Grundfos Oxiperm C 166-007G, Oxiperm C 166-050G, Oxiperm C 166-015G, Oxiperm C 166-025G, Oxiperm C 166-075G Operation And Service Manual

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Oxiperm® C

166 Fully-automatic Chlorine Dioxide Preparation System 166-007G, -015G, -025G,

-050G, -075G, -100G

Operation and Service Manual

Other languages

http://net.grundfos.com/qr/i/96709689

Read this manual completely and keep it!

No warranty in case of damages caused by incorrect operation.

Oxiperm C 166 G en

Imprint

Oxiperm® C 166 Fully-automatic Chlorine Dioxide Preparation System 166-007G, -015G, -025G, -050G, -075G, -100G

Operation and Service Manual

Editor: Grundfos Water Treatment Reetzstraße 85 • 76327 Pfinztal (Söllingen) Postfach 1160 • 76317 Pfinztal Tel. +49 72 40 61-0 / Fax. +49 72 40 61-211 Internet: www.grundfos.com

Subject to change.

Oxiperm C 166 G en

Assembly Information

Operating Authority:

GRUNDFOS customer no.:

Order no.:

Order no. of the device:

Serial no. of the device:

Date of commissioning:

Location of the device:

NOTE Please fill in this form after commissioning. This

allows easy maintenance for you and your GRUNDFOS service partner.

Used for:

Assembly Sketch

15.710018-V3.0

Content

Oxiperm C 166 G en

Assembly Information ..................................................................................... 3

Assembly Sketch ............................................................................................. 3

1 Of General Interest ................................................................................ 6

1.1 Introduction .................................................................................................6

1.2 Using this Paper ......................................................................................... 6

1.3 Warranty .....................................................................................................6

2 Safety Instructions ................................................................................ 7

2.1 Application of the Product ........................................................................... 7

2.2 Obligations of the Operating Authority ........................................................ 7

2.3 Averting Dangers ........................................................................................7

3 Technical Data ....................................................................................... 8

3.1 General Data .............................................................................................. 8

3.1.1 Data on Performance and Consumption .........................................8

3.1.2 Connection Data .............................................................................. 9

3.1.3 Weights and Measures .................................................................... 9

3.2 Components ............................................................................................. 10

3.2.1 Control Panel ................................................................................. 10

4 Installation............................................................................................ 11

4.1 Transport and Storage ..............................................................................11

4.2 Unpacking ................................................................................................. 11

4.3 Mounting ...................................................................................................11

4.3.1 Requirements for Mounting ...........................................................11

4.3.2 Mounting the System ..................................................................... 11

4.4 Connections .............................................................................................. 12

4.5 Electrical Connection ................................................................................12

5 Construction

and Function ........................................................................................ 13

5.1 Basics ....................................................................................................... 13

5.1.1 Application of Chlorine Dioxide in Water Treatment....................... 13

5.1.2 Preparation of

Chlorine Dioxide ............................................................................13

5.2 Components ............................................................................................. 14

5.3 Course of Function ................................................................................... 16

5.4 Operation and Display Elements .............................................................. 17

6 Preparations for Commissioning ....................................................... 19

6.1 Checking the Pressure Retention Valve and the Pulsation Damper .........19

6.2 Installation of the Float into the Solution Tank .......................................... 19

6.3 Checking the Flow Limits .......................................................................... 20

6.4 Filling of the Adjusting Vessel of the NaClO2 Dosing Pump .....................22

6.5 Filling of the Overflow of the Batch-Tank .................................................. 23

Oxiperm C 166 G en

7 Commissioning .................................................................................... 24

7.1 Filling the Reactor

with Water .................................................................................................24

7.1.1 Filling the Reactor while the System is switched off ...................... 24

7.1.2 Filling the Reactor while the System is switched on ...................... 24

7.2 Commissioning with Chemicals at Manual Operation Mode .................... 26

8 Operation ............................................................................................. 28

8.1 Automatic and

Manual Operation ..................................................................................... 28

8.1.1 Manual Operation ..........................................................................28

8.1.2 Automatic Operation ...................................................................... 29

8.2 Recording and Calling up the Error Messages .........................................29

8.3 Quitting the Error and Alarm Messages ...................................................30

8.4 Calling up the Level Data .......................................................................... 30

8.4.2 ClO2 Level ..................................................................................... 31

8.4.1 NaClO2 Levelvel ............................................................................ 31

8.4.3 Cl2 Level........................................................................................32

8.4.4 Replacement

of a Cl2 Battery ............................................................................. 32

8.4.5 Checking the Time-Invariants of the Level Messages ..................33

8.5 Flow Rates ................................................................................................ 34

8.6 Function "System Extern/Manual On-/Off" ..............................................36

8.7 System Settings ........................................................................................ 37

8.7.1 Setting of Language ...................................................................... 37

8.7.2 Setting of Contrast ......................................................................... 38

8.7.3 Setting of Date and Time ............................................................... 38

9 Possible Failures ................................................................................. 40

10 Maintenance ......................................................................................... 41

10.1 Differential Pressure

Regulator .................................................................................................. 41

10.2 Other Components ................................................................................... 42

11 Spare Parts........................................................................................... 42

11.1 Overview ................................................................................................... 43

11.2 Differential Pressure

Regulator .................................................................................................. 44

Appendix: Declaration of conformity

15.710018-V3.0

1 Of General Interest

1.1 Introduction

1.2 Using this Paper

Oxiperm C 166 G en

This Operation and Service Manual contains all information necessary for safe operation of the device being described here.

