Grundfos Oxiperm OCD-164 Installation And Operating Instructions Manual

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Oxiperm

OCD-164 (30-2000 g/h)

Installation and operating instructions

GRUNDFOS INSTRUCTIONS

Other languages

http://net.grundfos.com/qr/i/96709679

English (GB) Installation and operating instructions

Caution

Note

English (GB)

Original installation and operating instructions

Contents

1. General safety instructions

1.1 Introduction

1.2 Purpose of this manual

1.3 Symbols used in this document

1.4 Users

1.5 Obligations of the operator

1.6 Maintenance and service personnel

1.7 Correct usage

1.8 Inappropriate usage

1.9 Safety and monitoring equipment

1.10 Chemicals

2. Technical data

2.1 General data

2.2 Electrical data

2.3 Delivery state

3. Fundamentals

3.1 Chlorine dioxide for water treatment

3.2 Functional sequence

4. Design and function

4.1 Design of the system

4.2 Components

4.3 Mode of operation of the system

5. Installation

5.1 Transport and storage

5.2 Unpacking

5.3 Installation location

5.4 Installation scheme

5.5 Wall mounting

5.6 Hydraulic connection

5.7 Electrical connection

5.8 Interfaces RS-232, -422 and -485

6. Operation of control electronics

6.1 Program structure

6.2 Control and display elements

6.3 Automatic mode

6.4 Manual operation

6.5 Logbook

6.6 System choice

6.7 Units

6.8 Setup

6.9 Local/remote

7. Commissioning

7.1 Directives

7.2 System choice

7.3 Selection of operation mode

7.4 Venting of the bypass line

7.5 Calibrating the dosing pumps

7.6 Adjusting the dosing controllers

8. Operation of the system

8.1 Automatic operation

8.2 Manual operation

8.3 Faults

8.4 Error messages of the controller

8.5 Fuses and LEDs of the controller

8.6 Possible faults when changing the tank

9. Maintenance

9.1 Maintenance of the dosing pumps

9.2 Maintenance of the suction lines

9.3 Maintenance of reactor

9.4 Maintenance of injector

10. Spare parts kits and spare parts

10.1 DMI dosing pumps with double-head system

10.2 DMI dosing pumps with single-head system

10.3 Dosing pumps DMX 221

10.4 Bypass, post mixer, and dosing controller

10.5 Enclosure exhaust device

Page

10 10

11 11 11 12 14 14 15 17

18 19 19 19 19 20 20 20 23

24 24 24 27 29 30

31 33 34 35 36 36

37 37 38 39

40 41 41 41 42

10.6 Bypass with solenoid valve and flow limiter (standard version: solenoid valve)

10.7 Bypass, circulating pump 230 V - 50 Hz, 120 V - 60 Hz

10.8 Bypass (version solenoid valve/ball valve, batch mode)

2 2 2 3 3 3 3 3 3 3

5 7 7

8 8

10.9 Bypass for external booster pump

11. Accessories

11.1 External booster pump

11.2 Load unit for booster pump

11.3 Hose connections/hose

11.4 Gas sensor and gas warning device

12. Current setting data

13. Quick Guide

14. Disposal

1. General safety instructions

1.1 Introduction

The OCD-164 disinfection system is a state-of-the-art solution, which complies with recognised safety regulations. Conformity with applicable standards, directives and laws has been verified. Nevertheless, certain risks which cannot be prevented by the manufacturer are associated with the use of the system.

1.2 Purpose of this manual

• Inform users of optimum use of the system.

• Warn users of possible residual risks when using the system correctly, and identify measures that should be taken to avoid damage.

• Caution users against obvious misuse or inappropriate use of the system, and inform them of the necessary care that must be taken when operating the system.

1.3 Symbols used in this document

Warning If these safety instructions are not observed, it may

result in personal injury.

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

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

Information about possible residual risks can be found:

• on warning signs located at the installation site, and

• immediately before steps associated with a residual risk.

43 44 45 47

48 50 50 50

1.4 Users

Users are persons who are responsible for operating and monitoring the disinfection system at the installation location. The system must only be operated by trained and qualified personnel. Personnel must have appropriate technical knowledge and be familiar with the basic principles of measurement and control technology.

1.4.1 Obligations of the users

• Read this manual before operating the disinfection system.

• Be trained by qualified personnel from Grundfos Water Treatment in the operation of the system.

• Observe the recognised regulations governing safety in the workplace and accident prevention.

• Wear appropriate protective clothing in accordance with national regulations for the prevention of accidents when operating the system and handling chemicals.

• Keep secret the user code for the operating software.

1.4.2 User workstation

The disinfection system is electronically controlled. Users and service personnel operate the system via a display with control and display elements. See section 6.2 Control and display elements.

1.5 Obligations of the operator

The owner of the building or the operator of the disinfection system is responsible for the following:

• Keep this manual clearly accessible in the immediate vicinity of the system.

• Meet the installation requirements specified by the manufacturer (required water connections and fittings, environmental conditions, electrical connection, protective tube for dosing line (if necessary), audible or optical warning device for alarm messages (if necessary)).

• Ensure that water lines and fixings are regularly checked, serviced and maintained.

• Obtain official approval for storing chemicals, if necessary.

• Instruct users in the operation of the system.

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

• Ensure that the regulations for the prevention of accidents are observed in the installation location.

• Provide all users and service personnel with protective clothing (face mask, gloves, protective apron).

1.8 Inappropriate usage

Applications other than those listed in section 1.7 Correct usage are not in accordance with the intended use and are not permitted. The manufacturer, Grundfos Water Treatment, accepts no liability for any damage resulting from incorrect use.

The system comprises state-of-the-art components and has undergone safety-related testing.

Warning Unauthorised structural modifications to the system

may result in serious damage to the equipment and personal injury.

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

1.9 Safety and monitoring equipment

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

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

• alarm functions in the control system.

1.10 Chemicals

1.10.1 Chlorine dioxide concentration

In the reaction tank of the disinfection system, diluted sodium chlorite and diluted hydrochloric acid are mixed to create a chlorine dioxide concentration of approximately 20 g per litre of water. The chlorine dioxide solution is diluted again, and dosed into the main line to be disinfected, according to the requirements. According to the German drinking water ordinance (TrinkwV 2001), the chlorine dioxide concentration in drinking water must not exceed a maximum of 0.4 mg per litre of water.

The following safety instructions must be observed:

Warning Risk of explosion when using chemicals in too high a

concentration. Only use sodium chlorite in a diluted concentration of

7.5 % by weight in accordance with DIN EN 938. Only use hydrochloric acid in a diluted concentration

of 9.0 % by weight in accordance with DIN EN 939. The safety data sheets from the supplier must be

observed.

English (GB)

1.6 Maintenance and service personnel

The system may only be maintained and serviced by authorised service personnel from Grundfos Water Treatment.

1.7 Correct usage

The disinfection system is used to mix a diluted chlorine dioxide solution from 7.5 % sodium chlorite and 9 % hydrochloric acid. In accordance with the conditions described in this manual, it is used to dose the chlorine dioxide solution produced continuously or non-continuously into the (drinking) water line of a building or to feed it into a swimming pool, process water, wastewater or other industrial system for water disinfection.

Warning Risk of explosion and serious damage to equipment

and personal injury as a result of operating faults due to confusing the chemical containers or suction lines.

Do not confuse the containers. Observe the red and blue markings on chemical

pumps, suction lines and chemical containers: Red = HCl, blue = NaClO

Warning Risk of burns when skin and clothing come into

contact with sodium chlorite and hydrochloric acid. Affected skin and clothing must be washed

immediately in 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 regulations for the prevention of accidents.

1.10.2 Storing chemicals

English (GB)

• Chemicals must be stored in the appropriately marked original plastic containers.

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

• Empty and full containers must be kept closed, and stored exclusively in areas where national regulations for the prevention of accidents apply to storage.

1.10.3 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 (D) 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.

• 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.

For emergency phone numbers, please see the acceptance report.

2. Technical data

Caution

2.1 General data

2.1.1 Performance and consumption data

System

OCD-164

ClO

preparation capacity

at 6 bar

counterpressure

Max. system

pressure

50 Hz 60 Hz

Consumption of

components

HCl NaClO

Dilution water requirement for bypass system

Solenoid valve

(standard)

Bypass pump

internal/external

In batch mode

Min.

g/h l/h bar bar l/h l/h l/h l/h l/h l/h

-30 30 421 10 10 0.7 0.7 420 420 7.7 14

-120 120 426 9 6 2.9 2.9 420 420 31 55

-220 220 430 7 7 5.2 5.2 420 420 56 100

-350 350 437 9 9 8.3 8.3 420 420 89 160

-700 700 933 9 9 16.5 16.5 900 900 179 320

-1000 1000 948 9 9 24 24 900 900 258 450

-1500 1500 970 9 9 35 35 900 900 383 680

-2000 2000 996 9 6 48 48 900 900 517 900

General concentration range for all systems: 0.5 - 3.3 g/l

1) With max. preparation capacity, shortened reaction time

2) With admission pressure 2 bar higher compared with the pressure at the injection unit

3) Depends on flow losses of solution line up to injection unit

4) Concentration of ClO

5) Concentration of ClO

solution approx. 3.3 g/l. Inlet pressure for bypass water: 3-8 bar

solution approx. 2 g/l. Inlet pressure for bypass water: 3-8 bar

2.1.2 Temperatures and concentrations 2.1.3 Materials

Permissible concentration of NaClO2 solution 7.5 % by weight Permissible concentration of the HCl solution 9.0 % by weight Permissible ambient temperature 5 °C to 40 °C Permissible process water temperature

(bypass water) Permissible component temperature

(chemicals)

2 °C to 40 °C

5 °C to 40 °C

Storage temperature of system -5 °C to 50 °C Storage temperature of chemicals 5 °C to 40 °C

Permissible relative humidity

max. 80 %, non-condensing

Components Materials

Supporting frame PP Screws, washers and nuts 1.4301

Reactor

Grey PVC, 1.4571 painted

RAL 6017 Post-mixer Grey PVC Piping Grey PVC Gaskets FPM/PTFE

2.1.4 Connections and weights

Max.

English (GB)

Enclosure exhaust device

optional

Motive water

pressure

Motive water

requirements

Connection,

exhaust

device

Weight of system

164-OCD

Connection for bypass

(water inlet)

Connection for ClO

solution line

DN DN bar l/h DN kg

-30

800

-120 800 34

-220 800 34

-350 1300 57

-700 1300 62

20 20 5

-1000 1300 66

-1500 1300 76

-2000 1300 82

The solution line must be provided with a pressure relief valve set to 10 bar.

This is a safety measure for the case that a pressure of more than 10 bar occurs in the dilution water line while the chlorine solution line at the outlet side of the system is shut.

2.1.5 Dimensions

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English (GB)

Fig. 1 Dimensioning of the system with drillholes

OCD-164 A A1 B C E F G H K L M C1 C2

-30 700 740 650 40 800 760 230 148 148 410 9 DN 20 DN 20

-120 700 740 650 40 800 760 230 148 148 410 9 DN 20 DN 20

-220 700 800 650 40 800 760 230 148 148 410 9 DN 20 DN 20

-350 760 800 650 70 1010 970 268 135 181 470 11 DN 20 DN 20

-700 760 800 650 70 1010 970 268 135 181 470 11 DN 20 DN 20

-1000 760 800 650 70 1010 970 268 135 181 470 11 DN 20 DN 20

-1500 760 800 650 70 1300 1260 268 135 181 470 11 DN 20 DN 20

-2000 760 800 650 70 1300 1260 268 135 181 470 11 DN 20 DN 20

TM04 8193 4510

2.2 Electrical data

Max. permissible load of potential-free output contacts

Analog input 0/4-20 mA, load: 50 Ω Analog output 0/4-20 mA, load: max. 500 Ω Contact input max. 50 contacts/second Max. permissible mains

impedance with 90 Watt bypass

Max. permissible mains impedance with 340 Watt bypass

2.2.1 Power consumption

OCD-164 Power consumption [VA]

-30 to -220 300

-350 to -2000 650

2.2.2 IP codes

Component IP code

Electronics, dosing pumps, solenoid valve, flowmeter

Bypass pump IP44 Dosing controller IP67

250 V, 6 A, max. 550 VA

0.168 + j 0.168) Ω, (testing according to EN 61000-3-11)

0.059 + j 0.059) Ω, (testing according to EN 61000-3-11)

IP65

English (GB)

2.3 Delivery state

The compact chlorine dioxide system comprises:

• The preparation system, completely assembled and wired up, on a PP supporting frame, including dosing pumps and suction lines.

• Dosing controller for flow monitoring of hydrochloric acid and sodium chlorite.

• Tank-level monitor and empty indication for hydrochloric acid and sodium chlorite.

• Chlorine dioxide reactor.

• Bypass system with flowmeter and solenoid valve, or optionally

– circulating pump and flowmeter, – solenoid valve, dosing ball valve and flowmeter.

• Static mixer.

• Control electronics, directly mounted on the supporting frame, and wired up.

• Optional exhaust device: Injector with solenoid valve, electrically connected to the control electronics, supporting frame with side parts.

3. Fundamentals

Reactor

Bypass water

NaClO

HCl

ClO

solution

English (GB)

3.1 Chlorine dioxide for water treatment

Properties of chlorine dioxide

• Strong and fast oxidation and disinfection agent.

• Applications in the treatment of drinking, service, cooling, and waste water.

• Chemically unstable compound

– Can explosively decompose into chlorine and oxygen when

heated.

– Must be generated on site as required, since storage in

cylinders is not possible.

Advantages of chlorine dioxide compared to chlorine

• Largely good to very good bactericidal, virucidal and sporicidal effects in the complete pH range of drinking water (pH 6.5 - 9). The disinfecting effect of chlorine decreases with increasing pH value.

• No or reduced forming of trihalogen methanes.

• No generation of chloramines with ammonium or amino compounds.

• Highly reduced potential for generation of organic halogen compounds of high molecular weight.

• Good stability in water. Long bactericidal and bacteriostatic protection in the water network.

3.1.1 Preparation of chlorine dioxide

The chlorine dioxide preparation system was specially developed for the continuous or discontinuous preparation of a chlorine dioxide solution for water disinfection. The chlorine dioxide is generated according to the hydrochloric acid/sodium chlorite procedure in line with the following stoichiometric equation:

5 NaClO

Sodium chlorite + Hydrochloric acid <=> Chlorine dioxide + Sodium chlorite + Water

This system uses a 7.5 % NaClO solution in a volume ratio 1:1 for chemical reaction.

The reaction time is approx. 10 minutes. This application uses a multiple stoichiometric excess of hydrochloric acid for the following reasons:

• A non-critical chlorine dioxide concentration of 20 g ClO generated in the reactor.

+ 4 HCl <=> 4 ClO2 + 5 NaCl + 2 H2O

Warning The system must only be operated using a 9 %

hydrochloric acid solution and a 7.5 % sodium chlorite solution.

Commercially available solutions such as 24.5 % sodium chlorite or 32 % hydrochloric acid would generate an explosive concentration, and must therefore never be used undiluted in the system.

solution and a 9 % HCl

/l is

3.2 Functional sequence

• Three components are required to generate a chlorine dioxide solution:

– Hydrochloric acid (HCl) – Sodium chlorite (NaClO – Dilution water (bypass).

The added quantities of these components are defined by the process, and must not be changed. The flows of the individual components are therefore monitored by flowmeters and flow controllers.

Hydrochloric acid (9 % solution) and sodium chlorite (7.5 % solution) are dosed into the reactor with a volume ratio 1:1. There they react together, and generate an uncritical chlorine dioxide concentration of 20 g/l.

Following the reactor, the chlorine dioxide solution is diluted by the bypass water into a solution ready for use.

Fig. 2 Preparation of chlorine dioxide solution

)

TM04 8194 4510

Warning Gaseous chlorine dioxide is explosive above a

concentration of 300 g/m

• A good yield of chlorine dioxide is achieved with excess acid of 250-300 %. A further increase in the excess acid only results in a small improvement in the efficiency.

• Excess acid shifts the equilibrium of the disproportionation reaction between hydrochloric acid and sodium chlorite to the right, resulting in an optimum yield.

4. Design and function

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4.1 Design of the system

English (GB)

TM04 8196 4510

Fig. 4 Reactor with components, assembled on the back of

the supporting frame

Pos. Description

1 Dosing system for hydrochloric acid (HCl)

1.1 Dosing pump for hydrochloric acid Suction line with pre-empty and empty signal for HCl

1.2 (red)

1.3 Dosing controller for HCl flow monitoring

2 Dosing system for sodium chlorite (NaClO

2.1 Dosing pump NaClO Suction line with pre-empty and empty signal for NaClO

2.2 (blue)

2.3 Dosing controller for NaClO

flow monitoring

)

3 Bypass water feed pipe

TM04 8195 4510

Fig. 3 Complete system with components, assembled on a

supporting frame

3.1 Solenoid valve (optional circulating pump)

3.2 Impeller counter (flowmeter for bypass water)

3.3 Non-return valve

3.4 Flow limiter

4 Reactor

4.1 Reactor housing

4.2 Reactor valves

5 Post-mixer 6 Connection for ClO

solution line to the injection unit

7 Connection for bypass water 8 Controller with display 9 Injector for exhaust device (option)

4.2 Components

Note

English (GB)

4.2.1 Suction lines

The suction lines must be matched to the tank size and the system performance (diameter of suction line). They have a dual level-control unit.

