Grundfos oxiperm pro OCD-162 Installation And Operating Instructions Manual
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Grundfos oxiperm pro OCD-162 Installation And Operating Instructions Manual

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 (GB) Installation and operating instructions Original installation and operating instructions Measurement 5.7.1 Measuring cell CONTENTS 5.7.2 Calibrating the measuring cell 5.7.3 Calibration data Page 5.7.4 Monitoring the cleaning motor General information 5.7.5 Temperature compensation of the ClO value Target group 5.7.6 alarm value Purpose of this manual...
  • Page 3 7.19 Settings 11.9 Dosing pumps 7.19.1 Save 11.10 Measuring cell 7.19.2 Restore Decommissioning 7.19.3 Factory reset 12.1 Hydraulic components Operation 12.1.1 Dilution water hose Production 12.1.2 Suction lances 8.1.1 Starting the production 12.1.3 Dosing line 8.1.2 Terminating the production 12.1.4 Volume compensation bag Dosing 12.1.5 Activated carbon filter/adsorbent 8.2.1...

  • Page 4: General Information

    2.2 Intended use Oxiperm Pro OCD-162 is a system for the discontinuous preparation of a chlorine dioxide solution out of hydrochloric acid (HCl, 9 %) and sodium chlorite (NaClO , 7.5 %), and the...

  • Page 5: Improper Use

    2 g/l is generated in the reaction tank. Hence the Note We recommend that you install a gas warning device. Oxiperm Pro OCD-162 operates far out of the range of critical concentrations. 2.5.2 Storing chemicals Gaseous chlorine dioxide is a chemically unstable compound.

  • Page 6: Product Description

    3. Product description Fig. 1 System without cover and without peripheral devices; OCD-162-5 (left), OCD-162-30 (middle), OCD-162-60 (right) The system produces and doses ClO for the disinfection of – cooling water systems. drinking water, process water, cooling water and wastewater. Shock disinfection The system has a plastic frame, where the internal components This application requires an external batch tank where the ClO...

  • Page 7: Identification

    3.3 Identification 3.3.1 Type key Example: OCD-162-30-D/G1 OCD-162 Maximum capacity 5 g/h 10 g/h 30 g/h 230 V: 60 g/h, 115 V: 55 g/h dosing pump integrated mechanical dosing pump DMX (only for 30 g/h and 60 g/h) integrated digital dosing pump DDI (only for 30 g/h and 60 g/h) integrated SMART Digital dosing pump DDA (only for 5 g/h and 10 g/h) without dosing pump Supply voltage...

  • Page 8: Nameplate

    3.3.2 Nameplate 3.3.3 Product numbers production Product dosing Voltage [V] OCD-162- capacity Grundfos Water Treatment GmbH - Reetzstr. 85 - D-76327 Pfinztal pump [g/h] OCD-162 30-P/G1 95735171 5-S/G 95735153 230 V, S/N: 10000069 30G/H, 230V 50Hz, 850VA, IP 65 50/60 Hz...

  • Page 9: Technical Data

    4. Technical data 4.4 Dimensions, weights and capacities Letter symbols used in this section added quantity [mg/l] ClO2 OCD-162 max. dosing flow [l/h] DPmax stroke length [%] System frame with cover 765 x 765 x 766 x 1800 x concentration in batch tank [g/l] ClO2 (W x H x D) [mm] dosing coefficient [h/m...

  • Page 10: Dosing Pump For Clo 2

    4.6.2 Dosing pump for ClO Factory Measurement Range Resolution setting OCD-162 -5, -10 -30-D/G -30-P/G -60-D/G -60-P/G Measurement Dosing pump AQC-D11 7.5-16 16-10 60-10 35-10 60-10 Measuring cell AQC-D11 AQC-D6 Connection, PTFE suction side hose PTFE hose 9/12 Temperature [mm] measurement Connection, PTFE...
  • Page 11 Factory Factory Alarms Range Resolution Current output Range Resolution setting setting Current output for dosing 0...20 alarm pump (low) [mA] Current output for dosing Lower ClO alarm 0.00...upper ClO 0...20 0.15 0.01 pump (high) [mA] limit [mg/l] alarm limit Current output of ClO Lower ClO alarm 0...20...

