GRUNDFOS ALLDOS Oxiperm C 164 Series Operation manual

1
Oxiperm® C 164
Fully-automatic Chlorine Dioxi-
de Generation System
164 -150C, -450C, -750C,
-1300C, -2500C
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/96681303

215.710010-V5.0
Oxiperm 164 150-2500 g en
Imprint
Oxiperm®C 164
fully-automatic chlorine dioxide
generation system
164-150C, -450C, -750C, -1300C, -2500C
Operation and Service Manual
Version 5.0
Issued by:
ALLDOS Eichler GmbH
Reetzstraße 85 • D-76327 Pfinztal (Söllingen)
Postfach 1160 • 76317 Pfinztal
Tel. [phone] / Fax. [phone]
Subject to change.

315.710010-V5.0
Oxiperm 164 150-2500 g 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:
Grundfos Alldos customer No.:
Contract No.:
Order No. of device:
Serial number of device:
Put into service on:
Location of device:
Used for:
Installation diagram

415.710010-V5.0
Oxiperm 164 150-2500 g 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 .................................................................................. 11
3.2 Electrical Data ......................................................................................... 12
3.3 Delivery State .......................................................................................... 12
4 Fundamentals ........................................................................................13
4.1 Chlorine Dioxide for Water Treatment ..................................................... 13
4.1.1 Generation of Chlorine Dioxide ................................................... 13
4.2 Functional Sequence .............................................................................. 14
5 Design and Function .............................................................................15
5.1 System Design ........................................................................................ 15
5.2 Components ............................................................................................ 16
5.2.1 Suction Lines ............................................................................... 16
5.2.2 Dosing Pumps ............................................................................. 16
5.2.3 Dosing Controller ......................................................................... 17
5.2.4 Reactor ........................................................................................ 17
5.2.5 Bypass Line ................................................................................. 17
5.2.6 Post-mixer .................................................................................... 17
5.2.7 Purging Unit ................................................................................. 17
5.2.8 Preliminary Water Tank ................................................................ 18
5.2.9 Options ......................................................................................... 18
5.3 Mode of Operation of System .................................................................. 20
5.3.1 How the system operates in batch mode .................................... 21
6 Installation .............................................................................................22
6.1 Transport and Storage ............................................................................ 22
6.2 Unpacking ............................................................................................... 22
6.3 Installation Location ................................................................................ 22
6.4 Installation Diagrams .............................................................................. 23
6.4.1 Installation Diagram of Oxiperm 164 Chlorine
Dioxide System with Solenoid Valve ........................................... 24
6.4.2 Installation Diagram of Oxiperm 164 Chlorine
Dioxide System with Internal Bypass Pump ................................ 25
6.4.3 Installation Diagram of Oxiperm 164 Chlorine
Dioxide System with Batch Tank .................................................. 26
6.4.4 Installation Diagram of Oxiperm 164 Chlorine
Dioxide System with External Booster Pump and Load Unit ...... 27
6.4.5 Installation Diagram of Oxiperm 164 Chlorine
Dioxide System with Automatic Purging and Drain Unit ............. 28
6.5 Wall Mounting ......................................................................................... 29
6.6 Hydraulic Connection ............................................................................. 29
6.6.1 Bypass Line ................................................................................. 29
6.6.2 Safety Suction Unit Option ........................................................... 30