If the level of the components (HCl/NaClO

) drops to the first

stage ("Min" contact/pre-empty signal), the alarm "HCl- MIN" or "NaClO the controller display. The system remains in operation, the relay "pre-empty signal NaClO

MIN" is output. This is indicated by flashing of a LED on

/HCl" is activated.

The system is switched off when the second stage is reached ("Min"-"Min"contact/empty signal), and the alarm "HCl empty signal" or "NaClO

empty signal" is displayed, the "Alarm" is

activated and the alarm LED lights up red permanently. If a buzzer is connected to the potential-free output relay,

an audible signal is output.

4.2.2 Dosing pumps

The dosing pumps are mounted at the supporting frame. They operate according to the pulse/pause procedure. The stroke length is adjusted with a rotary knob. The stroke length is preset, but may have to be corrected following gauging of the pumps since the local pressure conditions depend on the application.

The dosing pumps for the systems OCD-164-30 to OCD-164-220 are delivered with an integral gauging system. Gauging of the dosing pumps for the systems OCD-164-350 to OCD-164-2000 is carried out using calibration cylinders on the suction side.

Refer to the table 2.1.1 Performance and consumption data for the dosing rate to be set for the pumps.

The dosing rates of the pumps should be set approximately the same (± 10-15 %) to guarantee uniform consumption of the chemicals.

The stroke length must not be adjusted any further following gauging.

4.2.3 Dosing controller

The dosing controllers guarantee that both chemicals flow into the system during operation. If the volume flow of one of the chemicals drops by more than 25-30 %, the dosing controller outputs an alarm and switches off the system.

The working point must be correctly set to guarantee safe functioning of the dosing controller, see section 7. Commissioning. A correctly set working point is indicated by the flashing LEDs on the controller flowchart, see section 6.2 Control and display

elements.

4.2.4 Reactor

The reactor is installed at the rear of the supporting frame. The non-return valves on the reactor inlet and outlet must be selected depending on the system pressure. Standard valves are suitable for a system pressure of less than 3 bar.

4.2.5 Bypass

The bypass water line dilutes the chlorine dioxide solution generated in the reactor (approx. 20 g/l) and routes it to the main water flow. Several versions of the bypass line are available:

• Bypass with solenoid valve and flow limiter

• Bypass with circulation pump

• Bypass with solenoid valve and dosing ball valve (batch mode)

• Bypass for external booster pump (and load unit), see section

10.9 Bypass for external booster pump.

The water in the bypass is monitored by a flowmeter. The flowmeter switches the system off, if the bypass water falls below a minimum flow; the LED on the flowchart flashes. The LED lights up permanently, if the water flow is above the minimum quantity, see section 6.2 Control and display elements.

Fit a particle filter upstream, if the bypass water is not free of solids.

4.2.6 Post-mixer

The chlorine dioxide solution is mixed with the bypass water in the post-mixer (standard).

4.2.7 Options

Power Supply

• 230 V, 50/60 Hz

• 115 V, 50/60 Hz.

Bypass

• Bypass with pump 230 V, 50/60 Hz

• Bypass with pump 115 V, 60 Hz

• Bypass with solenoid valve 230 V, 50/60 Hz and flow limiter (standard)

• Bypass with solenoid valve 115 V, 50/60 Hz and flow limiter

• Bypass for external booster pump, see section 10.9 Bypass for

external booster pump.

Suction lines

• Suction line 1.3 m for 30/60-litre tank (standard)

• Suction line 2.5 m for 30/60-litre tank

• Suction line 2.5 m for 200-litre tank.

Exhaust device

• Exhaust device, DN 20, 230 V 50/60 Hz (standard)

• Exhaust device, DN 20, 115 V 50/60 Hz

• Without exhaust device.

Reactor non-return valves

• System pressure less than 3 bar (standard)

• System pressure more than 3 bar.

Bus systems

• Profibus DP module

• Ethernet TCP/IP module.

Interface

• RS-232 interface

• RS-422 and RS-485 interface.

4.3 Mode of operation of the system

Positions in brackets, see fig. 4. When the system is started in normal mode, the solenoid valve

(3.1) opens. Dilution water flows to the post-mixer (5), the flow is controlled via the impeller counter (3.2).

The two dosing pumps simultaneously pass 9 % hydrochloric acid and 7.5 % sodium chlorite solution with a ratio of 1:1 into the reactor (4). The flow quantities of the chemicals are monitored by the dosing controllers (1.3 and 2.3).

The reaction between sodium chlorite and hydrochloric acid results in a chlorine dioxide solution with a concentration of 20 g/l in the reactor (4). The dwell time in the reactor is approx. 10 minutes.

In the subsequent mixer, this solution is diluted down to a concentration of max. 3.3 g ClO and performance setting, and passed on to the injection unit.

The system is switched off immediately, if one of the dosing controllers or the impeller counters detects a low flow.

Warning Chlorine dioxide is a toxic gas, hydrochloric acid and

sodium chlorite are highly corrosive chemicals which must be handled properly.

Installation and operating personnel must therefore be acquainted with the regulations concerning the handling of chlorine dioxide, hydrochloric acid and sodium chlorite.

In Germany, the accident prevention regulations UVV are applicable.

/l, depending on the system size

Note

A set of warning signs for the chlorine dioxide system

Bypass water

Reactor

ClO

solution

ClO

HCl

NaClO

Note

Caution

in accordance with the specifications is available under Order No 96727022 (515-662).

Please find further general information for operation of a chlorine dioxide system in:

– Accident prevention regulations "Chlorination of

water" (VGB 65 or GUV 8.15) – Directive on dangerous working materials – DIN 938 "Sodium chlorite solution for water

treatment; technical conditions of delivery" – DIN 939 "Hydrochloric acid for water treatment" – "Chlorine dioxide for water treatment" DVGW

directive, worksheet W 224 (German)

4.3.1 How the system operates in batch mode

In batch mode, a defined ClO (batch container), and transported to the injection units by means

solution is added to a holding tank

of dosing pumps. The ClO

3.3 g/l.

concentration can be adjusted within a range of 0.5 to

Fig. 5 Preparation of chlorine dioxide solution

For a concentration between 2 and 3.3 g/l, the quantity of bypass water is set via a dosing ball valve. In the case of concentrations below 2 g/l, the required quantity of bypass water for a 2 g/l solution is set. The desired concentration inside the solution container is then achieved by regulating the two dosing pumps.

The limits for the bypass water quantity are -50 % and +20 % of the target value. If the target value is undershot (up to -50 %), the system will automatically regulate the dosing flow of the chemical pumps for the current water quantity. This is achieved by means of a pulse-pause control on the dosing pumps. When the water quantity target value is undershot, the overall performance of the system is reduced by up to -50 %.

This control makes it possible to compensate pressure fluctuations in the bypass pipe.

Warning Protection units should be provided in addition, such

as separate collecting trays for the hydrochloric acid and sodium chlorite tanks.

Protective clothing for operators has to be provided. Furthermore, the specified warning signs, danger

information and first aid information must be positioned at the specified points.

5. Installation

5.1 Transport and storage

Warning Only transport the system, when it's empty, observe

the weight. Only use suitable lifting and transport equipment.

• Transport system carefully.

• Dry, cool storage location.

• Protect from direct sunlight.

5.2 Unpacking

• The system is tested at the factory and ready for connection.

• Check for damage, do not install or connect a damaged system!

• When unpacking, look for loosely packed components.

• Install as soon a spossible following unpacking.

Retain packaging material, of dispose of according to local regulations.

5.3 Installation location

The applicable local or country-specific regulations must be observed when selecting and designing the installation location for the chlorine dioxide system.

In Germany, the accident prevention regulations UVV are applicable.

The installation location for the system must fulfil the following requirements:

• The permissible ambient temperature of +5 to +40 °C must be guaranteed.

• The installation location must be vibration-free and isolated

TM04 8197 4510

fireproof from other rooms.

Reference to the dangers when using the chlorine dioxide system and to the relevant precautionary measures must be provided using appropriate signs at access points to the system rooms and to the associated chemical storage rooms.

English (GB)

5.4 Installation scheme

Note

Caution

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Select or set a contact water meter in such a way that, at max. installation output, the control pulses are not < 5 pulses/sec. Calculation of the contacts see section 7.3.3 Contact input.

The control for the system can process a max. rate of 50 pulses/sec. If a value greater than 50 pulses/sec. is calculated, use a different contact water meter.

If the pressure at the injection unit is < 1 bar, a pressure loading valve must be installed.

A pressure loading valve may not be used in installations with an internal centrifugal pump, as this pump only generates an increase in pressure of approx. 5 mWC.

For the dosing pumps DMI with Plus3 system, ensure that the container is always underneath the dosing pump, and the suction line is positioned in a downwards direction, so that the chemicals can easily flow back via the return pipe into the container.

Recommended L = min. 200 mm, see fig. 6.

TM04 8199 4510

Fig. 7 System with solenoid valve, installation scheme

Pos. Description

1 Supporting frame 2 Electronics 3 Connection for dilution water 4 Connection for solution line to the injection unit 5 Suction line for HCl dosing pump

TM04 8198 4510

Fig. 6 Installation scheme with suction line length

5.4.1 System with solenoid valve

The systemis delivered as a standard with a solenoid valve in the dilution water line. In this version, the supply of dilution water and the addition of chlorine dioxide solution are not carried out in the same water circuit.

Requirements

• 10 bar > water pressure > 1 bar.

• The counterpressure at the connection of the solution line should be at least 0.5 bar less than the inlet pressure of the dilution water.

With the chlorine dioxide solution line shut off (at the outlet) and an input pressure of more than 10 bar in the dilution water line (at the inlet), there is a danger that the system will be damaged.

The solution line must therefore be provided with an excess pressure valve set to 10 bar.

7 Main water pipe (supplied by the customer)

Isolating valve for the injection unit (supplied by the

customer)

9 Sample extraction (supplied by the customer)

10 Non-return valve (supplied by the customer)

Isolating valve for dilution water extraction (supplied by

the customer) Supporting frame exhaust device, with solenoid valve

(option) 13 Solution tank with level control (option) 14 External booster pump (option) 15 Load unit for the external booster pump

Pressure loading valve (supplied by the customer), if the 16

system pressure is < 1 bar

Inductive flowmeter (4-20 mA) or contact water meter for 17

proportional control of the system (observe the contacts

from the contact water meter).

6 Suction line for NaClO

dosing pump

5.4.2 System with internal bypass pump

Note



















1D&O2



+&O

Note

1D&O2



+&O











 

































1D&O2



+&O

As an option, the system can be delivered with an internal bypass pump instead of the solenoid valve. This version is required for treating closed water circuits, i.e. the sampling of dilution water and the addition of chlorine dioxide solution are present in the same water circuit.

The bypass pump is only designed for compensation of the internal friction losses of the system, and for counteracting the pressure losses of approx. 0.1 bar in the solution line to the injection unit.

The solution line to the injector should therefore be kept as short as possible. The geodetic difference in height between the connection of the solution line and the injection unit must not exceed 1 m.

English (GB)

TM04 8201 4510

Fig. 9 System with booster pump, installation scheme

Fig. 8 System with bypass pump, installation scheme

5.4.3 System with external booster pump and load unit

An external booster pump can be connected to the dilution water line as a further option. This version is required, if sampling of the dilution water and addition of the chlorine dioxide solution are not in the same water circuit, and the system pressure at the injector is higher than the pressure of the dilution water supply line. In this version, a load unit is required in addition, and is controlled directly by the system electronics, see fig. 42.

Booster pump and load unit must be selected separately (see section 11. Accessories).

5.4.4 System with solenoid valve/ball valve (batch tank)

As a further option, the dilution water line can also be selected with a solenoid valve and dosing ball valve.

This version is required if batch mode is present, i. e. a certain concentration of ClO

is prepared in a tank. Dosing of the ClO2

solution to the injection unit is carried out using dosing pumps. The concentration of the ClO

adjusted from 2 to 3.3 g/l.

solution in the tank can be

The set pressure must be adjusted to the local conditions during startup. The pressure retention valve must be set such that siphoning does not take place through emptying of the solution line when the system is switched off.

TM04 8200 4510

If the pressure set on the loading valve is too high, it may occur that the required quantity of bypass water cannot be correctly set.

If the bypass water is not free from solids, a dirt filter should be installed upstream.

TM04 8202 4510

Fig. 10 System with solenoid valve and ball valve

5.5 Wall mounting

Caution

Note

Caution

     



English (GB)

• The mounting material includes screws, wall plugs, washers and nuts.

• Mount the supporting frame on the wall using the enclosed mounting material. Select the mounting height such that the containers with chemicals can be located underneath, and that the controller display is easy to read. Drilling scheme see section 2.1.5 Dimensions.

• The liquid level of the containers when full with chemicals should always be below the dosing pumps.

The system must be freely accessible on the left and right for maintenance work (approx. 50-60 cm space).

The mounting material also contains a M6x20 countersunk screw for fixing a gas sensor, see section 11. Accessories, underneath the reactor.

5.6 Hydraulic connection

Warning Before hydraulic connection, disconnect the system

from the mains.

It must be possible to insert the suction lines (items 5 and 6) for hydrochloric acid and sodium chlorite into the tanks without tension.

• Install the suction hose, return hose and the two empty alarm cables of the suction line in the tank such that the bottom end of the suction line is approx. 1 cm above the base of the tank.

5.6.1 Bypass

• In the case of the version with solenoid valve, provide the dilution water supply line with an isolating valve, and route the remaining part of the line up to the inlet connection in PVC tube, and connect.

• In the case of the version with internal bypass pump, route the dilution water line in a PVC tube as directly as possible from the main water line up to the inlet connection. Provide a sampling shut-off valve on the main water line.

Warning If the sampling line and the solution line are

connected to the same water circuit, a non-return valve must be fitted in the main line between the dilution water sampling point and the injector in order to prevent circulation of the solution with dangerous building up of chlorine dioxide.

• Route chlorine dioxide solution line to the injection unit in PVC tube. An isolating valve should also be fitted in this line directly upstream of the injection unit.

5.6.2 Safety exhaust device (option)

1. Mount the safety exhaust device underneath the system

cabinet.

2. Cut the supplied PE hose to length, and connect to the

diaphragm check valve of the suction injector and to the associated screwed gland of the supporting frame (in the centre of the base).

3. Route the injector motive water line in PVC tube of DN 20,

and connect to the solenoid valve. Route the disposal line in PVC tube of DN 20, and connect to the outlet connection of the suction injector.

4. Insert the plug of the control voltage cable into the solenoid

valve socket and tighten the plug screw.

The motive water of the suction injector must be free from sand and suspended matter. It is therefore recommendable to install a dirt trap upstream of the solenoid valve.

TM04 8203 4510

Fig. 11 Safety exhaust device, installation scheme

Pos. Description

1 Disposal pipe (waste water/untreated water) DN 20 2 Suction injector 3 Solenoid valve 4 Pressure reducer 5 Water supply line 6 Booster pump

Connection - version A

This connection option is used if the pressure in the water line is > 4 bar, and there is an adequate total quantity of water (bypass water and motive water for the suction injector).

If the pressure is > 5 bar, there should be a pressure reducer (4) installed, so that the pressure upstream of the suction injection is between 4 and 5 bar.

Connection - version B

This connection option is used if the pressure in the water line is > 4 bar, i.e. the prescribed pressure upstream of the suction injection must be generated via a booster pump (6). If there is an adequate volume of water in the supply line (5) (sufficient water for the bypass and suction injector), the booster pump (6) can be connected to the water supply line (5).

The water supply to the booster pump (6) can be conducted via a separate water supply line at any time.

5.7 Electrical connection

Caution

Note

A direct connection of the system to the power supply is made using the terminals 1 (L1), 2 (N) and 3 (PE). Depending on the

Warning The electrical connection must only be carried out by

qualified personnel. Observe the local safety regulations! Switch off the power supply before connecting the

mains cable.

version, the power supply can be 230 V (AC) or 115 V (AC).

Connection to an incorrect power supply may destroy the system.

Make the electrical connection according to the enclosed connection diagram.

5.7.1 Terminal connection diagram

Fig. 12 Terminal connection diagram

5.7.2 Power supply

L N PE Description L N PE Description

1 2 3 Power input 16 17 18 4 5 6 Power output 19 20 21

-------------------------------------------

7 8 9 ------------------- 22 23 24 Solenoid valve/pump/bypass water

10 11 12 HCl dosing pump 25 26 27

13 14 15 NaClO

dosing pump 28 29 30

Solenoid valve: enclosure exhaust device

Solenoid valve: exhaust device for batch tank

English (GB)

TM04 8204 4510

5.7.3 Potential-free outputs

Root NO Description Function

31 33 Fault 31/33 open in case of fault 32 34 Pre-empty signal HCl/NaClO

32/34 open in case of pre-empty signal 37 39 Automatic 37/39 closed in case of "system active" 38 40 Tank run dry 38/40 open in case of dry run

5.7.4 Inputs +8 V

+8 V GND IN Description

59 (brown) 60 61 (blue) Dosing controller NaClO 63 (brown) 64 62 (blue) Dosing controller HCl

65 66 67 ------------------------------

69 (brown) 70 (white) 68 (green) Bypass water impeller counter

5.7.5 Inputs +12 V

English (GB)

+12 V GND IN Description Function

43 ------- 44 Batch tank ClO

45 ------- 46 Batch tank ClO

47 ------- 48 Batch tank ClO

49 ------- 50 Batch tank ClO

51 (brown) ------- 52 (white) Pre-empty signal NaClO

------- ------- 53 (green) Empty signal NaClO

------- ------- 54 (green) Empty signal HCl

55 (brown) ------- 56 (white) Pre-empty signal HCl

57 ------- 58 ----------------------------------71 (white) 72 (brown) 73 (green) Hall sensor NaClO 75 (white) 76 (brown) 74 (green) Hall sensor HCl pump 77 (white) 78 (brown) 79 (green)

83 - 84 Contact input water meter

85 - 86 Remote on/off Contact open: "Remote off"

87 - 88 Fault gas warning device Contact open: fault

89 - 90 Contact main water min. Contact open: min. contact main water

-8180

-----------------------------------

overflow

max.

min.

dry run

pump

NC Contact open in case of overflow

level above contact

ClO

NO contact Contact closed in case of "Max"

level above contact

ClO

NO contact Contact open in case of "Min"

level below contact

ClO

NO contact Contact open in case of dry run

level below contact

ClO

Contact open in case of pre-empty signal

level below contact

NaClO

Contact open in case of empty signal

level below contact

NaClO

NC Contact open in case of empty signal HCl level below contact NC Contact open in case of pre-empty signal HCl level below contact

-----------------------------------------

5.7.6 Analog signals

Shield IN/OUT Description

95 93 IN + Analog IN 96 97 OUT + Analog OUT

5.7.7 Profibus/Ethernet (option)

'39 '3*1' 5['7['3 5['7['1 3*1' 576

The controller can be optionally equipped with Profibus or Ethernet.

