increased too slowly. Level K1 was not reached in time.

Check the solenoid valve in the "Test relay" menu, see section 5.21.5. Check the water supply.

a) Filter in solenoid valve clogged, or faulty solenoid valve.

Check the solenoid valve. Replace the filter, or replace the solenoid valve.

b) Dilution water supply is not sufficiently open. Open the dilution water supply further.

c) Float switch in the reaction tank is damaged. Replace the float switch in the reaction tank.

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7. "Timeout pump HCl":– ClO2 production is terminated.– Alarm relay activated.

During HCl supply, the level in the reaction tank has increased too slowly between levels K1 and K2. Level K2 was not reached in time.

Check the hose from pump to reaction tank for assembly faults.Check the HCl pump in the "Test relay" menu, see section 5.21.5.

a) Insufficient performance of the HCl pump– Air in suction hose and/or dosing head. – Pump is not dosing.– Discharge hose is leaking, clogged, porous or

bent.

Check the discharge hose. Replace, if necessary.

b) HCl pump is not sucking in– Suction hose is leaking, clogged, porous or

bent.– Deposits at the foot valve.– Valve is not installed correctly or clogged.

Crystalline deposits in the valves.– Diaphragm is broken (leaking).– Valve tappet is torn out.– HCl container is empty.

• Check the suction hose and suction lance.

• Clean or replace the foot valve.• Clean the valves.• Replace the diaphragm.• Check the fill level of the HCl container.• If "empty HCl" is signalled, replace the

HCl container.

c) Flow in the pump not OK. Vent the system.

d) Pump is not running at all. Replace the pump.

e) Cable breakage at the controller. Check the cable from pump to controller. Replace the cable, if necessary.

f) Faulty controller. Check the controller. Replace, if necessary.

g) Float switch in the reaction tank is damaged. Replace the float switch in the reaction tank.

8. "Timeout pump NaClO2":– ClO2 production is terminated.– Alarm relay activated.

During NaClO2 supply, the level in the reaction tank has increased too slowly between levels K2 and K3. Level K3 was not reached in time.

Check the hose from pump to reaction tank for assembly faults.Check the NaClO2 pump in the "Test relay" menu, see section 5.21.5.

a) Insufficient performance of the NaClO2 pump. For other reasons, see alarm message 7. "Timeout pump HCl":.

See alarm message 7. "Timeout pump HCl":.

9. "Timeout H2O supply 2":– ClO2 production is terminated.– Alarm relay activated.

During the second addition of water, the level in the reaction tank has increased too slowly between levels K3 and K4. Level K4 was not reached in time.

a) See alarm message 6. "Timeout H2O supply 1":. Check the solenoid valve and water supply in "Test relay", see section 5.21.5. Check the water supply. See also alarm message 6. "Timeout H2O supply 1":.

10. "Timeout process":– ClO2 production is terminated.– Alarm relay activated.

After overflow, the level in the reaction tank has dropped back down to K1 too slowly.

a) Air bubbles in the overflow pipe. Vent the system.

b) Insufficient water supply. See alarm message 6. "Timeout H2O supply 1":.

11. "Timeout overflow":– ClO2 production is terminated.– Alarm relay activated.

During the third addition of water, no overflow from the reaction tank into the batch tank was determined.

a) Water supply and solenoid valve. Check the solenoid valve and water supply in the "Test relay" menu, see section 5.21.5.

b) Air bubbles in the overflow pipe. Vent the system.

12. "temperature error":– ClO2 production proceeds.

The temperature at the measuring cell has exceeded the set measuring range.

a) Faulty temperature sensor. Check the temperature sensor. Replace, if necessary.

b) Faulty cable of temperature sensor. Check the cable of the temperature sensor. Replace, if necessary.

c) Water temperature higher or lower than measuring range.

Check the water temperature.

d) Temperature measuring range set incorrectly. Correct the measuring range.

13. "slope error"– ClO2 production proceeds.

Plausibility check of calibration data. Calibration fault at calibration level.

Repeat the calibration, clean the cell, or replace the electrodes.

14. "fault of electrode/buffer":– ClO2 production proceeds.

Auto reading of buffer data. Calibration fault at calibration level.

Repeat the calibration, clean the cell, or replace the pH electrode.

15. Symmetry error:– ClO2 production proceeds.

Plausibility check of calibration data for asymmetry potential of pH. Calibration fault at calibration level.

Repeat the calibration, clean the cell, or replace the pH electrode.


Cause Remedy

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16. pH buffer difference error:– ClO2 production proceeds.

Two buffers with a pH difference of less than 1 pH were selected with buffer selection "other". Calibration fault at calibration level.

Check the buffer solutions. Repeat the calibration, and replace the electrode.

17. Calibration time exceeded:– ClO2 production proceeds.

Buffer timeout. Fault during pH and ORP calibration. An alarm is activated, if the calibration process does not have a stable measured value, if the time has elapsed. Calibration fault at calibration level.

Check the pH electrode and replace, if necessary.

18. Offset error:– ClO2 production proceeds.

Calibration fault at calibration level. Only during ORP calibration.

Repeat the ORP calibration, or replace the electrode.

19. Calibrate ORP electrode:– ClO2 production proceeds.

The set monitoring time is reached for the next calibration process (calibration interval).

Calibrate or replace the electrode.

20. "Water sensor fault":– ClO2 production proceeds.– Combined and setpoint

controller stop, and restart after fault elimination.

Stop the controller.

a) The float of the measuring cell is above the water sensor. The flow is too big.

Reduce the flow with the adjustment spindle of the measuring cell.

b) The float of the measuring cell float is below the water sensor. The flow is too small.

Increase the flow with the adjustment spindle of the measuring cell.

c) The sample-water extraction device or the hose to the measuring cell is clogged or leaking.

Check the sample-water extraction device and the hose to the measuring cell.

d) No sample-water flow in the measuring cell. Filter clogged.

Clean the filter of the measuring cell.

e) Lack of water at the sample-water extraction device.

Check the flow in the main line at the sample-water extraction device.

f) Faulty water sensor. Replace the water sensor.

g) Faulty cable from the measuring cell to the controller.

Replace the cable.

h) Faulty controller. Replace, if necessary.

i) Setting in the "Maintenance > Water sensor > N.C./N.O." menu does not correspond with terminal connections.

Setting can only be corrected using super user code.

21. Cleaning motor fault:– ClO2 production proceeds.– Alarm relay activated.– Combined and setpoint


Cleaning motor monitoring in the measuring cell indicates a fault.

Stop the system.

a) Faulty cleaning motor. Check the power supply of the cleaning motor. Replace the cleaning motor.

b) No power supply to the cleaning motor. Cable breakage.

Check the cable. Replace the cable.

c) Gas bubbles in the measuring cell. Vent the measuring cell.

22. "dosing time ClO2 exceeded":– ClO2 production proceeds.– Alarm relay activated.– Controller stops the ClO2

dosing pump, until the fault is eliminated.

