Grundfos Oxiperm OCD-164 Installation And Operating Instructions Manual
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Grundfos Oxiperm OCD-164 Installation And Operating Instructions Manual

Grundfos Oxiperm OCD-164 Installation And Operating Instructions Manual

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OCD-164 (30-2000 g/h)
Installation and operating instructions
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  • Page 1 GRUNDFOS INSTRUCTIONS Oxiperm ® OCD-164 (30-2000 g/h) Installation and operating instructions Other languages http://net.grundfos.com/qr/i/96709679...

  • Page 2: Table Of Contents

    English (GB) Installation and operating instructions Original installation and operating instructions 10.6 Bypass with solenoid valve and flow limiter (standard version: solenoid valve) Contents 10.7 Bypass, circulating pump 230 V - 50 Hz, 120 V - 60 Hz 44 10.8 Bypass (version solenoid valve/ball valve, batch mode) 45 Page 10.9 Bypass for external booster pump General safety instructions...

  • Page 3: Users

    Read this manual before operating the disinfection system. Unauthorised structural modifications to the system • Be trained by qualified personnel from Grundfos Water may result in serious damage to the equipment and Treatment in the operation of the system. personal injury.
  • Page 4 1.10.2 Storing chemicals • 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.

  • Page 5: Technical Data

    2. Technical data 2.1 General data 2.1.1 Performance and consumption data Max. system Consumption of Dilution water requirement for bypass system preparation capacity pressure components System In batch mode at 6 bar Solenoid valve Bypass pump 50 Hz 60 Hz NaClO OCD-164 counterpressure...
  • Page 6 2.1.5 Dimensions Fig. 1 Dimensioning of the system with drillholes OCD-164 DN 20 DN 20 -120 DN 20 DN 20 -220 DN 20 DN 20 -350 1010 DN 20 DN 20 -700 1010 DN 20 DN 20 -1000 1010 DN 20 DN 20 -1500 1300...

  • Page 7: Electrical Data

    2.2 Electrical data Max. permissible load of 250 V, 6 A, max. 550 VA 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 0.168 + j 0.168) Ω, (testing impedance with 90 Watt according to EN 61000-3-11)

  • Page 8: Fundamentals

    3. Fundamentals 3.2 Functional sequence • Three components are required to generate a chlorine dioxide 3.1 Chlorine dioxide for water treatment solution: Properties of chlorine dioxide – Hydrochloric acid (HCl) • Strong and fast oxidation and disinfection agent. – Sodium chlorite (NaClO •...

  • Page 9: Design And Function

    4. Design and function 4.1 Design of the system Fig. 4 Reactor with components, assembled on the back of the supporting frame Pos. Description Dosing system for hydrochloric acid (HCl) Dosing pump for hydrochloric acid Suction line with pre-empty and empty signal for HCl (red) Dosing controller for HCl flow monitoring Dosing system for sodium chlorite (NaClO...

  • Page 10: Components

    4.2 Components 4.2.6 Post-mixer The chlorine dioxide solution is mixed with the bypass water in 4.2.1 Suction lines the post-mixer (standard). The suction lines must be matched to the tank size and the 4.2.7 Options system performance (diameter of suction line). They have a dual level-control unit.

  • Page 11: Installation

    5. Installation A set of warning signs for the chlorine dioxide system in accordance with the specifications is available 5.1 Transport and storage under Order No 96727022 (515-662). Please find further general information for operation Warning of a chlorine dioxide system in: Only transport the system, when it's empty, observe –...

  • Page 12: Installation Scheme

    5.4 Installation scheme 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. Note The control for the system can process a max. rate of 50 pulses/sec.
  • Page 13 5.4.2 System with internal bypass pump 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.

