GRUNDFOS ALLDOS Oxiperm C 164 Series Operation manual

1
Oxiperm®C 164
Fully-automatic Chlorine Dioxide
Generation System
164 -4000C, -6000C, -7500C,
-10000C
Operation and Service Manual
Please read the Operation Manual completely and retain for future reference!
Damages resulting from operating errors cancel the guarantee.
Other languages
http://net.grundfos.com/qr/i/96681360

2
Oxiperm 164C 4-10 kg en
Imprint
Oxiperm®C 164
fully-automatic chlorine dioxide
generation system
164-4000C, -6000C, -7500C, -10000C
Operation and Service Manual
Issued by:
ALLDOS Eichler GmbH
Reetzstraße 85 • 76327 Pfinztal (Söllingen)
Postfach 1160 • 76317 Pfinztal
Tel. [phone] / Fax. [phone]
Subject to change.

315.710120-V6.0
Oxiperm 164C 4-10 kg en
Installation data
NOTE Please fill in this form following commissioning. It will
help you and your Grundfos-Alldos servicing partner to
adjust the device during subsequent corrections.
Owner:
ALLDOS customer No.:
Contract No.:
Order No. of device:
Serial number of device:
Put into service on:
Location of device:
Used for:
Installation diagram

4
Oxiperm 164C 4-10 kg en
Contents
Installation data ................................................................................................ 3
Installation diagram ......................................................................................... 3
1 General .................................................................................................... 7
1.1 Introduction................................................................................................ 7
1.2 Using this Document ................................................................................. 7
1.3 Guarantee ................................................................................................. 7
2 Safety Information .................................................................................. 8
2.1 Use of the System ..................................................................................... 8
2.2 Obligations of Owner................................................................................. 8
2.3 Avoidance of Danger ................................................................................ 8
3 Technical Data ........................................................................................ 9
3.1 General Data ............................................................................................. 9
3.1.1 Performance and Consumption Data ............................................ 9
3.1.2 Connection Data and Weights .................................................... 10
3.1.3 Dimensions .................................................................................. 10
3.2 Electrical Data ......................................................................................... 13
3.3 Delivery State .......................................................................................... 13
4 Fundamentals ........................................................................................14
4.1 Chlorine Dioxide for Water Treatment ..................................................... 14
4.1.1 Generation of Chlorine Dioxide ................................................... 14
4.2 Functional Sequence .............................................................................. 15
5 Design and Function .............................................................................16
5.1 System Design ........................................................................................ 16
5.2 Components ............................................................................................ 18
5.2.1 Suction Lines for the Chemicals .................................................. 18
5.2.2 Dosing Pump HCl/NaClO2 .......................................................... 18
5.2.3 Flowmeters .................................................................................. 19
5.2.4 Bypass Line ................................................................................. 19
5.2.5 Preliminary Dilution for Hydrochloric Acid .................................. 19
5.2.6 Reactor ........................................................................................ 19
5.2.7 Solution Tank for ClO2 ................................................................. 20
5.2.8 Overflow Unit for Solution Tank .................................................... 20
5.2.9 Suction for Solution Tank ............................................................. 20
5.2.10 Water Tank for Preliminary Dilution .............................................. 20
5.2.11 Purging Unit ................................................................................. 20
5.2.12 Options ......................................................................................... 21
5.3 Mode of Operation of System .................................................................. 22
6 Installation .............................................................................................24
6.1 Transport and Storage ............................................................................ 24
6.2 Unpacking ............................................................................................... 24
6.3 Installation Location ................................................................................ 24
6.4 Installation Diagrams .............................................................................. 25
6.4.1 Installation Diagram for Water Supply and
Connection of the Chemicals ...................................................... 25
6.4.2 Installation Diagram for Sampling of ClO2,
Suction and Overflow ................................................................... 26
6.5 Floor Mounting of
System Frame .......................................................................................... 27