The controller predefines maximum dosing flow for a longer period than the set time.

a) After a power supply failure, the solution in the batch tank has been diluted too much after flushing (setpoint and combined controllers).

Continue operation after flushing.

b) Poor water quality (setpoint and combined controllers).

Measure the water quality and the chlorine dioxide concentration in the main line.

c) Faulty water flow meter, or wrong setting of water flow meter (proportional and combined controllers).

Check the water flow meter. Replace, if necessary.

d) Faulty measuring cell cable or measuring cell. Check the cable of the measuring cell. Replace, if necessary.

e) HCl or NaClO2 container contains only water. Replace the HCl or NaClO2 container.

Controller is set incorrectly. Check the controller settings.

23. "wire breakage current output 2":– ClO2 production proceeds.– Alarm relay activated.– Combined and setpoint


The measured chlorine dioxide value can no longer be transmitted.

a) Cable breakage at the current output. Check the current output measurement with the "Test current" menu, see section 5.21.3. Replace the cable, if necessary.

b) Faulty controller. Replace the controller, if necessary.

24. "wire breakage current output 1":– ClO2 production proceeds.– Alarm relay activated.

Cable breakage at the controller output for the external dosing pump.

a) Cable breakage. Check the current output control with the "Test current" menu, see section 5.21.3. Replace the cable, if necessary.



Cause Remedy

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25. External error:– ClO2 production is terminated.– Alarm relay activated.– Controller stops the ClO2

dosing pump, until the fault is eliminated.

An external device, which is possibly connected to a fault input (terminal 51/52), indicates a fault.

a) Faulty external device. Check the external device.

b) Faulty cable to the external device. Replace, if necessary.

c) Faulty controller. Replace the controller.

26. "Annual maintenance due":– ClO2 production proceeds.

Maintenance overdue for 0-30 days.The alarm message disappears, if maintenance has been approved.

27. "K5"– ClO2 production proceeds.

Maintenance overdue for more than 30 days. Stop the system and execute maintenance.

28. "empty signal int. batch tank":– ClO2 production proceeds.– Warning relay activated.– Controller stops the ClO2

dosing pump after 20 seconds, until the fault is eliminated.

a) The error message appears in "Int. batch tank" mode (method 1-20 batches). No other process is running.

Check the operation mode. In "Int. batch tank" mode (method 1-20 batches), this is not a fault.

b) If the dosing pump empties the batch tank, before the final chlorine dioxide is available in the reaction tank.

If the message appears in every process, the controller must be reset. In the monitoring menu, check the measured value under "Service > Measurement".In the "Service > Controller ClO2" menu, check the displayed parameter. In the "Service > Water flow meter" menu, check the displayed values.

c) Faulty water flow meter. Check the water flow meter. Replace,if necessary.

d) Drain cock at the batch tank is open. Close the drain cock.

e) Faulty measuring cell (setpoint and combined controllers).

Check the measuring cell. Replace the measuring cell.

29. Reaction tank control fault:– ClO2 production is terminated.– Alarm relay activated.

Plausibility check of the float switch in the reaction tank.

a) Faulty float switch. Check the float switch in the reaction tank in the "Test level" menu, see section 5.21.6. Replace, if necessary.


30. Batch control fault:– ClO2 production is terminated.– Alarm relay activated.

Plausibility check of the float switch in the batch tank.

a) Faulty float switch. Check the float switch in the batch tank in the "Test level" menu, see section 5.21.6. Replace, if necessary.


31. "fault current input":– ClO2 production proceeds.– Alarm relay activated.– Combined controller and

proportional controller stop.

Cable breakage at current input 1• A water flow meter is connected, and the signal

exceeds the full-scale value of 20 mA.• A water flow meter with 4-20 mA is selected, and

the signal falls below 3.8 mA.If this fault appears, the controller is stopped (proportional and combined controllers).

a) Faulty water flow meter. Check the water flow meter. Replace, if necessary.

b) Faulty current input or controller. Check the current input and the controller. Supply with a defined current between 0 and 20 mA, and compare with display in the "Service > Water flow meter" menu.In case of damaged controller, replace controller.

c) Cable breakage between water flow meter and controller.

Replace the cable.

d) Water flow meter is connected with 0-20 mA, but the set value is 4-20 mA.

Correct the software setting.

32. ClO2 alarm value 1 or 2 exceeded or not reached:

– ClO2 production proceeds.– Alarm relay activated.

The set lower or set upper switching point for the alarm is exceeded or not reached.

Check the system and components of Oxiperm Pro. Check also the settings of the alarm values.


Cause Remedy

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8.2 Faults without error message

Fault Cause Remedy

The chlorine dioxide dosing pump stops. The DDA pump displays "ERROR".

The isolating valve of the dosing line is closed.

Open the isolating valve. If the Oxiperm Pro operates in 60 Hz mode, check if the multifunction valve is set to 6 bars at the overflow side. See also the installation and operating instructions of the multifunction valve.

Overdosing of chlorine dioxide dilution due to a free discharge.

The chlorine-dioxide dosing pump has a free discharge into a container. Even if the pump stops, the chlorine dioxide solution continues running into the container due to a siphon effect. The consequence is overdosing. The conditions are:• disconnected injection unit• dosing pump without multi-function valve.

Connect the multifunction valve at the pump. This will prevent uncontrolled flow of the dosing liquid through the dosing lines.

Perceptible smell of chlorine dioxide

The activated carbon filter or adsorption filter is saturated.

Exchange the activated carbon filter or adsorption filter.

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9. Dismantling and decommissioning the system
9.1 Preparing for dismantling

Warning

Incorrect dismantling may result in serious personal injury and damage to property. The system may only be dismantled by authorised service personnel trained by Grundfos.

Warning

Risk of burns due to the escape of chemicals from dismantled seals, valves, connections, hoses, lines or injection unit.

Flush the system twice in succession before starting to dismantle it.

Do not bring dismantled suction lances into contact, or place them in the same bucket. Always check the label.

Check that the reaction tank and batch tank are empty before dismantling them.

Drain the dosing line and put on protective clothing before dismantling it.

Do not use cleaning agents.

Chemicals react with oils, fats and acids, see section 1. General safety regulations.

Warning

Risk of gas poisoning due to the escape of chlorine dioxide from the dismantled gas hose, volume compensation bag and activated carbon filter.

Wear protective clothing (safety goggles, gloves, protective apron and breathing mask) when dismantling the gas hose and the activated carbon filter.

Do not hold your face over the reaction tank, the volume compensation bag or the activated carbon filter.

NoteIf the system is to be recommissioned at a later date, remove the hoses and lines very carefully and do not bend them. Tighten nuts by hand only.

Warning

Risk of electric shock from live lines.

Disconnect the system from the power supply before starting to dismantle it.

Checklist Done

1. Have the necessary tools ready.


3. Have ready two 10-litre buckets with water for cleaning the suction lances and suction hoses.

4. Have the following packaging materials ready:

– original packaging for the system and the cover

– original packaging for the measuring cell and measuring module, or mixing module

– original screw caps for the chemical containers

– box for dismantled hoses

– box for dismantled cables and screws.