515.710010-V5.0
Oxiperm 164 150-2500 g en
6.6.3 Preliminary Water Tank ................................................................ 31
6.7 Electrical Connection .............................................................................. 32
6.7.1 Profibus/Ethernet
(Option) ........................................................................................ 35
6.7.2 RS232 / RS422 / 485 Interface ................................................... 36
7 Operation of Control Electronics..........................................................37
7.1 Program Structure ................................................................................... 37
7.2 Control and Display Elements ................................................................ 38
7.3 Automatic Mode ...................................................................................... 40
7.4 Manual Mode .......................................................................................... 40
7.5 Logbook .................................................................................................. 40
7.6 System Selection ..................................................................................... 41
7.6.1 System Type ................................................................................. 41
7.6.2 Mode ............................................................................................ 41
7.6.3 Units of Measurement .................................................................. 42
7.7 Basic Setting ........................................................................................... 43
7.7.1 Language..................................................................................... 43
7.7.2 Min. Contact Water ....................................................................... 43
7.7.3 Current Output ............................................................................. 43
7.7.4 Code Function ............................................................................. 43
7.7.5 Reset Function ............................................................................. 44
7.7.6 Date/Time ..................................................................................... 44
7.7.7 Housing Suction .......................................................................... 46
7.7.8 Bus Options .................................................................................. 47
7.7.9 Program Version .......................................................................... 47
7.7.10 MIN Bypass Time ......................................................................... 47
7.7.11 Automatic start ............................................................................. 48
7.8 Service Mode .......................................................................................... 48
7.8.1 Venting of Bypass Water Line
and Dosing Pumps for NaClO2/HCl and H2O ............................ 48
7.8.2 Startup Mode ............................................................................... 49
7.8.3 Test Mode ..................................................................................... 50
7.8.4 Reactor Purging ........................................................................... 51
7.8.5 Reactor Temperature ................................................................... 51
7.9 Local / Remote ........................................................................................ 52
8 Startup ...................................................................................................53
8.1 Installation selection ............................................................................... 54
8.2 Mode selection ........................................................................................ 55
8.2.1 Batch Mode .................................................................................. 56
8.2.2 Current input ................................................................................ 57
8.2.3 Contact input ................................................................................ 58
8.2.4 Manual control ............................................................................. 60
8.2.5 Target value - external ................................................................. 60
8.3 Deaeration of the bypass line ................................................................. 61
8.3.1 Bypass pump (option) .................................................................. 61
8.3.2 Filling the Water Tank ................................................................... 62
8.4 Venting and Gauging the Dosing Pump for H2O .................................... 63
8.4.1 Venting ......................................................................................... 63
8.4.2 Gauging ....................................................................................... 64
8.5 Venting the Dosing Pumps for HCl and NaClO2 .................................... 65
8.5.1 Venting the Dosing Pumps DMX 221 .......................................... 65
8.5.2 Venting of Dosing Pumps DMI ..................................................... 66
8.6 Startup Mode ........................................................................................... 67
8.6.1 Batch Mode .................................................................................. 68
8.6.2 Current Input, Contact Input, Manual Control and
Target value - external Modes ..................................................... 70
8.7 Gauging the Dosing Pumps .................................................................... 71
8.7.1 Gauging the DMI Dosing Pumps for the Chemicals ................... 71
8.7.2 Calibrating the Dosing Pump DMX 221 for Chemicals ............... 72
8.8 Adjusting the Dosing Controllers ............................................................ 76