Profibus-DP module

The Profibus-DP connection is made via a 6-pin plug.

5.8 Interfaces RS-232, -422 and -485

The controller can optionally be equipped with interfaces.

5.8.1 Connection of RS-232 interface

English (GB)

Fig. 13 Profibus connection diagram

Plug Signal Description

0 RTS (CNTR-P/RTS) Control signal for repeater 1 PGND Shield/protective earth

2 RxD/TxD-N

3 RxD/TxD-P

4 DP GND Ground to DP 5 V

5DP 5 V

CNTR-N Control signal for repeater

Ethernet TCP/IP

• Ethernet 10 Base-T/100 Base-TX (10/100 MBit/s).

• Transport protocol TCP or UDP connection.

• The connection is made using an RJ 45 plug of category 5.

Received data/transmitted data Negative

Received data/transmitted data Positive

5 V supply for terminating resistors

TM04 8205 4510

Fig. 14 Connection diagram of RS-232 interface

5.8.2 Connection of RS-422 and -485 interfaces

Fig. 15 Connection diagram of RS-422 and-485 interfaces

TM04 8206 4510TM04 8207 4510

6. Operation of control electronics

Automatic

Manual operation

Logbook

Main menu

System choice Setup Service mode

Type 1, Type 2, etc.

System type Language Venting

Batch mode Operation mode

Min. contact water

Startup mode

Current input Units System choice Test mode

Contact input Current output

Manual control Code function

Target value external

Reset function

Date/time

Exhaust enclosure

Program version

Bypass MIN time

Auto start

English (GB)

6.1 Program structure

Fig. 16 Program structure

TM04 8208 4510

6.2 Control and display elements

11 10

15 14 13

678

Note

Fig. 17 Controller

Pos. Description

LED for dosing controller NaClO

• LED flashes: dosing controller set correctly LED for NaClO

• LED off: correct level

• LED flashes: pre-empty alarm active

• LED on: empty alarm active LED for bypass water

• LED on: bypass water is correct

• LED flashes: bypass water outside tolerance LED for dosing controller HCl

• LED flashes: dosing controller set correctly LED for HCl tank

• LED off: correct level

• LED flashes: pre-empty alarm

• LED on: empty alarm

6 Arrow keys for moving in the menus

Function keys

• [F1], [F2], and [F3]: select menu items

• [F4]: [Reset] key [Enter] key

• Confirm inputs [Escape] key

• Cancel or switch over to submenu 10 Display, 4-line 11 Master switch with [Emergency stop] function

LED for alarms

• LED on or flashing: present alarm

LED display of operation mode "automatic/manual"

• LED flashes: automatic control

LED for remote on/off mode

• LED flashes: remote on/off by min. contact for main 14

water

• LED on: remote on/off by external contact

LED for service mode

• LED flashes: system in [Service] menu

LED for alarms on the display

• LED on or flashing: present alarm

LED for connection of display to PLC

• LED on: connection correct

LED display

• LED on: display in operation

tank

The selection possibilities shown on the display are identified by the numbers 1, 2, and 3, e. g.:

Main menu 1 Automatic 2 Manual operation 3 Logbook

Menu selection is made using the keys [F1], [F2], [F3], e. g. the function key [F1] is used to select the menu item list under "1", etc.

Example

• Press the [F1] key to switch to the menu "Automatic".

• Press the [F2] key to switch to the submenu "Manual operation".

• Press the [F3] key to select the menu "Logbook".

• Press the [Escape] key to return to the main menu (9).

• Press the [Enter] key to confirm an input (8).

6.3 Automatic mode

TM04 8209 4510

In this operation mode the capacity of the system can be controlled automatically by incoming signals such as contact input, current input or Bus control.

In order to operate the system in "Automatic" mode, it is first necessary to select the system type and the operation mode, see section 6.6.2 Operation modes.

In "Manual control" mode there is no "Automatic" operation. "Automatic" operation is activated in the main menu using the [F1] key, and indicated by flashing on the display.

6.4 Manual operation

This operation mode facilitates the manual input of the dosing capacity by the display in the modes current input, contact input, manual control, or Bus control.

In order to operate the system in "Manual" mode, it is first necessary to select the system type and the operation mode.

"Manual" operation is activated in the main menu using the [F2] key, and indicated by flashing on the display.

6.5 Logbook

In the "Logbook" menu, all activated and acknowledged alarm messages are recorded. The operating hours can also be called in this menu.

• In the main menu, switch to the "Logbook" submenu using the [F3] key (Logbook).

Logbook 1 active alarms 2 event list 3 operating hours

• Use the [F1] key to display the alarm messages (if present).

• Use the [F2] key to call all events.

• The alarm messages can be deleted, if necessary. Switching to page 2 is possible using the [ARROW RIGHT] key, the buffer can be deleted using the [F1] key. Switching to page 1 is possible using the [ARROW LEFT] key.

• Use the [F3] key to display the operating hours.

Scroll in the respective menu using the [UP] and [DOWN] arrow keys.

English (GB)

6.6 System choice

Note

English (GB)

Define the system size and the operation mode in the "System choice" menu.

The input can be cancelled at any time using the [Escape] key. The activated system type or the activated mode is displayed flashing on the display.

6.6.1 System type

• Scroll in the main menu using the [ARROW RIGHT] key on page 2.

• Use the [F1] key to switch to the "System choice" menu.

• In the "System choice" menu, switch to the "System type" menu using the [F1] key.

• Select the system size using the [F1], [F2] or [F3] keys, scroll if necessary using the [ARROW RIGHT] or [ARROW LEFT] key.

After selection of the system type, the following message is displayed:

System type 164-XXXXD activated

• Use the [Enter] or [Escape] key to return to the "System choice" menu.

The system is preset in the factory. The selected type of system is displayed flashing in the "System choice" menu.

Check this setting for correctness prior to starting up, or select a new system type.

6.6.2 Operation modes

5 different operation modes can be selected:

• Batch mode The performance of the system (100 %) is controlled by the use of a buffer tank.

• Current input The system performance (2.5 - 100 %) is controlled via an external current input signal, e. g. 4-20 mA.

• Contact input The system performance (2.5 - 100 %) is controlled via an external contact input signal, e. g. from a contact water meter.

Set the contact water meter in such a way that, at max. performance the control contacts are not < 1 contact/sec.

If, in exceptional cases, this value is < 1, min. 0.25 contacts/sec., the bypass "Min" time must be increased.

The controller can process a maximum of 47 contacts/sec. If a value greater than 47 contacts/sec. is calculated, use a different contact water meter.

• Target value external The system performance (2.5 - 100 %) is controlled via a Bus system (can only be selected, if a bus system has been selected in the "Basic settings > Bus" menu).

The mode is factory-set, i.e. the selected mode is displayed flashing in the "Operation mode" menu.

Check that this mode is correct before commissioning; if necessary, select a new mode.

The entry of the parameters for current input and contact input is described in the Section on "Commissioning".

6.7 Units

Either metric or US units of measurement can be selected on the system:

Metric units US units

Bypass water [m

/h] Bypass water [gal/h] System capacity [g/h] System capacity [lb/day] Contact water meter

[contacts/litre]

Contact water meter [contacts/gal]

6.8 Setup

In the main menu, switch to the "Basic setting" menu using the [F2] key (scroll if necessary).

6.8.1 Language

• In the "Basic setting" menu, switch to the "Language" menu using the [F1] key.

• Select language using [ARROW RIGHT] or [ARROW LEFT] key.

• Confirm using [Enter].

• Use the [Enter] or [Escape] key to return to the "Basic setting" menu.

6.8.2 Min. contact water

The min. contact in the main water line (on site) switches the system to standby, if the set minimum main water flow is fallen below.

• In the "Basic setting" menu, select the "Min. contact water" menu using the [F2] key.

• Activate or deactivate the function using the [F1] or [F2] key.

Min. contact main water activated

Use the [Enter] or [Escape] key to return to the "Basic setting" menu. The selected function is displayed flashing in the "Min. contact water" menu.

6.8.3 Current output

• In the "Basic setting" menu, select the "Current output" menu using the [F3] key.

Example

Default quantity of ClO Main water quantity 30 m

0.3 ppm

Contact water meter 1 contact/litre

Max. system capacity 0.3 ppm x 30 m Contacts from water

meter

1 contact/litre x 30 m 1000/3600 = 8.33 contact/sec.

/h = 9 g/h

/h x

• Manual control The system performance (0-100 %) is controlled by manual input.

When "Manual control" is selected, the installation can only be started in "Manual mode". If the installation is started in "Automatic mode", an alarm message is displayed, and the system stops.

Current output ClO

capacity

0 % = XX mA 100 % = YY mA

• Press the [F1] key to select the variable input fields. Switching between the values (0 %; XX mA; 100 %; YY mA) is also carried out using the [F1] key.

• Enter individual values using the [UP] and [DOWN] keys (modify numerical values) and the [ARROW LEFT] and [ARROW RIGHT] keys (change input position).

• Confirm the set values using the [Enter] key. The selected current output is activated by pressing the [Enter] key again.

Current output XX - YY mA activated

• Use the [Enter] or [Escape] key to return to the "Basic setting" menu.

6.8.4 Code function

Note

2 different code functions can be selected:

• Level 1: Operators Authorisation for the menus "Automatic, "Manual operation", "Logbook" and "local/remote".

• Level 2: Parameters unlimited privileges

Level 1 and 2 are set to "0" each. This means unlimited privileges without password scanning.

The entered codes are reset by entering the number "1998". Then both levels are reset to "0".

• In the "Basic setting" menu, scroll to page 2 using the [ARROW RIGHT] key.

• Switch to "Code function" menu using the [F1] key.

Code function 1 Level 1 2 Level 2

Switch to operator selection using [F1] key.

Level 1 operator Code: 0

• Activate the input field using [F1] key.

• Enter code (max. 4 digits) using the arrow keys [RIGHT], [LEFT], (UP], and [DOWN].

• Confirm using [Enter] key.

• Use the [Enter] or [Escape] key to return to the "Code function" menu.

Switch to "Level 2 Parameters" using [F2] key.

• Activate the input field using [F1] key.

• Enter code as described for "Level 1".

• Use the [Enter] or [Escape] key to return to the "Code function" menu.

• Use [Escape] key again to return to "Basic setting" menu.

6.8.5 Reset function

In the "Basic setting" menu, select the reset function using the [F2] key, or scroll in the "Basic setting" menu.

Reset function Code: xxxx Input password

• Switch to the input field using the [F1] key, enter new code using the arrow keys [RIGHT], [LEFT], [UP], and [DOWN], enter code. Reset code: 6742

• Confirm using [Enter] key.

• Use the [Enter] or [Escape] key to return to the "Basic setting" menu.

6.8.6 Date/time

In the "Basic setting" menu, select the "Date/time" menu using the [F3] key.

Time setting 1 Time 2 Date 3 Daylight sav.

Time

• Switch to the "Time" menu using the [F1] key.

Time setting New Current XX:YY:ZZ 17.07.02 2 Accept

Use the [F1] key to activate the input fields for hours (XX), minutes (YY) and seconds (ZZ) (input field flashing). Switch from hours to minutes or seconds by pressing the [F1] key again.

• Use the [Escape] key to deactivate the input field.

Setting the time

Following activation of the respective input field using the [F1] key, set the new value using the arrow keys [RIGHT], [LEFT], [UP], and [DOWN].

• Confirm the new value in each case using the [Enter] key (input field no longer flashes).

Once all values have been set and confirmed using the [Enter] key, press the [F2] key (accept) to update the new time.

• Return to the "time setting" menu with the [escape] key, by pressing the [escape] key once again return to the "setup" menu.

Setting the date/day of week

• Switch to the "Date setting" menu using the [F2] key.

Date setting New Current XX.YY.ZZ 15.05.02 2 Accept

• Switch to the "Day of week" menu using the arrow [RIGHT] key, and back to the "Date setting" menu using the arrow [LEFT] key.

Day of week New Current XX.YY.ZZ 15.05.02 XX Monday 2 Accept

The setting is made analogous to the time setting, i.e. activate input fields using the [F1] key, set new value using the arrow keys [RIGHT], [LEFT], (UP], and [DOWN], and confirm with [Enter]. The new value is updated by pressing the [F2] key (accept).

• Use the [Escape] key to return to the "Time setting" menu.

Daylight saving time

• Switch to the "Daylight saving time" menu using the [F3] key.

Daylight saving time off Switch <off>

• Activate the input field using the [F1] key (input field flashing). Various settings can be selected using the [UP] and [DOWN] arrow keys.

Settings

ON Direct switching to daylight saving time MANUAL Manual entering of daylight saving time EU Pre-setting of daylight saving time for EU countries

• Confirm the settings using the [Enter] key.

• Use the [Escape] key to return to the "Time setting" menu.

English (GB)

MANUAL (manual daylight saving time)

Note

English (GB)

• In the "Daylight saving time" menu, switch to the "Manual daylight saving time" menu using the [RIGHT] arrow key.

In this menu you can redefine the daylight saving time.

• Activate the input field using the [F1] key (input field flashing). Enter the new values using the arrow keys [RIGHT], [LEFT], [UP], and [DOWN], and confirm using the [Enter] key.

• Activate the respective input fields by pressing the [F1] key as often as required.

Following manual setting of the daylight saving time, return to the "Daylight saving time" menu using the [LEFT] arrow key.

• Activate the input field using the [F1] key, and select "Manual" setting using the [UP] and [DOWN] keys.

• Confirm new setting using the [Enter] key.

• Use the [Escape] key to return to the "Time setting" menu, and press again to return to the "Basic setting" menu.

6.8.7 Enclosure exhaust device

The enclosure exhaust device is used to regularly exchange the air within the supporting frame. The exhaust device is time-controlled, defined by switch-on and switch-off times.

• In the "Basic setting" menu, scroll using the [RIGHT] and [LEFT] arrow keys.

• Switch to the "Exhaust enclosure" menu using the [F1] key.

Exhaust enclosure 1 ON/OFF <off> 2 Switch-on time 3 Switch-off time

• Activate or deactivate the injector using the [F1] key.

Switch-on time

• Switch to the "Switch-on time" menu using the [F2] key. The switch-on time is specified in minutes (0 to 30 minutes).

• Activate the input field using the [F1] key (flashing), enter numerical value using the [UP] and [DOWN] keys, change the input point using the arrow [LEFT] and [RIGHT] keys.

• Confirm using [Enter] key.

• Use the [Enter] or [Escape] key to return to the "Exhaust enclosure" menu.

Switch-off time

• Switch to the "Switch-off time" menu using the [F3] key, the switch-off time is specified in hours (0 to 24 hours).

The input is made analogous to the input for the "switch-on time".

6.8.8 Bus options

• In the "Basic setting" menu, scroll using the [RIGHT] and [LEFT] arrow keys.

• Use the [F2] key to switch to the "Bus options" menu.

Bus options 1 Profibus DP 2 Modbus 3 no bus >

For Ethernet, switch to display page 2.

• Select bus system using the [F2] or [F3] key.

• Use the [Enter] and [Escape] key to return to the "Basic setting" menu.

6.8.9 Program version

• In the "Basic setting" menu, switch to the "Program version" menu using the [F2] key.

Hardware C16 x_01 Software

SPS: ......

OP: ......

• Use the [Enter] or [Escape] key to return to the "Basic setting" menu.

• Use the [Escape] key to return to the main menu.

6.8.10 Bypass MIN time

• In the "Basic setting" menu, switch to the "Bypass MIN time" menu using the [F1] key.

Bypass MIN time new XXX s current XXX s 2 Accept

The bypass MIN time is factory-set to 60 seconds. This time can be adjusted between 20 and 210 seconds.

Changing the bypass MIN time

• Activate the input field using the [F1] key (flashing), enter numerical value using the [UP] and [DOWN] keys, change the input point using the arrow [LEFT] and [RIGHT] keys.

• Confirm using [Enter] key.

• Accept the new setting using the [F2] key. The "New" and "Current" values are now identical.