  • Page 12: Construction And Functioning

    5. Construction and functioning This section includes detailed information on the production Letter symbols used in this section process, as well as dosing control, measurement and flushing. added quantity [mg/l] Several parameters and the settings at a mechanical ClO pump ClO2 are explained.

  • Page 13: System With Mixing Module

    5.1.2 System with mixing module Fig. 4 OCD-162 with mixing module and measuring cell OCD-162 Main water line to be disinfected Dilution water extraction device with isolating valve Dilution water pipe Dirt trap Water meter Signal line of water meter Injection unit Dosing line Measuring cell...

  • Page 14: System With Measuring Module

    5.1.3 System with measuring module Fig. 5 OCD-162 with measuring module and two dosing pumps OCD-162 Main water line to be disinfected Dilution water extraction device with isolating valve Dilution water pipe Dirt trap Water meter Signal line of water meter Injection unit Dosing line Measuring cell...

  • Page 15: System With External Batch Tank

    5.1.4 System with external batch tank Fig. 6 OCD-162 with external batch tank and two dosing points OCD-162 Main water line to be disinfected Dilution water extraction device with isolating valve Dilution water pipe Dirt trap Water meter Signal line of water meter Injection unit Dosing line Additional ClO...

  • Page 16: Components

    5.2 Components NaClO (blue) (red) Fig. 7 OCD-162-5 (left) and OCD-162-10 (right) without cover Item Component Measuring and control unit Reaction tank Internal batch tank Adsorption filter NaClO dosing pump HCl dosing pump dosing pump Solenoid valve for dilution water Suction lances Chemical container Collecting tray...
  • Page 17 Fig. 8 OCD-162-30 (left) and OCD-162-60 (right) without cover Item Component Measuring and control unit Reaction tank Internal batch tank Adsorption filter NaClO dosing pump HCl dosing pump dosing pump Solenoid valve for dilution water Suction lances...

  • Page 18: Tank Levels

    5.3 Tank levels Reaction tank and internal batch tank Fig. 9 Reaction tank and internal batch tank (OCD-162-5/-10/-30) Level Description Level of first water supply HCl supply level NaClO supply level Level of second water supply Level for empty signal Maximum level Pos.
  • Page 19 Suction lances External batch tank Fig. 11 Level indicators of the suction lances Factory Level Description setting Contact open: low-level signal HCl N.O. Contact open: empty signal HCl N.O. Contact open: low-level signal NaClO N.O. Contact open: empty signal NaClO N.O.

  • Page 20: Operation Modes

    5.4 Production of ClO 5.4.1 Operation modes The system has to be set up according to the application. After starting up the production, the system runs automatically. Two operation modes are available. Operation with internal batch tank solution is generated in the reaction tank and stored temporarily in the internal batch tank. While the ClO solution is dosed into the line system, a new batch is produced in the reaction tank.
  • Page 21 1. Initially, the production process is terminated. 2. The operator starts the production in the menu. 3. The solenoid valve opens and water flows into the reaction tank. 4. The floater in the reaction tank reaches level K1. The solenoid valve closes.

  • Page 22: Production Status

    5.4.3 Production status The initial display shows a brief production status message, see section display. A more detailed status message is given in the 7.2 Initial production status menu, see 8.6.1 Production. Initial display Production status Description Production • not started "production terminated"...

  • Page 23: Flushing

    5.5 Flushing The system has to be flushed with water to remove any traces of chemicals in the suction hoses, pumps and reaction tank in the following situations: Note Prior to decommissioning prior to maintenance and repair. flushing put suct. lance into water [OK] flushing open drain cock [OK] Floater in reaction tank drops to K1...

  • Page 24: Actuating Variable (Y-Out)

    Setpoint control The setpoint control mode is particularly suitable for industrial • The setpoint control sends an actuating variable to the dosing water applications: pump. • A setpoint for the target ClO concentration in the main line • The dosing pump doses the corresponding quantity of ClO has to be specified.

