Grundfos Oxiperm Pro OCD-162-5, Oxiperm Pro OCD-162 Series, Oxiperm Pro OCD-162-10, Oxiperm Pro OCD-162-30, Oxiperm Pro OCD-162-60 Installation And Operating Instructions Manual
Oxiperm® Pro
OCD-162
Installation and operating instructions
GRUNDFOS INSTRUCTIONS
Declaration of conformity
Declaration of conformity
GB: EC declaration of conformity
We, Grundfos, declare under our sole responsibility that the products
Oxiperm® Pro, to which this declaration relates, are in conformity with
these Council directives on the approximation of the laws of the EC
member states:
— Machinery Directive (2006/42/EC).
Standards used: EN 809: 1998, EN ISO 12100-1+A1: 2009,
EN ISO 12100-2+A1: 2009.
— Low Voltage Directive (2006/95/EC).
Standard used: EN 61010-1: 2001 (second edition).
— EMC Directive (2004/108/EC).
Standards used: EN 61326-1: 2006,
EN 61000-3-2: 2006+A1: 2009+A2: 2009, EN 61000-3-3: 2008.
This EC declaration of conformity is only valid when published as part of
the Grundfos installation and operating instructions.
DK: EF-overensstemmelseserklæring
Vi, Grundfos, erklærer under ansvar at produkterne Oxiperm® Pro som
denne erklæring omhandler, er i overensstemmelse med disse af Rådets
direktiver om indbyrdes tilnærmelse til EF-medlemsstaternes lovgivning:
— Maskindirektivet (2006/42/EF).
Anvendte standarder: EN 809: 1998, EN ISO 12100-1+A1: 2009,
EN ISO 12100-2+A1: 2009.
— Lavspændingsdirektivet (2006/95/EF).
Anvendt standard: EN 61010-1: 2001 (anden udgave).
— EMC-direktivet (2004/108/EF).
Anvendte standarder: EN 61326-1: 2006,
EN 61000-3-2: 2006+A1: 2009+A2: 2009, EN 61000-3-3: 2008.
Denne EF-overensstemmelseserklæring er kun gyldig når den publiceres
som en del af Grundfos-monterings- og driftsinstruktionen.
ES: Declaración CE de conformidad
Nosotros, Grundfos, declaramos bajo nuestra entera responsabilidad
que los productos Oxiperm® Pro, a los cuales se refiere esta declaración,
están conformes con las Directivas del Consejo en la aproximación de
las leyes de las Estados Miembros del EM:
— Directiva de Maquinaria (2006/42/CE).
Normas aplicadas: EN 809: 1998, EN ISO 12100-1+A1: 2009,
EN ISO 12100-2+A1: 2009.
— Directiva de Baja Tensión (2006/95/CE).
Norma aplicada: EN 61010-1: 2001 (segunda edición).
— Directiva EMC (2004/108/CE).
Normas aplicadas: EN 61326-1: 2006,
EN 61000-3-2: 2006+A1: 2009+A2: 2009, EN 61000-3-3: 2008.
Esta declaración CE de conformidad sólo es válida cuando se publique
como parte de las instrucciones de instalación y funcionamiento de
Grundfos.
IT: Dichiarazione di conformità CE
Grundfos dichiara sotto la sua esclusiva responsabilità che i prodotti
Oxiperm® Pro, ai quali si riferisce questa dichiarazione, sono conformi
alle seguenti direttive del Consiglio riguardanti il riavvicinamento delle
legislazioni degli Stati membri CE:
— Direttiva Macchine (2006/42/CE).
Norme applicate: EN 809: 1998, EN ISO 12100-1+A1: 2009,
EN ISO 12100-2+A1: 2009.
— Direttiva Bassa Tensione (2006/95/CE).
Norma applicata: EN 61010-1: 2001 (seconda edizione).
— Direttiva EMC (2004/108/CE).
Norme applicate: EN 61326-1: 2006,
EN 61000-3-2: 2006+A1: 2009+A2: 2009, EN 61000-3-3: 2008.
Questa dichiarazione di conformità CE è valida solo quando pubblicata
come parte delle istruzioni di installazione e funzionamento Grundfos.
BG: EC декларация за съответствие
Ние, фирма Grundfos, заявяваме с пълна отговорност, че продуктите
Oxiperm® Pro, за които се отнася настоящата декларация, отговарят
на следните указания на Съвета за уеднаквяване на правните
разпоредби на държавите членки на ЕС:
— Директива за машините (2006/42/EC).
Приложени стандарти: EN 809: 1998, EN ISO 12100-1+A1: 2009,
EN ISO 12100-2+A1: 2009.
— Директива за нисковолтови системи (2006/95/EC).
Приложен стандарт: EN 61010-1: 2001 (второ издание).
— Директива за електромагнитна съвместимост (2004/108/EC).
Приложени
EN 61000-3-2: 2006+A1: 2009+A2: 2009, EN 61000-3-3: 2008.
Тази ЕС декларация за съответствие е валидна само когато е
публикувана като част от инструкциите за монтаж и експлоатация на
Grundfos.