If you require further information or if any problems arise which are not reflected in detail in this manual, contact GRUNDFOS directly for the information needed.

❏ Descriptions are written as plain text.

❏ Lists are indicated by squares (❏), sublists by dashes (-).

❏ Operation steps are indicated by bullets (●), substeps by small bullets (•).

❏ Cross-references are indicated by

❏ The headings

WARNING Danger of injuries and accidents!

WARNING, CAUTION

italic letters

and

and an arrow (➜).

NOTE

have the following meaning:

1.3 Warranty

CAUTION Danger of incorrect operation or damage to the product!

NOTE There is an exceptional feature.

PACKING MATERIAL Keep packing material or dispose of it according

to local rules.

Warranty in accordance with our general terms of sale and delivery shall only be valid, if

❏ the product is used according to the information within this paper,

❏ the product is not being opened or used improperly,

❏ maintenance and repair is implemented exclusively by authorized and

qualified personnel,

❏ original spare parts are used for repair.

NOTE In case of changes of hardware or software warranty

will not longer be valid. The software stays property of Grundfos Water Treatment. Copies are not allowed.

Oxiperm C 166 G en

2 Safety Instructions

2.1 Application of the Product

2.2 Obligations of the Operating Authority

2.3 Averting Dangers

Oxiperm® C 166 serves for preparing chlorine dioxide solution as described in this manual.

WARNING Other applications are not intended and are not

permitted. *UXQGIRV:DWHU7UHDWPHQW accept no

responsibility for damages caused by unintended use.

The operating authority of the system is responsible for

❏ instructing the operation personnel

❏ arranging regular maintenance

WARNING Before commissioning, read the GRUNDFOS

information paper "Function and Safety of Chlorination Plants".

Danger of explosion! The inner temperature of the reactor may not exceed 30 °C! Observe permissible temperature ranges for operating water and NaClO

Only use NaClO2 solution with a concentration of 24%!

Observe safety precautions for the used chemicals!

Switch off mains switch before doing maintenance work!

Do not open components of the device! Cleaning, maintenance and repair may only be executed by authorized qualified personnel!

15.710018-V3.0

Oxiperm C 166 G en

3 Technical Data

3.1 General Data

3.1.1 Data on Performance and Consumption

Order no. Capacity Components Operation water consumption Operation

ClO

kg/h l/h kg/h l/h l/h l/h l/h l/h bar

166-007G 0.75 245 0.49 3.5 150 90 700 940 5

166-015G 1.5 490 0.99 7.0 280 200 1100 1580 5

166-025G 2.5 815 1.65 11.8 470 340 2400 3200 5

166-050G 5.0 1620 3.3 23.5 940 680 2200 3790 5

166-075G 7.5 2440 4.9 35 1400 1000 3400 5800 5

166-100G 10 3250 6.6 47 1900 1300 4200 7400 5

consumption Injector Dilution Extraction total pressure

Cl2NaClO

Concentration of the prepared solution

Permissible concentration of the

NaClO2 solution

Permissible ambient temperature

Permissible temperature of

operation water and NaClO

Frame

Screws, disks and nuts

Reactor

Solution tank

Piping

Gaskets

3 g/l

24%

WARNING The inner temperature of the reactor may not exceed

40 °C! Observe permissible temperature ranges for operating water and NaClO2!

Only use NaClO2 solution with a concentration of 24%!

5 °C to 40 °C

5 °C to 30 °C

Materials

1.4301

PVC grey, glass fiber reinforced

PVC grey

FPM

Oxiperm C 166 G en

3.1.2 Connection Data

Order no. Cl

PE tube DN DN DN DN of vac. regulator

NaClO2Operation water Outlet ClO

Outlet of extraction injector Press. conn.

166-007G 8x11 10 25 20 20 1“

166-015G 8x11 10 25 32 20 1“

166-025G 8x11 10 25 32 20 1“

166-050G 8x11 10 25 32 25 1“

166-075G 10x14 10 32 50 25 1“

166-100G 10x14 10 32 50 25 1“

3.1.3 Weights and Measures

Order no. A B C D E F G H I K L Weight (kg)

166-007G 1500 1800 830 720 255 1440 624 160 97 652 140 210

166-015G 1500 1800 830 720 255 1440 624 160 97 610 140 235

166-025G 1500 1800 830 720 255 1440 624 160 97 610 140 250

166-050G 1500 1800 1400 400 255 1440 1240 160 97 665 140 330

166-075G 1500 1800 1400 400 255 1440 1240 160 97 665 140 370

166-100G 1500 1800 1400 400 255 1440 1240 160 97 665 140 400

Measures in mm.