6.8.11 Auto start

This function is used to perform an automatic system restart. This is required, if the system’s bypass water supply becomes compromised as a result of pressure fluctuations (bypass water undershoots the MIN limit) or if the bypass water overshoots the MAX limit.

The system will restart automatically following a set pause time. The number of start attempts (cycles) is configurable.

No. of cycles: 0-10 Pause time: 1-10 minutes "Automatic start" function is not activated, when the number of

cycles is set to 0. If the bypass water supply remains compromised after the set

number of cycles has elapsed, an alarm message will be output ("bypass water MIN" or "bypass water MAX").

In the "Basic setting" menu, switch to the "Automatic start" menu.

Auto start Cycles xxx Pause time xxx min 2 Accept

6.8.12 Startup mode

Note

The startup mode is used to fill the reactor with water. The dosing pumps can be gauged, and the dosing controllers can be readjusted at the same time.

• In the "Service mode" menu, switch to the "Startup mode" menu using the [F2] key.

Startup mode 1 Batch concentration 2 Bypass water 3 Start

• Use the [F2] key to switch to the "Bypass water" menu.

2 Bypass water <off> setpt.: 420 l/h actual: 0 l/h 1 Limit -xx %/+xxx % >

• Activate or deactivate the bypass using the [F1] key.

The "setpt." value shows what quantity of water is required (depending on system size). The "actual" value shows the current water flow, "Limit" defines the minimum and maximum bypass water quantities.

• Switch to the impeller counter contacts display using the arrow [RIGHT] key.

Bypass water Pulses XX.X lmp./s Water YYY l/h 2 Accept <

Warning Enter a new quantity of water using the [F1] key only

in case of batch concentration error, see section

9. Maintenance!

If this input is used incorrectly, the factory settings can be restored using the reset function.

• Use the arrow [LEFT] key to return to the "Bypass water ON/OFF" menu.

• Use the [Escape] key to return to the "Startup mode" menu.

• Use the [F3] key to switch to the "Startup mode/Start?" menu.

Startup mode Start?

Use the [Enter] key to start the startup mode (startup time approx. 13 minutes).

Startup mode can be cancelled at any time using the [Escape] key.

The remaining time during which the system is in startup mode is output on the display. The system switches off automatically at the end of the startup time.

Startup mode finished

6.8.13 Test mode

The Test mode permits checking of current output, relay, display and LEDs.

Current output

In the "Service mode" menu, switch to the "Test mode" menu using the [F3] key.

• In the "Test mode" menu, switch to "Test current output" using the [F1] key.

Check the individual current outputs using the [F1] to [F3] keys.

• Activate the current outputs using the [F1], [F2] and [F3] keys.

• Deactivate using the [Escape] key, returning to the "Test mode" menu.

Relay

Checking of relays for: NaClO exhaust system, automatic/manual, error message, pre-empty

pump, HCl pump, bypass,

and dry-run.

• Activate using the [F1] to [F3] keys, scrolling if necessary; Deactivate by pressing the [F1] to [F3] keys again.

• Use the [Escape] key to return to the "Test mode" menu.

Display

• In the "Test mode" menu, switch to the display test using the [F3] key.

• Set the contrast using the [UP] and [DOWN] keys.

• Activate using the [Enter] key.

• Deactivate using the [Enter] key (press 2x), or the [Escape] key.

• Use the [Escape] key to return to the "Test mode" menu.

LED

• In the "Test mode" menu, scroll using the arrow [RIGHT] and [LEFT] keys, and switch over to the LED test using the [F1] key.

• Activate using the [Enter] key.

• Deactivate using the [Enter] or the [Escape] key.

• Use the [Escape] key to return to the "Service mode" menu or to the main menu.

6.9 Local/remote

The "local/remote" menu is only displayed, if a bus system was selected in the "setup/Bus" menu.

• Scroll with the arrow [RIGHT] key in the main menu.

• Use the [F1] key to switch to the "local/remote" menu.

Local/remote 1 local control 2 remote control

Select control mode using the [F1] or [F2] key.

local control/remote control activated

Use the [Enter] or [Escape] key to return to the main menu.

• Local control: operation and control of the system on site

• Remote control: control of the system via a bus system.

English (GB)

If the Startup mode is cancelled prematurely and then restarted, the startup time commences again at approx. 20 minutes.

• Use the [Escape] key to return to the "Service mode" menu.

7. Commissioning

Note

English (GB)

The system should always be commissioned with water. To do this, immerse both suction lines into a tank filled with water.

Commissioning must only be carried out by authorized specialists.

7.1 Directives

As a result of the applicable accident prevention regulations, chlorine dioxide systems may only be commissioned when their correct condition has been checked by a specialist.

The chlorine dioxide systems must be checked by a specialist each time they are restarted. This test must be repeated every 6 to 12 months according to the regulations.

Only persons who have been appropriately trained may be commissioned with operation and maintenance of the chlorine dioxide systems and the handling of chemicals.

Commissioning must only be carried out by trained specialists using appropriate instructions.

7.2 System choice

Define the system size and the operation mode in the "System choice" menu.

• The input can be cancelled at any time using the [Escape] key.

• Use the arrow [right] key in the main menu to switch to page 2 in the display.

Main menu < 1 System choice 2 Basic settings 3 Service mode >

• Use the [F1] key to switch to the "System choice" menu.

System choice 1 System type 2 Operation mode

• In the "System choice" menu, switch to the "System type" menu using the [F1] key.

• Press [F1], [F2] or [F3] to select the system size. If necessary, scroll to the left or right using the arrow keys.

The preset system size is displayed flashing; if necessary select a new size.

Once the system type has been selected, the following message appears on the display:

System type OCD-164-XXXD activated

• Use the [Enter] or [Escape] key to return to the "System choice" menu.

7.3 Selection of operation mode

The chlorine dioxide system can be operated in four different modes:

• Batch mode

• Current input

• Contact input

• Manual control

• Target value external

The preset mode is displayed flashing; if necessary select a new mode.

When "Manual control" is selected, the installation can only be started in "Manual mode". If the installation is started in "Automatic mode", an alarm message is displayed, and the system stops.

Main menu

Main menu 1 Automatic 2 Manual operation 3 Logbook >

• Switching to page 2 is possible using the arrow [RIGHT] key. Display page 2

Main menu < 1 System choice 2 Basic settings 3 Service mode >

• Use the [F1] key to switch to the "System choice" menu.

System choice 1 System type 2 Operation mode

• Use the [F2] key to switch to the "Operation mode" menu. Display page 1

Operation mode 1 Batch mode 2 Current input 3 Contact input >

If necessary, use the arrow key to scroll to page 2. Display page 2

Operation mode 1 Manual control 2 Target value ext.

The "Target value ext." menu option is only visible if a bus system has been selected in the "Basic settings/bus options" menu.

7.3.1 Batch mode

Note

Activating the operation mode "Others"

• In the "Operation mode" menu, switch to the "Others" menu using the [F1] key.

Batch mode activated

• Use the [Enter] and [Escape] key to return to the "System choice" menu.

Ensure that the level contacts of the batch containers are connected and correctly set up. Faulty settings may result in error messages in the batch mode.

Setting the concentration

• Use the [Escape] key to switch to the "Main menu", display page 2.

Main menu < 1 System choice 2 Basic settings 3 Service mode >

• Use the [F3] key to switch to the "Service mode" menu.

Service mode 1 Venting 2 Startup mode 3 Test mode

• In the "Service mode" menu, switch to the "Startup mode" menu using the [F2] key.

Startup mode 1 Batch concentration 2 Bypass water 3 Start

• Use the [F1] key to switch to the "Batch concentration" menu.

Batch concentration

3.0 g/l ClO

The default batch concentration is 3.0 g/l.

• Any concentration in the range of 2 to 3.3 g/l ClO entered.

can be

• Press the [F1] key to select the concentration input field.

• Enter the value by pressing the [UP] or [DOWN] buttons (to change the number) and the [LEFT] and [RIGHT] arrow buttons (to change the input position).

• Press the [Enter] key to confirm the entry.

• Use the [Enter] and [Escape] key to return to the "Startup mode" menu.

7.3.2 Current input

• In the "Operation mode" menu, switch to the "Current input" menu using the [F2] key.

Selection

[F1] key 0-20 mA [F2] key 4-20 mA [F3] key Others

When selecting the [F1] (0-20 mA) key, for example, the display shows:

Current input added 0.00 ppm Max. flow H

0000.0 m

The quantity (ppm) of ClO

/hb >

added, and the max. flow in the main

water line are entered in this menu.

The value for the amount of ClO2 added is a "starting value", which does not necessarily have to correspond to a ClO the system, because the control calculation is unable

measurement downstream of

to factor in consumption in the solution line.

• Switch to the variable field "0.00" using the [F1] key.

• Use the [UP] and [DOWN] keys to change the numerical value, and the arrow [LEFT] and [RIGHT] keys to change the input field.

• Enter the value to be added.

• Use the [F1] key to switch to the variable field "Max. flow H and enter the max. volume of water.

• Confirm using [Enter] key.

• Use the [Enter] key again to switch to the menu:

Current input < 0 g/h = 0 mA 9 g/h = 20 mA

The requisite system capacity is now calculated here, relative to the amount to be added (ppm) and the existing max. flow rate of H

Example:

Default quantity of ClO Main water quantity: 30 m Max. system capacity: 0.3 ppm x 30 m

: 0.3 ppm

/h = 9 g/h

If the calculated system capacity is greater than the size of the system, only the max. possible system capacity (e.g. 10 g/h) can be dosed.

• Use the [Enter] key to switch to the menu:

Current input < Flow of H Max xxx.x m Min xxx.x m

O0 mA

The max. and min. volume of water, which can be supplied with

through the set quantity to be added (ppm), and the

ClO

installation size are specified in this menu. The system switches off below the min. water quantity (system capacity < 2.5 %).

• Activate the operation mode using the [Enter] key.

Current input 0-20 mA activated

• Use the [Enter] key to return to the "Operation mode" menu.

• Press the [Escape] key twice to return to the main menu.

Analogous procedure for "4-20 mA" and the "Others" current input.

In the case of the "Others" current input, current input signals between 0 and 20 mA can be variably set.

Basic load setting

Current input < 0 g/h = 0 mA 9 g/h = 20 mA

Use the [F1] key to switch to the variable field 0 g/h, and set a basic load.

The basic load depends on the system type. It is bigger than 2.5 % of the system capacity.

For example, for the system type OCD-164-1000 the basic load is bigger than 0.25 g/h.

English (GB)

7.3.3 Contact input

Note

English (GB)

In the "System choice" menu, switch to the "Contact input" menu using the [F3] key.

Contact input Max. flow of H

0000.0 m

/h >

The max. flow in the main water line are entered in this menu.

• Use the [F1] key to switch to the variable field "0000.0 m and enter the max. flow rate. Enter using the [UP], [DOWN], [LEFT], [RIGHT] arrow keys analogous to the "Current input" entry.

• Confirm using [Enter] key.

• Use the [Enter] or [RIGHT] arrow key to switch to the menu:

Contact input < added 0.00 ppm Water meter

00.000 pulses/litre >

The quantity (ppm) of ClO contact water meter are entered in this menu.

added and the pulses/litre of the

• Switch to the variable field "0.00" using the [F1] key.

• Use the [UP] and [DOWN] keys to change the numerical value, and the arrow [LEFT] and [RIGHT] keys to change the input field.

• Enter the value to be added.

• Use the [F1] key to switch to the variable field "water meter

00.000", and enter the contacts of the existing contact water meter.

• Confirm using [Enter] key.

The control for the system can process a max. rate of 50 pulses/sec. If a value greater than 50 pulses/sec. is calculated, use a different contact water meter.

• Use the [Enter] or [RIGHT] arrow key to switch to the menu:

Contact input <

0 g/h = 0.00 pulses/sec. 9 g/h = 8.33 pulses/sec.

The requisite system capacity, as well as the pulses output by the water meter are now calculated in this menu.

Example:

Default quantity of ClO Main water quantity: 30 m

: 0.3 ppm

/h Contact water meter: 1 pulse/litre Max. system capacity: 0.3 ppm x 30 m

Water meter:

1 pulse/litre x 30 m

8.33 pulses/sec.

/h = 9 g/h

Select or set the contact water meter in such a way that, at max. system capacity, at least 5 pulses/sec. are transmitted to the controller.

• Use the [Enter] key to switch to the menu:

Contact input < Flow of H Max. xxx.x m Min. xxx.x m

The max. and min. volume of water, which can be supplied with

through the set quantity to be added (ppm), and the system

ClO

size, are specified in this menu. The system switches off below the min. water quantity (system capacity < 2.5 %).

/h",

/h x 1000/3600 =

1. Confirm using [Enter] key.

Contact input activated

2. Use the [Enter] key to return to the "Operation mode" menu.

3. Press the [Escape] key twice to return to the main menu.

The preset water flow rate in the "contact or current input" mode is [m

/h].

Use the [F1] key to select other displayed units: [l/s] and [%].

Basic load setting

Contact input < 0 g/h = 0.00 pulses/sec. 9 g/h = 8.33 pulses/sec.

Use the [F1] key to switch to the variable field 0 g/h, and set a basic load.

The basic load depends on the system type. It is bigger than 2.5 % of the system capacity.

For example, for the system type OCD-164-1000 the basic load is bigger than 0.25 g/h.

7.3.4 Manual control

• Scroll with the arrow [RIGHT] key in the "Operation mode" menu.

Display page 2

Operation mode < 1 Manual control 2 Target value ext.

• Select the "Manual control" mode using the [F1] key.

Manual control activated

• Use the [Enter] and [Escape] key to return to the "Operation mode" menu.

When "Manual control" is selected, the installation can only be started in manual mode.

7.3.5 Target value external

• Scroll with the arrow [RIGHT] key in the "Operation mode" menu.

Display (page 2)

Operation mode < 1 Manual control 2 Target value ext.

The "Target value ext." menu option is only visible, if a bus system has been selected in the "Basic settings/bus options" menu.

• Select the "Bus control" mode using the [F2] key.

Target value external activated

• Use the [Enter] and [Escape] key to return to the "Operation mode" menu.

7.4 Venting of the bypass line

Note

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Caution

Note

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









In order to ensure that the installations work properly, the bypass water line must be vented each time it is commissioned.

• In the main menu, switch to the "Service mode" menu using the [F3] key. If necessary, use the arrow keys [RIGHT] and (LEFT] to scroll.

Service mode 1 Venting 2 Startup mode 3 Test mode

• Use the [F1] key to switch to the "Venting" menu.

Venting 1 Bypass <off> 2 HCl pump <off> 3 NaClO

• Use the [F1] key to activate the bypass line (solenoid valve or bypass pump).

"Bypass <ON>" appears on the display. The bypass line can now be vented.

7.4.1 Bypass pump (option)

Use the [F1] key to activate or deactivate the bypass, i.e. the solenoid valve or the bypass pump.

• Turn the vent screw on the front of the pump motor counter-clockwise, and unscrew it fully using a spanner.

• After venting, refit and tighten the vent screw (1).

Use the [F1] key to switch the bypass off again; the current status, "Bypass <OFF>", appears on the display.

The bypass pump only works and vents correctly, if the bypass water at the suction connection of the pump is at a pressure of at least 0.05 bar (0.5 m WC).

pump <off>

7.4.2 Venting of the dosing pumps (HCl and NaClO

)

Fig. 19 Venting the pumps

The procedure for both dosing pumps is identical

Before the dosing pump is switched on, the dosing medium should be sucked through the overflow hose (3) by the pump with the aid of the syringe, which is included. Insert the syringe onto the overflow hose (3) at the end of the suction line, and carefully draw the dosing medium through the pump until the pre-chamber is filled with water. Open the spindle (4) (normal operation).

Commission the dosing pumps using the [F2] (HCl pump) and [F3] (NaClO

pump) keys. As long as the respective keys are

pressed, the pumps remain switched on. The display shows e.g. "HCl pump <ON>".

The pumps are switched off when the buttons are released. The display shows e.g. "HCl pump <OFF>".

Both dosing pumps must be vented.

• Open the dosing head venting spindle (1) by turning it counter-clockwise.

• Switch on the dosing pumps using the [F2] or [F3] keys.

• Set the stroke adjustment knob to 90-100 %.

• Close the venting spindle once dosing medium flows back into the tank bubble-free out of the vent hose (2).

• If the venting process is not performed correctly or if it is interrupted, briefly close and re-open the vent screw (1) repeatedly (max. 1 turn).

English (GB)

TM04 8210 4511

The dosing pump is completely vented, if the LED for dosing controller monitoring flashes evenly.

If the stroke setting changes during venting, the preset stroke length must be re-adjusted following the venting process.

Fig. 18 Bypass pump with vent screw (1)

TM04 8210 4510

• The pumps are switched off when the buttons are released.

7.4.3 Dosing pumps for the systems OCD-164-350 to

Note

100





Caution

Note

English (GB)

OCD-164-2000

With the system sizes OCD-164-350 to OCD-164-2000, dosing pumps with integral pressure relief and vent valves are used. The pressure relief valve protects the complete pressure side of the dosing line system from an impermissibly high buildup of pressure.

Fig. 20 System with pressure relief and vent valve

Pos. Description

1 "Venting" position 2 "Operation" position 3 Venting hose

The pressure relief valve can be opened manually, thus serving as a vent valve at the same time.

• Rotate the knob such that the smaller cut-out is positioned on the nub of the dosing head (1). The rotary knob is then further away from the dosing head, and the valve spring is relieved.

• Switch on the dosing pumps using the [F2] or [F3] keys.