стандарти: EN 61326-1: 2006,
DE: EG-Konformitätserklärung
Wir, Grundfos, erklären in alleiniger Verantwortung, dass die Produkte
Oxiperm® Pro, auf die sich diese Erklärung bezieht, mit den folgenden
Richtlinien des Rates zur Angleichung der Rechtsvorschriften der
EU-Mitgliedsstaaten übereinstimmen:
— Maschinenrichtlinie (2006/42/EG).
Normen, die verwendet wurden: EN 809: 1998,
EN ISO 12100-1+A1: 2009, EN ISO 12100-2+A1: 2009.
— Niederspannungsrichtlinie (2006/95/EG).
Norm, die verwendet wurde: EN 61010-1: 2001 (zweite Ausgabe).
— EMV-Richtlinie (2004/108/EG).
Normen, die verwendet wurden: EN 61326-1: 2006,
EN 61000-3-2: 2006+A1: 2009+A2: 2009, EN 61000-3-3: 2008.
Diese EG-Konformitätserklärung gilt nur, wenn sie in Verbindung mit der
Grundfos Montage- und Betriebsanleitung veröffentlicht wird.
FR: Déclaration de conformité CE
Nous, Grundfos, déclarons sous notre seule responsabilité, que les
produits DDA, DDC et DDE, auxquels se réfère cette déclaration, sont
conformes aux Directives du Conseil concernant le rapprochement
des législations des Etats membres CE relatives aux normes énoncées
ci-dessous :
— Directive Machines (2006/42/CE).
Normes utilisées : EN 809: 1998, EN ISO 12100-1+A1: 2009,
EN ISO 12100-2+A1: 2009.
— Directive Basse Tension (2006/95/CE).
Norme utilisée : EN 61010-1: 2001 (deuxième édition).
— Directive Compatibilité Electromagnétique CEM (2004/108/CE).
Normes utilisées : EN 61326-1: 2006,
EN 61000-3-2: 2006+A1: 2009+A2: 2009, EN 61000-3-3: 2008.
Cette déclaration de conformité CE est uniquement valide lors de sa
publication dans la notice d'installation et de fonctionnement Grundfos.
NL: EC overeenkomstigheidsverklaring
Wij, Grundfos, verklaren geheel onder eigen verantwoordelijkheid dat
de producten Oxiperm® Pro waarop deze verklaring betrekking heeft,
in overeenstemming zijn met de Richtlijnen van de Raad in zake de
onderlinge aanpassing van de wetgeving van de EG Lidstaten
betreffende:
— Machine Richtlijn (2006/42/EC).
Gebruikte normen: EN 809: 1998, EN ISO 12100-1+A1: 2009,
EN ISO 12100-2+A1: 2009.
— Laagspannings Richtlijn (2006/95/EC).
Gebruikte norm: EN 61010-1: 2001 (tweede editie).
— EMC Richtlijn (2004/108/EC).
Gebruikte normen: EN 61326-1: 2006,
EN 61000-3-2: 2006+A1: 2009+A2: 2009, EN 61000-3-3: 2008.
Deze EC overeenkomstigheidsverklaring is alleen geldig wanneer deze
gepubliceerd is als onderdeel van de Grundfos installatie- en
bedieningsinstructies.
2
PL: Deklaracja zgodności WE
My, Grundfos, oświadczamy z pełną odpowiedzialnością, że nasze
wyroby Oxiperm® Pro, których deklaracja niniejsza dotyczy, są zgodne
z następującymi wytycznymi Rady d/s ujednolicenia przepisów prawnych
krajów członkowskich WE:
— Dyrektywa Maszynowa (2006/42/WE).
Zastosowane normy: EN 809: 1998, EN ISO 12100-1+A1: 2009,
EN ISO 12100-2+A1: 2009.
— Dyrektywa Niskonapięciowa (LVD) (2006/95/WE).
Zastosowana norma: EN 61010-1: 2001 (drugie wydanie).
— Dyrektywa EMC (2004/108/WE).
Zastosowane normy: EN 61326-1: 2006,
EN 61000-3-2: 2006+A1: 2009+A2: 2009, EN 61000-3-3: 2008.
Deklaracja zgodności WE jest ważna tylko i wyłącznie wtedy kiedy jest
opublikowana przez firmę Grundfos i umieszczona w instrukcji montażu
i eksploatacji.
RU: Декларация о соответствии ЕС
Мы, компания Grundfos, со всей ответственностью заявляем, что
изделия Oxiperm® Pro, к которым относится настоящая декларация,
соответствуют следующим Директивам Совета Евросоюза об
унификации законодательных предписаний стран-членов ЕС:
— Механические устройства (2006/42/ЕС).
Применявшиеся стандарты: EN 809: 1998,
EN ISO 12100-1+A1: 2009, EN ISO 12100-2+A1: 2009.
— Низковольтное оборудование (2006/95/EC).
Применявшийся стандарт: EN 61010-1: 2001 (второе издание).
— Электромагнитная совместимость (2004/108/EC).
Применявшиеся стандарты: EN 61326-1: 2006,
EN 61000-3-2: 2006+A1: 2009+A2: 2009, EN 61000-3-3: 2008.
Данная декларация о соответствии ЕС имеет силу только
публикации в составе инструкции по монтажу и эксплуатации на
продукцию производства компании Grundfos.
в случае
SE: EG-försäkran om överensstämmelse
Vi, Grundfos, försäkrar under ansvar att produkterna Oxiperm® Pro, som
omfattas av denna försäkran, är i överensstämmelse med rådets direktiv
om inbördes närmande till EU-medlemsstaternas lagstiftning, avseende:
— Maskindirektivet (2006/42/EG).