  • Page 14: Wall Mounting

    5.5 Wall mounting • 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.

  • Page 15: Electrical Connection

    5.7 Electrical connection 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 version, the power supply can be 230 V (AC) or 115 V (AC). The electrical connection must only be carried out by Connection to an incorrect power supply may destroy qualified personnel.
  • Page 16 5.7.5 Inputs +12 V +12 V Description Function ------- Batch tank ClO overflow Contact open in case of overflow level above contact NO contact ------- Batch tank ClO max. Contact closed in case of "Max" level above contact NO contact ------- Batch tank ClO min.

  • Page 17: Interfaces Rs-232, -422 And -485

    5.7.7 Profibus/Ethernet (option) 5.8 Interfaces RS-232, -422 and -485 The controller can be optionally equipped with Profibus or The controller can optionally be equipped with interfaces. Ethernet. 5.8.1 Connection of RS-232 interface Profibus-DP module The Profibus-DP connection is made via a 6-pin plug. Fig.

  • Page 18: Operation Of Control Electronics

    6. Operation of control electronics 6.1 Program structure Manual Automatic Logbook operation Main menu System choice Setup Service mode Type 1, Type 2, System type Language Venting etc. Min. contact Batch mode Operation mode Startup mode water Current input Units System choice Test mode Contact input...

  • Page 19: Control And Display Elements

    6.2 Control and display elements 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.

  • Page 20: System Choice

    6.6 System choice • Target value external The system performance (2.5 - 100 %) is controlled via a Bus Define the system size and the operation mode in the "System system (can only be selected, if a bus system has been choice"...
  • Page 21 6.8.4 Code function Time • Switch to the "Time" menu using the [F1] key. 2 different code functions can be selected: • Level 1: Operators Time setting Authorisation for the menus "Automatic, "Manual operation", Current "Logbook" and "local/remote". XX:YY:ZZ 17.07.02 •...
  • Page 22 MANUAL (manual daylight saving time) 6.8.9 Program version • In the "Daylight saving time" menu, switch to the "Manual • In the "Basic setting" menu, switch to the "Program version" daylight saving time" menu using the [RIGHT] arrow key. menu using the [F2] key. In this menu you can redefine the daylight saving time.

  • Page 23: Local/Remote

    6.8.12 Startup mode 6.8.13 Test mode The startup mode is used to fill the reactor with water. The dosing The Test mode permits checking of current output, relay, display pumps can be gauged, and the dosing controllers can be and LEDs. readjusted at the same time.

  • Page 24: Commissioning

    7. Commissioning 7.3 Selection of operation mode The chlorine dioxide system can be operated in four different The system should always be commissioned with modes: water. To do this, immerse both suction lines into a Note • Batch mode tank filled with water. •...
  • Page 25 7.3.1 Batch mode The value for the amount of ClO added is a "starting Activating the operation mode "Others" value", which does not necessarily have to correspond to a ClO measurement downstream of Note • In the "Operation mode" menu, switch to the "Others" menu the system, because the control calculation is unable using the [F1] key.
  • Page 26 7.3.3 Contact input 1. Confirm using [Enter] key. In the "System choice" menu, switch to the "Contact input" menu Contact input using the [F3] key. activated Contact input 2. Use the [Enter] key to return to the "Operation mode" menu. Max.

  • Page 27: Venting Of The Bypass Line

    7.4 Venting of the bypass line 7.4.2 Venting of the dosing pumps (HCl and NaClO 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.
  • Page 28 7.4.3 Dosing pumps for the systems OCD-164-350 to 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.

  • Page 29: Calibrating The Dosing Pumps

    7.4.4 "Current input, Contact input, Manual control, Target 7.5 Calibrating the dosing pumps value ext." modes Details of the dosing rate required for the size of Checking the bypass water installation in question can be found in the table in •...

  • Page 30: Adjusting The Dosing Controllers

    Dosing pumps for the systems OCD-164-220 to 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.