515.710120-V6.0
Oxiperm 164C 4-10 kg en
6.6 Hydraulic Connection ............................................................................. 28
6.6.1 Bypass Line ................................................................................. 28
6.6.2 Supply Line for Chemicals .......................................................... 28
6.6.3 Sampling Line for Chlorine Dioxide ............................................ 28
6.6.4 Discharge Line for Suction Injector for Solution Tank ................. 28
6.7 Electrical Connection .............................................................................. 29
6.7.1 Profibus/Ethernet
(Option) ........................................................................................ 32
6.7.2 RS232 / RS422 / 485 Interface ................................................... 33
7 Operation of Control Electronics..........................................................34
7.1 Program Structure ................................................................................... 34
7.2 Control and Display Elements ................................................................ 35
7.3 Automatic Mode ...................................................................................... 37
7.4 Manual Mode .......................................................................................... 37
7.5 Logbook .................................................................................................. 37
7.6 System Selection ..................................................................................... 38
7.6.1 System Type ................................................................................. 38
7.6.2 Operating Mode ........................................................................... 38
7.7 Basic Setting ........................................................................................... 39
7.7.1 Language..................................................................................... 39
7.7.2 Min. Contact Water ....................................................................... 39
7.7.3 Code Function ............................................................................. 39
7.7.4 Reset Function ............................................................................. 40
7.7.5 Date/Time ..................................................................................... 40
7.7.6 Bus Options .................................................................................. 42
7.7.7 Program Version .......................................................................... 42
7.7.8 Automatic start ................................................................................ 43
7.8 Service Mode .......................................................................................... 44
7.8.1 Venting of Bypass Water Line and Dosing Pumps for
NaClO2 / HCl and H2O ................................................................ 44
7.8.2 Setting Data ................................................................................. 45
7.8.3 Test Mode ..................................................................................... 46
7.8.4 Reactor Temperature ................................................................... 47
7.9 Local / Remote ........................................................................................ 47
8 Startup ...................................................................................................48
8.1 Selection of System and Operating Mode .............................................. 49
8.2 Checking of Limit Contacts of Flowmeters.............................................. 49
8.2.1 Limit Contacts for 164-4000 C ..................................................... 50
8.2.2 Limit Contacts for 164-6000 C ..................................................... 50
8.2.3 Limit Contacts for 164-7500 C ..................................................... 50
8.2.4 Limit Contacts for 164- 10000 C ................................................ 51
8.3 Start-up operation, filling reactor with water ........................................... 51
8.4 Filling of Water Tank ................................................................................ 52
8.5 Venting and Adjustment of the H2O Pump ............................................. 55
8.6 Venting and Adjustment of the Pump for HCl/NaClO2 ........................... 57
8.7 Venting and Adjustment of the Bypass line ............................................ 60
8.8 Venting the Line for the Suction Injector ................................................. 60
8.9 Filling the Overflow
System on the Solution Tank ................................................................... 61

6
Oxiperm 164C 4-10 kg en
9 Operation of the System .......................................................................62
9.1 Auto / Manual .......................................................................................... 62
9.1.1 Automatic Mode ........................................................................... 62
9.1.2 Manual Mode ............................................................................... 64
9.2 Gauging of the Dosing Pump for HCl/NaClO2 ....................................... 65
9.2.1 Gauging of HCl ............................................................................ 66
9.2.2 Gauging of NaClO2 ..................................................................... 66
10 Alarms/Errors ........................................................................................67
10.1 Acknowledgment of an alarm ................................................................. 67
10.2 Faults ....................................................................................................... 68
10.3 Error Messages of Controller .................................................................. 69
10.4 Fuses/LEDs of Controller ........................................................................ 71
11 Maintenance .......................................................................................... 72
11.1 Maintenance of Dosing Pumps ............................................................... 72
11.1.1 Dismounting and Cleaning the Valves ........................................ 73
11.1.2 Dismounting the Diaphragm of the Dosing Pump ....................... 75
11.2 Maintenance of Valves of Reactor and Purging Line ............................. 77
11.3 Checking of Temperature Sensor ........................................................... 79
11.4 Maintenance of the Suction Injector ....................................................... 80
11.5 Maintenance of Valves on the Suction Pulsation Damper...................... 82
11.6 Maintenance of the Solution Tank for ClO2 ............................................ 83
12 Details on the Components .................................................................. 85
12.1 Water Unit ................................................................................................... 85
12.2 Solenoid Valves for Purging and Suction Injector ...................................... 86
12.3 Pump for Dilution Water ............................................................................. 86
12.4 Valves in Bypass Line................................................................................. 86
12.5 Pulsation Damper ....................................................................................... 87
12.6 Impeller Meter ............................................................................................. 88
12.7 Flow Limiter ............................................................................................. 88
12.8 Water Tank for Preliminary Dilution ......................................................... 89
12.9 Leakage Monitoring ................................................................................ 90
13 Spare Parts Sets ....................................................................................91
14 Current Setting Data ..............................................................................92
EC Conformity Declaration

715.710120-V6.0
Oxiperm 164C 4-10 kg en
1 General
1.1 Introduction
This Operation and Service Manual contains all information for safe operation of
the described device.
Should you require further information, or should problems occur which are not
handled in sufficient depth in this document, please request the information directly
from Grundfos-Alldos.
1.2 Using this Document
❏Descriptions are written in normal continuous text.
❏Lists are identified by squares (❏), subdivisions by dashes (-).
❏Steps requiring operations are identified by bold dots (●), subdivisions by
smaller dots (•).
❏Cross-references are indicated by
italic letters and an arrow (➜).
❏The safety instructions WARNING , CAUTION, NOTE and
PACKAGING have the following meanings:
!
WARNING Danger of injuries and accidents!
CAUTION Danger of malfunctioning or damage to device!
NOTE Exceptional feature.
PACKAGING Retain packaging material, or expose of according to
local regulations.
1.3 Guarantee
A guarantee claim in the sense of our general conditions of sale and delivery can
only be recognized if
❏the device has been used according to the information in this Operation
Manual,
❏the device has not been opened or incorrectly handled in any manner,
❏repairs have only been carried out by authorized specialists,
❏only original spare parts have been used during repairs.
NOTE Interventions in the hardware or software cancel the
guarantee and liability.
Software remains the property of ALLDOS Eichler
GmbH. Reproduction is not permitted.