• Return the rotary knob to the "Operation" position (2) when dosing medium flows out of the venting hose (3) back into the tank without bubbles.

The dosing pump is completely vented, if the LED for dosing controller monitoring flashes evenly.

• The pumps are switched off when the buttons are released.

• Use the [Escape] key to return to the "Service mode" menu.

Setting the bypass water quantity for batch operation

• Use the [F2] key to switch to the "Bypass water" menu.

2 Bypass water <off> target XXX l/h actual: YYY l/h 1 limit: - 50 %/+ 20 %

The target value is calculated and displayed on the basis of the entered concentration and size of the system. In this menu, the bypass water (actual value) must be set to the required amount of water (target value).

Fig. 21 Setting the bypass water quantity at the ball valve

To change the water quantity use the ball valve at the back of the system.

• Use the [F2] key to switch on the bypass water (solenoid valve). Use the dosing ball valve to match the actual value to the target value.

Open the ball valve carefully, and adjust actual value to target value from bottom direction. If the ball valve

TM04 8212 4510

is opened too far, the actual value can be displayed wrongly.

If the actual flow is changed, the changed flow is displayed correctly after approx. 8-10 seconds.

If it is difficult to set the water amount using the ball valve, slightly loosen both screws on the valve. Set the water amount, and then retighten the screws. Check the tightness of the ball valve.

• Use the [F2] key to switch off the bypass water again.

Changing the limit

• Use the [F1] key to switch to the input field -50/+20 %.

• Enter the value by pressing the [UP] or [DOWN] keys (to change the number), and the [LEFT] and [RIGHT] arrow keys (to change the input position).

Switching from -50 % to +20 % is carried out using the [F1] key.

• Press the [Enter] key to confirm the entry.

• Use the [Escape] key to return to the "Startup mode" menu.

Due to the processing of the signals by the SPS control (PLC), the displayed bypass water quantity may vary slightly.

This is not significant, because the variations are always within a certain range.

The bypass water must later be checked again in automatic mode or in manual mode, as the pressure conditions in the system may change as a result of further operation of the dosing pumps.

Starting of startup mode

• Use the [F3] key to switch to the "Startup mode/start" menu.

• Press the [Enter] key to start the startup mode.

Startup mode activated Runtime xxx s

The remaining time for the startup mode is shown on the display. If it has expired, the system switches off automatically.

TM04 8213 4510

Startup mode finished

• Use the [Enter] or [Escape] key to return to the "Startup" menu.

• Use the [Escape] key to return to the "Service mode" menu or to the "Main menu".

7.4.4 "Current input, Contact input, Manual control, Target

Caution

Note













value ext." modes

Checking the bypass water

• In the main menu, scroll to page 2 using the [ARROW RIGHT] key.

• Switch to the "Service mode" menu using the [F3] key.

• In the "Service mode" menu, switch to the "Startup mode" menu using the [F2] key.

Display with startup mode

Startup mode 2 Bypass water 3 Start

• Use the [F2] key to switch to the "Bypass water" menu.

2 Bypass water <off> target XXX l/h actual: YYY l/h 1 limit: -XX/+600 %

• Use the [F2] key to switch on the bypass water (solenoid valve or bypass pump).

The target value is defined by the system choice. The actual value shows the current water quantity flowing through the bypass.

Starting of startup mode

• Use the [F3] key to switch to the "Startup/start" menu.

• Press the [Enter] key to start the startup mode.

Startup mode activated Runtime xxx s

The remaining time for the startup mode is shown on the display. If it has expired, the system switches off automatically.

Startup mode finished

• Use the [Enter] and [Escape] key to return to the "Startup mode" menu.

• Use the [Escape] key to return to the "Service mode" menu or to the "Main menu".

7.5 Calibrating the dosing pumps

Details of the dosing rate required for the size of installation in question can be found in the table in

2.1.1 Performance and consumption data under

"Consumption of components". As diluted chemicals are used in these installations,

the consumption data may be compared 1:1 with water.

Calibration can be done with water.

The dosing pumps with double head system can also be calibrated at any time in regular mode without interrupting the process sequence.

Fig. 22 Calibrating the dosing pump

Warning Don't let the calibration tube run empty. Re-open the isolating valve in good time.

• Shut the isolating valve (4) at the calibration tube (5). The supply from the tank is now interrupted. The calibration tube is slowly emptied.

• Using a stopwatch, time how long it takes for the dosing volume of 0 to 10 ml (10-ml measuring glass) and of 0 to 5 ml (5-ml measuring glass).

• Open the isolating valve (4) at the calibration tube (5).

• Calculate the dosing flow: 10-ml measuring glass: V (l/h) = 36/t (s) 5-ml measuring glass: V (l/h) = 18/t (s)

If the calibrated dosing volume deviates from the target value (table), the dosing rate is corrected with the stroke adjustment button (on the dosing pump) and checked once again.

If a pump deviation occurs, use the stroke adjustment button to re-adjust it and re-calibrate it.

Consumption of components, see table in section

2.1.1 Performance and consumption data.

If several calibration attempts are made, ensure that the suction lines do not become filled with air. If necessary, deaerate the pump again.

English (GB)

TM04 8211 4510

Dosing pumps for the systems OCD-164-220 to

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English (GB)

OCD-164-2000

1. Calibration is made using calibration cylinders.

2. Fill both calibration cylinders with water up to a certain mark.

3. Place the suction lines into the calibration cylinders.

4. Use a stopwatch to determine the time required to dose a particular quantity of liquid.

5. Remove the suction lines from the calibration cylinders, read off the new value, and calculate the dosing performance.

6. If the calibrated dosing volume deviates from the setpoint (table), the dosing rate is corrected with the stroke adjustment button (on the dosing pump) and checked once again. Consumption of components, see table in section

2.1.1 Performance and consumption data.

7. If a pump deviation occurs, use the stroke adjustment button to re-adjust it and re-calibrate it.

If several calibration attempts are made, ensure that the suction lines do not become filled with air. If necessary, deaerate the pump again.

Consumption of components, see table in section

2.1.1 Performance and consumption data.

7.6 Adjusting the dosing controllers

The dosing controllers can be adjusted during startup mode. Consumption of components, see table in section

2.1.1 Performance and consumption data.

Fig. 23 Dosing controller

Pos. Description

1 Clamping nut 2 Adjusting screw 3Sensor

The dosing controllers are correctly set, if the LEDs on the controller flowchart flash regularly, see section 6.2 Control and

display elements, items 1 and 4.

If the LEDs are off, the dosing controllers are set too high. If the LEDs flash very rapidly (or light up permanently), the dosing controllers are set too low.

Adjustment

1. Loosen the clamping nut (1).

2. Readjust the sensor using the adjusting screw (2).

3. If the LED is off, the sensor is set too high.

4. Adjust the sensor from above to the correct working point, until the LED flashes regularly.

5. Adjust the sensor about approx. 1 mm lower with the adjustment screw (2).

6. Fix the sensor using the clamping nut (1).

TM04 8215 4510

8. Operation of the system

Note

Before the system is started, the system size and operation mode must be selected.

Independent from the operation mode, the menu structure remains the same, the only difference is in the display of the prevailing signals, i.e. current input in mA, contact input in 1/s and manual mode in %.

Main menu

Main menu 1 Automatic 2 Manual operation 3 Logbook >

8.1 Automatic operation

In "Manual control" mode, automatic operation is impossible.

8.1.1 Current input/contact input

• In the main menu, switch to the "Automatic > start" menu using

the [F1] key.

Auto: x.x/y.y Start? Dosing xxx % Bypass xxx l/h ClO

Depending on the mode setting, the x.x/y.y field indicates the prevailing current signal in mA or the prevailing contacts (contact water meter) in 1/s.

• Activate or deactivate the system using the [Enter] key.

The display changes from "start?" to "active" or from "active" to "start?". The display shows the most important information about the operation of the system. Further information, such as levels, dosing pumps and bypass water, can be obtained by scrolling with the arrow keys to the pages 2 and 3. Display page 2

Auto: start? < 1 Level 3 Logbook >

Level

• Use the [F1] key to switch to the "Level" menu.

Level HCl: MIN - MAX

: MIN - MAX

NaClO

• Use the [Escape] key to return.

On page 2, scroll on with the arrow keys: Display page 3

Auto: Start? < 1 Dosing pumps 2 Bypass >

x.x g/h >

Dosing pump

• Use the [F1] key to switch to the "Dosing pumps" menu.

NaClO2H = X D = Y HCl H = X D = Y

The Hall sensor signals and the signals from the flow controllers can be checked in this menu.

The values displayed here are not identical to the dosing stroke details from the individual dosing pumps, e.g. 120 strokes/min, because the calculation does not relate to 1 minute.

The default value changes as the installation runtime progresses, whereby the following evaluation is decisive.

H = X: Hall sensor signals D = X: flow controller signals.

D = H

Each of the Hall sensor signals from the dosing pump is fed back by the flow controller.

More flow controller signals are fed back, i.e. if the

D > H

deviation is too large, this reduces the precision of the flow monitor, although the system keeps running (there is no error message).

Too few dosing controller signals are fed back, the

D < H

system goes into malfunction mode. The dosing controller settings have to be checked.

The installation is correctly set at D = H whereby a few extra dosing controller signals (D > H) have no bearing on the precision of the system.

• Use the [Escape] key to return.

Bypass water

• Use the [F2] key to switch to the "Bypass water" menu.

Bypass water <off> setpt.: xxx l/h actual: xxx l/h 1 limit: -XX/+600 %

The target and actual value for the bypass water can be checked in this menu. The limits can also be changed in this menu.

Changing the limit

• Use the [F1] key to switch to the input field -XX or +600 %

• Enter the value by pressing the [UP] or [DOWN] keys (to change the number), and the [LEFT] and [RIGHT] arrow keys (to change the input position).

• Switching from -XX to +600 or from +600 to -XX is carried out using the [F1] key.

• Press the [Enter] key to confirm the entry.

• Use the [Escape] key to return.

If a new system size is set, the preset limits for the new system are loaded.

English (GB)

8.1.2 Batch mode

Note

English (GB)

• In the main menu, switch to the "Automatic start" menu using the [F1] key. Display page 1

Auto: Start? Dosing: xxx % Bypass: xxx l/h

: x,x g/h >

ClO

The x.x field shows the set batch concentration.

• Activate or deactivate the system using the [Enter] key. The display changes from "start?" to "active", or from "active" to "start?". The display shows the most important information about the operation of the system. Further information, such as levels, dosing pumps and bypass water, can be obtained by scrolling with the arrow keys to the pages 2 and 3. Display page 2

Auto: Start? < 1 Level

Level

• Use the [F1] key to switch to the "Level" menu.

Level HCl: MIN - MAX

:MIN - MAX

NaClO

:MIN - MAX

ClO

• Use the [Escape] key to return. On page 2, scroll on with the arrow keys: Display page 3

Bypass water

Use the [F2] key to switch to the "Bypass water" menu.

Bypass water <off> setpt.: XXX l/h actual: YYY l/h 1 limit: - 50 %/+ 20 %

The target and actual value for the bypass water can be checked in this menu. The limits can also be changed in this menu.

Changing the limit

• Use the [F1] key to switch to the input field -50 or +20 %

• Enter the value by pressing the [UP] or [DOWN] keys (to change the number), and the [LEFT] and [RIGHT] arrow keys (to change the input position).

• Switching from -XX to +50 or from +20 % to -XX is carried out using the [F1] key.

• Press the [Enter] key to confirm the entry.

• Use the [Escape] key to return.

If a new system size is set, the preset limits for the new system are loaded.

In batch mode, the limit values for the bypass water can only be changed within the range ± 20 %.

Changing the batch concentration

See section 7.3.1 Batch mode, setting the concentration

Auto: Start? < 1 Dosing pumps 2 Bypass

Dosing pump

• Use the [F1] key to switch to the "Dosing pumps" menu.

NaClO

H = X D = Y

HCl H = X D = Y

The Hall sensor signals and the signals from the flow controllers can be checked in this menu.

H = X: Hall sensor signals D = X: flow controller signals.

The values displayed here are not identical to the dosing stroke details from the individual dosing pumps, e.g. 120 strokes/min, because the calculation does not relate to 1 minute.

The default value changes as the installation runtime progresses, whereby the following evaluation is decisive.

D = H

Each of the Hall sensor signals from the dosing pump is fed back by the flow controller.

More flow controller signals are fed back, i.e. if the

D > H

deviation is too large, this reduces the precision of the flow monitor, although the system keeps running (there is no error message).

Too few dosing controller signals are fed back,

D < H

the system goes into malfunction mode. The dosing controller settings have to be checked.

The installation is correctly set at D = H whereby a few extra dosing controller signals (D > H) have no bearing on the precision of the system.

• Use the [Escape] key to return.

8.1.3 Target value external

Note

System capacity control and processing the input and output signals via the bus system.

• Select the bus system used in the "Basic Settings/Bus Options" menu, see section 6.8.8 Bus options.

• Activate the bus control in the "Operation mode" (page 2). Scroll with the arrow [RIGHT] key in the "Operation mode" menu. Select the "Bus control" mode using the [F2] key.

Target value external activated

• Use the [Enter] and [Escape] key to return to the main menu. Display page 1

Main menu 1 Automatic 2 Manual operation 3 Logbook >

• Switch to page 3 using the arrow [RIGHT] key.

Main menu < 1 local/remote

The "local/remote" menu is only displayed, if a bus system was selected in the "Basic settings/Bus options" menu.

• Use the [F1] key to switch to the "local/remote" menu.

Local/remote 1 local control 2 remote control

• Select control mode using the [F1] or [F2] key.

local control/remote control activated

• Use the [Enter] or [Escape] key to return to the main menu.

Local control

Operation and control of the installation on-site, by manual entry of the installation capacity in % terms in "Manual" mode.

Remote control

Control of the installation via the bus system in "Automatic" mode.

Auto: x.x % Start? Dosing: xxx % Bypass: xxx l/h

: x.x g/h >

ClO

8.2 Manual operation

Irrespective of the selected mode, the system can only be activated in "Manual" mode if the installation capacity has been set manually in %.

Given the pulse pause control of the dosing pumps for HCl and NaClO

2.5 % are not possible. A dosing capacity set on the display less than 2.5 %

leads to dosing of 0 %. A dosing capacity set on the display more than 95 %

leads to a dosing capacity of 100 %.

• In the main menu, switch to the "Manual > start?" menu using the [F1] key.

Manual: x.x % Start? Dosing: xxx % Bypass: xxx l/h ClO

The input field "x.x" shows the dosing capacity setting in %.

Setting the dosing capacity

• Select the input field "x.x" using the [F1] key.

• Use the [UP] and [DOWN] keys to change the numerical value, and the arrow [LEFT] and [RIGHT] keys to change the input field. Dosing capacity range from 0 to 100 %.

• Confirm entry using [Enter] key.

The display pages 2 and 3 (levels, dosing pump, bypass) are analog to automatic operation, see section 8.1 Automatic operation.

8.2.1 Manual mode for batch

The operation and functions are the same as in automatic mode, except the solution container is not continually filled between the contacts MIN and MAX as in automatic operation, but rather is only filled once up to the MAX contact. Then the system shuts down.