15.710018-V3.0

3.2 Components

3.2.1 Control Panel

Degree of protection

Oxiperm C 166 G en

IP 54

Control

Power supply

Operator's language

Maximum permissible load

of the potential-free contacts

optional Description

Control panel with PLC and operation keyboard (standard version) Functions:

- comfortable plain-text operator guidance

- complete control of the system

- password protection

- automatic switch off in case of errors

- remote switching

- output contacts for operational state and error messages

- printer connection

- input and monitoring of the delay times for limit switching functions

without control panel (with terminal box)

Index no. Description

V000 / V020 Power supply 230 V (50/60 Hz) (standard version)

V001 / V021 Power supply 115 V (50/60 Hz)

V150 terminal box 115 / 230 V (50/60 Hz)

Index no. Description

F000 Operator's language German (standard version)

F001 Operator's language Englisch

F002 Operator's language French

Ohmic and inductive load 250 V AC1, 2 A

50 V DC1, 2 A

Power consumption

Further Options

CAUTION Radioshielding for connected consumers must be

provided by the customer.

Order no. Power consumption (VA)

166-007G approx. 300 VA

166-015G approx. 300 VA

166-025G approx. 300 VA

166-050G approx. 300 VA

166-075G approx. 300 VA

166-100G approx. 550 VA

Empty indication for Cl2 and NaClO Profibus DP-Interface

Oxiperm C 166 G en

4 Installation

4.1 Transport and Storage

4.2 Unpacking

WARNING Observe weight of the system! Only use suitable lifting

● Handle with care, do not throw!

❏ Dry and cool storage place. Avoid direct sunlight!

● Check the device for damages.

• Do not mount or install damaged devices!

● Mount as soon as possible after unpacking.

CAUTION Keep packing material or dispose of it according to

and transportation devices! Transportation only when the system is empty!

local rules.

4.3 Mounting

4.3.1 Requirements for Mounting

4.3.2 Mounting the System

WARNING The chlorine containers and the vacuum regulator have

Mounting the system

● Erect the system on a horizontal foundation.

WARNING Observe maximum floor load!

to be located in a separate room according to local safety regulations.

➜

Observe information pater "Function and safety of

Chlorination Plants"!

15.710018-V3.0

4.4 Connections

Oxiperm C 166 G en

CAUTION Required conditions for the operation water for

trouble-free operation:

❏

constant pressure (min. 5 bar, max. 6 bar)

❏

drinking water quality

● Connect the operation water line to connection 3.1.

● Connect the NaClO

● Connect the Cl2 supply line (coming from the vacuum regulator) to

connection 2.1.

● Connect the ClO

● Connect the discharge connection of the extraction injector (8) to an

appropriate discharge.

supply line to connection 1.1.

withdrawal line to connection 9.

4.5 Electrical Connection

WARNING Electrical connection only by authorized qualified

personnel! Observe local safety regulations!

Mortal danger! Switch off mains power before connecting the mains supply!

NOTE Establish electrical connections according to the

enclosed connection chart.

● Lead the mains line to the control panel and connect it according to the enclosed connection chart.

- Cable cross-section: min. 1.5 mm

• Provide a back-up fuse with a capacity of 10 A.

Oxiperm C 166 G en

5 Construction

and Function

5.1 Basics

5.1.1 Application of Chlorine Dioxide in Water Treatment

Properties of chlorine dioxide

❏ Strong and fast oxidizing and disinfecting agent

❏ Wide range of application in drinking-, service-, cooling- and waste water

treatment

❏ chemically instable compound

- can explosively decompose to chlorine and oxygene when being under pressure, heated or exposed to UV rays

- has to be produced on demand at the place of use

Observe chap. 2.3 (Averting dangers)!

➜

Advantages of chlorine dioxide in comparison to chlorine

❏ Over the whole pH range of drinking water (pH 6.5-9), chlorine dioxide has a

good to very good bactericidal, virucidal and sporicidal effect. (The disinfecting effect of chlorine is reduced when the pH value rises!)

❏ No forming of haloforms (trihalomethanes) with decomposable water

contents

❏ No forming of chloramines with ammonia or aminocompounds

❏ Strongly reduced formation potential of higher-molecular organic halogene

compounds

❏ Good stability in water

- suitable bactericidal and bacteriostatic protection of water networks.