8V6.0
Oxiperm 164C 4-10 kg en
2 Safety Information
2.1 Use of the System
Oxiperm®C 164 is used to generate a chlorine dioxide solution within the context
of the possible applications described in this manual.
!
WARNING Other applications are considered as non-approved,
and are not permissible. ALLDOS Eichler GmbH cannot
be held liable for any damage resulting from such use.
2.2 Obligations of Owner
The owner of the plant is responsible for
❏training of operating personnel and
❏implementation of regular maintenance.
2.3 Avoidance of Danger
!
WARNING Before starting up, it is essential that you read the
ALLDOS information document "Function and safety of
chlorination systems".
Danger of explosion!
The permissible temperature ranges for process water
and chemicals must not be violated!
Observe the safety information for the used chemicals!
Work on the system must only be carried out at
standstill and with the master switch switched off!
Do not open the device components! Cleaning,
maintenance and repairs must only be carried out by
specialists authorized by ALLDOS!
Purge the reactor when carrying out maintenance work
on it!

915.710120-V6.0
Oxiperm 164C 4-10 kg en
3 Technical Data
3.1 General Data
3.1.1 Performance and
Consumption Data
NOTE An increase or decrease in the total system
performance is only possible within a range of approx.
+/-10% since certain limits are defined in the PLC
program for safety reasons.
If the generated quantity of ClO2 is too large, it is also
possible to shift the MAX contact down on the solution
tank in order to produce less ClO2.
Concentration of prepared solution
3 g/l
Permissible concentration of NaClO2 solution 24.5% w/w
Permissible concentration of HCl solution 33% w/w
Permissible ambient temperature +5 °C to +40 °C
Permissible process water temperature (bypass water) +2 °C to +40 °C
Permissible component temperature (chemicals) +5 °C to +30 °C
Storage temperature of system -5 °C to +50 °C
Storage temperature of chemicals +5 °C to +40 °C
Permissible relative humidity Max. 80%, no condensation
Materials
System frame PP
Screws, washers and nuts 1.4301
Reactor Gray PVC
Solution tank Gray PVC
Piping Gray PVC
Gaskets FPM / PTFE
System Op. pressure
Bypass Prelim. dilution Suction from Total
NaClO2/HCl H2O (with 3 g/l) for HCl solution tankwater quantity
(kg/h) (l/h) (l/h) (l/h) (l/h) (l/h) (l/h) (l/h) (bar)
164-4000C 4 1333 24 24 1150 140 1400 2690 4 - 5
164-6000C 6 2000 37 37 1720 215 1900 3835 4 - 5
164-7500C 7,5 2500 47 47 2150 265 2300 4715 4 - 5
164-10000C 10 3333 63 63 2860 355 3100 6315 4 - 5
Dilution water requirement for bypass systemConsumption of
components *
performance *
ClO2
generation

10 V6.0
Oxiperm 164C 4-10 kg en
3.1.3 Dimensions
P1 Process water connection (bypass, predilution for HCI)
P2 Connecting pipe for NaClO2
P3 Connecting pipe for HCI
P4 Extraction pipe for suction injector (solution container)
P5 Extraction pipe for ClO2
3.1.2 Connection Data and Weights
Max. backpressure System
System for suction injector weight
solution tank
(bar) (kg)
164-4000C 1,5 225
164-6000C 1,5 245
164-7500C 1,5 290
164-10000C 1,5 315
ClO2 solution
Connection for
25
25
Connection for
bypass water
(DN) (DN)
inlet line
32
32
Connection for
suction
solution tank
50
32
32
50 20
20
20
Connection for
HCl /NaClO2
line
(DN)
20
25
(DN)
25
25
25
ABCDEFGHKLMNO
164-4000C 1660 1800 1150 1600 804 280 900 282 180 780 100 150 260
164-6000C 1660 1800 1150 1600 804 280 900 282 180 780 100 150 260
164-7500C 1800 1800 1350 1740 1004 280 900 282 180 920 100 150 260
164-10000C 1800 1800 1350 1740 1004 280 900 282 180 920 100 150 260
P1 P2 P3 P4 P5
164-4000C DN 25 DN 20 DN 20 DN 25 DN 32
164-6000C DN 25 DN 20 DN 20 DN 25 DN 32
164-7500C DN 32 DN 20 DN 20 DN 25 DN 50
164-10000C DN 32 DN 20 DN 20 DN 25 DN 50
System
Total water
Bypass Bypass Bypass quantityat a
(at 2 g/l) (at 3 g/l) (at 3,3 g/l)concentration of 2 g/l
(l/h) (l/h) (l/h) (l/h)
164-4000C 1810 1150 1020 3400
164-6000C 2715 1720 1530 4900
164-7500C 3395 2150 1920 6000
164-10000C 4525 2860 2560 8000
Water required for bypass system