Grundfos Oxiperm Pro OCD-162 Installation And Operating Instructions Manual
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Grundfos Oxiperm Pro OCD-162 Installation And Operating Instructions Manual

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GRUNDFOS INSTRUCTIONS
®
Oxiperm
Pro
OCD-162
Installation and operating instructions

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Summary of Contents for Grundfos Oxiperm Pro OCD-162

  • Page 1 GRUNDFOS INSTRUCTIONS ® Oxiperm OCD-162 Installation and operating instructions...

  • Page 2: Table Of Contents

    English (US) Installation and operating instructions Original installation and operating instructions. Maintenance 10.1 Cleaning CONTENTS Accessories list Page Photos Disposal Limited warranty Symbols used in this document Warning General safety instructions Prior to installation, read these installation and Purpose of these operating instructions operating instructions.

  • Page 3: Limited Warranty

    Products manufactured by GRUNDFOS PUMPS CORPORATION 3.1 Purpose of these operating instructions (Grundfos) are warranted to the original user only to be free of These operating instructions inform about operating and defects in material and workmanship for a period of 24 months...

  • Page 4: Authorized Service Personnel

    Immediately wash affected skin and clothing with 2000 ppm (2 g/l) is generated in the reactor. Hence the water. Oxiperm Pro OCD-162 operates far out of the range of critical concentrations. Warning Danger of explosion in case of overdosage: At a concentration of...
  • Page 5 3.8.3 Procedure in case of an emergency The general safety regulations and regulations for the procedure in case of an emergency apply. See NIOSH, OSHA, EN 12671 guidelines. Actions in case of an emergency: • Ventilate the installation location immediately. •...

  • Page 6: Product Description

    The suction lance cables send low-level and empty signals to the controller. The Oxiperm Pro OCD-162 is connected to two water lines: • The potable water line for supplying dilution water and flushing water.

  • Page 7: Application Examples

    4.1 Application examples 4.2.2 Flow-rate-proportional dosing 1. The controller is set to "proportional controller". Oxiperm Pro OCD-162 disinfection systems can be used for different types of applications: 2. A contact water meter or flow meter measures the water flow rate in the main water line, and continuously sends measured 4.1.1 Disinfection of potable water lines...

  • Page 8: Components Of A Standard System

    4.3 Components of a standard system Blue Fig. 2 Components of a standard system (Oxiperm Pro OCD-162-5, -10)
  • Page 9 Analyzer and controller with plain text display main water line Sample water line to measuring cell (AQC) Sample-water extraction device Measuring cell (Grundfos AQC-D11) for checking the chlorine dioxide concentration in the main water line Power supply connection See the photos in section...
  • Page 10 Blue Fig. 3 OCD-162-5, -10 system with measuring cell and without extension module Fig. 4 Complete system with measuring cell (e.g. OCD-162-30, -60)
  • Page 11 Dosing line Injection unit for dosing chlorine dioxide (ClO ) into the main water line Sample water line Sample-water extraction device Grundfos AQC-D11 measuring cell Power supply connection/main switch Connection cable for measuring cell Sample-water drain Connection cable for cleaning motor...

  • Page 12: Peripheral Devices And Accessories

    Protective pipe for the ClO line, installed from the dosing pump to the injection unit. • Grundfos DIT photometer: measures the chlorine dioxide concentration after dosing and useful for system calibration. • Sample-water filter (in case of insufficient water quality).
  • Page 13 4.5.2 Oxiperm Pro OCD-162-30, -60 Fig. 6 Hydraulic connections OCD-162-30, -60 Pos. Description Tubing for both suction lances on the suction side of 5, 6 the NaClO and HCl dosing pumps Tube at the drain cock of the batch tank (only installed...

  • Page 14: Power Supply Connections And Electronic Connections

    Selects the next menu item, or sets a Button [Down] The Oxiperm Pro OCD-162 is equipped with an electronic lower numerical value controller. The controller has connections for the following: Button [OK] Confirms the menu selection •...
  • Page 15 During operation, press [Esc] to access the display level: ..5 °C 23 mg/l pH 7 Fig. 9 "prod. running" display level The header indicates the status. The positions are explained in the table below. Legend Pos. Message Description "prod. running" Chlorine dioxide production is active.