  • Page 25: Dosing Coefficient (Kd)

    5.6.13 Dosing coefficient (KD) 5.7.4 Monitoring the cleaning motor Internal value used to calculate the actuating variable for The cleaning motor is monitored indirectly by regularly checking proportional control: the current ClO value. Store the measured ClO ClO2 value in V(t DPmax ClO2 added quantity [mg/l]...

  • Page 26: Clo 2 Alarm Value

    5.7.6 ClO alarm value 5.9 ClO pump type An alarm is triggered, if the measured ClO value violates an The dosing pump for ClO can be mechanical or digital. upper or lower limit. A mechanical pump is controlled by power-on (T ) and power-off ).

  • Page 27: Installation

    (minimum wall thickness for the Do not bend the hoses and cables. mounting screws 0.1 m) or the OCD-162-30, -60 system to be Oxiperm Pro OCD-162-30 and -60 systems must be floor-mounted. transported in an upright position.

  • Page 28: Additional Modules

    Warning Risk of fire and corrosion due to incorrect storage of chemicals. Do not store HCl and NaClO near grease, flammable or oxidising substances, oils, acids or salts. Obtain approval for storing chemicals. 1. Remove the cover of the system. 2.

  • Page 29: Hydraulic Installation

    6.6 Hydraulic installation Fig. 23 OCD-162-05 (-10) Fig. 25 OCD-162-60 Pos. Description Hose from the internal batch tank to the drain cock Hose of suction lance Dosing line from the dosing pump to the injection unit Solenoid valve with connection for dilution water 6.6.1 System frame 1.

  • Page 30: External Dosing Pump

    6.6.2 External dosing pump 6.7 Electrical installation The external dosing pump is not a standard component. Warning Warning Only authorised service staff may connect the Incorrect installation may result in personal injury electronic components. and damage to property. Only authorised service staff may connect an Warning external dosing pump to the system.

  • Page 31: Measuring Cell

    6.7.2 Measuring cell 6.7.3 Bypass mixing module Connect the cable from the flow switc h to the terminals 49/50, AQC-D1/ -D11 measuring cell see section 14. Terminal connections. Connect the measuring electrode and counter-electrode as well as the sample-water sensor, Pt100 temperature sensor, pH/ORP 6.7.4 Dosing stop input electrode and cleaning motor to the control unit.

  • Page 32: External Batch Tank

    6.7.8 External batch tank 6.7.9 Power supply cable The external batch tank is delivered with a level indicator with 3 Warning bistable changeover switches, see figure and section 5.3 Tank Incorrect electrical connections may result in serious levels. personal injury and damage to property. Make sure that the status indicator field of each changeover Electrical connections may only be carried out by switch is black when the floater is at the bottom.

  • Page 33: Commissioning

    7. Commissioning 7.2 Initial display The initial display is the first screen that appears after turning on This section includes information on how to start the system after the system. having installed all components. The control elements are described. The navigation between the prod.

  • Page 34: Navigation

    7.3 Navigation Use the [OK] and [Esc] keys to navigate between the main menu and the initial display. production terminated 24.5 °C 3 4 5 0.23 mg/l 7.35 pH [OK] [Esc] main menu operation monitoring function tests commissioning service super-user Fig.

  • Page 35: Menu Structure

    7.5 Menu structure Service-user code required Super-user code required Main menu Submenu 1 Submenu 2 Submenu 3 Submenu 4 start production terminate start operation ClO2 dosing stop change container NaClO2 Main menu Submenu 1 Submenu 2 Submenu 3 Submenu 4 status batch counter production...
  • Page 36 Main menu Submenu 1 Submenu 2 Submenu 3 Submenu 4 Submenu 5 Submenu 6 Submenu 7 Deutsch language English ..date date/time time external batch tank internal no. of batches display contrast ClO2 AQC-D1 /-D11 temp. comp. cleaning motor ClO2 + pH measuring cell...
  • Page 37 Main menu Submenu 1 Submenu 2 Submenu 3 Submenu 4 Submenu 5 Submenu 6 proport. ctrl. setpoint ctrl. control mode combined ctrl. dosing control setpoint added quantity ctrl. parameters prop. range XP reset time TN deriv. time TV max. dosing time dos.