5. Flush the system, see section 5.18 Flushing.

6. Switch off the system, see section 5.24 Switching off the system. Switch off the main switch.

7. Remove the cover from the system and pack it into its original packaging.

8. Dismantle the hydraulic components as described.

9. Dismantle the electrical components as described.

10. Leave the system and accessories to dry for 24 hours.

11. Pack the system and the accessories.

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9.2 Dismantling the hydraulic components

9.2.1 Dismantling the dilution water hose

1. Close the dilution water isolating valve, remove and coil up the hose.

2. Remove the cover from the system.

3. Unscrew the screw connection on the solenoid valve, and detach the dilution water hose from the solenoid valve.

9.2.2 Dismantling the suction lances

1. Unfasten the screw connection on the suction hose from the hydrochloric acid pump. Place the suction lance and suction hose in a bucket of water. Rinse thoroughly with water. Place on a cloth to dry.

2. Unfasten the screw connection on the suction hose from the sodium chlorite pump. Place the suction lance and suction hose in the other bucket of water. Rinse thoroughly with water. Place on a cloth to dry.

3. Close the hydrochloric acid container with the original cover and set aside for disposal.

4. Close the sodium chlorite container with the original cover and set aside for disposal.

9.2.3 Dismantling the dosing line

1. Drain the dosing line at the multi-function valve, see section 6.5.3.

2. Detach the dosing line from the multi-function valve. Drain the chlorine dioxide into a bucket.

3. Detach the dosing line from the injection unit. Remove it from the protective pipe and coil it up. Drain the chlorine dioxide into a bucket.

4. Lay out the dosing line in the open air to allow chlorine dioxide residues to escape.

5. If applicable, detach the dosing line of the external dosing pump from the batch tank. Lay out the dosing line in the open air to allow chlorine dioxide residues to escape.

9.2.4 Unscrewing the gas hose from the volume compensation bag

1. Put on a breathing mask.

2. Squeeze the volume compensation bag with the hands to let gas residues escape via the activated carbon filter or adsorption filter.

3. Unfasten the screw connection between the hose and the volume compensation bag. Detach the hose to let gas residues escape.

9.2.5 Dismantling the activated carbon filter (OCD-162-05, -10) or adsorption filter (OCD-162-30, -60)

1. Put on a breathing mask.

2. See section 6.7 or 6.8

3. Remove the activated carbon filter or adsorption filter, and dispose of it in a professional way.

9.2.6 Dismantling the measuring cell (if applicable)

1. Detach the hose from the sample-water extraction device, and detach it from the measuring cell.

2. Detach the sample-water discharge hose from the measuring cell, and coil it up.

9.2.7 Dismantling the measuring or mixing module (if applicable)

• Detach the two hoses connecting the measuring or mixing module to the main line.

9.3 Dismantling the electrical components

1. Detach the power supply cable from the main switch.

2. Detach the cable from the water flow meter on the main line, if applicable.

3. Detach the power supply cable from the controller.

4. Detach the cable from the water flow meter, if applicable.

5. Detach all cables from the measuring cell, if applicable.

6. Detach the cable from the measuring or mixing module, if applicable.

9.4 Dismantling the system frame

1. Get two people to hold the system frame.

2. OCD-162-5 and -10: Unfasten the three fixing screws in the system frame, remove the system from the wall and place it on a working surface.OCD-162-30 and -60: Loosen the four fixing screws on the floor.

3. Leave the system and accessories for at least 24 hours before packing to allow them to dry out.

9.5 Packing the system for transport

1. After it has dried out, place the system frame in its original packaging, add the suction lances and insulating material, and place the packed cover on top.

2. Pack the dry hoses in a box.

3. Pack the cables in a box. Place the fixing screws in a bag and store in the box with the cables.

4. If applicable, place the measuring cell and the accessories in the original packaging, add insulating material and seal ready for transport.

5. If applicable, place the mixing module or the measuring module and the installation accessories, cables and hoses in the original packaging, add insulating material and seal ready for transport.

6. Add the installation and operating instructions, and seal the box ready for storage or transport. Include the delivery note.

9.6 Final dismantling steps

1. Leave the empty chemical containers for disposal.

2. Take away the activated carbon filter for disposal.

3. Pour the contents of the buckets down the drain. Rinse the buckets thoroughly with water.

4. Clean the installation room.

9.7 Temporary storage of the dismantled system

If the dismantled system is to be installed again (at another site) and recommissioned, note the following points:

• The storage conditions (temperature, humidity, room conditions, etc.) must correspond to the conditions at the installation site, see sections 4.1 and 11.

• Storage of the system is permitted.

Caution Do not bend the cables and hoses.

Warning

For transportation, the OCD-162-030 and -060 has to be fastened with wood screws on the pallet.

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9.8 Recommissioning after dismantling

If the dismantled system is to be installed again (at another site) and recommissioned, the instructions in this manual have to be observed.

10. Disposal

Before dismantling, the Oxiperm Pro system must be completely rinsed with water in order to remove the chemicals from the reaction tank, the hoses and the pumps. The dosing line must be placed outdoors to let residual chlorine dioxide escape.

For environmentally friendly disposal, the operating company should hand over the Oxiperm Pro system or its parts to a private disposal service. If there is none in your region, send the system to the nearest Grundfos company.

Warning

When the system is dismantled, the screw connection between the gas hose and the volume compensation bag is disconnected to allow residual gas to escape.

Remember to reconnect the gas hose when reinstalling the system.

When the system is dismantled, the used activated carbon filter is removed and disposed of.

Remember to fit a new activated carbon filter when reinstalling the system.

Note

The Oxiperm Pro disinfection system and its associated parts must be disposed of in an environmentally friendly way.

The system may only be dismantled by authorised service personnel trained by Grundfos.

The operating company is responsible for ensuring an environmentally friendly disposal.

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11. Technical data

11.1 Identification

11.1.1 Type key

Example: Oxiperm Pro OCD-162-30-D/G1

* Note: It is recommended to use a digital dosing pump for direct dosing of the product solution.