615.710010-V5.0
Oxiperm 164 150-2500 g en
9 Operation of the installation ................................................................. 77
9.1 Automatic Mode ...................................................................................... 77
9.1.1 Current input/Contact input .......................................................... 77
9.1.2 Batch Mode .................................................................................. 79
9.1.3 Target value - external ................................................................. 81
9.2 Manual Mode .......................................................................................... 82
9.2.1 Manual Mode for Batch ................................................................ 82
10 Alarms/Errors ........................................................................................83
10.1 Acknowledgment of an alarm ................................................................. 83
10.2 Faults ....................................................................................................... 84
10.3 Error Messages of Controller .................................................................. 86
10.4 Fuses/LEDs of Controller ........................................................................ 88
10.5 Possible Errors when changing the tank ................................................ 89
11 Maintenance .......................................................................................... 90
11.1 Maintenance of Dosing Pumps ............................................................... 90
11.1.1 Dismounting and Cleaning the Valves ........................................ 90
11.1.2 Dismounting the Diaphragm ....................................................... 91
11.1.3 Spare Parts for Dosing Pumps .................................................... 92
11.2 Maintenance of Suction Lines ................................................................ 95
11.3 Maintenance of Reactor .......................................................................... 95
11.4 Maintenance of Suction Injector ............................................................. 97
12 Details on the Versions .........................................................................99
12.1 Housing Suction ...................................................................................... 99
12.2 Solenoid Valve .......................................................................................... 100
12.3 Flow Limiter + Vane Anemometer ............................................................ 100
12.4 Purging Units (Ball valve) ..................................................................... 101
12.4 Drain Unit ................................................................................................. 102
12.5 Purging Units (Solenoid valve) ................................................................ 103
12.6 Circulating Pump ...................................................................................... 103
12.8 Solenoid valve (batch mode) ................................................................... 104
12.9 Vane Anemometer .................................................................................... 104
12.7 Ball Valve (batch mode) ............................................................................ 104
12.10 Post-mixer ............................................................................................... 105
12.11 Pressure loading valve DN20 ................................................................ 105
13 Spare Parts Sets .................................................................................. 106
13.1 Spare Pumps for HCl, NaClO2 and H2O.............................................. 107
14 Accessories ......................................................................................... 108
14.1 External Booster Pump ......................................................................... 108
14.1.1 Technical Data ........................................................................... 108
14.1.2 Booster pumps ........................................................................... 108
14.2 Load Unit for Booster Pump .................................................................. 109
14.3 Hose Connections ................................................................................ 111
14.4 Gas Sensor + Gas Warning Device ...................................................... 111
15 Current setting data ............................................................................. 112
Short guide
Declaration of conformity

715.710010-V5.0
Oxiperm 164 150-2500 g 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 Grundfos Alldos.
Reproduction is not permitted.

815.710010-V5.0
Oxiperm 164 150-2500 g 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. Grundfos Alldos 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
Grundfos 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 Grundfos Alldos!

915.710010-V5.0
Oxiperm 164 150-2500 g en
3 Technical Data
3.1 General Data
3.1.1 Performance and
Consumption Data
* Generation performance and consumption of components are increased
by approx. 20% in 60-Hz operation
1) With max. generation performance, shortened reaction time
2) With input pressure 2 bar higher compared with the pressure at the injection
unit
3) Depends on flow losses of solution line up to injector
4) Concentration of ClO2solution approx. 3,3 g/l,
Input pressure for bypass water: 3 - 8 bar
5) Concentration of ClO2solution approx. 2 g/l,
Input pressure for bypass water: 3 - 8 bar
General concentration range for all systems: 0.5 - 3.3 g/l
Tolerance of flow limiter (bypass line)
+/- 10%
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, 1.4571 painted RAL 6017
Post-mixer Gray PVC
Piping Gray PVC
Gaskets FPM / PTFE
S
y
stem
50 Hz 60 Hz 1
)
HCl NaClO2 H2O Standard MIN Standard MIN min. 4
)
max. 5
)
(g/h) (l/h) (bar) (bar) (l/h) (l/h) (l/h) (l/h) (l/h) (l/h) (l/h) (l/h) (l/h)
164-150C 150 428 9 6 1,0 1,0 5,5 420 63 420 63 30 70
164-450C 450 442 9 6 2,8 2,8 16 420 126 420 126 90 200
164-750C 750 937 9 6 4,8 4,8 27 900 315 900 315 150 340
164-1300C 1300 962 9 6 8,2 8,2 46 900 405 900 405 260 590
164-2500C 2500 1022 7 6 16 16 90 900 630 900 630 510 1150
back-pressure
performance *
Consumption of
components *
Max. s
y
stem
pressure
Internal/external
ClO2
g
eneration
In batch mode
Dilution water requirement for b
y
pass s
y
stem
At 6 bar
Solenoid valve 2) Bypass pump 3)
(standard)