  • Page 38: Initial Startup

    Menu Submenu 1 Submenu 2 Submenu 3 cal. meas. value cal. result ClO2 cal. cycle cal. meas. value cal. result calibration [Cal] cal. cycle cal. meas. value cal. result cal. cycle manually dosing [Man] 7.6 Initial startup 7.10 Display contrast Adjust the display contrast in "main menu >...

  • Page 39: Measuring Range

    7.11.2 Measuring range 7.11.3 Current output 1. "main menu > commissioning > measurement > on > 1. "main menu > commissioning > measurement > on > current measuring range" output". The parameters in the display depend on the selected measuring Predefined ranges cell.

  • Page 40: Dosing Control Setup

    2. Select the range. 7.15 Dosing pump setup "main menu > commissioning > dosing pump" max. flow 10 m3/h dosing pump int./ext. pump 3. Enter the maximum flow. pump type others max. capacity Enter the current value for the start and the end of the measuring stroke length range.

  • Page 41: Stroke Length

    7.15.4 Stroke length 7.19 Settings "main menu > commissioning > dosing pump > stroke length" All settings made during the commissioning can be saved. stroke length Use the function "restore" only, if the settings have Note been saved before. Otherwise the factory settings 100 % are loaded.

  • Page 42: Operation

    "main menu > operation > ClO2 dosing > start" others freely adjusted within the set pH measuring range (difference of at least 1 pH). ClO2 dosing 6. Select "Grundfos", for example. start buffer temp. stop 25 °C 8.2.2 Stopping ClO dosing "main menu >...

  • Page 43: Orp Value

    8.3.3 ORP value 8.4 Changing the chemical containers 1. Prepare a glass jar with ORP buffer solution. The chemical containers should be replaced in the following situations: 2. Prepare an empty 10-litre bucket. 3. Press [Cal] > "ORP > cal. meas. value". •...

  • Page 44: Deaerating The Pump Manually

    8.5 Deaerating the pump manually 8.6.2 List of events The history of up to 99 faults and messages can be viewed by Warning scrolling through the list. Risk of serious personal injury and damage to "main menu > monitoring > list of events" equipment due to incorrect handling of chemicals.

  • Page 45: Dosing Status

    8.6.4 Dosing status "main menu > monitoring > dosing control" For control status description, see section 5.6 Dosing control. dosing control y-out: 75 % setp: 0.2 mg/l setpoint ctrl. 83 % 300 s Qmax: 100 % min. Ton: 1.0 s 8.6.5 Water meter status 1.

  • Page 46: Fault Finding

    9. Fault finding This section includes an overview of alarm messages, a list of possible errors and remedies, and a description of how to test the functions of the system. 9.1 Fault overview The alarm messages are shown in the initial display. Reaction Alarm message Alarm...

  • Page 47: Faults With Error Message

    9.2 Faults with error message Service staff only Error message Cause Remedy Change the HCl or NaClO container. HCl or NaClO container is almost empty. OCD-162-05, -10: the chemical containers "low level HCl" or "low level must be positioned under the system. NaClO2"...
  • Page 48 Error message Cause Remedy Check the hose from the pump to the During NaClO supply, the level in the reaction tank reaction tank for assembly faults. has increased too slowly between the levels K2 and Check the NaClO pump in the "relays" K3.
  • Page 49 Error message Cause Remedy Fault during pH calibration. Two buffers with a pH Check the buffer solutions. Repeat the "fault of electrode/buffer" difference of less than 1 pH were selected. calibration, and replace the electrode. Fault during ClO , pH and ORP calibration. This alarm is activated, if the calibration process does Check the pH electrode and replace, if "calibration time exceeded"...
  • Page 50 Error message Cause Remedy Stop the system and perform maintenance. "annual maintenance due" Acknowledge maintenance: "main menu > Maintenance overdue for less than 30 days. service > maint. release". Stop the system and perform maintenance. "maintenance date exceeded" Acknowledge maintenance: "main menu > Maintenance overdue for more than 30 days.