  • Page 31: Operation Of The System

    8. Operation of the system Dosing pump • Use the [F1] key to switch to the "Dosing pumps" menu. Before the system is started, the system size and Note operation mode must be selected. NaClO H = X D = Y Independent from the operation mode, the menu structure H = X D = Y...
  • Page 32 8.1.2 Batch mode Bypass water Use the [F2] key to switch to the "Bypass water" menu. • In the main menu, switch to the "Automatic start" menu using the [F1] key. Bypass water <off> Display page 1 setpt.: XXX l/h Auto: Start? actual:...

  • Page 33: Manual Operation

    8.1.3 Target value external 8.2 Manual operation System capacity control and processing the input and output Irrespective of the selected mode, the system can signals via the bus system. Note only be activated in "Manual" mode if the installation • Select the bus system used in the "Basic Settings/Bus capacity has been set manually in %.

  • Page 34: Faults

    8.3 Faults Fault Cause Remedy 1. During venting of the a) The venting spindle in the dosing head is a) Open the venting spindle by approx. 1 turn; dosing pumps, the suction incorrectly set if necessary, open or close it further line does not fill with liquid, b) Suction and pressure valves in the dosing b) Remove the suction and pressure valves,...

  • Page 35: Error Messages Of The Controller

    8.4 Error messages of the controller No. Fault Cause Remedy NaClO NaClO level in tank too low Pre-empty signal HCl level in tank too low Refill tank NaClO NaClO tank empty Empty signal HCl tank empty Dosing controller NaClO Dosing controller incorrectly set Readjust controller Dosing controller defective Replace controller...

  • Page 36: Fuses And Leds Of The Controller

    8.5 Fuses and LEDs of the controller 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.

  • Page 37: Maintenance

    9. Maintenance 9.1.2 Dismantling the diaphragm For safety reasons, the dosing diaphragm should be replaced Warning after a maximum of 2000 operating hours. Before any maintenance work, i.e. when exchanging 1. Insert the suction lines of the pumps into a water tank, and run parts and gaskets, the entire system has to be rinsed the system until the dosing heads of the pumps have been with water.

  • Page 38: Maintenance Of Reactor

    9.3 Maintenance of reactor 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.

  • Page 39: Maintenance Of Injector

    9.4 Maintenance of injector The injector consists of nozzle, diffuser and holder with Do not use any sharp objects to clean the nozzles. diaphragm non-return valve. Hydrochloric acid has proved to be the best cleaning The sucked-in chlorine dioxide is mixed with the motive water in Caution agent.

  • Page 40: Spare Parts Kits And Spare Parts

    10. Spare parts kits and spare parts 10.1 DMI dosing pumps with double-head system OCD-164 Product No. 96641420 (553-1486) -120 -220 91835902 (553-1488) Fig. 29 Exploded view of DMI dosing head Pos. Description Suction/Discharge valve DN 4 Venting cartridge Dosing diaphragm Dosing diaphragm Oval-head screw O-ring, Viton...

  • Page 41: Dmi Dosing Pumps With Single-Head System

    10.2 DMI dosing pumps with single-head system 10.4 Bypass, post mixer, and dosing controller Spare parts kits comprise: OCD-164 Product No. • O-rings for bypass line and post-mixer • Non-return valve, DN 20, for bypass line 96688816 (553-1403-3) -120 • O-rings and flat gaskets for the bypass line -220 96688818...

  • Page 42: Enclosure Exhaust Device

    10.5 Enclosure exhaust device Fig. 32 Spare parts for exhaust device Pos. OCD-164 Description Product No. -30 to -220 95729411 (12.5998-200) 50.1 -350 to -1000 Lateral part 95729412 (12.5999-200) -1500 to -2000 95729413 (12.5999-210) -30 to -220 96691986 (545-1000-1) 50.3 Injector -350 to -2000 96693040...

  • Page 43: Bypass With Solenoid Valve And Flow Limiter (Standard Version: Solenoid Valve)

    10.6 Bypass with solenoid valve and flow limiter (standard version: solenoid valve) Fig. 33 Spare parts for exhaust device Pos. OCD-164 Description Product No. 30.1 Screw connection, DN 20 96688360 (53.055-25) 30.2 Union nut, DN 20 91835736 (53.058-25) 30.3 O-ring 91835574 (52.141) -30 to -2000...