Tillämpade standarder: EN 809: 1998,
EN ISO 12100-1+A1: 2009, EN ISO 12100-2+A1: 2009.
— Lågspänningsdirektivet (2006/95/EG).
Tillämpad standard: EN 61010-1: 2001 (andra upplagan).
— EMC-direktivet (2004/108/EG).
Tillämpade standarder: EN 61326-1: 2006,
EN 61000-3-2: 2006+A1: 2009+A2: 2009, EN 61000-3-3: 2008.
Denna EG-försäkran om överensstämmelse är endast giltig när den
publiceras som en del av Grundfos monterings- och driftsinstruktion.
PT: Declaração de conformidade CE
A Grundfos declara sob sua única responsabilidade que os produtos
Oxiperm® Pro, aos quais diz respeito esta declaração, estão em
conformidade com as seguintes Directivas do Conselho sobre
a aproximação das legislações dos Estados Membros da CE:
— Directiva Máquinas (2006/42/CE).
Normas utilizadas: EN 809: 1998, EN ISO 12100-1+A1: 2009,
EN ISO 12100-2+A1: 2009.
— Directiva Baixa Tensão (2006/95/CE).
Norma utilizada: EN 61010-1: 2001 (segunda edição).
— Directiva EMC (compatibilidade electromagnética) (2004/108/CE).
Normas utilizadas: EN 61326-1: 2006,
EN 61000-3-2: 2006+A1: 2009+A2: 2009, EN 61000-3-3: 2008.
Esta declaração de conformidade CE é apenas válida quando publicada
como parte das instruções de instalação e funcionamento Grundfos.
SI: ES izjava o skladnosti
V Grundfosu s polno odgovornostjo izjavljamo, da so naši izdelki
Oxiperm® Pro, na katere se ta izjava nanaša, v skladu z naslednjimi
direktivami Sveta o približevanju zakonodaje za izenačevanje pravnih
predpisov držav članic ES:
— Direktiva o strojih (2006/42/ES).
Uporabljeni normi: EN 809: 1998,
EN ISO 12100-1+A1: 2009, EN ISO 12100-2+A1: 2009.
— Direktiva o nizki napetosti (2006/95/ES).
Uporabljena norma: EN 61010-1: 2001 (druga izdaja).
— Direktiva o elektromagnetni združljivosti (EMC) (2004/108/ES).
Uporabljeni normi: EN 61326-1: 2006,
EN 61000-3-2: 2006+A1: 2009+A2: 2009, EN 61000-3-3: 2008.
ES izjava o skladnosti velja samo kadar je izdana kot del Grundfos
instalacije in navodil delovanja.
Pfinztal, 20 July 2012
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 EC declaration of conformity.
Declaration of conformity
3
English (GB) Installation and operating instructions
Caution
Note
English (GB)
Original installation and operating instructions.
CONTENTS
1. General safety instructions
1.1 Purpose of these operating instructions
1.2 Symbols used in this document
1.3 Operators
1.4 Obligations of the operating company
1.5 Authorised service personnel
1.6 Correct usage
1.7 Inappropriate usage
1.8 Safety and monitoring equipment
1.9 Chemicals
2. Product description
2.1 Application examples
2.2 Functional principle
2.3 Components of a standard system
2.4 Peripheral devices and accessories
2.5 Hydraulic connections
2.6 Power supply connections and electronic connections
2.7 Operation modes
2.8 Display and control elements
2.9 Access codes
2.10 Menu structure
3. Technical data
3.1 Identification
3.2 Performance and consumption
3.3 Temperatures and humidity
3.4 Dimensions
3.5 Oxiperm Pro OCD-162-30 and OCD-162-60
3.6 Weights and capacities
3.7 Permissible chemicals
3.8 Materials
3.9 Dosing pumps
3.10 Dilution water
3.11 Main water line
3.12 Permissible measuring cell type
3.13 Product numbers OCD-162-5, -10
3.14 Product numbers OCD-162-30, -60
3.15 Electrical data
3.16 Controller inputs
3.17 Controller outputs
4. Transport and packaging
4.1 Unpacking
4.2 Transport damages
5. Installation
5.1 Preparing the installation location
5.2 Preparing for installation
6. Operation
6.1 Switching on the system
6.2 Starting operation
6.3 Interrupting operation
6.4 Continuing operation after an interruption
6.5 Flushing
6.6 Manually venting the dosing pump
6.7 Modifying setup
6.8 Monitoring the production and dosing process
6.9 Setting the warning relay and alarm relay
6.10 Configuring the warning relay
6.11 Faults with error message
6.12 Faults without error message
6.13 Calibration
6.14 Stopping chlorine dioxide dosing
6.15 Switching off the system
7. Maintenance
7.1 Cleaning
8. Accessories list
9. Photos
10. Disposal
Page
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Warnin g
Prior to operation, read these installation and
operating instructions.
4
1. General safety instructions
4
4
1.1 Purpose of these operating instructions
4
These operating instructions inform about operating and
5
monitoring the system. For information on installation,
5
maintenance, servicing and dismantling, please see the separate
5
Service Instructions.