  • Page 16: Access Codes

    Access is enabled for 60 minutes after entry of the code. 4.9.2 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 initial startup.
  • Page 17 Submenu 2 Submenu 3 Submenu 4 Submenu 5 cal. meas. value [N/A] cal. result h/m3 µA, mg/l cal. cycle on/off GRUNDFOS, cal. meas. value DIN/NIST, others calibration slope µA, mg/l cal. result asym. mV cal. cycle on/off cal. meas. value cal.

  • Page 18: Technical Data

    5. Technical data 5.1 Identification 5.1.1 Type key Example: Type key Oxiperm Pro OCD-162-30-P/H3 Oxiperm Pro OCD-162 Max. Capacity 5 g/h 10 g/h 30 g/h 55 g/h Operation mode integrated mechanical dosing pump, DMX integrated Digital Dosing pump DDI integrated SMART Digital Dosing pump DDA...
  • Page 19 5.1.2 Nameplate OCD-162 5S/H3 162-005-10000 5/N: 07/64064 10, 11, 12 5g/h, 120V, 50/60Hz, 850Watt 95735155P1107380764064 Fig. 10 Nameplate (for OCD-162-5-S/H3) Pos. Description Type designation Product name Model Serial number Chlorine dioxide production capacity Product number Country of origin Year and week of production Marks of approval, NSF 61 PWT, ETL, CE mark, etc.

  • Page 20: Technical Data

    5.2 Technical data OCD model Chlorine dioxide generator 162-5 162-10 162-30 162-60 production [lbs/day (grams/hr)] 0.26 (5) 0.53 (10) 1.59 (30) 2.9 (55) concentration [ppm] 2000 Max continuous ClO dosing feed rate* (i.e. max. ClO pump output [gal/hr (l/hr)] 0.66 (2.5) 1.32 (5) 3.96 (15) 7.26 (27.5)
  • Page 21 OCD model Chlorine dioxide generator 162-5 162-10 162-30 162-60 Conforms to ANSI/UL Std. 61010-1 Electrical safety 4007209 Chlorine Dioxide Generator model numbers OCD-162-5, OCD-162-10, OCD-162-30 and OCD-162-60 are certified to NSF 61-2011 requirements found in clause 3.3.2. (a) These chemical generators are certified for use exclusively at public water treatment facilities.

  • Page 22: Dimensions

    5.3.1 Oxiperm Pro OCD-162-5 and OCD-162-10 30.11 in (765 mm) 19.68 in (500 mm) 12.92 in. (328 mm) Ø 0.41 in. (10.5 mm) Ø 0.41 in. (10.5 mm) Ø 0.41 in. (10.5 mm) Fig. 11 Dimensional sketch, Oxiperm Pro OCD-162-5 and OCD-162-10...
  • Page 23 5.3.2 Oxiperm Pro OCD-162-30 and OCD-162-60 30.16 in (766 mm) 22.36 in (568 mm) 25.98 in (660 mm) 19.69 in (500 mm) Ø 0.41 in (10.5 mm) 22.83 in (580 mm) Fig. 12 Dimensional sketch, Oxiperm Pro OCD-162-30/-60...

  • Page 24: Weights And Capacities

    5.4 Weights and capacities 5.5 Permissible chemicals Nominal concentration of NaClO solution W x H x D 7.5 % by weight* Oxiperm Pro (quality according to EN 938) [in (mm)] Nominal concentration of HCl solution 30.12 x 30.16 x 13.00 9.0 % by weight* OCD-162-5, -10 (quality according to EN 939)

  • Page 25: Product Numbers

    6. Product numbers Preparation Weight [lbs (kg)] Oxiperm Pro type Product number capacity [g/h] ClO dosing pump type DDA AR 58-67 (26-30) OCD-162-5-S/H3 95735155 DDA AR 62-71 (28-32) OCD-162-10-S/H3 95735163 DDI AR 153-155 (69-70) OCD-162-30-P/H3 95735178 DDI AR 186-188 (84-85) OCD-162-60-P/H3 95736304 Notes:...

  • Page 26: Transport And Packaging

    7. Transport and packaging 8. Installation Installation is described in detail in the separate Service Warning Instructions. This subsection can be used by the operating Increased risk of damage to equipment and company to plan installation. personal injury as a result of operating faults due to transport damage.

  • Page 27: Preparing For Installation

    Store the manuals in authorized service personnel trained by a dry place where the operators may reference Grundfos. them as needed. Switch off the power supply before starting work. 2. Measure the pressure and temperature in the Carry out power supply connection according to dilution water line and in the main water line.