11.1.2 Nameplate

Fig. 54 Nameplate (for OCD-162-5-D/G)

Oxiperm Pro OCD-162 -30 -D /G 1

Max. capacity

5 5 g/h

10 10 g/h

30 30 g/h

60 60 g/h / (USA 55 g/h)

Chlorine dioxide dosing pump

D integrated mechanical dosing pump DMX

P integrated digital dosing pump DDI *

S integrated SMART Digital dosing pump DDA *

N without integrated dosing pump

Supply voltage

G 220-240 V, 50/60 Hz

H 110-120 V, 50/60 Hz

Suction lance

for 30-litre chemical container (length of suction hose 1.3 m)

1 for 60-litre chemical container (length of suction hose 3.0 m)

2 for 200-litre/1000-litre chemical container (length of suction hose 5.0 m)

3 for 55-gallon chemical container (length of suction hose 3.0 m)

TM

03

69

57

45

06

Pos. Description

1 Type designation

2 Product name

3 Model

4 Serial number

5 Chlorine dioxide production capacity

6 Product number

7 Country of origin

8 Year and week of production

9 Marks of approval, CE mark, etc.

10 Voltage [V]

11 Frequency [Hz]

12 Power consumption

13 Safety instruction: Please read this manual

OCD-162 5D/G162-005-100005/N: 07/640645g/h, 230V, 50/60Hz, 850Watt95702474P1107380764064

1

34

7 8 9

6

2

5 121110

13

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11.2 Performance and consumption

11.3 Temperatures and humidity

11.4 Dimensions, weights and capacities

Chlorine dioxide production capacity

OCD-162-5 5 g/h

OCD-162-10 10 g/h

OCD-162-30 30 g/h

OCD-162-6060 g/h

USA 55 g/h

Concentration of the chlorine dioxide solution

Approx. 2 g/l 2000 ppm

Consumption of hydrochloric acid

OCD-162-5 Approx. 0.17 l/h




Consumption of sodium chlorite





Dilution water at 3-6 bar (drinking water quality in accordance with EU drinking water ordinance)


OCD-162-10 Approx. 4.8 l//h

OCD-162-30 Approx. 14.8 l//h

OCD-162-60: Approx. 32.5 l//h

Max. counterpressure of chlorine dioxide dosing pump

OCD-162-5, -1010 bar

OCD-162-30, -60

Permissible relative air humidity (no condensation)

Maximum 80 %

Permissible ambient temperature 5 to 35 °C

Permissible temperature of dilution water 10 to 30 °C

Permissible temperature of chemicals 10 to 35 °C

Storage temperature of the system (not connected)

-5 to 50 °C

Storage temperature of chemicals 5 to 40 °C

Permissible height above sea level, where the system is allowed to be operated.

2000 m

System frame with cover Oxiperm ProOCD-162-5, -10OCD-162-30, -60

W x H x D [mm]765 x 766 x 330 765 x 766 x 550

Total height OCD-162-30, -60 181 mm

Gross weight

OCD-162-5OCD-162-10OCD-162-30-DOCD-162-30-POCD-162-60-DOCD-162-60-P

30 kg32 kg80 kg79 kg

100 kg99 kg

Net weight

OCD-162-5OCD-162-10OCD-162-30-DOCD-162-30-POCD-162-60-DOCD-162-60-P

26 kg28 kg70 kg69 kg85 kg84 kg

Volume compensation bag

OCD-162-5OCD-162-10OCD-162-30OCD-162-60

2 l (1 unit)4 l (2 units)12 l (1 unit)24 l (2 units)

Total volume of reaction tank

OCD-162-5OCD-162-10OCD-162-30OCD-162-60

1.00 l1.80 l6.10 l

13.40 l

Total volume of batch tank

OCD-162-5OCD-162-10OCD-162-30OCD-162-60

1.00 l1.80 l7.00 l

13.90 l

Filling volume of reaction tank

OCD-162-5OCD-162-10OCD-162-30OCD-162-60

0.87 l1.67 l5.52 l11.96 l

Filling volume of batch tank

OCD-162-5OCD-162-10OCD-162-30OCD-162-60

0.87 l1.67 l6.50 l

13.00 l

Distance between bottom edge of frame and floor

OCD-162-5, -10 Approx. 1 m

Total length of suction lance including suction hose

OCD-162-5, -10 1.3 m

Total length of suction lance including suction hose

OCD-162-30, -60 3.0 m or 5.0 m

Dimensions of collecting trays

Accessories

W x H x D [mm]485 x 270 x 550

Weight of collecting trays

2 x 5.5 kg

Dimensions of external batch tank (50 l)

L x W x H [mm]840 x 530 x 1640diameter: 315 mm

Dimensions of external batch tank (100 l)

L x W x H [mm]840 x 530 x 2000diameter: 315 mm

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11.5 Permissible chemicals

* All technical data refer to the nominal concentrations.In operation, deviations up to ± 10 % of the chemical concentrations are permissible. Yet they can change the performance data of the system specified here.

11.6 Materials

11.7 Dosing pumps

11.8 Dilution water

11.9 Main water line

11.10 Permissible measuring cell type

11.11 Product numbers OCD 162-5, -10

All dosing pumps are applicable for 50/60 Hz.

11.12 Product numbers OCD 162-30, -60

All dosing pumps are applicable for 50/60 Hz.

Nominal concentration of sodium chlorite (NaClO2) solution (quality according to EN 938)

7.5 % by weight *

Nominal concentration of hydrochloric acid (HCl) solution (quality according to EN 939)

9.0 % by weight *

System frame PE

Cover EPP

Reaction tank/batch tank PVC

Hoses PTFE/PE

Seals FPM/PTFE/FKM

Heads of dosing pumps PVC

HCl/NaClO2OCD-162-5, -10OCD-162-30OCD-162 -60

DDE 6-10DDE 15-4DMX 35-10

OCD-162-5, -10Connection on suction sideConnection on discharge side

PE hose 4/6PTFE hose 4/6

OCD-162-30, -60Connection on suction sideConnection on discharge side

PVC hose 6/12PTFE hose 9/12

ClO2

OCD-162-5-P/G, -P/HOCD-162-10-P/G, -P/H

DDA 7.5-16

Connection on suction sidePTFE hose 4/6

Connections on discharge side

OCD-162-30-D/GOCD-162-30-P/GOCD-162-60-D/GOCD-162-60-P/G

DMX 16-10DDI 60-10DMX 35-10DDI 60-10

Connection on suction sidePTFE hose 9/12

Connections on discharge side

Dilution water extraction deviceSee data booklet

Oxiperm Pro OCD-162

Hose connection for dilution water at the solenoid valve

Hose 6/9 mm or 6/12 or pipe PVC 10/12 mm

Water flow meter and cable See data booklet Oxiperm Pro OCD-162Tapping sleeve for injection unit

AQC-D1 Measures ClO2 + pH or ORP

AQC-D6 Measures ClO2

Connections for sample-water extraction and drain

See data booklet Oxiperm Pro OCD-162

Product No. OCD-162 Voltage Dosing pump

95707848

5 g/h

230 VDDA 7.5-16

95707849 115 V

95702476 230 V Without dosing pump95702477 115 V

95707850

10 g/h

230 VDDA 7.5-16

95707851 115 V

95702480 230 V Without dosing pump95702481 115 V

Product No.