5
5
1.2 Symbols used in this document
5
The safety instructions are identified by the following symbols:
7
8
8
9
Information about possible residual risks can be found:
• on warning signs located at the installation site
• at the beginning of each section in this manual
• immediately before steps associated with a residual risk.
Warnin g
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.
1.3 Operators
Operators are persons who are responsible for operating and
monitoring the system at the installation location. The system
may only be operated by trained and qualified personnel.
The system is electronically controlled. Operators operate the
system via a display with control elements.
Obligations of the operator
• Be trained by qualified personnel from Grundfos 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
(Germany GUV-V D5).
• Keep secret the operator code for the operating software.
4
1.4 Obligations of the operating company
Note
Owners of the building and/or operators of the Oxiperm Pro
disinfection system are obliged to:
• Consider this manual to be part of the product and make sure
that it is kept clearly accessible in the immediate vicinity of the
system for the entire service life of the system.
• Meet the installation requirements specified by the
manufacturer, see section 5.1.
• Make sure that water lines and fittings are regularly checked,
serviced and maintained.
• Obtain official approval for storing chemicals, if necessary.
• Instruct operators in the operation of the system.
• Make sure that the labels supplied by the manufacturer are
attached and clearly visible in the installation location.
For illustration, see section 9. Photos .
• Provide the operator code for the operating software only to
operators who have received appropriate technical training.
• Make sure that the regulations for the prevention of accidents
are observed in the installation location (Germany GUV-V D5).
• Provide all operators and service personnel with protective
clothing in accordance with the regulations for the prevention
of accidents (Germany GUV-V D5): face mask, gloves,
protective apron, breathing mask.
• If the system is supplied without a dosing pump, provide an
external dosing pump prior to installation. Only authorised
service personnel trained by Grundfos is allowed to connect it
to the Oxiperm Pro.
1.5 Authorised service personnel
The system may only be maintained and serviced by authorised
service personnel trained by Grundfos.
1.6 Correct usage
Oxiperm Pro OCD-162 is a system for the discontinuous
preparation of a chlorine dioxide solution out of hydrochloric acid
(9 %) and sodium chlorite (7.5 %), and the continuous dosing of
this solution for water disinfection.
1.7 Inappropriate usage
Applications other than those listed in section 1.6 Correct usage
are not in accordance with the intended use and are not
permitted. The manufacturer, Grundfos, accepts no liability for
any damage resulting from incorrect use.
A chlorine dioxide solution with an uncritical concentration of 2 g/l
is generated in the reactor. Hence the Oxiperm Pro OCD-162
operates far out of the range of critical concentrations.
Danger of explosion in case of overdosage: at a concentration of
more than 30 g/l the chlorine dioxide solution can explode.
Gaseous chlorine dioxide is a chemically unstable compound.
At concentrations over 300 g/m
oxygen explosively without external impact.
Warning
Unauthorised structural modifications to the
system may result in serious damage to
equipment and personal injury.
It is forbidden to dismantle, modify, change the
structure of, bridge, remove, bypass or disable
components, including safety equipment.
3
, it decomposes into chlorine and
1.8 Safety and monitoring equipment
The system is fitted with the following safety and monitoring
equipment:
• cover on the system frame
• two collecting trays for the two chemical containers
(accessories)
• safety/multi-function valve at the dosing pump
• solenoid valve at the dilution water inlet
• volume compensation bag and activated-carbon filter for ClO
gas that escapes from the reaction tank
• alarm functions in the controller.
1.9 Chemicals
1.9.1 Chlorine dioxide concentration
In the reaction tank of the Oxiperm Pro OCD-162, diluted sodium
chlorite and diluted hydrochloric acid are mixed to create a
chlorine dioxide solution with a concentration of approximately
2 gram per litre of water. According to the disinfection
requirement, the Oxiperm Pro OCD-162 doses the diluted
chlorine dioxide solution into the main line to be disinfected.
The chlorine dioxide concentration in drinking water must not
exceed a maximum of 0.4 milligram per litre of water according to
the German drinking water ordinance.
Warnin g
Risk of explosion when using chemicals in too
high concentrations.
Only use sodium chlorite in a diluted
concentration of 7.5 % by weight in accordance
with EN 938.
Only use hydrochloric acid in a diluted
concentration of 9.0 % by weight in accordance
with EN 939.
Observe the safety data sheets from the
chemicals supplier.
Warnin g
Risk of explosion when mixing up chemical
containers or suction lances. Possible
consequences are personal injury and serious
damage to equipment.
Do not mix up chemical containers or suction
lances.
Observe the labels on chemical containers,
suction lances and pumps:
red = HCl, blue = NaClO
Warnin g
Risk of burns when skin and clothing come into
contact with sodium chlorite and hydrochloric
acid.
Immediately wash affected skin and clothing with
water.
Warnin g
Risk of irritation to eyes, respiratory system and
skin, if chlorine dioxide is inhaled.
When changing the chemical containers, wear
protective clothing in accordance with the
regulations for the prevention of accidents
(Germany GUV-V D5).
.
2
English (GB)
2
Warnin g
The temperature of the chlorine dioxide solution
stored in an external batch tank may not exceed
40 °C.
Risk of outgassing at more than 40 °C.
We recommend the installation of a gas warning
device.