  • Page 28: Operation

    9. Operation 9.1.1 Adjusting the process (how many batches) To specify whether just one batch or several batches of chlorine All software menus can be selected from the "main menu" using dioxide is to be prepared, or whether the production process the [Up] and [Down] buttons, and accessed using [OK].

  • Page 29: Terminating Production And Clo2 Dosing

    9.3 Terminating production and ClO dosing 9.4 Continuing production after an interruption 9.3.1 Terminating chlorine dioxide production 9.4.1 Continuing production after terminating chlorine dioxide production 1. "main menu > settings" > [OK]. During commissioning and in normal operation: Start chlorine settings dioxide production: start...

  • Page 30: Flushing

    9.5 Flushing 9.5.1 Preparing to flush 1. Before starting to flush, have ready the following items: Warning – Empty 5 gallon (10 liter) plastic buckets (1 bucket for Risk of poisoning from chlorine dioxide gas. OCD-162-5, -10, -30, and 2 buckets for OCD-162-60) Do not mix sodium chlorite and hydrochloric –...

  • Page 31: Manually Venting The Dosing Pump

    9.5.3 Starting flushing 9.5.5 Terminating flushing 1. Menu > Service > Process > Flushing The flushing process can be terminated any time using the [Esc] key. flushing 9.5.6 Responding to flushing faults put suct. lance into water [OK] It can take five minutes to rinse the pumps. If the following error message appears after five minutes, proceed as follows: 2.

  • Page 32: Modifying Setup

    9.7 Modifying setup 9.7.3 Setting the time 1. "main menu > commissioning" > [OK]. Setup is selected as follows: 2. "date/time" > [OK]. 1. "main menu > commissioning" > [OK]. 3. "time" > [OK]. 4. Press the [Up] or [Down] button to set the commissioning time, main menu confirm with [OK].

  • Page 33: Monitoring The Production And Dosing Process

    9.8 Monitoring the production and dosing process main menu service settings status list of events production flushing terminate start status l/min maintenance date age of ClO2 [N/A] HCl/NaClO ClO2 temperature measured value cal. logbook ctrl. parameters water meter temp. comp. relays level indicators [N/A]...
  • Page 34 9.8.1 Current measured values for ClO , water temperature pH value and pH/ORP 1. "main menu > service" > [OK]. 2. "[N/A]" > [OK]. The measured values in this menu are only displayed, if "[N/A]" has been enabled. [N/A] If the AQC-D6 measuring cell has been selected, ClO2 Note Note...
  • Page 35 ORP value 9.8.2 Current control parameters 1. "main menu > service" > [OK]. Not for applications with external batch tank. 2. "[N/A]" > [OK]. Parameters for the setpoint controller 1. "main menu > service" > [OK]. [N/A] 2. "ctrl. parameters" > [OK]. ClO2 Temperature ctrl.
  • Page 36 Parameters for the proportional controller 9.8.4 Process status 1. "main menu > service" > [OK]. 1. "main menu > service" > [OK]. 2. "ctrl. parameters" > [OK]. 2. "settings" > [OK]. 3. "status" > [OK]. ctrl. parameters y-out:....75 % int.
  • Page 37 9.8.6 Number of ClO batches 9.8.9 Indicating the "age of ClO2" in the reaction tank and in batch tank 1. "main menu > service > process > production". 1. "Main menu > Service > Process > Production ClO2". After 9999 batches, the display is reset to 0. production production batches...

  • Page 38: Setting The Warning Relay And Alarm Relay

    9.9 Setting the warning relay and alarm relay main menu operation ClO2 alarm dos. time monit. max. dosing time lower limit upper limit hysteresis alarm delay [N/A] [N/A] Fig. 17 Structure of the "change container" menu "change container" is only visible, if "[N/A]" or a controller is activated, see "commissioning". "ClO2 alarm"...

  • Page 39: Configuring The Warning Relay

    9.10 Configuring the warning relay The factory setting is "[N/A]" If the alarm is to be triggered by a downward violation: The warning relay is activated whenever an alarm is signalled, and remains active until the alarm is confirmed (collective 3.
  • Page 40 9.10.2 Setting the hysteresis 9.10.5 Replacing a chemical container The hysteresis indicates the tolerance of the alarm value OCD-162-5, -10: Make sure that the chemical Note Note (alarm value ± 0.5 x hysteresis). In this menu, you set the containers are positioned under the system. hysteresis for the two alarm values: 1.