  • Page 51: Faults Without Error Message

    9.3 Faults without error message Fault Cause Remedy Open the isolating valve. If the system operates in 60 Hz The ClO dosing mode, check if the multi-function valve is set to 6 bars at The isolating valve of the dosing line is closed. pump stops.

  • Page 52: Level Indicators

    9.4.6 Level indicators NaClO suction lance "main menu > function tests > level indicators > suction lances > For illustrations and description of the tank level indicators, NaClO2" please see section 5.3 Tank levels. Status of level indicators NaClO2 The display indicates the status of the level indicators. K9:........

  • Page 53: Maintenance

    10. Maintenance 10.1 Flushing This section includes information on how to prepare and carry out Warning the regular maintenance work. The order numbers of the relevant Risk of serious personal injury and damage to maintenance kits are mentioned at the beginning of each section. equipment due to incorrect handling of chemicals.

  • Page 54: Dosing Pumps

    Starting flushing 1. "main menu > service > flushing" flushing put suct. lance into water [OK] 2. Press [OK], if the suction lances are in the water. flushing open drain cock [OK] 3. Press [OK], if the internal batch tank is empty. flushing close drain cock [OK] 4.

  • Page 55: Solenoid Valve

    10.3 Solenoid valve Connection pieces 10.3.1 OCD-162-5 / -10 OCD-162 Connection pieces (A) Order no. G 5/8 female thread for hose 6/9: for OCD-162- Spare parts Order no. 95727673 input of solenoid valve -05, -10 5, 10 3 O-rings, cap, strainer and valve 95702990 G 5/8 female thread for hose 4/6: for 95727672...

  • Page 56: Reaction Tank And Internal Batch Tank

    10.4 Reaction tank and internal batch tank Warning OCD-162-30 Risk of burns due to the escape of chemicals from hoses, reaction tank, internal batch tank and Level indicator dismantled dosing line. Risk of gas poisoning due to the escape of ClO from the dismantled gas hose.

  • Page 57: Ocd-162-5, -10: Volume Compensation Bag And Activated Carbon Filter

    OCD-162-60 Fig. 44 OCD 162-60: reaction tank Pos. Spare parts Fig. 45 Maintaining the activated carbon filter Level indicator connection on top of the reaction tank (see fig. 43) Pos. Description Level indicator connection at bottom of the internal batch tank (see fig.

  • Page 58: Ocd-162-30, -60: Volume Compensation Bag And Adsorption Filter

    7. Unfasten the connection piece (6) for the top valve from the 10.6.4 Replacing the adsorbent valve support. Unscrew and remove the valve, and screw in a new valve (5). Fasten the connection piece again. Observe the flow direction. 8. Unfasten the bottom valve from the valve support. Unscrew and remove the valve, and screw in a new valve (5).

  • Page 59: Replacing The Lower O-Ring

    10.6.5 Replacing the lower O-ring 1. Detach the valve support (10) from the bottom screw connection (11). 2. Remove the O-ring, and fit a new O-ring (12). 10.6.6 Replacing the valves in the valve support 1. Unfasten the connection piece (8) for the top valve from the valve support.

  • Page 60: Repair

    11. Repair This section includes the information of how to replace complete 11.2 Suction lance components of the system. The order number of the spare parts 1. Untwist the screw cap from the suction lance in the chemical you find in section 15.

  • Page 61: Level Indicators

    11.5 Level indicators 14. Attach the connection for the dosing pump supply line. 15. Slide the control unit back into place, and fasten the screws. Replacing the level indicator in the reaction tank 16. Dispose of the old reaction tank with internal batch tank in a 1.

  • Page 62: Decommissioning

    12. Decommissioning This section includes the information of how to decommission 12.1.3 Dosing line hydraulic and electric components. Beside this you find a 1. Drain the dosing line at the multi-function valve. description of packaging and storing the system. 2. Detach the dosing line from the multi-function valve. Drain the solution into a bucket.

  • Page 63: Packaging For Transport

    2. Pack the dry hoses in a box. appropriate waste collection services. If this is not 3. Pack the cables in a box. possible, contact the nearest Grundfos company or 4. Place the fixing screws in a bag and store in the box with the service workshop.