5.1.2 Preparation of Chlorine Dioxide

Chemical reaction

2 NaClO

sodium chlorite chlorine chlorine dioxide sodium chloride

❏ sodium chlorite

- solution with a concentration of 24%, containing 300 g/l NaClO

❏ chlorine

- solution of approx. 3.5 g/l Cl

❏ chemical reaction in the reactor:

- with the size and construction of the reactor a maximum effectivity in

❏ Following the reactor: chlorine dioxede solution is diluted to an application-

suiting concentrationof aprox. 2 to 3 g/l

+Cl

chlorine dioxide production can be achieved. Nearly 100% of the components react with each other

→→

→ 2 ClO

→→

+ 2 NaCl

15.710018-V3.0

5.2 Components

Oxiperm C 166 G en

1 Dosing system for NaClO

1.1 Connection for NaClO

1.2 Suction pulsation damper

1.3 Suction aid

1.4 Piston-diaphragm dosing pump

1.5 Pulsation damper

1.6 Flow meter for NaClO

with limit switch

2 Dosing system for chlorine gas

2.1 Cl

2.2 Flow meter for Cl

2.3 Cl

2.4 Differential pressure regulator for Cl

2.5 Injector for Cl

vacuum connection from the vacuum regulator

with limit switch

rate valve

3 Operation water supply

3.1 Connection for operation water

3.2 Water supply for the extraction injector

3.3 Water supply for injector and subsequent dilution

3.4 Flow meter for injector operation water with limit switch

3.5 Flow meter for subsequent dilution with limit switch

3.6 Rate valves for the water flow

4 Panel for PLC and operation keyboard

5 ClO

reactor

6 Solution tank with level sensors (min., max., dry-run and overflow)

7 Carbon filter

8 Discharge connection of the extraction injector

9 ClO

withdrawal connection

15.710018-V3.0

5.3 Course of Function

Oxiperm C 166 G en

❏ For preparing a chlorine dioxide solution, four components are necessary:

- Chlorine gas

- Solution water

- Sodium chlorite

- Dilution water

The amounts of these components are determined by the preparation method and may therefore not be changed. The flow rates of the single components are monitored by rotameters.

❏ In the injector, the chlorine gas is mixed with the solution water and flows

into the reactor.

❏ The sodium chlorite is also being dosed into the reactor.

❏ In the reactor, the reaction of chlorine solution and sodium chlorite takes

place, forming chlorine dioxide.

❏ The solution formed in the reactor flows into the solution tank and is being

mixed with the dilution water. This produces a ready-to-use chlorine dioxide solution.

❏ The ready-to-use solution can now being withdrawn from the solution tank.

❏ The extraction injector continuously sucks residual chlorine gas out of the

reactor and leads it to a carbon filter.

❏ The solution tank is equipped with level sensors.

In automatic operation, the system is

- switched on when the min. level is reached.

- switched off when the max. level is reached.

- switched off if at least one of the component's flows is out of the permissible limits. This switching-off takes place after a time delay.

Chlorine gas

Reactor

Injector

Solution water NaClO

ClO

solution WithdrawalChlorine solution

Solution tank

Dilution water

Oxiperm C 166 G en

5.4 Operation and Display Elements

Operation keyboard

SIEMENS

F1 F2 F3

K1 K2

8 9

E F

4 5 6

A B C

1 2 3

. 0 +/-

SHIFT

SIMATIC OP 7

K3 K4

INS

HELP

DEL

HELP

SHIFT

ESC

ACK

ENTER

Keys

(soft keys)

These keys lead to actions which are being displayed above the corresponding key. Their function depends on the current state of the device, e.g. a certain submenu.

NOTE Keep keys pressed down until the selected function

has been activated/deactivated.

Function keys

On/off automatic operation, LED on the key lights up while automatic operation

On/off manual operation, LED on the key lights up while manual operation

Shows error messages

15.710018-V3.0

Resets alarm messages which are to be acknowledged (FSA +/-). In this case the LED on the key is flashing.

8 9

D E F

4 5 6

A B C

1 2 3

0 +/-

Oxiperm C 166 G en

System keys

These keys have fixed basic functions of the PLC.

The cursor keys are used for moving the cursor to a place on the display where a parameter has to be changed.

The numerical keys are used for the input of numeric values, like numbers or passwords.

NOTE Always double-click on ESC (Escape) to activate.

ESC

The ESC key (Escape) is used for

- interrupting the current action without changing any values resp. without overtaking values that have been changed,

- to exit help pages.

ENTER

The ENTER key is used for

- confirming changed values,

- activating the input of symbolic values.

ACK The ACKNOWLEDGE key is used for acknowleding error messages.

HELP

The HELP key is used for calling help pages on the current display situation.

Oxiperm C 166 G en

6 Preparations for

Commissioning

6.1 Checking the Pressure Retention Valve and the Pulsation Damper

CAUTION Before commissioning, all components of the system

must be ready to start.

➜➜

➜

Observe chap. 4.4 (connections)

➜➜

Pressure retention valve for versions C 166-050 to C-166-100

● Verify the setting measure 7 mm.