10 15.710010-V5.0
Oxiperm 164 150-2500 g en
3.1.2 Connection Data and Weights
CAUTION The solution line must be provided with an excess
pressure valve (set to 10 bar) for the case that a
pressure of more than 10 bar occurs in the system with
the chlorine dioxide solution line shut (at the Oxiperm®
C164 outlet) as a result of a correspondingly high input
pressure (at the Oxiperm®C164 inlet) in the dilution
water line.
System
System weight
Suction
connection
(DN) (kg)
164-150C 20 58
164-450C 20 62
164-750C 20 68
164-1300C 20 90
164-2500C 20 110 5 130020
20
20
20
20
20
20
20 20
20
5 1300
5 1300
5 1300
5 1300
pressure requirements
(bar) (l/h)(DN) (DN)
forcing water
inlet
Housing suction
(option)
Connection for
bypass water ClO2 solution line
Connection for
forcing pressure

1115.710010-V5.0
Oxiperm 164 150-2500 g en
3.1.3 Dimensions
Dimensions in mm.
ABC K
EFGH LMC1C2
164-150C 820 760 70 130
1340 1300 258 156 475 ø 11 DN 20 DN 20
164-450C 820 760 70 130
1340 1300 258 156 475 ø 11 DN 20 DN 20
164-750C 820 760 70 130
1340 1300 258 156 475 ø 11 DN 20 DN 20
164-1300C 850 790 70 1301460 1420 278 145 500 ø 11 DN 20 DN 20
164-2500C 850 790 70 130
1460 1420 278 145 520 ø 11 DN 20 DN 20
A1
860
860
860
890
890

12 15.710010-V5.0
Oxiperm 164 150-2500 g en
3.2 Electrical Data
Power consumption Order No. Power consumption (VA)
164-150C 550VA
164-450C 550 VA
164-750C 550 VA
164-1300C 900 VA
164-2500C 1100 VA
Max. permissible loading of
loating output contacts 250 V / 6 A, max. 550 VA
Analog input 0(4) - 20 mA Load: 50 Ohm
Analog output 0(4) - 20 mA Load: max. 500 Ohm
Contact input Max. 50 pulses/second
Max. permissible mains impedance C164
With 90 Watt bypass (0.168 + j 0.168) Ohm (testing according to EN 61000-3-11)
With 340 Watt bypass (0.059 + j 0.059) Ohm (testing according to EN 61000-3-11)
Degree of protection IP 65 Electronics
IP 65 Dosing pumps
IP 65 Solenoid valve
IP 44 Bypass pump
IP 67 Dosing controller
IP 65 Flowmeter
3.3 Delivery State
The Oxiperm®C 164 compact chlorine dioxide system comprises:
❏The generation system, completely assembled and wired up, on a
PP system frame, including dosing pumps and suction line and water tanks
for preliminary dilution of the hydrochloric acid
❏Dosing controller for flow monitoring of hydrochloric acid, sodium chlorite
and dilution water for hydrochloric acid
❏Tank level monitor and empty signalling system for hydrochloric acid
and sodium chlorite
❏Chlorine dioxide reactor with temperature sensor
❏Bypass system with flowmeter and solenoid valve, or optionally
- Circulating pump and flowmeter
- Solenoid valve, dosing ball valve and flowmeter
❏Static mixer
❏Control electronics, directly mounted on system frame and wired up
With housing suction option:
❏Suction injector with solenoid valve, electrically connected to the control
electronics, system frame with side parts and back part.