5
1.9.2 Storing chemicals
English (GB)
• Chemicals must be stored in the appropriately marked original
plastic containers (20 to 33 litres).
• Do not store chemicals near grease, flammable substances,
oils, oxidising substances, acids or salts.
• Empty and full containers must be kept closed, especially in
areas where national regulations for the prevention of
accidents apply to storage (Germany GUV-V D5).
1.9.3 Procedure in case of an emergency
The general safety regulations and regulations for the procedure
in case of an emergency, as specified in EN 12671 apply.
Actions in case of an emergency:
• Ventilate the installation location immediately.
• Wear protective clothing (safety goggles, gloves, respirator
and/or self-contained breathing apparatus, protective apron).
• Implement initial help measures
– In case of contact with the eyes, rinse immediately with
plenty of water for at least 15 minutes. Consult a doctor.
– In case of contact with the skin, wash immediately with
plenty of water. Remove all contaminated clothing.
– In case gas is inhaled, move the casualty to a source of
fresh air. Avoid taking deep breaths.
Consult a doctor (look out for a racing pulse, as vasodilating
treatment may be required).
• Spillages
– In case of contact with clothing, remove the clothing
immediately and wash with plenty of water.
– Chemical spillages in buildings must be washed away with
water.
– Chlorine dioxide spillages can be doused with sodium
thiosulphate, and washed away with water.
• Escaped gas
– Escaped gas can be rinsed away with water from a
sprinkling system.
• Firefighting
– Aqueous solutions of chlorine dioxide are not directly
flammable. Extinguish the surrounding fire with water,
preferably using a fire sprinkler system to dilute the ambient
gas. Inform the fire brigade of the installed production
capacity and any harmful starting substances that are being
stored (precursor substances) so that precautions can be
taken regarding possible risks.
6
2. Product description
Fig. 1 Oxiperm Pro OCD-162 without cover and peripheral devices
English (GB)
TM03 6914 4506
Oxiperm Pro OCD-162 disinfection systems produce and dose
chlorine dioxide for the disinfection of drinking water, process
water, cooling water and wastewater.
Oxiperm Pro OCD-162 disinfection systems consist of a plastic
system frame, on which the internal components are mounted.
They are prepared for wall- or floor-mounting, and covered by a
plastic cover.
The chemicals are supplied from two original chemical
containers, which are located in two collecting trays directly under
the system (OCD-162-5, -10) or in a separate tray for each
container next to the system (OCD-162-30, -60). A suction lance
is inserted in each container and is permanently connected to the
corresponding chemical dosing pump. The suction lance cables
send low-level and empty signals to the controller.
Oxiperm Pro OCD-162 is connected to two water lines:
• The drinking water line for supplying dilution water and
flushing water.
• The main water line to be disinfected, into which the final
chlorine dioxide solution is dosed.
7
2.1 Application examples
English (GB)
Oxiperm Pro OCD-162 disinfection systems can be used for
different types of applications:
2.1.1 Disinfection of drinking water lines
• The flow rate of the water in drinking water lines can fluctuate
greatly (peak times when water is used for bathing and
cooking).
• The type and level of contamination in the water
(disturbance variables) are not known or are very varied.
• Examples: drinking water lines in:
– hotels, multi-storey buildings
– schools, hospitals, nursing homes
– showers in sports facilities
– food and beverage plants
– waterworks.
2.1.2 Disinfection of industrial systems
• The water quantity in industrial systems is relatively constant.
• The type and level of contamination in the water
(disturbance variables) are measured and hardly ever change.
•Examples:
– bottle cleaning plants in breweries
– industrial process water or wastewater systems
– cooling water systems.
2.1.3 Shock disinfection (with external batch tank)
• Applications requiring large quantities of disinfectant in a short
time
• Example: cleaning of whirlpool baths.
2.2 Functional principle
2.2.1 Production of chlorine dioxide
Chlorine dioxide is prepared in the reaction tank as follows:
Water, hydrochloric acid and sodium chlorite are added until a
specific level is reached. During the reaction time, a diluted
chlorine dioxide solution is produced. The reaction tank is filled
with water. With a concentration of approximately 2 gram of
chlorine dioxide per litre of water, the final solution flows through
a pipe (overflow) located in the middle of the reaction tank into
the batch tank below.
From the batch tank, the dosing pump doses the final chlorine
dioxide solution to the injection unit, where it is injected into the
main water line to be disinfected.
There are two different operation modes for the production of
chlorine dioxide.
"Internal batch tank" mode: Chlorine dioxide solution is generated
in the internal batch tank, and dosed into the line system, until the
batch tank is empty. There are two ways of refilling the batch
tank:
– First method "1-20": You determine how many times the
batch tank is refilled by choosing a number in the range of
1 to 20.
– Second method "0 = continuous": The batch tank is refilled
continuously.
• "External batch tank" mode: Chlorine dioxide solution is
generated in the internal batch tank, and dosed into an
external batch tank for storage. After emptying the external
batch tank, chlorine dioxide production is restarted in a
continuous process.
2.2.2 Flow-rate-proportional dosing
Suitable for drinking water applications:
1. The controller is set to "proportional controller".
2. A contact water meter or flow meter measures the water flow
rate in the main water line, and continuously sends measured
values to the controller.
3. The proportional controller calculates the required chlorine
dioxide dosing volume in proportion to the water flow rate in
the main line.