OCD-162 VoltageSuction

hoseDosing pump

95718444

30 g/h

230 V

3.0 m

DMX 15-1095718445 115 V

95718446 230 VDDI 60-10

95718447 115 V

95718448 230 V

5.0 m

DMX 15-1095718449 115 V

95718450 230 VDDI 60-10

95718451 115 V

95718452

60 g/hUSA 55 g/h

230 V

3.0 m

DMX 35-1095718453 115 V

95718454 230 VDDI 60-10

95718455 115 V

95718456 230 V

5.0 m

DMX 35-1095718457 115 V

95718458 230 VDDI 60-10

95718459 115 V

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11.13 Electrical data

11.14 Controller inputs

11.15 Controller outputs

11.16 Terminal connection plan

Power supply connection115 V or 230 V,

50/60 Hz

Input power of the basic system without external consumer load

OCD-162-5, -10 Max. 100 VA

OCD-162-30 Max. 180 VA

OCD-162-60 Max. 320 VA

Input power of the whole system Max. 850 VA

Maximum permissible load on the potential-free output contacts

Max. 550 VA(250 V x 2 A)

Enclosure class of electronics

IP65Enclosure class of dosing pump

Enclosure class of solenoid valve

Input Description

Analog input for flow meter

Current input 0(4)-20 mALoad: 50 Ω

Analog input

Chlorine dioxide concentrationMeasuring cell (optional)

Pt100 temperature sensor in the measuring cell

Contact input(compound-loop control)

Contact water meterMaximum 50 impulses/secondMaximum voltage: 13 V

External input: stop

For process enabling and for external fault

mV input pH or ORP

53, 54, H2OSample-water sensor input for the measuring cellMaximum voltage: 13 V

Switching input Description

K1 Reaction tank: water supply to level K1

K2 Reaction tank: HCl supply level

K3 Reaction tank: NaClO2 supply level

K4 Reaction tank: water supply to level K4

K5Batch tank levelEmpty signal

K6Batch tank levelMaximum level

K7HCl container level: low-level signalContact open: low-level signal HCl

K8HCl container level: empty signalContact open: empty signal HCl

K9NaClO2 container level: low-level signalContact open: low-level signal NaClO2

K10NaClO2 container level: empty signalContact open: empty signal NaClO2

K11 External batch tank: min. level

K12 External batch tank: max. level

K13 External batch tank: max. -max. level

Outputs Description

Analog output0(4)-20 mA

Current outputControl

Analog output for external device (proportional to ClO2 concentration)

Current outputMeasured value for check measurements0(4)-20 mALoad: 500 Ω

Solenoid valve for water supply Relay 1

Dosing pump for HCl Relay 2

Dosing pump for NaClO2 Relay 3

Alarm relay (changeover contact)Potential-free output

Relay 4

Warning relayPotential-free output

Relay 5

Dosing pump for ClO2 Relay 6

Power supply Connection L N PEFactory-

fitted

Power supply cable mains-in 2 4 6 No

Measuring cell cleaning motor

out 8 10 12 No

External device, non-switching

out 14 16 18 No

External device, non-switching

out 20 22 24 No

Dosing pump for HCI HCl 1 3 5 Yes

Dosing pump for NaClO2

NaClO2 7 9 11 Yes

Solenoid valve H2O 13 15 17 Yes

Dosing pump for ClO2 ClO2 19 21 23 Yes

Electrically isolated outputs

Connection COM/N.O./N.C.Factory-

fitted

Collective fault output

Alarm 25/27/29No

Warning 26/28/30

Analog signals

Connection GND INFactory-

fitted

Measuring electrode

M – 69 brown

No

Counter-electrode

G/C – 71 white

Reference electrode

B/R – 70 inside cable

GND-CL – – 72 screen

pH/ORPmV input

In+GND_pH

–73 inside cable74 screen

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Fig. 55 Terminal connection plan

Each of the power supply outputs "out A", "out B" and "out C" can be charged with a maximum of 100 VA. If a device with protective earthing conductor is connected, the conductor must be connected correctly at the corresponding output.

Inputs Connection INFactory-

fitted

Contact water meter up to 50 impulses/second

_ _ _63 +13 V * 62 screen

64

NoCurrent input signal

mA IN–IN+, screen

66 IN–62 screen

65 IN+

Sample-water sensor

H2O54 brownIN++13 V *

53 blueIN–

Reaction tank level

Reaction tank40 brownGND

41 grey42 yellow43 green44 white

Yes

Low-level signalEmpty signal

HCl33 brownGND

31 white32 green

Low-level signalEmpty signal

NaClO234 brownGND

35 white36 green

Batch tank level

Batch39 brownGND

37 white38 green

External batch tank

min. levelmax. levelmax. -max. levelGND

45464748

No

Pt100 temperature sensor

Pt10056 black GND

55 blue

External release for dosing

Stop 50 49

Fault input, for example for gas warning device

Fault 52 51

Caution * Maximum voltage: 13 V

Outputs Connection GND INFactory-

fitted

Current output 1Control

mA out 158 Out–59 screen

57 Out+

NoCurrent output 2ClO2 measurement

mA out 260 Out–59 screen

61 Out+

TM

03

69

28

45

06

6967

74

71

7068

6664

6260

5856

5452

5048

444

4240

3836

3937

3533

31

342

4745

4341

5553

5149

6361

5957

65

B/R

Pt 100

3028

26

2927

25

HC

l

H O2

MG

/C

NaC

lO2

HC

l2

1

2422

2018

1614

1210

86

42

123

2119

1715

1311

97

53

PE

NL

PE

NL

PE

NL

LN

PE

PE

NL

PE

NL

PE

NL

LN

PE

NO

NC

NO

NC

ClO2

NaC

lO2

H O 2

K6K5

K8

K7

K9K1

0K1

K2K3

K4

!

3

K11

K12 6

K13

7372

-12V

pH

Red

ox

Ala

rmm

A o

ut

Ext

. b

atc

h t

an

k

mA

ou

t

Ba

tch

ta

nk

Ma

ins

inO

ut

AO

ut

BO

ut

CW

arn

ing

Re

act

ion

ta

nk

Stop

Fault

mA

inp

HO

RP

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12. Spare parts
12.1 Spare parts for OCD-162-5, -10

Part Description Version Product No.

Dosing pump for HCl230 V

DDE 10-6, complete

98163454

115 V, USA cable 98163456


230 V 98163419

115 V, USA cable 98163440

Dosing pump for ClO2

230 VDDA, complete

98163484

115 V, USA cable 98163486

Suction lance for HClfor 30-litre container

complete

98163672

for 55-gallon container 98163679

Suction lance for NaClO2

for 30-litre container 98163639


Hose PTFE 4/6, redto reaction tank

1.5 m

96727507

Hose PTFE 4/6, blue 96727509

Hose PTFE 4/6, white to volume compensation bag 96727482

Hose PE 6/9to solenoid valve 10 m

96727412

Hose PE 6/12 96653571

Hose PE 8/11, transparent for reaction tank drain 1.25 m 95717381

Connection G 5/8 female/hose 4/6 for dosing line of multi-function valveU2 metric connection set for Europe, PVDF, for hoses 4/6, 6/9

97691904

Connection G 5/8 female/hose 1/4 x 3/8

for dosing line of multi-function valve, USAU7 connection set USA, PVDF, for hoses 1/8 x 1/4 and ...