1315.710010-V5.0
Oxiperm 164 150-2500 g en
4 Fundamentals
4.1 Chlorine Dioxide for Water
Treatment
Properties of chlorine dioxide
❏Strong and fast oxidation and disinfection agent
❏Applications in the treatment of drinking, service, cooling and waste water
❏Chemically unstable compound
- Can explosively decompose into chlorine and oxygen when heated
- Must be generated on site as required since storage in cylinders is
not possible
➜
Observe notes on avoidance of danger in Section 2.3!
Advantages of chlorine dioxide compared to chlorine
❏Largely good to very good bactericidal, virucidal and sporicidal effects in
the complete pH range of drinking water (pH 6.5 - 9)
(the disinfecting effect of chlorine decreases with increasing pH value!)
❏No or reduced forming of trihalogen methanes
❏No generation of chloramines with ammonium or amino compounds
❏Highly reduced potential for generation of organic halogen compounds of
high molecular weight
❏Good stability in water
- Long bactericidal and bacteriostatic protection in the water network
4.1.1 Generation of Chlorine
Dioxide
The Oxiperm®C 164 was specially developed for the continuous or discontinuous
generation of a chlorine dioxide (ClO2) solution for water disinfection. The chlorine
dioxide is generated according to the hydrochloric acid (HCl) / sodium chlorite
(NaClO2) procedure in line with the following stoichiometric equation:
5 NaClO2 + 4 HCl 4 ClO2+ 5 NaCl + 2 H2O
Sodium chlorite Hydrochloric acid Chlorine dioxide Sodium chloride Water
!
WARNING The Oxiperm®C 164 is used with 33 % hydrochloric
solution and 24,5 % sodium chlorite solution and a
predefined quantity of dilution water.
If undiluted, the components 33 % hydrochloric solution
and 24,5 % sodium chlorite solution will generate an
explosive concentration!
Therefore, the components 33 % hydrochloric solution
and 24,5 % sodium chlorite solution may only be used
in the Oxiperm®C 164 with a predefined quantity of
dilution water.
The reaction time is approx. 10 minutes (in agreement with the German directive
DVGW, worksheet W 224).

14 15.710010-V5.0
Oxiperm 164 150-2500 g en
According to the Oxiperm®C 164 application, a multiple stoichiometric excess of
hydrochloric acid is used for the following reasons:
❏A non-critical chlorine dioxide concentration of 20 g ClO2/ l is generated in
the reactor of the Oxiperm®C 164.
!
WARNING A chlorine dioxide solution with a concentration of
30 g / l may explode if a gas area is present above the
solution.
Gaseous chlorine dioxide is explosive above a
concentration of 300 g / m3.
❏A good yield of chlorine dioxide is achieved with excess acid of 250 -
300%. A further increase in the excess acid only results in a small
improvement in the efficiency.
❏Excess acid shifts the equilibrium of the disproportionation reaction
between hydrochloric acid and sodium chlorite to the right, resulting in an
optimum yield.
4.2 Functional Sequence
❏Three components are required to generate a chlorine dioxide solution:
- Hydrochloric acid (HCl)
- Dilution water (H2O) for HCl
- Sodium chlorite (NaClO2)
- Dilution water (bypass )
The added quantities of these components are defined by the process, and
must not be changed. The flows of the individual components are therefore
monitored by flowmeters and flow controllers.
❏Hydrochloric acid (33% solution) and sodium chlorite (24.5% solution) are
dosed into the reactor with a volume ratio 1:1 together with the dilution
water for HCl.
❏Hydrochloric acid and sodium chlorite react together in the reactor and
generate a concentration of approx. 20 g/l
❏Following the reactor, the chlorine dioxide solution is diluted by the bypass
water into a solution ready for use.
Reactor
HCl
NaClO2 Bypass wa t er H2O
ClO2 solution

1515.710010-V5.0
Oxiperm 164 150-2500 g en
5 Design and Function
5.1 System Design
Legend:
1 Dosing system for hydrochloric acid (HCl)
Item 1.1 Dosing pump for hydrochloric acid
Item 1.2 Suction line with advanced and main empty alarm
for HCl (red)
Item 1.3 Dosing controller for HCl flow monitoring
2 Dosing system for sodium chlorite (NaClO2)
Item 2.1 Dosing pump for sodium chlorite
Item 2.2 Suction line with advanced and main empty alarm
for NaClO2 (blue)
Item 2.3 Dosing controller for NaClO2flow monitoring
3 Bypass water line
Item 3.1 Solenoid valve (circulating pump as option)
Item 3.2 Flowmeter for bypass water
Item 3.3 Check valve
Item 3.4 Flow limiter
4 Reactor
Item 4.1 Reactor housing
Item 4.2 Reactor valves
Item 5 Post-mixer
Item 6 Connection for ClO2solution line to injector
Item 7 Connection for bypass water
Item 8 Controller with display
Item 9 Injector for housing suction (option).
AAPP