4. The proportional controller sends the corresponding output
signals to the dosing pump.
5. The dosing pump doses the required quantity of chlorine
dioxide solution from the batch tank into the main water line.
6. An optional measuring cell monitors the chlorine dioxide
concentration in the main line.
2.2.3 Setpoint-controlled dosing
Suitable for industrial water applications:
1. The controller is set to "setpoint controller". A setpoint for the
desired chlorine dioxide concentration in the main line is
specified.
2. A measuring cell monitors the chlorine dioxide concentration
in the main line, and sends actual values to the controller.
3. The setpoint controller compares the incoming actual values
with the setpoint. Based on the deviation, it calculates the
quantity of chlorine dioxide solution (actuating variable)
required to achieve the desired concentration.
4. The setpoint controller sends output signals to the dosing
pump.
5. The pump doses the corresponding quantity of chlorine
dioxide solution from the batch tank into the main water line.
A combined controller is also available for applications with
setpoint controller and flow meter, see separate Service
Instructions.
8
2.3 Components of a standard system
Blue
Red
English (GB)
Fig. 2 Components of a standard system (Oxiperm Pro OCD-162-5, -10)
2.3.1 External components
Pos. Component
1a Water line for dilution water and flushing water
1b Dilution water extraction device with isolating valve
Container for sodium chlorite (NaClO
concentration of 7.5 % by weight) with suction lance and
3
, diluted
2
collecting tray
Container for hydrochloric acid (HCl, diluted
4
concentration of 9 % by weight) with suction lance and
collecting tray
11 Main water line to be disinfected
12 Flow meter (or contact water meter)
14 Dosing line
Injection unit for dosing chlorine dioxide (ClO
15
main water line
) into the
2
16 Hose for sample water
17 Sample-water extraction device
Measuring cell for checking the chlorine dioxide
18
concentration in the main water line (optional)
19 Power supply connection
See the photos in section 9. Photos.
2.3.2 Internal components
Pos. Component
2 Solenoid valve for dilution water and flushing water
5 Dosing pump for sodium chlorite (NaClO
)
2
6 Dosing pump for hydrochloric acid (HCl)
7 Reaction tank with float switch
Batch tank with float switch and drain cock for chlorine
8
dioxide (ClO
)
2
9 Volume compensation bag for chlorine dioxide gas
10 Activated carbon filter for chlorine dioxide gas
Dosing pump with multi-function valve for chlorine
13
dioxide
Electronic controller with measured-value sensor for
20
check measurements
21 Display of the controller
TM03 6897 4506
9
2.4 Peripheral devices and accessories
Red
Blue
English (GB)
2.4.1 Accessories for the dilution water line
• Isolating valve
• Dilution water extraction device (if necessary with double
nipple and connection piece for hose).
• Hose with connection to solenoid valve.
Isolating valve and extraction device are not required, if the
bypass mixing module with dilution water connection has been
selected.
2.4.2 Accessories for the main water line
• Contact water meter or flow meter (in case of a new water
line: water flow meter providing signals, or ultrasonic flow
meter).
• Tapping sleeve for the injection unit.
• Protective pipe for the dosing line, installed from the dosing
pump to the injection unit.
• DIT photometer: measures the chlorine dioxide concentration
after dosing.
• Sample-water filter (in case of insufficient water quality).
2.4.3 Measuring cell
• Measuring cell
• Tapping sleeve for sample-water extraction at the main line.
• Hose from the sample-water extraction device to the
measuring cell.
• Hose from the measuring cell to the sample-water drain.
2.4.4 Extension modules
The standard system can be extended with:
• Measuring cell for cold and hot water (main water up to 50 °C,
pressure 4 bar).
• Measuring module for cold and hot water (main water up to
70 °C, pressure 8 bar).
• The use of a bypass mixing module is recommended in order
to optimise mixing and reduce the risk of corrosion and in case
of fluctuations in the main water flow
Fig. 3 OCD-162-5, -10 system with measuring cell and without extension module
10
TM03 6918 4506
Fig. 4 Complete system with measuring cell (e.g. OCD-162-30, -60)
17
1a
14
1b
19
15
23
26
12
24
25
16
18
17
11
English (GB)
TM04 0951 1509
Pos. Component
1a Water line for dilution water and flushing water
2.5 Hydraulic connections
2.5.1 Oxiperm Pro OCD-162-5, -10
1b Dilution water extraction device with isolating valve
Container for sodium chlorite (NaClO
concentration of 7.5 % by weight) with suction lance and
3
, diluted
2
collecting tray
Container for hydrochloric acid (HCl, diluted
4
concentration of 9 % by weight) with suction lance and
collecting tray
11 Main water line to be disinfected
12 Flow meter (or contact water meter)
14 Dosing line
Injection unit for dosing chlorine dioxide (ClO
15
main water line
) into the
2
16 Hose for sample water
17 Sample-water extraction device
18 Measuring cell
19 Power supply connection/main switch
23 Connection cable for measuring cell
Fig. 5 Hydraulic connections OCD-162-05, -10
TM04 8542 1312
24 Sample-water drain
25 Connection cable for cleaning motor
26 Hose for dilution water
Pos. Description
Hoses for both suction lances on the suction side of the
5, 6
NaClO
and HCl dosing pumps
2
Hose at the drain cock of the batch tank (only installed
8
for flushing and venting)
Dosing line from the chlorine dioxide dosing pump to
14
the injection unit at the main line or to the injection unit
at the mixing module or to the external batch tank
26 Dilution water hose at the solenoid valve
11
2.5.2 Oxiperm Pro OCD-162-30, -60
OCD-162-30
OCD-162-60
English (GB)
Fig. 6 Hydraulic connections OCD-162-30, -60
Pos. Description
Hoses for both suction lances on the suction side of the
5, 6
NaClO
and HCl dosing pumps
2
Hose at the drain cock of the batch tank
8
(only installed for flushing and venting)
Dosing line from the dosing pump to the injection unit at
14
the main line, or to the injection unit at the mixing
module, or to the external batch tank
26 Dilution water hose at the solenoid valve
2.5.3 System connections
• Dilution water hose at the solenoid valve (26)
• Hoses for suction lances (5, 6)
• Dosing line from the dosing pump to the injection unit at the
main line, or to the injection unit at the mixing module, or to
the external batch tank (14)
• Hose at the drain cock of the batch tank (8)
2.5.4 External dosing pump connection
If the system has been supplied without a dosing pump, the
dosing line of an external dosing pump is connected to the batch
tank.