Pulsation damper for the piston-diaphragm dosing pump

● Adjust the following pressure values:

- C 166-007 to C 166-025: 1,5 - 1,7 bar

- C 166-050 to C 166-100: 1,5 - 1.7 bar

● Check the density

Observe the operation and service manual of this device!

➜

6.2 Installation of the Float into the Solution Tank

● Install the float into the transparent guide pipe

• Slatten the union nut at the guide pipe (at the bottom and at the top)

• Remove the guide pipe

• Install the float.

CAUTION Observe the fitting position!

15.710018-V3.0

• Screw the union nut

6.3 Checking the Flow Limits

Oxiperm C 166 G en

NOTE The setting points of the limit contacts "max/min" are

at the top of these contacts.

➜➜

➜

Observe the maximum and minimum values in the

➜➜

following table!

Flowmeter for für injection operating water, diluting water

MIN

MAX

1a setting point for the maximum flow

1b setting point for the minimum flow

Flowmeter for NaClO

ca. 1 mm

Oxiperm C 166 G en

Flow meter for Cl

➜

Observe the fitting position of the limit contacts!

• Turn the limit contact "min" about 180°

- Label "min" is on its head.

max

5-6 mm

min

1a Setting point for the maximum Cl2 flow

1b Setting point for the minimum Cl

2a Fitting position of the limit contact "max"

2b Fitting position of the limit contact "min" (label on its head)

flow

15.710018-V3.0

Oxiperm C 166 G en

● Check the flow limits regarding following table and reset the limits if necessary.

Basic settings and corresponding limits

minimum maximum flow limit flow limit

C 166-007 G: diluting water (l/h) 90 80 100

injection operating water (l/h) 150 140 160 NaClO Cl

(l/h) 3.5 2.7 3.8

(g/h) 490 450 550

C 166-015 G diluting water (l/h) 200 180 220

injection operating water (l/h) 280 260 300 NaClO Cl

(l/h) 7.0 7.7 6.3

(g/h) 980 880 1100

C 166-025 G diluting water (l/h) 340 310 360

injection operating water (l/h) 470 430 510 NaClO Cl

(l/h) 11.8 10 13

(g/h) 1650 1500 1800

C 166-050 G diluting water (l/h) 680 620 740

C 166-075 G diluting water (l/h) 1000 900 1100

C 166-100 G diluting water (l/h) 1300 1100 1500

6.4 Filling of the Adjusting Vessel of the NaClO

Dosing Pump

injection operating water (l/h) 940 860 1020 NaClO Cl

(l/h) 23.5 21 25

(g/h) 3300 3000 3600

injection operating water (l/h) 1400 1200 1600 NaClO Cl

(l/h) 35 31 39

(g/h) 4900 4400 5400

injection operating water (l/h) 1900 1700 2100 NaClO Cl

(l/h) 47 42 52

(g/h) 6600 6000 7300

● Turn the 3-port ball valve to sucking position.

● Open the ball valve for NaClO

● Fill the adjustment vessel up to approx. 0.5 l in order to get the air out of the NaClO

supply line (use the hand pump mounted at the back side).

Oxiperm C 166 G en

6.5 Filling of the Overflow of the Batch-Tank

● Open the upper screwing

● Filling in water, ca. 150-200mm

● Close again the upper screwing

150-200mm

15.710018-V3.0

7 Commissioning

7.1 Filling the Reactor with Water

7.1.1 Filling the Reactor while the System is switched off

Oxiperm C 166 G en

CAUTION At first fill only water into the reactor!

Do not dose any chemicals (NaClO2 or Cl2)!

NOTE The reactor can be filled either while the system is

switched off or on.

● Unscrew the cover of the reactor.

● Fill the reactor completely with water.

● Screw the reactor cover again.

7.1.2 Filling the Reactor while the System is switched on

CAUTION Check the tightness of the reactor cover at operating

system and tigthen it again if necessary.

● Unscrew the vacuum tube for Cl2 or close the Cl2 adjustment valve.

● Turn on power by the main switch at the cabinet.

Observe the operation manual of the display in chap. 8!

➜

The display shows the main menu:

man : 0 Auto Man

K1 K2 K3 FS LS

● Quit the error messages (z.B. LSA --, dry run of the solution container)

by pressing

ACK

local Alarm RESET

Oxiperm C 166 G en

NOTE Keep keys pressed down until the selected function

has been activated/deactivated.

NOTE To return to the main menu, double-click on

● Press

Enter password

● In "User" field: Enter: 9

● Switch to the

● In "Password" field Enter: 100

● Switch to the

● Press key

for manual operation.

TAB

next input field, "Password", using key

TAB

next input field, "OK", using key

ENTER

again.

ESC

key.

On the display the menu "manual operation" is shown:

manual operation (K2) + key Fx:

1DP0

1 1Y01

off

● Close the ball valves for operating water and diluting water.

● Press the key water.

● Set the flow rates of the operating water and of the diluting water by adjusting the ball valves at the flow meter.