In manual mode, the system does not automatically switch on when the MIN contact in the solution container is reached.

dosing capacity ranges under

: x.x g/h >

English (GB)

8.3 Faults

English (GB)

Fault Cause Remedy

1. During venting of the dosing pumps, the suction line does not fill with liquid, despite 100 % setting

2. LED for the bypass water flashes when the installation is started. There is too little or no dilution water flowing through the bypass line

3. Startup mode is automatically interrupted

4. The dosing pumps are not dosing, or the LEDs for the flow monitor are not flashing

5. Imprecise dosing pump capacity

6. Alarm signal: only manual mode

7. System is started, display indicates "active", but does not dose or the bypass water is not flowing

8. Alarm signal: "Dosing controller HCl" or "Dosing controller NaClO

a) The venting spindle in the dosing head is

incorrectly set

b) Suction and pressure valves in the dosing

head have dried out, making them leak slightly

c) Leaks between the lower end of the suction

line and the connection nipple on the floater switch foot valve

a) No dilution water available b) The coil in the solenoid valve is defective,

the valve remains closed

c) The counterpressure at the injection unit is too

high

d) The admission pressure of the solenoid valve

is too low

e) The bypass pump has not been correctly

vented

f) Isolation valve upstream of the system and/or

in the chlorine dioxide solution line to the injection unit is closed

g) Flow meter operation impaired by

contaminated dilution water a) The water tank is empty b) The float switch in the suction line is stuck c) The float switch is defective d) Air in the suction line or in the dosing head of

the pump a) Air in the suction line b) Injection unit is blocked c) The suction or discharge valves are not

correctly fitted

a) The dosing head has not been correctly vented b) Counterpressure fluctuations c) Suction and discharge valves are dirty

a) "Manual" mode has been selected, although

the system has been started in automatic mode a) Remote ON/OFF active, i.e. the system has

been set to standby via this contact b) Min. contact main water active, i.e. the volume

of main water is too low a) Air in the suction line b) No liquid in the pump calibration system, the

isolation valve on the calibration tube is closed c) Diaphragm or pressure sensor in the flow

controller are defective

a) Open the venting spindle by approx. 1 turn;

if necessary, open or close it further

b) Remove the suction and pressure valves,

dip them in clean water and shake them; Screw them back in and vent the pump again

c) Remove the suction line from the container,

check that the suction hose is positioned correctly on the nipple, correct it if necessary

and vent it once again a) Check the dilution water supply line b) Replace the coil c) Reduce the counterpressure at the injection

unit, or possibly increase the admission

pressure (max. 10 bar) d) Increase the admission pressure (min. 1 bar) e) Vent the bypass pump again f) Open the isolation valve g) Remove the flow meter and clean it in clean

water

a) Refill the water tank b) Check the float switch, clean it, if necessary c) Exchange the float switch d) Vent the dosing pumps again

a) Vent the suction line and dosing head with

the dosing pump set to 100 % dosing

capacity b) Open the injection unit isolation valve or

reduce the counterpressure at the injection

unit c) The suction and pressure valves in the

dosing head must be installed in such a way

that the flow direction arrow points upwards a) Repeat the venting process b) Install a pressure loading valve downstream

of the Oxiperm system c) Clean the valves a) Acknowledge the alarm and start the system

in manual mode a) Switch remote ON/OFF to ON b) Increase the main water volume or deactivate

the min. contact

a) Vent the suction line and dosing head with

the dosing pump set to 100 % dosing

capacity b) Open the isolation valve and vent the pump c) Check the flow controller

8.4 Error messages of the controller

No. Fault Cause Remedy

Pre-empty signal

2 HCl HCl level in tank too low 3

Empty signal

4 HCl HCl tank empty 5 Dosing controller NaClO

NaClO

6 Dosing controller HCl 7 Level "Max-Max" Solution tank: ClO

8 Level "Min-Min" Solution tank: ClO

Flow

Bypass water Flow

Bypass water

"Min" Bypass water too low Increase flow of bypass water

"Max" Bypass water too high Reduce flow of bypass water

11 Fault gas warning device Gas alarm Eliminate leakage 12 ------------------------ ----------------------------------- -------------------------------------13 Open-circuit at current output Cable broken Replace cable 14

Hall sensor defective

16 H2O 17

HCl

24 VDC, too large Controller defective Check controller 18 24 VDC, too small Fuse SI 12 defective Replace fuse 19 15 VDC, too large Controller defective Check controller 20 15 VDC, too small Fuse SI 9 defective Replace fuse 21 -15 VDC, too large Controller defective Check controller 22 -15 VDC, too small Fuse SI 9 defective Replace fuse

Voltage

23 8 VDC, too large Controller defective Check controller 24 8 VDC, too small Fuse SI 11 defective Replace fuse 25 12 VDC, too large Controller defective Check controller 26 12 VDC, too small Fuse SI 11 defective, inputs overloaded Replace fuse, check connection 27 -12 VDC, too large Controller defective Check controller 28 -12 VDC, too small Fuse SI 11 defective Replace fuse 29 Reactor temperature too high Dilution water too low, H 30 Reactor temperature rise too high Dilution water too low, H 31 Battery in PLC exhausted Battery exhausted Replace battery

32 Dosing controller H

Preliminary H

tank

"Max-Max"

34 Flow HCl min Dosing quantity too low 35 Flow HCl max Dosing quantity too high 36 Flow NaClO 37 Flow NaClO 38 Flow H 39 Flow H 40 Fault level ClO

min Dosing quantity too low

max Dosing quantity too high

O Dilution min. Dosing quantity too low

O Dilution max. Dosing quantity too high

41 Fault level HCl

43 Fault level H2O 44 Open-circuit in temperature sensor Temperature sensor defective Replace sensor 45 Short-circuit Short-circuit Check controller 46 Fault bypass water flow Leakage in solenoid valve Replace solenoid valve

47 Fault: only manual mode possible

NaClO2 level in tank too low

NaClO2 tank empty

Dosing controller incorrectly set Dosing controller defective

overflow level reached Check "Max" contact

dry-run level reached

Cable broken, component defective Exchange cable or component15 NaClO

O pump defective

Dosing controller incorrectly set, dosing controller defective

Overflow level in preliminary tank for H reached

O is

Level switch on solution tank defective

Level switch of suction line defective42 Fault level NaClO

"Manual" mode has been selected, although the system has been started in automatic mode

Refill tank

Readjust controller Replace controller

Check "Min" contact Check dosing quantity of the pump Check system status "ON/OFF"

Check H

O setting of the pump,

replace pump

Readjust controller Replace controller

Check float switch in tank

Check dosing pump or quantity

Check level switch

When "Manual control" is selected, start the system in manual mode

English (GB)

6,

6, 6, 6,

6, 6,

6, 6,

6,

6, 6, 6,

6,

  

Note

8.5 Fuses and LEDs of the controller

Fig. 24 Dosing controller

Pos. Description Ampere

Backup fuse, solenoid valve, system

SI 1

drain Backup fuse, solenoid valve, H

SI 2

rinsing Backup fuse, solenoid valve, bypass

SI 3

water Backup fuse, NaClO

SI 4

dosing pump

(NaClO2/HCl)

SI 5 Backup fuse, HCl dosing pump 6.3 A SI 6 Backup fuse, H

Backup fuse, solenoid valve, enclosure

SI 7

exhaust Backup fuse, solenoid valve, exhaust

SI 8

device, preliminary

O dosing pump 6.3 A

SI 9 Internal supply voltage ± 15 V 100 mA

SI 10 Main fuse of the system 10 A SI 19 Internal supply voltage ± 12 V / +8 V 100 mA SI 12 Internal supply voltage +24 V 2 A SI 13 Internal supply voltage +5 V 1 A

1 LED (green) - RUN 2 LED (red) - ERROR 3 LED (red) - battery 4 LED (yellow) - WATCHDOG 5 Battery

In the correct operating state, the LED (1) is green, and the LED (4) is yellow. If there is a fault, e.g. if no more programs are available or the memory card is defective, the LED (1) is green and the LED (2) is red.

In this case:

• Turn the controller off and on again. If the error still occurs:

• Switch off the controller, remove the battery, switch the controller on again. Wait for the program to be loaded from the memory. Insert the battery again. If the error still occurs:

• Reinstall the program, or change the memory card.

1 A

6.3 A

1 A

Fuse: ∅5 x 20 mm, slow-blow

8.6 Possible faults when changing the tank

Each of the suction lines has a pre-empty and an empty-signal contact. If the level in the container reaches the "pre-empty signal" contact, an alarm message appears on the display, yet the system does not stop.

If the level reaches the "empty signal" contact, an alarm message appears on the display, and the system shuts down.

Pre-empty signal

A ON ACK 1/1 Pre-empty signal NaClO

23-04-10 14:36:12

The system remains in operation until the empty-signal contact is activated.

Empty signal

A ON ACK 1/1 Empty signal

TM04 8216 4510

The system switches off automatically.

Change of tank at "pre-empty" alarm

The "pre-empty" alarm appears on the display.

1. Remove the suction line from the tank.

2. The system switches off automatically, the "HCl or NaClO empty" alarm is displayed.

3. Fit the suction line into the new tank.

4. Press the [F4] key to acknowledge the two alarm messages.

5. Press [Enter] to re-activate the system.

Change of tank at "empty" alarm

The "empty" alarm appears on the display.

1. Remove the suction line from the tank.

2. Fit the suction line into the new tank.

3. Press the [F4] key to acknowledge the two alarm messages.

4. Press [Enter] to re-activate the system.

NaClO

23-04-10 14:36:12

Warning Only use standard tanks. Never pour the contents of the tank into another one!

There is a great danger of residual chemicals being poured into the wrong tank.

The procedure is identical for both tanks: If both tanks are changed, up to 4 alarm messages have to be acknowledged, before the system can be re-activated.

9. Maintenance

Note

      













Warning Before any maintenance work, i.e. when exchanging

parts and gaskets, the entire system has to be rinsed with water.

Before maintenance work, all chemicals must be completely removed!

When handling acids or lyes, wear appropriate protective clothing.

Maintenance and repair work must only be carried out by authorized specialists.

According to the German accident prevention regulations GUV 8.15 and VGB 65 § 19, chlorine dioxide systems must be regularly checked for safety, at least once a year and prior to every startup, by a specialist.

This check can be carried out by the after-sales servicing department during the six-monthly maintenance.

9.1 Maintenance of the dosing pumps

A drop in performance of the dosing pumps may be caused by contamination in the suction and discharge valves.

9.1.1 Dismantling and cleaning the valves

1. Unscrew the suction and discharge valves.

2. Use a pin (∅2) to press out the ball cage, ball and O-ring from below.

3. Replace damaged parts.

When re-assembling, observe the correct position of the parts, see fig. 25.

9.1.2 Dismantling the diaphragm

For safety reasons, the dosing diaphragm should be replaced after a maximum of 2000 operating hours.

1. Insert the suction lines of the pumps into a water tank, and run the system until the dosing heads of the pumps have been well purged with water.

2. Open venting screws by one rotation until the venting lines are also purged. Switch off the system.

3. Loosen the four dosing head screws.

4. Remove the dosing head, and unscrew the diaphragm by rotating to the left.

Assembly

1. Insert the intermediate ring so that the relief hole points downwards.

2. Screw in the diaphragm.

3. Switch on the pump briefly until the diaphragm is located at the rear dead point.

4. Carefully fit the dosing head, and uniformly and gently tighten the screws in a diagonally opposite sequence, so that the dosing head is not damaged.

5. Vent the pump.

9.2 Maintenance of the suction lines

The suction lines are equipped with foot valves and filter nuts. The Reed contacts are integrated in the suction line body. The floats with magnet core are located axially on the valve body and are sliding.

The foot valve should be dismantled and cleaned occasionally, at the latest when the suction performance drops.

The function symbol (NO contact) must be present on the top surface of the two floats.

If this is not the case, disconnect the float and reverse the polarity.

English (GB)

Fig. 25 Construction of the valves

Pos. Description

1 Valve body 2 Ball cage 3 Seat 4Ball 5 O-ring

When installing the valves, make sure that the flow direction is correct (arrow).

The O-ring must be inserted correctly into the provided groove.

OCD-164 Product No.

-30 to -220 95730320 (553-1995)

-350 to -2000 95730321 (553-1996)

TM04 8217 4510

TM04 8221 4510

Fig. 26 Suction line, spare parts

Pos. Description

1 Float switch, PVC 2Ball 3 Valve seat, grey PVC 4 Filter nut, PVC grey

9.3 Maintenance of reactor

Note

English (GB)

Warning Prior to any maintenance work on the reactor, rinse

the system with water until no more chemicals are present.

Check the valves on the reactor for leaks each time maintenance work is carried out. Replace valves if necessary.

For reasons of safety, no spare parts are offered for reactors, apart from the valves.

In case of faults, the entire reactor must be exchanged.

9.3.1 Spare valves (3 per reactor)

OCD-164 System pressure Product No.

-30 to -220

-350 to -2000

The reactor valves are not identical to the valves of the dosing pumps.

Do not interchange the valves!

< 3 bar 91836549 (553-640) > 3 bar 96689071 (553-641) < 3 bar 91836550 (553-642) > 3 bar 96689073 (553-643)

Fig. 27 Reactor with valves

Pos. Description

Val veB

TM04 8222 4510

9.4 Maintenance of injector

Caution



   

      

     







 



 











The injector consists of nozzle, diffuser and holder with diaphragm non-return valve.

The sucked-in chlorine dioxide is mixed with the motive water in the diffuser, and transported to the disposal line.

The diaphragm non-return valve prevents water from penetrating the PE line when the exhaust device is switched off.

If water containing heavy deposits is used, this can lead to losses in performance when sucking. The nozzle must be cleaned in this case. Regularly clean the filter of the dirt trap (if fitted).

Do not use any sharp objects to clean the nozzles. Hydrochloric acid has proved to be the best cleaning agent.

Observe the regulations for handling hydrochloric acid.

English (GB)

Fig. 28 Sectional drawing of injector

Pos. Description Product No. Pos. Description Product No.

10 Diffuser 96681122 (12.6420-3019) 130 Diaphragm 91834695 (12.312-4) 20 Nozzle 96681126 (12.6421-401) 140 Cylinder screw 96687994 (50.1054) 25 Twisting part 96681053 (12.5577-300) 150 Disc 96688017 (50.1326) 30 Base 96681054 (12.5578-200) 155 Hexagon nut 96681142 (12.6583-400) 40 Pressure spring 91836364 (12.2493-400) 160 O-ring 91835590 (52.164) 50 Threaded ring 91834667 (12.175-4) 170 Diaphragm seat 91834700 (12.375-4) 60 Seat 91834662 (12.120-4) 180 O-ring 91835566 (52.125) 70 O-ring 91835573 (52.139) 190 O-ring 91835609 (52.277) 80 Diaphragm ring 91834701 (12.376-4) 200 Plug 96687957 (48.1210) 90 Top part 96681051 (12.5575-310) 210 O-ring 91835574 (52.141) 95 Base part 96681052 (12.5576-210) 220 Union nut 91835736 (53.058-25)

110 Union nut 91834741 (12.561-4) 230 Insert 96688366 (53.056-25)

120 Piston 91834666 (12.171-4) 240 Flat gasket 96681143 (12.6584-410)

TM04 8223 4510

10. Spare parts kits and spare parts















English (GB)

10.1 DMI dosing pumps with double-head system

OCD-164 Product No.

-30

-120

-220 91835902 (553-1488)

96641420 (553-1486)

Fig. 29 Exploded view of DMI dosing head

Pos. Description

3 Suction/Discharge valve DN 4

4 Venting cartridge 17 Dosing diaphragm 21 Dosing diaphragm 37 Oval-head screw 73 O-ring, Viton

TM04 8218 4510

10.2 DMI dosing pumps with single-head system























OCD-164 Product No.

-30

-120

-220 96688818 (553-1411-3)

Fig. 30 Exploded view of DMI dosing head

Pos. Description

3 Venting cartridge

7 Dosing diaphragm 11 Flat gasket 13 Suction/Discharge valve DN 4 18 Cylinder screw 19 Disc 11 Flat gasket

96688816 (553-1403-3)

10.3 Dosing pumps DMX 221

OCD-164 Product No.

-350

-700

-1000 91835950 (553-521-3)

-1500 96634413 (553-522)

-2000 91835954 (553-522-3)

91835948 (553-520-3)

10.4 Bypass, post mixer, and dosing controller

Spare parts kits comprise:

• O-rings for bypass line and post-mixer

• Non-return valve, DN 20, for bypass line

• O-rings and flat gaskets for the bypass line

• Spare parts set for dosing controller

OCD-164

-30

-120

-220 With < 3 bar 96689109 (553-745)

-220 Without < 3 bar 91836563 (553-1717)

-220 With > 3 bar 96689110 (553-745.1 )

TM04 8219 4510

-220 Without > 3 bar 96729526 (553-1717.1)

-350 -------

-700 -------

-1000 -------

-1500 -------

-2000 -------

Further spare parts

Description Product No.

Post-mixer 96708931 (12.5861-300) Pressure loading valve, DN 8 96635200 (525-0567) Pressure loading valve, DN 20 96376567 (525-1113) Set of micro-fuses for electronics 96688774 (553-1095) Discharge hoses for HCl/NaClO

with connection (pump/reactor) Battery for CR-2032 electronics ------------ ------------

Plus3

system

With < 3 bar 96689088 (553-720)

Without < 3 bar 96729524 (553-1716)

With > 3 bar 96689089 (553-720.1)

Without > 3 bar 96729525 (553-1716.1)

With > 3 bar 96689089 (553-720.1)

Without > 3 bar 96729525 (553-1716.1)

With < 3 bar 96689088 (553-720)

Without < 3 bar 96729524 (553-1716)

System

pressure

< 3 bar 96689090 (553-722) > 3 bar 96689091 (553-722.1) < 3 bar 96689092 (553-723) > 3 bar 96689093 (553-723.1) < 3 bar 96689094 (553-724) > 3 bar 96689095 (553-724.1) < 3 bar 96689096 (553-725) > 3 bar 96689097 (553-725.1) < 3 bar 96689098 (553-726) > 3 bar 96689099 (553-726.1)

Product No.

91836658 (553-1711)

English (GB)

Fig. 31 Exploded view of DMX 221 dosing head

Pos. Description

1 Dosing diaphragm, PTFE/NBR 2 Shaped gasket, NBR 3 Grooved ring, Perbunan 8 Suction/Discharge valve DN 8

TM04 8219 4510

10.5 Enclosure exhaust device

 











  

 

English (GB)

Fig. 32 Spare parts for exhaust device

Pos. OCD-164 Description Product No.

-30 to -220

50.1

50.3

50.5

50.6 Screw-in part, DN 20 96688372 (53.057-25)

50.7 Union nut, DN 20 91835736 (53.058-25)

50.8 O-ring 91835574 (52.141)

50.9 Reduction, short, DN 20/DN 15 96688439 (53.183-25-20)

50.10 Connection nipple 96708988 (12.6416-400)

50.11 Solenoid valve, 230 V, 50 Hz 96687772 (45.10245-1/2)

50.12

50.13 Cable gland, M16 x 1.5 96726056 (45.10131)

50.14 Cable gland, M20 x 1.5 96687755 (45.10132)

50.15 PE hose 8/11 96687899 (47.1320008)

50.16 Screw, M6 x 25 96726750 (50.461)

50.18

50.20 -30 to -2000 Knurled nut, M6 95729417 (50.1570)

-350 to -1000 95729412 (12.5999-200)

-1500 to -2000 95729413 (12.5999-210)

-30 to -220

-350 to -2000 96693040 (545-2000-1)

-30 to -2000

-30 to -220

-350 to -1000 95729415 (12.6237-310)

-1500 to -2000 95729416 (12.6237-320)

Lateral part

Injector

Insert, DN 20 96688366 (53.056-25)

Solenoid valve, 115 V, 60 Hz 96687775 (45.10249-1/2) Connection cable 96708949 (12.6023-420)

Rear wall

95729411 (12.5998-200)

96691986 (545-1000-1)

95729414 (12.6237-300)

TM04 8224 4510

10.6 Bypass with solenoid valve and flow limiter (standard version: solenoid valve)



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      

     

'1

Fig. 33 Spare parts for exhaust device

Pos. OCD-164 Description Product No.