2.5.5 Measuring cell connections
The measuring cell is hydraulically connected to the main line.
After dosing, the chlorine dioxide concentration, temperature and
pH/ORP value of the sample water are measured in the
measuring cell. The measuring cell has connections for the
following:
• hose from the sample-water extraction device to the
measuring cell
• hose from the measuring cell to the sample-water drain.
For more detailed information, see the installation and operating
instructions for the measuring cell.
2.5.6 Measuring module connections
The measuring module is hydraulically connected to the main
line. The measuring module has connections for the following:
• hose from one tapping sleeve to the measuring module
• hose from the measuring module to another tapping sleeve at
the main line.
For more detailed information, see the installation and operating
instructions for the measuring module.
2.5.7 Mixing module connections
The mixing module is hydraulically connected to the main line and
the Oxiperm Pro system. The mixing module has connections for
the following:
• dosing line from the dosing pump to the injection unit in the
mixing module
• hose from one tapping sleeve to the mixing module
• hose from the mixing module to another tapping sleeve at the
main line.
For more detailed information, see the installation and operating
instructions for the mixing module.
TM04 0953 1509
12
2.6 Power supply connections and electronic
54321
.........
24
,
5
°C
pH
7
,
35
5
4
3
2
1
0,23 mg
/
l
1
2
6
7
4/3
5
8
connections
The Oxiperm Pro OCD-162 is equipped with an electronic
controller. The controller has connections for the following:
• power supply cable to the main switch
• cable from the flow meter or contact water meter
• cable from external batch tank to level control, if applicable
• cables for measuring cell AQC-D1 or AQC-D6, if applicable:
– measuring electrode and counter-electrode
– sample-water sensor
– Pt100 temperature sensor
– pH electrode (for pH or ORP) (AQC-D1 only)
– cleaning motor (AQC-D1 only)
• cables from the measuring module, if applicable:
– measuring electrode and counter-electrode
– sample-water sensor
– Pt100 temperature sensor
• cable from the mixing module, if applicable:
– flow controller.
For additional connections, see the separate Service Instructions.
2.7 Operation modes
During commissioning, the Oxiperm Pro OCD-162 system is set
up according to the application. After switching on and starting up
the chlorine dioxide production via the menu commands, the
system runs fully automatically.
Two operation modes are available for the production of chlorine
dioxide:
• "Internal batch tank" mode: Chlorine dioxide solution is
generated in the internal batch tank, and dosed into the line
system, until the batch tank is empty. There are two ways of
refilling the batch tank:
– First method "1-20": You determine how many times the
batch tank is refilled by choosing a number in the range of
1 to 20.
– Second method "0 = continuous": The batch tank is refilled
continuously.
• "External batch tank" mode: Chlorine dioxide solution is
generated in the internal batch tank, and dosed into an
external batch tank for storage. After emptying the external
batch tank, chlorine dioxide production is restarted in a
continuous process.
Dosing is controlled automatically by the controller. In manual
operation, the controller can be switched off.
2.8 Display and control elements
Fig. 7 Display and control elements
Button or LED Function
Button [Esc] Cancels command, exits menu
Button [Up]
Button [Down]
Button [OK] Confirms the menu selection
Button [Cal] Calibration
Button [Man] Manual operation
LED "Alarm" Alarm (red)
LED "Caution" Warning (yellow)
LED "Cal" Calibration (yellow)
LED "Man" Manual operation (yellow)
2.8.1 Displays
After switching on the system, the following display appears:
Fig. 8 Starting the system
Press [OK] to access the "Main menu":
Selects the previous menu item,
or sets a higher numerical value
Selects the next menu item, or sets a
lower numerical value
English (GB)
TM03 6900 4506
TM03 6921 4506
Main menu
Process
Controller ClO2
Alarm
Service
Setup
Maintenance
During operation, press [Esc] to access the display level:
TM03 6922 4506
Fig. 9 "process running" display level
13
The header indicates the status. The positions are explained in the table below.
6
6
English (GB)
Legend
Pos. Message Description
"process running" Chlorine dioxide production is active.