97691907

Connection G 1/4 male/hose 4/6 to input of reaction tank 2 pieces 95717382

Solenoid valve for dilution water230 V

without screw connections95717903

115 V 95717904

Level indicator of reaction tank 4 switching points 95717905

Level indicator of batch tank 2 switching points 95717906

Reaction tank with batch tankOCD-162-5

complete95717907

OCD-162-10 95717911

Drain cock at the batch tank complete 95717384

Volume compensation bag 1 piece 95717908

Activated carbon filter 1 piece 95717909

Valve at the activated carbon filter inlet and outlet valve 2 pieces 95717436

Multi-function valve complete 95704598

Cover complete 95703064

Electronic controller, 230 V

OCD-162-5

complete 95715737

Electronic controller, 115 V complete 95715738

Electronic controller, 230 V GRÜNBECK 95715739

Electronic controller, 230 V

OCD-162-10

complete 95715740

Electronic controller, 115 V complete 95715741

Electronic controller, 230 V GRÜNBECK 95715742

Strainer for input of solenoid valve 5 pieces 95717437

System frame 98163701

T-piece for PTFE hose 4/6 to volume compensation bag 1 piece 95714891

Set of hoses 4/6, with connections for suction lances red and blue, 1.5 m each 98163781

Connection pieces between connection for hose and solenoid valve, see figure 56.

G 5/8 female/hose 6/9 for input of solenoid valve

1 complete set

95727673

PE hose 1/4 x 3/8 for input of solenoid valve, USA

95727674

G 5/8 female/hose 4/6 for output of solenoid valve

95727672

85

En

glis

h (G

B)

Fig. 56 Solenoid valve OCD-162-05, -10 (exploded view)

Connection for hoses 6/9 and 6/12for input of solenoid valve

95717385

Connection for PE hose 1/4 x 3/8, USA 95717528

Connection G 3/8 female/hose 4/6 for output of solenoid valve 2 pieces 95717529

Connection G 5/8 female/hose 4/6 for internal connections 5 pieces 98163817

Fastening set hose clamps and screws 95717531

Part Description Version Product No.

TM

04

85

25

13

12

Pos. Component

A Connection pieces between connection for hose and solenoid valve

A

86

En

gli

sh

(G

B)

12.1.1 Photos OCD-162-5, -10

Fig. 57 OCD-162-5, -10

TM

03

69

59

45

06

Pos. Component

1 Controller with display and control elements

2 Reaction tank

3 Batch tank

4 Adsorption filter



7 Dosing pump for chlorine dioxide (ClO2)

8 Solenoid valve for dilution water

87

En

glis

h (G

B)

12.2 Spare parts for OCD-162-30, -60

Parts Description Version Product No.

Dosing pump for HCl

OCD-162-30

230 V

DDE 15-4, complete

98163904

115 V, USA cable 98163921


230 V 98163923

115 V, USA cable 98163925


230 VDMX, complete

95715682

115 V, USA cable 95715681

115-230 VDDI, complete

95715632

115 V, USA cable 95735144

Dosing pump for HCl

OCD-162-60

230 V

DMX, complete

95717388

115 V, USA cable 95717389


230 V 95717390

115 V, USA cable 95717391


230 V 95716872

115 V, USA cable 95716873

115-230 VDDI, complete

95715632

115 V, USA cable 95735144

Suction lance for HCl

for 60-litre container

complete

98164260


for 200-/1000-litre container 98164293

Suction lance for NaClO2

for 60-litre container 98164258


for 200-/1000-litre container 98164291

Hose PTFE 9/12 for internal connection 1.5 m 96727489

Hose PE 6/9to solenoid valve 10 m

96727412

Hose PVC 6/12 96653571

Hose PVC 8/11 for drain of reaction tank 1.25 m 95717381

Connection G 5/8 female/hose 6/9 and 9/12

for dosing line of multi-function valveU2 metric connection set for Europe, PVDF, for hoses 4/6, 6/9

97691904

Connection G 5/8 female/hose 1/4 x 3/8

for dosing line of multi-function valve, USAU7 connection set USA, PVDF, for hoses 1/8 x 1/4 and ...

97691907

Connection G 1/4 male/hose 4/6 from output of reaction tank 2 pieces 95717382

Solenoid valve for dilution water230 V

without screw connections95717444

115 V 95717445

Level indicator of reaction tank

OCD-162-30

4 switching points 95717446


Reaction tank with batch tank complete 95717448

Level indicator of reaction tank

OCD-162-60

4 switching points 95717455


Reaction tankcomplete

95717457

Batch tank 95717458

Drain cock at the batch tank complete 95717384

Volume compensation bag 1 piece 95717449

Adsorption filter 1 piece 95717450

Valve at the adsorption filter inlet and outlet valve 2 pieces 95717436

Multi-function valve

complete

95704598

Cover 95717438

Foot cover 95717443

Electronic controller, 230 V 95715743

Electronic controller, 115 V 95715744

88

En

gli

sh

(G

B)

Fig. 58 Solenoid valve OCD-162-30, -60 (exploded view)

Strainer for input of solenoid valve 5 pieces 95717437

System frame 95717451

Foot 95717452

Hose PTFE 4/6, whiteto volume compensation bag

1.5 m 96727482

T-piece for PTFE hose 4/6 1 piece 95714891

Connection pieces between connection for hose and solenoid valve, see figure 58.

G 5/8 male/G 1/4 male for input of solenoid valve

1 complete set

95723464

G 1/4/G 5/8 male for output of solenoid valve

95723463

Connection for PE hose 6/9for input of solenoid valve

95717385

Connection for PE hose 1/4 x 3/8, USA 98165337

Non-return valve for dosing line 2 pieces 98165354

Connection G 5/8 female/hose 9/12 for internal connections 5 pieces 98165381

Fastening set hose clamps and screws 95717459

Pipe elbow at input of reaction tank 95717386

Parts Description Version Product No.

TM

04

85

26

13

12

Pos. Component

A Connection pieces between connection for hose and solenoid valve

A

89

En

glis

h (G

B)

12.2.1 Photos OCD-162-30, -60

Fig. 59 OCD-162-30, -60

TM

04

09

62

13

12

1

24

3

6

5

3

7

5

4

8

6

2

18

9

7

910

10 10

Pos. Component

1 Batch tank with drain cock

2 Reaction tank with connections on top

3 Controller with display and control elements

4 Adsorption filter



7 Solenoid valve for dilution water

8 Multi-function valve

9 Dosing pump for chlorine dioxide (ClO2)

10 Suction set

90

En

gli

sh

(G

B)
13. Accessories list
Prior to installation, the operator must purchase the following accessories according to the product numbers in the Oxiperm Pro OCD-162 data booklet and the technical data.