16 15.710010-V5.0
Oxiperm 164 150-2500 g en
5.2 Components
5.2.1 Suction Lines
The suction lines must be matched to the tank size and the system performance
(diameter of suction line).
They have a two-stage level monitoring feature.
If the level of the components (HCl / NaClO2) drops to the first stage (MIN contact/
advanced empty alarm), the alarm "HCl – MIN" or "NaClO2– MIN" is output on the
controller as an advanced warning.
This is indicated by flashing of the LED on the controller flowchart (see Section
"Control and display elements on the controller", item 2 and item 5).
The system remains in operation following an advanced empty alarm. A relay
"Advanced empty alarm NaClO2/ HCl" is activated.
The system is switched off when the second stage is reached (MIN-MIN contact/
main empty alarm), and the alarm "HCl – empty alarm" or "NaClO2– empty alarm"
is output on the controller.
The "Alarm" relay is then activated (see Section "Control and display elements on
the controller", item 22). The alarm LED lights up red permanently. If a buzzer is
connected to the floating output relay, an audible signal is output.
5.2.2 Dosing Pumps
The dosing pumps are mounted at the bottom end of the system frame. The suction
ends of the suction lines lead to the pumps. The stroke length is adjusted using a
rotary knob on the dosing pumps. The pumps are not frequency-controlled, they
operate according to the pulse/pause procedure.
The stroke length is preset, but may have to be corrected following gauging of the
pumps since the local pressure conditions depend on the application.
Gauging of the dosing pumps is carried out on the system using the respective
gauging system.
Refer to the Table "Performance and consumption data", Section 3.1.1 for the
dosing rate to be set for the pumps.
The dosing rates of the pumps should be set approximately the same (+/- 10-15%)
to guarantee uniform consumption of the chemicals.
The stroke length must not be adjusted any further following gauging.
Item 10 Dosing pump for H2O
Item 10.1 Suction line for H2O
Item 10.2 Dosing controller for H2O flow monitoring
Item 11 Gauging system for H2O dosing pump
Item 12 Water tank for preliminary dilution, with float valve and
overflow contact
Item 13 Gauging system for HCl (164-1300/2500)
Item 14 Gauging system for NaClO2(164-1300/2500)
Item 15 Purging unit for reactor
Standard version: ball valve
Option: solenoid valve and drain unit

1715.710010-V5.0
Oxiperm 164 150-2500 g en
5.2.3 Dosing Controller
The dosing controllers guarantee that both chemicals flow into the system during
operation. If the volume flow of one of the chemicals drops by more than 25 – 30%,
the dosing controller outputs an alarm and switches off the system.
The working point must be correctly set to guarantee safe functioning of the dosing
controller (see Section "Startup"). A correctly set working point is indicated by the
flashing LEDs on the controller flowchart (see Section "Control and display
elements on the controller", item 1 and item 5).
5.2.4 Reactor
The reactor is positioned at the rear of the system frame. The check valves on the
reactor inlet and outlet must be optionally selected depending on the system back-
pressure. In the standard version, valves are fitted for a system back-pressure
< 3 bar. Each reactor has a temperature sensor which activates the purging unit
should the temperature in the reactor rise.
5.2.5 Bypass Line
The bypass water line dilutes the chlorine dioxide solution generated in the reactor
(approx. 20 g/l) and routes it to the main water flow.
Several versions of the bypass line are available:
❏Bypass with solenoid valve and flow limiter
❏Bypass with circulating pump and flow limiter
❏Bypass with solenoid valve and dosing ball valve (batch mode)
❏Bypass for external booster pump (see Section 14, Accessories, for booster
pump and load unit)
The water in the bypass is monitored by a flowmeter which switches the system off
if the bypass water falls below a minimum flow. Falling below the minimum water
quantity is also indicated by a flashing LED on the flowchart. The LED lights up
continuously if the water flow is above the minimum quantity (see Section "Control
and display elements on the controller", item 3).
The bypass lines with solenoid valve or internal/external booster pump are
equipped with a flow limiter. The flow is limited - independent of the input pressure
(1 to 10 bar) - to a max. water quantity of 420 l/h or 900 l/h, tolerance range +/- 10%.
The min. water quantity differs for each Oxiperm system, see also Section 3.1.1,
Performance and Consumption Data.
NOTE Fit a particle filter upstream if the bypass water is not
free of solids.
5.2.6 Post-mixer
The chlorine dioxide solution is mixed with the bypass water in the post-mixer. The
systems are delivered as standard with a post-mixer.
5.2.7 Purging Unit
Each Oxiperm C 164 for concentrated chemicals is fitted with a purging unit. A ball
valve is used for the standard systems. The reactor can therefore be filled with water
without problem prior to maintenance work. A purging unit with solenoid valve and
drain unit is also available as an option (see Section 5.1, System Design, items 15,
16). This drain unit also serves to automatically purge the reactor with water should
its temperature rise (with too little dilution water). When using a purging unit with
solenoid valve and drain unit, it is recommendable to directly connect the outlet
of the drain unit (solenoid valve) to a neutralization plant.