  • Page 44: Bypass, Circulating Pump 230 V - 50 Hz, 120 V - 60 Hz

    10.7 Bypass, circulating pump 230 V - 50 Hz, 120 V - 60 Hz Fig. 34 OCD-164-700 to -2000 Pos. OCD-164 Description Product No. 30.1 Screw connection, DN 20 96688360 (53.055-25) 30.5 -30 to -2000 Reduction, short 96688439 (53.183-25-20) 30.6 Connection nipple 96688427 (53.095-20-1/2)

  • Page 45: Bypass (Version Solenoid Valve/Ball Valve, Batch Mode)

    10.8 Bypass (version solenoid valve/ball valve, batch mode) Fig. 35 OCD-164-30 to OCD-164-220 Fig. 36 OCD-164-350 Fig. 37 OCD-164-700 to OCD-164-2000...
  • Page 46 Pos. 164-OCD Description Product No. -30 to -220 Pressure loading valve, DN 8 95729419 (12.6473-320) 30.40 -350 to -2000 Pressure loading valve, DN 20 96376567 (525-1113) Solenoid valve, PVC, 230 V, 50 Hz 96688597 (53919-10) 30.50 -30 to -2000 Solenoid valve, PVC, 115 V, 60 Hz 91836553 (53.919-11) -350 to -2000...

  • Page 47: Bypass For External Booster Pump

    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 Union nut, DN 20 91835736 (53.058-25) 30.3 O-ring 91835574 (52.141) 30.4 -30 to -2000 Screw-in part, DN 20 96688372 (53.057-25) 30.5 Reduction, short 96688439 (53183-25-20)

  • Page 48: Accessories

    11. Accessories 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 [kP a] C R , C R E 1 -36 (E ) 50 Hz IS O 9906 Annex A...
  • Page 49 11.1.3 Dimensions Fig. 40 Dimensioning of booster pump Dimensions Net weight Pump type Motor [kW] Oval flange DIN flange Oval DIN flange flange B1 + B2 B1 + B2 CR 1-2 CR 1-3 CR 1-4 0.37 CR 1-5 CR 1-6 CR 1-7 CR 1-8 CR 1-9...

  • Page 50: Load Unit For Booster Pump

    11.2 Load unit for booster pump 11.3 Hose connections/hose The booster pump is connected to the controller of the system via Hose connection, DN 20 Product No. a load unit. Hose connection DN 20 - ID 25 mm 96727534 (529-050) with 2 hose clamps.

  • Page 51: Current Setting Data

    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 Default ClO Operation mode Batch mode Batch concentration: Current input 0-20 mA 4-20 mA others Contact input Contact water meter: Pulses/litre Manual control Bus control...

  • Page 52: Quick Guide

    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.

  • Page 53: Declaration Of Conformity

    My firma Grundfos prohlašujeme na svou plnou odpovědnost, že výrobek Oxiperm OCD-164, to which the declaration below relates, are in Oxiperm OCD-164, na který se toto prohlášení vztahuje, je v souladu s conformity with the Council Directives listed below on the approximation níže uvedenými ustanoveními směrnice Rady pro sblížení...
  • Page 54 Declaration of conformity RU 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...
  • Page 55 Siu Wai Industrial Centre Turkey Poland GRUNDFOS Canada Inc. 29-33 Wing Hong Street & GRUNDFOS POMPA San. ve Tic. Ltd. Sti. 2941 Brighton Road GRUNDFOS Pompy Sp. z o.o. 68 King Lam Street, Cheung Sha Wan Gebze Organize Sanayi Bölgesi Oakville, Ontario ul.
  • Page 56 96709679 1117 ECM: 1215430 www.grundfos.com...

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