➜

For setting data see table "Basic settings" in chap.6.3!

● Adjust the pressure of the operating water to 5 bar (at the pressure reducer)

NOTE So long as air is still in the reactor, the Cl2 injector

does not reach the full power! In this case the float in the Cl2 measuring tube is pulsing.

off

to open the valve for operating water and for diluting

1Y02 off

15.710018-V3.0

As soon as the reactor is completely filled with water the float stopps pulsing.

Oxiperm C 166 G en

❏ LED at the alarm symbol

run of the solution container) is active, until the water niveau in the reactor has passed the contact "dry run".

is illuminated, alarm message (LSA--, dry

7.2 Commissioning with Chemicals at Manual Operation Mode

● Switch off the system by

- either, if in the transparent float-pipe of the solution container the water can be seen.

- or, if the water niveau has passed the contact "dry run".

● Connect the vacuum tube for Cl2 again.

NOTE Adjust the flow rates according to table

"Basic settings" in chap.6.3!

● In the main menu: Switch by key

➜

Observe the procedure in chap. 7.1.2!

➜

Observe the operation of the display in chap. 8!

The display shows the menu "manual operation":

to manual operation

manual operation (K2) + key Fx:

1DP0

1 1Y

off off

● Switch on the NaClO2 dosing pump by key

• Adjust the NaClO handwheel at the dosing pump.

➜

Observe the operation manual of the dosing pump!

CAUTION In order to ensure an exact NaClO2 flow rate, the NaClO

● Open the valve for operating water and diluting water by key

• Adjust the flow rates of the operating water and diluting water by means of the ball valves at the flow meter.

• Adjust the pressure of the operating water to 5 bar by means of the pressure reducer.

flow rate at the measuring tube by means of the

dosing pump must be readjusted after commissioning! This should be done by means of the adjusting vessel!

1Y02 off

Oxiperm C 166 G en

• Adjust the Cl

Cl2 measuring tube.

● Open the valve of the suction injector by key

flow rate by mens of the setting screw at the

• Adjust the pressure of the operating water for the suction injector

to 3 bar by means of the pressure reducer.

● Switch off the system by keys when the Cl

solution is visible at the bottom of the solution container

and

, or by

(color: dark yellow).

CAUTION While commissioning the reactor was completely filled with

water. Therefore the concentration of the ClO2 solution is still below the required value of approx. 3 g/l.

● Dose immediately, empty or neutralize the first filling of the solution container (diluted ClO

solution)

● When the solution container is emptied switch on the system again (to automatic operation).

➜

Observe the following chap. 7.3!

❏ After further 3 or 4 reactor fillings the ClO2 solution concentration in the

solution container will reach the required value of approx. 3 g/l.

NOTE During manual operation the system is automatically

switched off by the overflow contact of the solution container.

In order to switch on the system again, the solution niveau must be below the overflow contact!

15.710018-V3.0

8 Operation

Oxiperm C 166 G en

● Turn on the system by the main switch.

❏ The display shows the main menu:

8.1 Automatic and Manual Operation

8.1.1 Manual Operation

man : 0 Auto Man

K1 K2 K3 FS LS

NOTE Keep keys pressed down until the selected function

has been activated/deactivated.

NOTE To return to the main menu, double-click on

● In the "main menu": Switch to "manual operation" by key

- LED on the key lights up.

local Alarm RESET

K4 Sy

ESC

key.

The menu "Manual operation" is shown on the display:

manual operation (K2) + Key Fx:

1DP0

1 1Y

off off

Function of the softkeys

Switch on/off the dosing pump by manual operation.

Open the valves for operating/diluting water.

Open the valve of the suction injector.

1Y02 off

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8.1.2 Automatic Operation

The display shows the "main menu".

ESC

● If necessary press key

in order to return to the main menu.

8.2 Recording and Calling up the Error Messages

❏ "Manual operation" must be switched off (LED on

● Switch on/off the system by key

is not illuminated).

NOTE While automatic operation the limit contact "Max" at

the solution container switches off the system automatically, the limit contact "Min" switches on.

➜➜

➜

Compare to chap. 7.2 (automatic switching during

➜➜

manual operation)

All error messages will be automatically recorded in chronological order so that the causes of trouble can be recognized as soon as possible.

NOTE For recording the error messages in correct

chronological order, the actual date and time must be set up.

➜➜

➜

Observe chap. 8.7.3 "Setting up date and time"

➜➜

Calling up error messages (2 possible procedures)

● Either: Press key

● Or: Press the keys

in menu "manual operation".

and

The display shows the list of the error messages:

12.4.2006 12:21:xx FSA+ 1F03 Flow max. motive water Cl2

❏ Type of error

❏ Date and time of error

one after the other.

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8.3 Quitting the Error and Alarm Messages

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● Go to the message of interest by pressing the cursor keys or .

● Scroll to the plain-text of the message by cursor key .