30.1

30.2 Union nut, DN 20 91835736 (53.058-25)

30.3 O-ring 91835574 (52.141)

30.4 Screw-in part, DN 20 96688372 (53.057-25)

30.5 Reduction, short 96688439 (53.183-25-20)

30.6 Connection nipple 96688427 (53.095-20-1/2)

30.7

30.11

30.30 Insert, DN 20, G 1/2" IG 96708974 (12.6202-400)

30.31 Flowmeter FHKU 100 91834753 (12.6010-1)

30.32 O-ring 96688273 (52.416)

30.40 Post-mixer 95727697 (12.7136-300)

-30 to -2000

-30 to -350 Solenoid valve 230 V, with flow limiter 8 l/min 95729444 (12.3532-420)

-30 to -350 Solenoid valve 115 V, with flow limiter 8 l/min 95729445 (12.3532-421)

-700 to -2000 Solenoid valve 230 V, with flow limiter 16 l/min 95728307 (12.3532-423)

-700 to -2000 Solenoid valve 115 V, with flow limiter 16 l/min 95729446 (12.3532-424)

-30 to -2000

Screw connection, DN 20 96688360 (53.055-25)

Flat gasket 96728862 (54.027)

English (GB)

TM04 8225 4510

10.7 Bypass, circulating pump 230 V - 50 Hz, 120 V - 60 Hz



    



English (GB)

Fig. 34 OCD-164-700 to -2000

Pos. OCD-164 Description Product No.

30.1

30.5 Reduction, short 96688439 (53.183-25-20)

30.6 Connection nipple 96688427 (53.095-20-1/2)

30.10

30.12

30.13

30.14

30.15

30.16 Reduction, short 96688440 (53.183-32-25)

30.17 Flat gasket 96728862 (54.027)

30.18 Screw-in part, G 1/2" 95723548 (12.6492-410)

30.31 Impeller counter FHKU 100 91834753 (12.6010-1)

30.32 O-ring 96688273 (52416)

30.40 Post-mixer 95727697 (12.7136-300)

-30 to -2000

-30 to -350

-700 to -2000 95720032 (53.625-160)

-30 to -2000

Screw connection, DN 20 96688360 (53.055-25)

Flow limiter, 8 or 16 l/min

Circulation pump, 115 V/60 Hz 96688549 (53.650-105) Circulation pump, 230 V/50 Hz 96688548 (53.650-001) Union nut, DN 25 96688378 (53.058-32) Vers. 115 V/union nut, DN 20 91835736 (53.058-25) O-ring 91835567 (52.126) Vers. 115 V/flat gasket 96728899 (54.142) Insert, DN 25 96680700 (12.3503-400) Vers. 115 V/insert, DN 20 96688366 (53.056-25)

TM04 8229 4510

95729418 (53.625-80)

10.8 Bypass (version solenoid valve/ball valve, batch mode)



       





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

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



Fig. 35 OCD-164-30 to OCD-164-220

English (GB)

TM04 8226 4510

Fig. 36 OCD-164-350

Fig. 37 OCD-164-700 to OCD-164-2000

TM04 8227 4510

TM04 8228 4510

English (GB)

Pos. 164-OCD Description Product No.

30.40

30.50 -30 to -2000

30.51

30.52 -350 to -2000 Reduction, short 96688439 (53.183-25-20)

30.53 -350 to -2000 Reduction, short 96688438 (53.183-20-16)

30.54 -2000 Bush 96688411 (53.081-25)

30.57 -700 to -2000 Screw-in part, DN 20 96688372 (53.057-25)

30.58 -700 to -2000 O-ring 91835574 (52141)

30.60

30.61 -700 to -2000 Union nut, DN 20 91835736 (53.058-25)

30.62

30.63

30.64 Reduction, short 96688439 (53.183-25-20) 3065 Reduction, short 96688438 (53.183-20-16)

30.67 Adhesive pipe, PVC, DN 10 95729425 (12.1471)

30.80 Connection nipple 96681152 (12.6674-400)

30.81 O-ring 91835569 (52.131)

30.82 Screw connection, DN 10 96728050 (53.863-16)

-30 to -220 Pressure loading valve, DN 8 95729419 (12.6473-320)

-350 to -2000 Pressure loading valve, DN 20 96376567 (525-1113) Solenoid valve, PVC, 230 V, 50 Hz 96688597 (53919-10) Solenoid valve, PVC, 115 V, 60 Hz 91836553 (53.919-11)

-350 to -2000 Ball valve, DN 10 95729424 (53.564-16)

-30 Needle valve 95700504 (12.6675-400)

-120 to -220 Needle valve 95718301 (12.6675-420)

-700 to -2000 Impeller counter FHKU 100 91834753 (12.6010-1)

-220 Impeller counter FHKU 40 91836632 (12.6010-2)

-350 Impeller counter FHKU 56 95712071 (12.6010-3)

-120 Impeller counter FHKU 20 96681088 (12.6010-5)

-30 Impeller counter FHKU 15 91836552 (12.6010-6)

-30 to -350 Insert, G 1/4" 95729420 (12.6739-400)

-700 to -2000 Insert, DN 20- G 1/2" 96708974 (12.6202-400) O-ring for FHKU 100 96688273 (52.416) O-ring for FHKU 15-56 91835625 (52.337)

-30 to -2000

10.9 Bypass for external booster pump

    

 

Fig. 38 Assembly drawing OCD-164-700 to OCD-164-2000

Pos. OCD-164 Description Product No.

30.2

30.3 O-ring 91835574 (52.141)

30.4 Screw-in part, DN 20 96688372 (53.057-25)

30.5 Reduction, short 96688439 (53183-25-20)

30.6 Connection nipple 96688427 (53.095-20-1/2)

30.10

30.11

30.30 Screw-in part, DN 20, G 1/2", IG 96708974 (12.6202-400)

30.31 Impeller counter FHKU 100 91834753 (12.6010-1)

30.32 O-ring 96688273 (52.416)

30.40 Post-mixer 95727697 (12.7136-300)

-30 to -2000

-30 to -350 Flow limiter, 8 l/min 95729418 (53.625-80)

-700 to -2000 Flow limiter, 16 l/min 95720032 (53.625-160)

-30 to -2000

Union nut, DN 20 91835736 (53.058-25)

Flat gasket 96728862 (54.027)

English (GB)

TM04 8230 4510

11. Accessories

0.0 0.2 0.4 0.6 0.8 1.0 1.2 1.4 1.6 1.8 2.0 2.2

Q [m³/h]

100

120

140

160

180

200

220

[m]

0.0 0.1 0.2 0.3 0.4 0. 5 0.6

Q [l/s]

400

800

1200

1600

2000

[kP a]

CR, CRE 1

50 Hz

IS O 9906 Annex A

-2

-3 (E )

-4

-5

-6

-7 (E )

-8

-9

-10

-11 (E )

-12

-13

-15 (E )

-17

-19 (E )

-21

-23 (E )

-25

-27

-30 (E )

-33

-36 (E )

English (GB)

11.1 External booster pump

The booster pump is selected according to the difference between the pressure of dilution water supply and the system pressure at the injection unit.

11.1.1 Technical data

Fig. 39 Technical data for the booster pump, material SS 1.4404

11.1.2 Pump types

Pump type

Increase of

pressure

Version Voltage

CR 1-3 Approx. 18 m CR 1-5 Approx. 30 m 95701941 (660-0018-1) CR 1-7 Approx. 40 m 95720986 (660-0019-1) CR 1-9 Approx. 52 m

with connection screwing, DN 25

CR 1-11 Approx. 62 m 95729341 (660-0021-1)

3 x 220-240 V /

380-415 V, 50 Hz

Nominal current

[A]

1.66 0.377

2.5 0.55

TM04 8231 4510

Motor [kW] Product No.

95713041 (660-0017-1)

95729340 (660-0020-1)

11.1.3 Dimensions

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English (GB)

Fig. 40 Dimensioning of booster pump

Pump type Motor [kW]

CR 1-2

CR 1-4 272 463 297 488 CR 1-5 290 481 315 506 CR 1-6 308 499 333 524 CR 1-7 326 517 351 542 25 CR 1-8

CR 1-10 380 571 405 596 CR 1-11 398 589 423 614 27 CR 1-12 CR 1-13 440 671 465 696 25 CR 1-15 476 707 501 732 26 30 CR 1-17 CR 1-19 548 779 573 804 34 CR 1-21 584 815 609 840 30 35 CR 1-23 620 851 645 876 31 36 CR 1-25 CR 1-27 733 1014 CR 1-30 787 1068 - 46 CR 1-33 CR 1-36 895 1216 - 49

0.37

0.55

0.75

1.1

1.5

2.2

Oval flange DIN flange

B1 B1 + B2 B1 B1 + B2

254 445 279 470

344 535 369 560

422 653 447 678 24

512 743 537 768

Dimensions Net weight

697 978

841 1162 - 47

D1 D2

141 109

178 110

Oval

flange

DIN flange

TM04 8237 4510

23CR 1-3

26CR 1-9 362 553 387 578

11.2 Load unit for booster pump

Note

Caution

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Caution

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English (GB)

The booster pump is connected to the controller of the system via a load unit.

Fig. 41 Load unit for booster pump

Pos. Description

Motor-protective circuit breaker The nominal current of the pump is adjusted at the

motor-protective circuit breaker, see data sheet of booster pump.

Connection cable

The load unit is connected to the controller of the system. Terminal 22 = L, terminal 23 = N, terminal 24 = PE

If a system with bypass for the external booster pump is selected, observe the following table for the selection of the load unit.

When adjusting the motor-protective circuit breaker, observe the nominal current of the dosing pump.

Pump type Electrical data Product No.

CR 1-3 CR 1-5 CR 1-7

CR 1-9, CR 1-11

1.6 - 2.5 A, 230 V, 50/60 Hz 96728835 (535-50)

1.6 - 2.5 A, 115 V, 50/60 Hz 96728836 (535-51)

2.5 - 4.0 A, 230 V, 50/60 Hz 96728837 (535-52)

2.5 - 4.0 A, 115 V, 50/60 Hz 96728838 (535-53)

11.3 Hose connections/hose

Hose connection, DN 20 Product No.

Hose connection DN 20 - ID 25 mm with 2 hose clamps.

96727534 (529-050)

Fig. 43 Hose connection

Connection screwing Product No.

Connection screwing for external booster pump Rp 1" AG - ID 25 mm

96727536 (529-051)

with 2 hose clamps.

TM04 8232 4510

Fig. 44 Connection screwing for external booster pump

PVC hose Length Product No.

5 m 95700198 (526-030/5)

PVC hose, ID 25 mm, PN 6

10 m 95700852 (526-030/10) 25 m 95729449 (526-030/25)

Max. system pressure for PVC hose 6 bar. For a higher system pressure, install a PVC pipe

(DN 16).

11.4 Gas sensor and gas warning device

The gas sensor can be mounted at the rear of the system underneath the reactor. The required fastening screw (countersunk screw M6x20) is included in the mounting material of the system.

Description Product No.

Gas sensor 91835237 (314-011) Conex DIS-G gas warning unit 96644515 (307-2000)

Observe the installation and operating instructions of the Conex DIS-G gas warning unit or the 314 gas sensor.

TM04 8234 4510

TM04 8235 4510

Fig. 42 Terminal connection diagram load unit (booster pump)

The gas sensor cannot be connected directly to the controller of the system. A gas warning unit is required in addition. Cabling is carried out on site.

TM04 8233 4510

12. Current setting data

Settings of the system

System type OCD-164-030 OCD-164-120 OCD-164-220 OCD-164-350

OCD-164-700 OCD-164-1000 OCD-164-1500 OCD-164-2000

Main water quantity m3/h

Default ClO

Operation mode

Batch mode Batch concentration: g/l

Current input 0-20 mA 4-20 mA others

Contact input Contact water meter: Pulses/litre

Manual control

Bus control

Flow rates

Bypass water quantity l/h Limit - % + %

Flow NaClO

Flow HCl l/h Stroke setting of pump %

l/h Stroke setting of pump %

ppm

English (GB)

System mode

Automatic operation

Manual operation Dosing flow %

Startup

Date

Company

Signature

Remarks

13. Quick Guide

F1 F2 F3 F4

Main menu 1 Automatic 2 Manual operation 3 Logbook

12 3

F1 F2 F3 F4

Auto: 20 mA Dosing Bypass ClO

active

100 %

435 l/h

10 g/h

F1 F2 F3 F4

Dosing Bypass ClO

3 Logbook

100 %

435 l/h

10 g/h

English (GB)

Fig. 45 Controller, overview

Pos. Description

Display

• 1 = Switch to submenu using [F1].

• 2 = Switch to submenu using [F2].

• 3 = Switch to submenu using [F3]. Function keys [F1], [F2, [F3]

• Switch to respective submenu. Arrow keys

• Scroll in respective menu. [F4] key

• Acknowledge alarm messages. [Enter] key

• Switch system on/off.

• Confirm inputs. [Escape] key

• Return to preceding menu.

• Return to main menu (press key several times).

• Cancel input.

Example: automatic mode, current input signal

TM04 8236 4510

Fig. 46 Display in operating state

In the operating state, the most important information is displayed, such as dosing, bypass water quantity, and system capacity.

The user cannot switch to the submenus using the [F1], [F2], [F3] and [F4] keys.

Logbook

• Press the [UP] or [DOWN] arrow key.

TM04 8236 4510

Fig. 47 Display in operating state

• Subsequently press the [F3] key. The "Logbook" menu with the items "active alarms", "alarm list", and "operating hours" is now loaded.

• Use the [Escape] key to return to the automatic operation display menu.

14. Disposal

This product or parts of it must be disposed of in an environmentally sound way:

1. Use the public or private waste collection service.

2. If this is not possible, contact the nearest Grundfos company

or service workshop.

Declaration of conformity 1

GB: EU declaration of conformity

We, Grundfos, declare under our sole responsibility that the products Oxiperm OCD-164, to which the declaration below relates, are in conformity with the Council Directives listed below on the approximation of the laws of the EU member states.

DE: EU-Konformitätserklärung

Wir, Grundfos, erklären in alleiniger Verantwortung, dass die Produkte Oxiperm OCD-164, auf die sich diese Erklärung beziehen, mit den folgenden Richtlinien des Rates zur Angleichung der Rechtsvorschriften der EU-Mitgliedsstaaten übereinstimmen.

FI: EU-vaatimustenmukaisuusvakuutus

Grundfos vakuuttaa omalla vastuullaan, että tuotteet Oxiperm OCD-164, joita tämä vakuutus koskee, ovat EU:n jäsenvaltioiden lainsäädännön lähentämiseen tähtäävien Euroopan neuvoston direktiivien vaatimusten mukaisia seuraavasti.

IT: Dichiarazione di conformità UE

Grundfos dichiara sotto la sua esclusiva responsabilità che i prodotti Oxiperm OCD-164, ai quale si riferisce questa dichiarazione, sono conformi alle seguenti direttive del Consiglio riguardanti il riavvicinamento delle legislazioni degli Stati membri UE.

PT: Declaração de conformidade UE

A Grundfos declara sob sua única responsabilidade que os produtos Oxiperm OCD-164, aos quais diz respeito a declaração abaixo, estão em conformidade com as Directivas do Conselho sobre a aproximação das legislações dos Estados Membros da UE.

SI: Izjava o skladnosti EU

V Grundfosu s polno odgovornostjo izjavljamo, da je izdelek Oxiperm OCD-164, na katerega se spodnja izjava nanaša, v skladu s spodnjimi direktivami Sveta o približevanju zakonodaje za izenačevanje pravnih predpisov držav članic EU.

CZ: Prohlášení o shodě EU

My firma Grundfos prohlašujeme na svou plnou odpovědnost, že výrobek Oxiperm OCD-164, na který se toto prohlášení vztahuje, je v souladu s níže uvedenými ustanoveními směrnice Rady pro sblížení právních předpisů členských států Evropského společenství.

ES: Declaración de conformidad de la UE

Grundfos declara, bajo su exclusiva responsabilidad, que los productos Oxiperm OCD-164 a los que hace referencia la siguiente declaración cumplen lo establecido por las siguientes Directivas del Consejo sobre la aproximación de las legislaciones de los Estados miembros de la UE.

FR: Déclaration de conformité UE

Nous, Grundfos, déclarons sous notre seule responsabilité, que les produits Oxiperm OCD-164, auxquels se réfère cette déclaration, sont conformes aux Directives du Conseil concernant le rapprochement des législations des États membres UE relatives aux normes énoncées ci-dessous.

NL: EU-conformiteitsverklaring

Wij, Grundfos, verklaren geheel onder eigen verantwoordelijkheid dat de producten Oxiperm OCD-164, waarop de onderstaande verklaring betrekking heeft, in overeenstemming zijn met de onderstaande Richtlijnen van de Raad inzake de onderlinge aanpassing van de wetgeving van de EU-lidstaten.