  • Page 64: Terminal Connections

    14. Terminal connections High voltage (230 V / 115 V) Outputs Low voltage Fig. 48 Terminal connection plan High voltage (230 V / 115 V) Colour abbreviations according to IEC 60757 IEC 60757 colour black brown white green grey yellow blue Outputs The outputs are electrically isolated.
  • Page 65 Low voltage Fig. 51 Terminal connection plan - right section Terminals Caption Description Factory-fitted 31 (WH) low-level signal ● 32 (GN) HCl/A HCl suction lance empty signal ● 33 GND (BN) 35 (WH) low-level signal ● 36 (GN) NaClO NaClO suction lance empty signal ●...

  • Page 66: Accessories

    15. Overview spare parts, maintenance kits and accessories 15.1 Spare parts OCD-162-5, -10 Spare parts Description Version Order no. 230 V 98163454 for HCl 115 V 98163456 DDE 10-6, complete 230 V 98163419 Dosing pump for NaClO 115 V 98163440 230 V 98163484 for ClO...
  • Page 67 Spare parts Description Version Order no. G 5/8 female for hose 6/9: for input of 95727673 pieces between connection solenoid valve for hose and solenoid valve, PE hose 1/4 x 3/8: for input of solenoid 1 complete set 95727674 Fig. 37 Solenoid valve valve, USA OCD-162-05, -10: exploded G 5/8 female for hose 4/6 for output of...

  • Page 68: Spare Parts Ocd-162-30, -60

    15.2 Spare parts OCD-162-30, -60 Spare parts Description Version Order no. 230 V 98163923 HCl dosing pump 115 V 98163925 DDE 15-4, complete 230 V 98163904 NaClO dosing pump 115 V 98163921 OCD-162-30 220-240 V 95715682 DMX 16-10, complete 115 V 95715681 dosing pump 230 V...
  • Page 69 Spare parts Description Version Order no. Strainer for input of solenoid valve 5 pieces 95717437 System frame 95717451 Foot 95717452 Hose PTFE 4/6, white 1.5 m 96727482 to volume compensation bag T-piece for PTFE hose 4/6 1 piece 95714891 G 5/8 male/G 1/4 male: for input of solenoid 95723464 Connection pieces between connection valve...

  • Page 70: Maintenance Kits

    Dosing pump DDA 7.5-16 (230 V / 115 V) 97751181 Available Solenoid valve (230 V / 115 V) 95702990 Accessories from Grundfos O-rings for reaction tank and internal batch tank 95702992 Activated carbon filter and volume compensation Protective clothing ● 95702994 Plastic buckets Complete kit with dosing pump DDA 7.5-16...

  • Page 71: Declaration Of Conformity

    GR: ∆ήλωση συμμόρφωσης ΕΚ/ΕΕ HR: EU deklaracija sukladnosti Εμείς, η Grundfos, δηλώνουμε με αποκλειστικά δική μας ευθύνη ότι το Mi, Grundfos, izjavljujemo s punom odgovornošću da je proizvod προϊόν Oxiperm® Pro OCD-162, στο οποίο αναφέρεται η παρακάτω Oxiperm® Pro OCD-162, na koja se izjava odnosi u nastavku, u skladu s δήλωση, συμμορφώνεται...
  • Page 72 — EMC Directive (2014/30/EU). Standards used: EN 61326-1:2013, EN 61000-3-2:2015, EN 61000-3-3:2014. This EC/EU declaration of conformity is only valid when published as part of the Grundfos installation and operating instructions (publication number 98561817). Pfinztal, 20th April 2016 Ulrich Stemick...
  • Page 73 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 75 Phone: +852-27861706 / 27861741 Telefax: +47-22 32 21 50 Canada Telefax: +852-27858664 Turkey Poland GRUNDFOS Canada Inc. GRUNDFOS POMPA San. ve Tic. Ltd. Sti. Hungary 2941 Brighton Road GRUNDFOS Pompy Sp. z o.o. Gebze Organize Sanayi Bölgesi Oakville, Ontario GRUNDFOS Hungária Kft.
  • Page 76 98561817 0716 ECM: 1188710 www.grundfos.com...

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