ESC

● Click on

several times if necessary).

❏ If various error messages are active, the last error message is displayed.

● Quit the error message by key

are illuminated) by key

key (single click) to go back to the error list.

ESC

key (single click) to go back to the main menu (double-click

ACK

. Both LED go out.

8.4 Calling up the Level Data

NOTE Hold key down until the LED goes out.

NOTE All contacts to record the status of NaClO2 and Cl2 are

already installed .

➜➜

➜

The assignment of the connections is shown in

➜➜

the enclosed connection diagrams!

The display shows the "main menu"

ESC

If necessary press the key

● Press the key

(LS) to change over to the submenu "Level".

to go back to the main menu. (Double-click)

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8.4.1 NaClO

Level Level

Level

Level Level

VEL

On the display the "level" is indicated:

level LS:

NaClO2

ClO2

LSALL

max

min-

Cl2

Indicated states of NaClO2:

❏ LSALL dry run

❏ LSAL minimum level

❏ min-max normal operation

❏ LSAH maximum level

NOTE If the level limits ("min"or "max") are passed (LSAL or

LSAH are visible on the display) the automatically running system will be switched off after a certain time-invariant.

8.4.2 ClO

Level Level

Level

Level Level

● Quit the error messages.

● Check the NaClO

● Quit the alarm messages.

On the display the "level LS" is indicated:

container and fill it up if necessary.

level LS: NaClO2

ClO2

in-max

LSALL

Cl2

Indicated states of ClO2:

❏ LSALL dry run

❏ LSAL minimum level

❏ min-max normal operation

❏ LSA++ overflow

15.710018-V3.0

The alarm message is active (LED at the alarm symbol

as the level in the solution container is below of the contact "dry run"(LSALL),

NOTE During manual operation the system is automatically

switched off by the overflow contact.

During the automatic operation the contacts "Max" and "Min" switch the system off and on, respectively.

is illuminated) as long

8.4.3 Cl2 Level

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On the display the menu "level LS" is indicated:

level LS: NaClO2

ClO2

n-max n-max

Cl2

● Press the cursor key to change over to the menu "Cl2 battery".

8.4.4 Replacement of a Cl2 Battery

- on the display the states of both Cl

batteries (1 and 2) are indicated.

Cl2 battery:

operation

RESET

Indicated states for Cl2:

❏ operation Cl

❏ empty Cl

❏ stand-by Cl

❏ Status message "empty" is displayed in the menu "Cl2 battery".

❏ Error and alarm message, LED at the alarm symbol

battery is operating

battery is empty

battery was replaced, battery is ready for work

lights up.

● Quit the error message.

● Replace the Cl

● Quit the status message "empty" by the keys

respectively.

❏ The status message "stand-by" is displayed.

❏ LED at the alarm symbol

NOTE The replacement procedure and the concerning status

Status message on the display during normal operation, i.e.

❏ battery 1: operation

❏ battery 2: stand-by

battery.

goes out.

messages are identical for both Cl2 batteries.

and

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8.4.5 Checking the Time-Invariants of the Level Messages

● Press the key

● Change over to the menu "Cl

● Check the time-invariants.

• Press cursor key

NaClO

-level message".

T(LSAH NaClO2):

(LS) to change over to the submenu "Level".

battery" by cursor key .

to change over to the menu "time-invariant of

{nnn}s T(LSAL NaClO2): {nnn}s T(LSALL NaClO2):

• Press cursor key again to change over to the menu "time-

invariant of ClO

level message".

T(LSAHH ClO2): T(LSAH ClO2):

{nnn}s

{nnn}s T(LSAL ClO2): {nnn}s T(LSALL ClO2):

{nnn}s

● Reset delay times as necessary:

• Use cursor keys to select the time to be changed.

ENTER

• Press

• Use number keys or arrow keys to set new times.

key.

ENTER

• Confirm with

• Click display.

●l Double-click

on cursor key several times then go back to "Level"

ESC

key.

key to return to the main menu.

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8.5 Flow Rates

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The display shows the "main menu"

● Press the key

FS NaClO2 FS CL2

FS H2O 1F03: FS H2O 1F04:

- The flow rates of NaClO2, Cl2, injector operating water and diluting water are displayed.

❏ Status messages

- ok normal operation

- FSAL minimum flow

- FSAH maximum flow

NOTE If the flow limits ("min" or "max") were passed the

to change over to the menu "FS flow rate":

1F01:

1F02: ok

ok ok

system wil be switched off automatically after a certain time-invariant.

In case of failures

● Quit the error and alarm messages.

➜

Observe chap. 8.3!

● Switch on the system.

● Readjust the flow rates.

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Check the time-invariants for the flow rate messages

The display shows the menu "FS flow rate"

● Press cursor key to go to the menu "time-invariants".