Accessories to be purchased

Y = Available from GrundfosN = Not available from Grundfos

1. Container with sodium chlorite (diluted concentration of 7.5 % by weight in accordance with EN 938)

2. Container with hydrochloric acid (diluted concentration of 9 % by weight in accordance with EN 939)

N

3. Two collecting trays for the chemical containers Y

4. Inductive or ultrasonic flow meter, if necessary Y

5. Flow meter connection cable, if necessary Y

For dilution water line (if no mixing module with dilution water connection has been ordered):

6. Tapping sleeve Y

7. Extraction device Y

8. Connection for dilution water hose Y

9. Sample-water filter (in case of insufficient water quality)

Y

For main water line:

10. Tapping sleeve for injection unit Y

11. Two tapping sleeves for extension module, if necessary Y

12. Tapping sleeve for sample-water extraction Y

Oxiperm Pro hoses:

13. Hose between dilution water extraction device and solenoid valve

Y

14. Dosing line between dosing pump and injection unit Y

Measuring cell hoses:

15. Hose between measuring cell and sample-water extraction device

Y

16. Hose between measuring cell and drain Y

For mixing module, if installed:

17. Hose between mixing module and main water line and hose back to mixing module

Y

18. Dosing line between dosing pump and injection unit in mixing module

Y

Or for measuring module, if installed: Y

19. Hose between measuring module and main water line and hose back to measuring module

Y

20. Protective pipe for dosing hose N

21. Main switch N

Cables:

22. Oxiperm Pro power supply cable N

23. Power cable for measuring module or mixing module, if necessary

N

24. Protective clothing Y

25. Two 10-litre plastic buckets N

26. 100 g sodium thiosulfate (20 g per flushing process) N

91

Gru

nd

fos

co

mp

anie

s

ArgentinaBombas GRUNDFOS de Argentina S.A.Ruta Panamericana km. 37.500 Lote 34A1619 - GarinPcia. de Buenos AiresPhone: +54-3327 414 444Telefax: +54-3327 411 111

AustraliaGRUNDFOS Pumps Pty. Ltd. P.O. Box 2040 Regency Park South Australia 5942 Phone: +61-8-8461-4611 Telefax: +61-8-8340 0155

AustriaGRUNDFOS Pumpen Vertrieb Ges.m.b.H.Grundfosstraße 2 A-5082 Grödig/Salzburg Tel.: +43-6246-883-0 Telefax: +43-6246-883-30

BelgiumN.V. GRUNDFOS Bellux S.A. Boomsesteenweg 81-83 B-2630 Aartselaar Tél.: +32-3-870 7300 Télécopie: +32-3-870 7301

BelarusПредставительство ГРУНДФОС в Минске220123, Минск,ул. В. Хоружей, 22, оф. 1105Тел.: +(375) 17 233 97 65Факс: (375) 17 233 97 69E-mail: [email protected]

Bosnia/HerzegovinaGRUNDFOS SarajevoTrg Heroja 16,BiH-71000 SarajevoPhone: +387 33 713 290Telefax: +387 33 659 079e-mail: [email protected]

BrazilBOMBAS GRUNDFOS DO BRASILAv. Humberto de Alencar Castelo Branco, 630CEP 09850 - 300São Bernardo do Campo - SPPhone: +55-11 4393 5533Telefax: +55-11 4343 5015

BulgariaGrundfos Bulgaria EOODSlatina DistrictIztochna Tangenta street no. 100BG - 1592 SofiaTel. +359 2 49 22 200Fax. +359 2 49 22 201email: [email protected]

CanadaGRUNDFOS Canada Inc. 2941 Brighton Road Oakville, Ontario L6H 6C9 Phone: +1-905 829 9533 Telefax: +1-905 829 9512

ChinaGrundfos AlldosDosing & DisinfectionALLDOS (Shanghai) Water Technology Co. Ltd.West Unit, 1 Floor, No. 2 Building (T 4-2)278 Jinhu Road, Jin Qiao Export Process-ing ZonePudong New Area Shanghai, 201206Phone: +86 21 5055 1012Telefax: +86 21 5032 0596E-mail: [email protected]

ChinaGRUNDFOS Pumps (Shanghai) Co. Ltd.50/F Maxdo Centre No. 8 Xing Yi Rd.Hongqiao Development ZoneShanghai 200336PRCPhone: +86-21 6122 5222 Telefax: +86-21 6122 5333

CroatiaGRUNDFOS CROATIA d.o.o.Cebini 37, BuzinHR-10010 ZagrebPhone: +385 1 6595 400 Telefax: +385 1 6595 499www.grundfos.hr

Czech RepublicGRUNDFOS s.r.o.Čapkovského 21779 00 OlomoucPhone: +420-585-716 111Telefax: +420-585-716 299

DenmarkGRUNDFOS DK A/S Martin Bachs Vej 3 DK-8850 Bjerringbro Tlf.: +45-87 50 50 50 Telefax: +45-87 50 51 51 E-mail: [email protected]/DK

EstoniaGRUNDFOS Pumps Eesti OÜPeterburi tee 92G11415 TallinnTel: + 372 606 1690Fax: + 372 606 1691

FinlandOY GRUNDFOS Pumput AB Mestarintie 11 FIN-01730 Vantaa Phone: +358-3066 5650 Telefax: +358-3066 56550

FrancePompes GRUNDFOS Distribution S.A. Parc d’Activités de Chesnes 57, rue de Malacombe F-38290 St. Quentin Fallavier (Lyon) Tél.: +33-4 74 82 15 15 Télécopie: +33-4 74 94 10 51

GermanyGRUNDFOS Water Treatment GmbHReetzstraße 85D-76327 Pfinztal (Söllingen)Tel.: +49 7240 61-0 Telefax: +49 7240 61-177E-mail: [email protected]

GermanyGRUNDFOS GMBHSchlüterstr. 3340699 ErkrathTel.: +49-(0) 211 929 69-0 Telefax: +49-(0) 211 929 69-3799E-mail: [email protected] in Deutschland:E-mail: [email protected]

GreeceGRUNDFOS Hellas A.E.B.E. 20th km. Athinon-Markopoulou Av. P.O. Box 71 GR-19002 Peania Phone: +0030-210-66 83 400 Telefax: +0030-210-66 46 273

Hong KongGRUNDFOS Pumps (Hong Kong) Ltd. Unit 1, Ground floor Siu Wai Industrial Centre 29-33 Wing Hong Street & 68 King Lam Street, Cheung Sha Wan Kowloon Phone: +852-27861706 / 27861741 Telefax: +852-27858664

HungaryGRUNDFOS Hungária Kft.Park u. 8H-2045 Törökbálint, Phone: +36-23 511 110Telefax: +36-23 511 111

IndiaGRUNDFOS Pumps India Private Limited118 Old Mahabalipuram RoadThoraipakkamChennai 600 097Phone: +91-44 4596 6800

IndonesiaPT GRUNDFOS Pompa Jl. Rawa Sumur III, Blok III / CC-1 Kawasan Industri, Pulogadung Jakarta 13930 Phone: +62-21-460 6909 Telefax: +62-21-460 6910 / 460 6901