1
Headers
2
Relays
3
Symbol
4
Symbol
"process stop" Chlorine dioxide production has been stopped.
"process termination" Chlorine dioxide production has been terminated by a menu command or alarm.
"Flushing" Flushing is started automatically or manually.
1
2 Relay for hydrochloric acid pump: display as for 1.
3 Relay for sodium chlorite pump: display as for 1.
4 Alarm relay: display as for 1.
5 Warning relay: display as for 1.
Relay for solenoid valve:
White number on a black background: relay active.
Black number on a white background: relay not active.
Symbol for the relay of the interpulse controller.
Symbol for relay stop of the interpulse controller.
Symbol for continuous controller: Box with plotted line.
The height of the line is proportional to the actuating variable (chlorine dioxide dosing volume).
Line not visible: actuating variable = 0 %. Line fills the entire box: actuating variable = 100 %.
Symbol for stop of the continuous controller: White box with a diagonal line through it.
Symbol for external disturbance value input (water flow as impulse/current signal).
5
Symbol
6
Val ue
7
Val ue
8
Val ue
e.g. 24.5 °C Water temperature, display value is only available with connected measuring cell.
e.g. 0.23 mg/l Chlorine dioxide concentration, display value is only available with connected measuring cell.
e.g. 7.35 pH value in the sample water, display value is only available with connected measuring cell.
Box with plotted triangle.
The black fill is proportional to the flow (the greater the fill, the greater the flow, 0-100 %).
(only visible, if proportional or combined controller is configured).
2.9 Access codes
When the system is ready for operation, the "Main menu" cannot
be accessed without a code. Two different access authorisations
or security levels are assigned for all submenus.
Each code automatically enables the levels below it.
2.9.1 Operator code
By default, all operator menus can initially be accessed without a
code. When the menu selection has been confirmed with [OK], a
code request is not displayed.
Once the operator has entered his operator code ("Main menu >
Setup > change code"), the code request appears before any
operator submenu can be accessed. The modified operator code
must only allow access for operators with appropriate technical
training and experience. Access is enabled for 60 minutes after
entry of the code.
2.9.2 Service code
This code is reserved for trained Grundfos service engineers.
Access is enabled for 30 minutes after entry. The service code is
necessary for commissioning.
14
2.10 Menu structure
The submenus vary in submenus for operators (with operator
code) and service engineers (with service code).
All software menus can be selected from the "Main menu" using
the [Up] and [Down] buttons, and accessed using [OK].
Press [Esc] to return to the menu level above.
2.10.1 Operator menus (part 1)
Main menu Submenu 1 Submenu 2 Submenu 3 Submenu 4 Submenu 5
Start
Process
Terminate
Operation
Process
Main menu
Service
Measurement
1
Controller ClO2
Water flow meter
Test display
Program version
Language
Setup
Date/time
Code function
Main menu
Display Contrast
Alarm value ClO2
4
Alarm
Dos. time monit.
1The "Measurement" submenu only appears, if it is enabled in the "Setup" menu.
2The "Water flow meter" submenu only appears, if a "Water flow meter" is enabled in the "Setup" menu.
3 Depending on the type of water flow meter enabled.
4 The alarm settings are only available, if "Measurement" has been enabled. The alarm relay is activated, if previously set alarm values
for chlorine dioxide are exceeded or not reached, if the maximum dosing time is exceeded, and in case of a fault.
5 Depending on the setting in the "Setup" menu.
Start Start ClO2 production?
Back
Terminate
Terminate ClO2
production?
Back
Int. batch tank
0 = continuous
1-20 (adjustable)
Ext. batch tank On/Off
Status Display: process status
List of events
Batches
Production ClO2
Chemicals HCl/NaClO2 reset
Age of ClO2 (mm:ss)
Maintenance
Flushing
ClO2
Temperature
pH or ORP
E.g. 5 impulses/sec. =
2
50 % or 10 mA = 50 %
5
Start
Terminate
Measured value
CalData-LogBook
°C or °F
(Measured value)
Measured value
CalData-LogBook
3
Deutsch
English
(all listed)
Date
Time
Daylight.sav.t.
Begin, End, time shift
(± x hours), Off
Change
Delete
Alarm off
Alarm value 1: 0.15 mg/l
Alarm on
Alarm value 2: 0.70 mg/l
Hysteresis: 0.01
Alarm delay: 0 sec.
Off
On Max. dosing time
Upward violation or
downward viol.
Upward violation or
downward viol.
English (GB)
15
Operator menus (part 2)
English (GB)
Main menu Submenu 1 Submenu 2 Submenu 3 Submenu 4 Submenu 5
CAL meas. value
chlorine dioxide
calibration
manual operation Controller ClO2 On/Off
Operators can view the current input value of the water flow
meter as well as the impulses/second, or the value in mA and the
calculation in percent, see section 6.8.3.
The value is also displayed, if the defined input values are
exceeded or not reached (a water flow meter malfunction is
visible here).
pH
ORP
CAL result slope: µA, mg/l
CAL cycle On/Off
CAL meas. value
CAL result
CAL cycle On/Off
CAL meas. value
CAL result asym.mV
CAL cycle On/Off
GRUNDFOS,
DIN/NIST, others
Slope µA, mg/l
asym. mV
16
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