  • Page 41: Faults With Error Message

    2. Empty signal HCl or NaClO Change the HCl or NaClO container. – ClO production stops, and Oxiperm Pro OCD-162-05, -10 - the continues after elimination of HCl or NaClO container is empty. chemical containers must be positioned the fault.
  • Page 42 Error message, Cause Remedy reaction of Oxiperm Pro 7. "Timeout pump HCl": During HCl supply, the level in the reaction tank has Check the hose from pump to reaction tank – ClO production is terminated. increased too slowly between levels K1 and K2. for assembly faults.
  • Page 43 Error message, Cause Remedy reaction of Oxiperm Pro 14. "fault of electrode/buffer": Repeat the calibration. Call Service to Auto reading of buffer data. Calibration fault at – ClO production proceeds. clean the measuring cell or to replace the calibration level. pH electrode.
  • Page 44 Error message, Cause Remedy reaction of Oxiperm Pro 23. "wire breakage current output 2": The measured chlorine dioxide value can no longer – ClO production proceeds. be transmitted. – Alarm relay activated. a) Cable breakage at the current output. Call Service to replace. –...
  • Page 45 Error message, Cause Remedy reaction of Oxiperm Pro 31. "fault current input": Cable breakage at current input 1 – ClO production proceeds. • A water flow meter is connected, and the signal – Alarm relay activated. exceeds the full-scale value of 20 mA. Call Service.

  • Page 46: Faults Without Error Message

    Connect temperature sensor. temperature compensation. fluctuate on display. c) Electrostatic charge of controller by rubbing the Do not rub hands on/against the cover. cover. 9.13 Calibration calibration GRUNDFOS DIN/NIST cal. meas. value cal. meas. value cal. meas. value others h/m3 µA/mg/l h/m3 cal.
  • Page 47 To calibrate the chlorine dioxide measured value, a reference μA measurement must be taken. This can be made with the Grundfos DIT photometer and the usual reagents. The determined reference value is entered by correcting the current measured value in the display.
  • Page 48 (difference of at least 1 pH) -57.88 mV/pH within the set pH measuring range. [N/A] -0.6 mV 8. GRUNDFOS > [OK]. 18. Remove the pH electrode from the buffer solution, and rinse buffer temp. with water. 25 °C 19.

  • Page 49: Manually Starting Or Stopping Clo2 Dosing

    10. "cal. result" > [OK]. The "ORP offset value is displayed as the 9.14 Manually starting or stopping ClO dosing result (for example 2 mV). This is the deviation between the 1. Press [Man]. entered mV value and the measured mV value of the buffer –...

  • Page 50: Maintenance

    10. Maintenance 11. Accessories list The Oxiperm Pro OCD-162 disinfection system must be serviced Prior to installation, the operator must purchase the once a year. The current and next maintenance date are following accessories according to the product numbers in the displayed in the operating software.

  • Page 51: Photos

    12. Photos Fig. 21 OCD-162-5, -10 Pos. Component Controller with display and control elements Reaction tank Batch tank Adsorption filter Dosing pump for 7.5 % sodium chlorite (NaClO Dosing pump for 9 % hydrochloric acid (HCl) Dosing pump for chlorine dioxide (ClO Solenoid valve for dilution water...
  • Page 52 Fig. 22 OCD-162-30, -60 Pos. Component Batch tank Reaction tank Controller with display and control elements Adsorption filter Dosing pump for 7.5 % sodium chlorite (NaClO Dosing pump for 9 % hydrochloric acid (HCl) Solenoid valve for dilution water Multi-function valve Dosing pump for chlorine dioxide (ClO Suction lance...

  • Page 53: Disposal

    13. Disposal The Oxiperm Pro OCD-162 disinfection system and its associated parts must be disposed of in an environmentally friendly way. Note Note The system may only be dismantled by authorized personnel trained by Grundfos. The operating company is responsible for ensuring an environmentally friendly disposal.
  • Page 54 Normas aplicadas: 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 Esta declaración CE de conformidad sólo es válida and operating instructions. cuando se publique como parte de las instrucciones de instalación y funcionamiento de...
  • Page 55 GRUNDFOS Kansas City GRUNDFOS Canada GRUNDFOS México 17100 West 118th Terrace 2941 Brighton Road Boulevard TLC No. 15 Olathe, Kansas 66061 Oakville, Ontario L6H 6C9 Canada Parque Industrial Stiva Aeropuerto Phone: (913) 227-3400 Phone: +1-905 829 9533 C.P. 66600 Apodaca, N.L. México...
  • Page 56 98429356 0214 ECM: 1129973 www.grundfos.com www.grundfos.us...

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