IrelandGRUNDFOS (Ireland) Ltd. Unit A, Merrywell Business ParkBallymount Road LowerDublin 12 Phone: +353-1-4089 800 Telefax: +353-1-4089 830

ItalyGRUNDFOS Pompe Italia S.r.l. Via Gran Sasso 4I-20060 Truccazzano (Milano)Tel.: +39-02-95838112 Telefax: +39-02-95309290 / 95838461

JapanGRUNDFOS Pumps K.K.Gotanda Metalion Bldg. 5F,5-21-15, Higashi-gotandaShiagawa-ku, Tokyo, 141-0022 JapanPhone: +81 35 448 1391Telefax: +81 35 448 9619

KoreaGRUNDFOS Pumps Korea Ltd.6th Floor, Aju Building 679-5Yeoksam-dong, Kangnam-ku, 135-916Seoul, KoreaPhone: +82-2-5317 600Telefax: +82-2-5633 725

LatviaSIA GRUNDFOS Pumps Latvia Deglava biznesa centrsAugusta Deglava ielā 60, LV-1035, Rīga,Tālr.: + 371 714 9640, 7 149 641Fakss: + 371 914 9646

LithuaniaGRUNDFOS Pumps UABSmolensko g. 6LT-03201 VilniusTel: + 370 52 395 430Fax: + 370 52 395 431

MalaysiaGRUNDFOS Pumps Sdn. Bhd.7 Jalan Peguam U1/25Glenmarie Industrial Park40150 Shah AlamSelangor Phone: +60-3-5569 2922Telefax: +60-3-5569 2866

MexicoBombas GRUNDFOS de México S.A. de C.V. Boulevard TLC No. 15Parque Industrial Stiva AeropuertoApodaca, N.L. 66600Phone: +52-81-8144 4000 Telefax: +52-81-8144 4010

NetherlandsGRUNDFOS NetherlandsVeluwezoom 351326 AE AlmerePostbus 22015 1302 CA ALMERE Tel.: +31-88-478 6336 Telefax: +31-88-478 6332 E-mail: [email protected]

New ZealandGRUNDFOS Pumps NZ Ltd.17 Beatrice Tinsley CrescentNorth Harbour Industrial EstateAlbany, AucklandPhone: +64-9-415 3240Telefax: +64-9-415 3250

NorwayGRUNDFOS Pumper A/S Strømsveien 344 Postboks 235, Leirdal N-1011 Oslo Tlf.: +47-22 90 47 00 Telefax: +47-22 32 21 50

PolandGRUNDFOS Pompy Sp. z o.o.ul. Klonowa 23Baranowo k. PoznaniaPL-62-081 PrzeźmierowoTel: (+48-61) 650 13 00Fax: (+48-61) 650 13 50

PortugalBombas GRUNDFOS Portugal, S.A. Rua Calvet de Magalhães, 241Apartado 1079P-2770-153 Paço de ArcosTel.: +351-21-440 76 00Telefax: +351-21-440 76 90

RomaniaGRUNDFOS Pompe România SRLBd. Biruintei, nr 103 Pantelimon county IlfovPhone: +40 21 200 4100Telefax: +40 21 200 4101E-mail: [email protected]

RussiaООО ГрундфосРоссия, 109544 Москва, ул. Школьная 39Тел. (+7) 495 737 30 00, 564 88 00Факс (+7) 495 737 75 36, 564 88 11E-mail [email protected]

Serbia GRUNDFOS Predstavništvo BeogradDr. Milutina Ivkovića 2a/29YU-11000 Beograd Phone: +381 11 26 47 877 / 11 26 47 496Telefax: +381 11 26 48 340

SingaporeGRUNDFOS (Singapore) Pte. Ltd. 24 Tuas West Road Jurong Town Singapore 638381 Phone: +65-6865 1222 Telefax: +65-6861 8402

SloveniaGRUNDFOS d.o.o.Šlandrova 8b, SI-1231 Ljubljana-ČrnučePhone: +386 1 568 0610Telefax: +386 1 568 0619E-mail: [email protected]

South AfricaGrundfos (PTY) Ltd.Corner Mountjoy and George Allen RoadsWilbart Ext. 2Bedfordview 2008Phone: (+27) 11 579 4800Fax: (+27) 11 455 6066E-mail: [email protected]

SpainBombas GRUNDFOS España S.A. Camino de la Fuentecilla, s/n E-28110 Algete (Madrid) Tel.: +34-91-848 8800 Telefax: +34-91-628 0465

SwedenGRUNDFOS AB (Box 333) Lunnagårdsgatan 6 431 24 Mölndal Tel.: +46 31 332 23 000 Telefax: +46 31-331 94 60

SwitzerlandGRUNDFOS ALLDOS International AGSchönmattstraße 4 CH-4153 ReinachTel.: +41-61-717 5555Telefax: +41-61-717 5500E-mail: [email protected]

SwitzerlandGRUNDFOS Pumpen AG Bruggacherstrasse 10 CH-8117 Fällanden/ZH Tel.: +41-1-806 8111 Telefax: +41-1-806 8115

TaiwanGRUNDFOS Pumps (Taiwan) Ltd. 7 Floor, 219 Min-Chuan Road Taichung, Taiwan, R.O.C. Phone: +886-4-2305 0868Telefax: +886-4-2305 0878

ThailandGRUNDFOS (Thailand) Ltd. 92 Chaloem Phrakiat Rama 9 Road,Dokmai, Pravej, Bangkok 10250Phone: +66-2-725 8999Telefax: +66-2-725 8998

TurkeyGRUNDFOS POMPA San. ve Tic. Ltd. Sti.Gebze Organize Sanayi Bölgesi Ihsan dede Caddesi,2. yol 200. Sokak No. 20441490 Gebze/ KocaeliPhone: +90 - 262-679 7979Telefax: +90 - 262-679 7905E-mail: [email protected]

UkraineТОВ ГРУНДФОС УКРАЇНА 01010 Київ, Вул. Московська 8б, Тел.:(+38 044) 390 40 50 Фах.: (+38 044) 390 40 59E-mail: [email protected]

United Arab EmiratesGRUNDFOS Gulf DistributionP.O. Box 16768Jebel Ali Free ZoneDubaiPhone: +971-4- 8815 166Telefax: +971-4-8815 136

United KingdomGRUNDFOS Pumps Ltd. Grovebury Road Leighton Buzzard/Beds. LU7 8TL Phone: +44-1525-850000 Telefax: +44-1525-850011

U.S.A.GRUNDFOS Pumps Corporation 17100 West 118th TerraceOlathe, Kansas 66061Phone: +1-913-227-3400 Telefax: +1-913-227-3500

UzbekistanПредставительство ГРУНДФОС в Ташкенте700000 Ташкент ул.Усмана Носира 1-й тупик 5Телефон: (3712) 55-68-15Факс: (3712) 53-36-35

Addresses revised 27.04.2012

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