RU: Декларация о соответствии нормам ЕС

Мы, компания Grundfos, со всей ответственностью заявляем, что изделия Oxiperm OCD-164, к которым относится нижеприведённая декларация, соответствуют нижеприведённым Директивам Совета Евросоюза о тождественности законов стран-членов ЕС.

— Machinery Directive (2006/42/EC).

Standards used: EN 809:2012, DIN EN ISO 12100:2010 EN ISO 13849-1:2008.

— Low Voltage Directive (2014/35/EU).

Standard used: EN 61010-1:2011-07.

— EMC Directive (2014/30/EU).

Standards used: EN 61000-3-11:2001 EN 61000-6-2:2006 EN 61000-6-4:2007+A1:2011 EN 61326-1:2013.

This EU declaration of conformity is only valid when published as part of the Grundfos installation and operating instructions (publication number 96709679).

Pfinztal, 1 May 2016

Declaration of conformity

Ulrich Stemick

Technical Director

Grundfos Water Treatment GmbH

Reetzstr. 85, D-76327 Pfinztal, Germany

Person authorised to compile technical file and

empowered to sign the EU declaration of conformity.

Declaration of conformity RU

Declaration of conformity RU 2

Установки автоматические для приготовления и дозирования диоксида хлора типа Oxiperm модели OCD 164, Pro OCD 162 сертифицированы на соответствие требованиям Технических регламентов Таможенного союза: ТР ТС 004/2011 «О безопасности низковольтного оборудования»; ТР ТС 010/2011 «О безопасности машин и оборудования»; ТР ТС 020/2011 «Электромагнитная совместимость технических средств». Сертификат соответствия:

№ TC RU C-DK.АИ30.B.01026, срок действия до 19.10.2019г.

Выдан: Органом по сертификации продукции

«ИВАНОВО-

СЕРТИФИКАТ» ООО «Ивановский Фонд Сертификации». Адрес: 153032, Российская Федерация, г. Иваново, ул.

Станкостроителей, д.1.

Истра, 1 марта 2016 г.

Касаткина В. В.

Руководитель отдела качества,

экологии и охраны труда

ООО Грундфос Истра, Россия

143581, Московская область,

Истринский район,

дер. Лешково, д.188

Argentina

Bombas GRUNDFOS de Argentina S.A. Ruta Panamericana km. 37.500 Centro Industrial Garin 1619 - Garin Pcia. de B.A. Phone: +54-3327 414 444 Telefax: +54-3327 411 111

Australia

GRUNDFOS Pumps Pty. Ltd. P.O. Box 2040 Regency Park South Australia 5942 Phone: +61-8-8461-4611 Telefax: +61-8-8340 0155

Austria

GRUNDFOS Pumpen Vertrieb Ges.m.b.H. Grundfosstraße 2 A-5082 Grödig/Salzburg Tel.: +43-6246-883-0 Telefax: +43-6246-883-30

Belgium

N.V. GRUNDFOS Bellux S.A. Boomsesteenweg 81-83 B-2630 Aartselaar Tél.: +32-3-870 7300 Télécopie: +32-3-870 7301

Belarus

Представительство ГРУНДФОС в Минске 220125, Минск ул. Шафарнянская, 11, оф. 56 Тел.: +7 (375 17) 286 39 72, 286 39 73 Факс: +7 (375 17) 286 39 71

E-mail: minsk@grundfos.com

Bosnia/Herzegovina

GRUNDFOS Sarajevo Trg Heroja 16, BiH-71000 Sarajevo Phone: +387 33 713 290 Telefax: +387 33 659 079 e-mail: grundfos@bih.net.ba

Brazil

BOMBAS GRUNDFOS DO BRASIL Av. Humberto de Alencar Castelo Branco, 630 CEP 09850 - 300 São Bernardo do Campo - SP Phone: +55-11 4393 5533 Telefax: +55-11 4343 5015

Bulgaria

Grundfos Bulgaria EOOD Slatina District Iztochna Tangenta street no. 100 BG - 1592 Sofia Tel. +359 2 49 22 200 Fax. +359 2 49 22 201 email: bulgaria@grundfos.bg

Canada

GRUNDFOS Canada Inc. 2941 Brighton Road Oakville, Ontario L6H 6C9 Phone: +1-905 829 9533 Telefax: +1-905 829 9512

China

Grundfos Alldos Dosing & Disinfection

ALLDOS (Shanghai) Water Technology Co. Ltd. West Unit, 1 Floor, No. 2 Building (T 4-2) 278 Jinhu Road, Jin Qiao Export Processing Zone Pudong New Area Shanghai, 201206 Phone: +86 21 5055 1012 Telefax: +86 21 5032 0596 E-mail: grundfosalldos-C N@grundfos.com

China

GRUNDFOS Pumps (Shanghai) Co. Ltd. 10F The Hub, No. 33 Suhong Road Minhang District Shanghai 201106 PRC Phone: +86-21 6122 5222 Telefax: +86-21 6122 5333

COLOMBIA

GRUNDFOS Colombia S.A.S. Km 1.5 vía Siberia-Cota Conj. Potrero Chico, Parque Empresarial Arcos de Cota Bod. 1A. Cota, Cundinamarca Phone: +57(1)-2913444 Telefax: +57(1)-8764586

Croatia

GRUNDFOS CROATIA d.o.o. Cebini 37, Buzin HR-10010 Zagreb Phone: +385 1 6595 400 Telefax: +385 1 6595 499 www.hr.grundfos.com

GRUNDFOS Sales Czechia and Slovakia s.r.o.

Čapkovského 21 779 00 Olomouc Phone: +420-585-716 111

Denmark

GRUNDFOS DK A/S Martin Bachs Vej 3 DK-8850 Bjerringbro Tlf.: +45-87 50 50 50 Telefax: +45-87 50 51 51 E-mail: info_GDK@grundfos.com www.grundfos.com/DK

Estonia

GRUNDFOS Pumps Eesti OÜ Peterburi tee 92G 11415 Tallinn Tel: + 372 606 1690 Fax: + 372 606 1691

Finland

OY GRUNDFOS Pumput AB Trukkikuja 1 FI-01360 Vantaa Phone: +358-(0)207 889 500

France

Pompes 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

Germany

GRUNDFOS Water Treatment GmbH Reetzstraße 85 D-76327 Pfinztal (Söllingen) Tel.: +49 7240 61-0 Telefax: +49 7240 61-177 E-mail: gwt@grundfos.com

Germany

GRUNDFOS GMBH Schlüterstr. 33 40699 Erkrath Tel.: +49-(0) 211 929 69-0 Telefax: +49-(0) 211 929 69-3799 E-mail: infoservice@grundfos.de Service in Deutschland: E-mail: kundendienst@grundfos.de

Greece

GRUNDFOS Hellas A.E.B.E. 20th km. Athinon-Markopoulou Av. P.O . B o x 71 GR-19002 Peania Phone: +0030-210-66 83 400 Telefax: +0030-210-66 46 273

Hong Kong

GRUNDFOS 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

Hungary

GRUNDFOS Hungária Kft. Park u. 8 H-2045 Törökbálint, Phone: +36-23 511 110 Telefax: +36-23 511 111

India

GRUNDFOS Pumps India Private Limited 118 Old Mahabalipuram Road Thoraipakkam Chennai 600 097 Phone: +91-44 4596 6800

Indonesia

PT. GRUNDFOS POMPA Graha Intirub Lt. 2 & 3 Jln. Cililitan Besar No.454. Makasar, Jakarta Timur ID-Jakarta 13650 Phone: +62 21-469-51900 Telefax: +62 21-460 6910 / 460 6901

Ireland

GRUNDFOS (Ireland) Ltd. Unit A, Merrywell Business Park Ballymount Road Lower Dublin 12 Phone: +353-1-4089 800 Telefax: +353-1-4089 830

Italy

GRUNDFOS Pompe Italia S.r.l. Via Gran Sasso 4 I-20060 Truccazzano (Milano) Tel.: +39-02-95838112 Telefax: +39-02-95309290 / 95838461

Japan

GRUNDFOS Pumps K.K. 1-2-3, Shin-Miyakoda, Kita-ku Hamamatsu 431-2103 Japan Phone: +81 53 428 4760 Telefax: +81 53 428 5005

Korea

GRUNDFOS Pumps Korea Ltd. 6th Floor, Aju Building 679-5 Yeoksam-dong, Kangnam-ku, 135-916 Seoul, Korea Phone: +82-2-5317 600 Telefax: +82-2-5633 725

Latvia

SIA GRUNDFOS Pumps Latvia Deglava biznesa centrs Augusta Deglava ielā 60, LV-1035, Rīga, Tālr.: + 371 714 9640, 7 149 641 Fakss: + 371 914 9646

Lithuania

GRUNDFOS Pumps UAB Smolensko g. 6 LT-03201 Vilnius Tel: + 370 52 395 430 Fax: + 370 52 395 431

Malaysia

GRUNDFOS Pumps Sdn. Bhd. 7 Jalan Peguam U1/25 Glenmarie Industrial Park 40150 Shah Alam Selangor Phone: +60-3-5569 2922 Telefax: +60-3-5569 2866

Mexico

Bombas GRUNDFOS de México S.A. de C.V. Boulevard TLC No. 15 Parque Industrial Stiva Aeropuerto Apodaca, N.L. 66600 Phone: +52-81-8144 4000 Telefax: +52-81-8144 4010

Netherlands

GRUNDFOS Netherlands Velu we zo om 35 1326 AE Almere Postbus 22015 1302 CA ALMERE Tel.: +31-88-478 6336 Telefax: +31-88-478 6332 E-mail: info_gnl@grundfos.com

New Zealand

GRUNDFOS Pumps NZ Ltd. 17 Beatrice Tinsley Crescent North Harbour Industrial Estate Albany, Auckland Phone: +64-9-415 3240 Telefax: +64-9-415 3250

Norway

GRUNDFOS Pumper A/S Strømsveien 344 Postboks 235, Leirdal N-1011 Oslo Tlf.: +47-22 90 47 00 Telefax: +47-22 32 21 50

Poland

GRUNDFOS Pompy Sp. z o.o. ul. Klonowa 23 Baranowo k. Poznania PL-62-081 Przeźmierowo Tel: (+48-61) 650 13 00 Fax: (+48-61) 650 13 50

Portugal

Bombas GRUNDFOS Portugal, S.A. Rua Calvet de Magalhães, 241 Apartado 1079 P-2770-153 Paço de Arcos Tel.: +351-21-440 76 00 Telefax: +351-21-440 76 90

Romania

GRUNDFOS Pompe România SRL Bd. Biruintei, nr 103 Pantelimon county Ilfov Phone: +40 21 200 4100 Telefax: +40 21 200 4101 E-mail: romania@grundfos.ro

Russia

ООО Грундф ос ул. Школьная, 39-41 Москва, RU-109544, Russia Тел. (+7) 495 737 30 00, 564 8800 Факс (+7) 495 737 75 36, 564 8811

E-mail grundfos.moscow@grundfos.com

Serbia

GRUNDFOS Predstavništvo Beograd Dr. Milutina Ivkovića 2a/29 YU-11000 Beograd Phone: +381 11 26 47 877 / 11 26 47 496 Telefax: +381 11 26 48 340

Singapore

GRUNDFOS (Singapore) Pte. Ltd. 25 Jalan Tukang Singapore 619264 Phone: +65-6681 9688 Telefax: +65-6681 9689

Slovakia

GRUNDFOS s.r.o. Prievozská 4D 821 09 BRATISLAVA Phona: +421 2 5020 1426 sk.grundfos.com

Slovenia

GRUNDFOS LJUBLJANA, d.o.o. Leskoškova 9e, 1122 Ljubljana Phone: +386 (0) 1 568 06 10 Telefax: +386 (0)1 568 0619 E-mail: tehnika-si@grundfos.com

South Africa

Grundfos (PTY) Ltd. Corner Mountjoy and George Allen Roads Wilbart Ext. 2 Bedfordview 2008 Phone: (+27) 11 579 4800 Fax: (+27) 11 455 6066 E-mail: lsmart@grundfos.com

Spain

Bombas GRUNDFOS España S.A. Camino de la Fuentecilla, s/n E-28110 Algete (Madrid) Tel.: +34-91-848 8800 Telefax: +34-91-628 0465

Sweden

GRUNDFOS AB (Box 333) Lunnagårdsgatan 6 431 24 Mölndal Tel.: +46 31 332 23 000 Telefax: +46 31-331 94 60

Switzerland

GRUNDFOS ALLDOS International AG Schönmattstraße 4 CH-4153 Reinach Tel.: +41-61-717 5555 Telefax: +41-61-717 5500 E-mail: grundfosalldos-CH@grundfos.com

Switzerland

GRUNDFOS Pumpen AG Bruggacherstrasse 10 CH-8117 Fällanden/ZH Tel.: +41-44-806 8111 Telefax: +41-44-806 8115

Taiwan

GRUNDFOS Pumps (Taiwan) Ltd. 7 Floor, 219 Min-Chuan Road Taichung, Taiwan, R.O.C. Phone: +886-4-2305 0868 Telefax: +886-4-2305 0878

Thailand

GRUNDFOS (Thailand) Ltd. 92 Chaloem Phrakiat Rama 9 Road, Dokmai, Pravej, Bangkok 10250 Phone: +66-2-725 8999 Telefax: +66-2-725 8998

Turkey

GRUNDFOS POMPA San. ve Tic. Ltd. Sti. Gebze Organize Sanayi Bölgesi Ihsan dede Caddesi,

2. yol 200. Sokak No. 204 41490 Gebze/ Kocaeli Phone: +90 - 262-679 7979 Telefax: +90 - 262-679 7905 E-mail: satis@grundfos.com

Ukraine

Бізнес Центр Європа Столичне шосе, 103 м. Київ, 03131, Україна Телефон : (+38 044) 237 04 00 Факс.: (+38 044) 237 04 01

E-mail: ukraine@grundfos.com

United Arab Emirates

GRUNDFOS Gulf Distribution P.O. Box 16768 Jebel Ali Free Zone Dubai Phone: +971-4- 8815 166 Telefax: +971-4-8815 136

United Kingdom

GRUNDFOS Pumps Ltd. Grovebury Road Leighton Buzzard/Beds. LU7 4TL Phone: +44-1525-850000 Telefax: +44-1525-850011

U.S.A.

GRUNDFOS Pumps Corporation 17100 West 118th Terrace Olathe, Kansas 66061 Phone: +1-913-227-3400 Telefax: +1-913-227-3500

Uzbekistan

Grundfos Tashkent, Uzbekistan The Representative Office of Grundfos Kazakhstan in Uzbekistan 38a, Oybek street, Tashkent Телефон: (+998) 71 150 3290 / 71 150 3291 Факс: (+998) 71 150 3292

Addresses revised 09.08.2017

Grundfos companies

96709679 1117

ECM: 1215430

www.grundfos.com

The name Grundfos, the Grundfos logo, and be think innovate are registered trademarks owned by Grundfos Holding A/S or Grundfos A/S, Denmark. All rights reserved worldwide. © Copyright Grundfos Holding A/S

Grundfos Oxiperm OCD-164 Installation And Operating Instructions Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

English (GB)

1. General safety instructions

1.1 Introduction

1.2 Purpose of this manual

1.3 Symbols used in this document

1.4 Users

1.4.1 Obligations of the users

1.4.2 User workstation

1.5 Obligations of the operator

1.8 Inappropriate usage

1.9 Safety and monitoring equipment

1.10 Chemicals

1.10.1 Chlorine dioxide concentration

1.6 Maintenance and service personnel

1.7 Correct usage

1.10.2 Storing chemicals

1.10.3 Procedure in case of an emergency

2. Technical data

2.1 General data

2.1.1 Performance and consumption data

2.1.2 Temperatures and concentrations 2.1.3 Materials

Components Materials

2.1.4 Connections and weights

2.1.5 Dimensions

2.2 Electrical data

2.2.1 Power consumption

2.2.2 IP codes

2.3 Delivery state

3. Fundamentals

3.1 Chlorine dioxide for water treatment

3.1.1 Preparation of chlorine dioxide

3.2 Functional sequence

4. Design and function

4.1 Design of the system

4.2 Components

4.2.1 Suction lines

4.2.2 Dosing pumps

4.2.3 Dosing controller

4.2.4 Reactor

4.2.5 Bypass

4.2.6 Post-mixer

4.2.7 Options

4.3 Mode of operation of the system

4.3.1 How the system operates in batch mode

5. Installation

5.1 Transport and storage

5.2 Unpacking

5.3 Installation location

5.4 Installation scheme

5.4.1 System with solenoid valve

5.4.2 System with internal bypass pump

5.4.3 System with external booster pump and load unit

5.4.4 System with solenoid valve/ball valve (batch tank)

5.5 Wall mounting

5.6 Hydraulic connection

5.6.1 Bypass

5.6.2 Safety exhaust device (option)

5.7 Electrical connection

5.7.1 Terminal connection diagram

5.7.2 Power supply

5.7.3 Potential-free outputs

5.7.4 Inputs +8 V

5.7.5 Inputs +12 V

5.7.6 Analog signals

5.7.7 Profibus/Ethernet (option)

5.8 Interfaces RS-232, -422 and -485

5.8.1 Connection of RS-232 interface

5.8.2 Connection of RS-422 and -485 interfaces

6. Operation of control electronics

6.1 Program structure

6.2 Control and display elements

6.3 Automatic mode

6.4 Manual operation

6.5 Logbook

6.6 System choice

6.6.1 System type