T(FSAH): T(FSAL): STOP FSHL:

❏ Status messages:

- no stop no stop of the system

- FSAL system will be switched off in case of minimum flow rate

- FSAH system is switched off in case of maximum flow rate

- FSAHL system will be switched off in case of both limit messages,

● Check the time-invariants for the flow rate messages and readjust them if necessary.

● Change the status messages:

• Select new status message using cursor keys

{nnn}s

{no stop/FSAL/FSAH/FSAHL}

minimum and maximum flow rate

or .

• Press

• Reenter times/statuses using number keys or arrow keys.

key.

ENTER

• Confirm using

● Use cursor key

ESC

key to return to the main menu.

key.

to return to "Flow rate" display or double-click

15.710018-V3.0

8.6 Function "System Extern/Manual On-/Off"

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NOTE Check the assignment of the connections by means of

the enclosed connection diagrams, if the function "extern/manual-change over" is installed.

After the power is turned on by the main switch the system is in the manual operation status.

❏ The display shows the "main menu".

Status messages

❏ man Manual switching.

❏ ext Remote switching by a potential free contact

❏ 0 The key

❏ 1 The key

Switch to external

❏❏

❏ Cursor is on "man" display.

❏❏

is not active (LED off) or external contact is off.

is active (LED on) or external contact is on.

ENTER

● Press

key. Use cursor keys or to switch to "ext".

ENTER

● Press

Switch to manual

❏❏

❏ Cursor is on "ext" display.

❏❏

key.

ENTER

● Press

key. Use cursor keys or to switch to "man".

● Press

ENTER

key.

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8.7 System Settings

8.7.1 Setting of Language

NOTE Cancel incorrect entries using

(double-click).

ESC

key to exit sub-menus.

key to switch to "OP7 home screen"

● In main menu use

● Use

key to scroll right to "System".

key to switch to the "System settings" sub-menu.

Double-click

ESC

key

● Use

key to scroll right to "Language".

key to switch to the "Language" sub-menu.

key to select language

● Return to main menu using necessary)

ESC

key (double-click, several times if

15.710018-V3.0

8.7.2 Setting of Contrast

● Switch to "Language/contrast" menu

see section 8.7.1.

➜

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8.7.3 Setting of Date and Time

● Set contrast + using

● Set contrast - using

● Double-click

ESC

key to return to the "System settings" menu.

key.

Switch to "Date/time" sub-menu

● Switch to the system menu using

● Use

keys to scroll right to "System".

key in the home screen.

● Use

key to switch to the "System settings" sub-menu.

key to switch to "Date/time" screen (double-click).

● Activate submenu with

key.

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Aktuelles Datum einstellen

● Press

● Enter the current date using the number keys.

key. Use cursor key or to switch to date field.

ENTER

● Confirm with

Aktuelle Uhrzeit einstellen

TAB

● Use

key to switch to time field.

key.

ENTER

● Press

● Use number keys to enter current time (hours/minutes).

key Use cursor key or to switch to time field.

ENTER

● Confirm with

key.

● Double-click

ESC

key to return to the "System settings" menu.

15.710018-V3.0

9 Possible Failures

Failure Cause Remedy

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Failures occuring while operation, are analysed by the PLC and displayed on the terminal screen.

● Search and remove the causes.

● Quit the error message.

● Switch again to automatic operation if necessary.

The flow rate of the injector operating water is to high or to low.

The flow rate of the diluting water is to high or to low.

The flow rate of NaClO2 is to high or to low.

The flow rate of Cl2 is to high or to low.

Adjustment valve is misadjusted. Readjust the flow rate.

Admission pressure is not correct. Readjust the admission pressure.

The nozzle of the Cl2 injector is dirty. Clean the nozzle.

Limit contacts are misadjusted. Readjust the contacts.

Adjustment valve is misadjusted. Readjust the flow rate.

Admission pressure is not correct. Readjust the admission pressure.

Limit contacts are misadjusted. Readjust the contacts.

Supply line is plugged. Clean the line.

The dosing pump is misadjusted. Readjust the pump.

NaClO2 container is empty. Fill up the container.

Limit contacts are misadjusted. Readjust the contacts.

Adjustment valve is misadjusted. Readjust the flow rate.

Flow rate of injector operating water is misadjusted.

Operating pressure for the

injector is misadjusted.

The nozzle of the Cl2 injector is dirty. Clean the nozzle.

Limit contacts are misadjusted. Readjust the contacts.

Cl2 batteries are empty. Exchange the batteries.

Overflow of the solution container. Limit contact „max“ is defect. Exchange the contact.

Error message „Cl2 battery empty“. One of the Cl2 batteries is empty. Exchange the battery.

Error message „NaClO2 –min/LSA“. NaClO2 container is empty. Fill up the container.

Readjust the flow rate.

Readjust the admission pressure.

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10 Maintenance

Dosing pump

Suction pulsation damper

Injector for Cl

Extraction injector

Vacuum regulator

other components

WARNING Switch off the whole system before doing cleaning and

Cleaning and maintenance rates:

➜