18 15.710010-V5.0
Oxiperm 164 150-2500 g en
5.2.9 Options
Power supply Code Description
V000 Power supply 230 V (50/60 Hz)
V001 Power supply115 V (50/60 Hz)
Bypass Code Description
B000 Bypass line with pump 230 V 50/60 Hz
Purging with ball valve
B001 Bypass line with pump 115 V 60 Hz
Purging with ball valve
B010 Bypass line with solenoid valve 230 V 50/60 Hz and flow limiter
Purging with ball valve
B011 Bypass line with solenoid valve 115 V 50/60 Hz and flow limiter
Purging with ball valve
B012 Bypass line with solenoid valve 230 V 50/60 Hz and ball valve
Purging with ball valve
B013 Bypass line with solenoid valve 115 V 50/60 Hz and ball valve
Purging with ball valve
B014 Bypass line for external booster pump for 115/230 V 50/60 Hz
power supply, Purging with ball valve
B015 Bypass line for external booster pump for 230 V 50/60 Hz power
supply, Purging with ball valve
B016 Bypass line for external booster pump for 115 V 50/60 Hz power
supply, Purging with ball valve
B020 Bypass line with solenoid valve 230 V 50/60 Hz and flow limiter
Purging with solenoid valve / drain unit
B021 Bypass line with solenoid valve 115 V 50/60 Hz and flow limiter
Purging with solenoid valve / drain unit
B022 Bypass line with pump 230 V 50 Hz
Purging with solenoid valve / drain unit
B023 Bypass line with pump 115 V 60 Hz
Purging with solenoid valve / drain unit
B024 Bypass line with solenoid valve 230 V 50/60 Hz and ball valve
Purging with solenoid valve / drain unit
B025 Bypass line with solenoid valve 115 V 50/60 Hz and ball valve
Purging with solenoid valve / drain unit
B026 Bypass line for external booster pump for 230 V 50/60 Hz power
supply. Purging with solenoid valve / drain unit
B027 Bypass line for external booster pump for 115 V 50/60 Hz power
supply. Purging with solenoid valve / drain unit
(see Section 14, Accessories, for booster pump and load unit)
5.2.8 Preliminary Water Tank
The preliminary water tank for dilution of the hydrochloric acid (HCl) is located
underneath the system. It is continuously filled with water via a float valve. The water
supply is via the bypass line of the Oxiperm system which is located at the rear of
the system rack. Filling of the preliminary tank can be interrupted using an
additional ball valve located at the rear of the rack.
An additional float switch prevents overflowing of the preliminary tank should the
float valve malfunction.

1915.710010-V5.0
Oxiperm 164 150-2500 g en
Suction lines Code Description
T000 Suction line 1.3 m for 30/60 l tank (standard version)
T002 Suction line 2.5 m for 30/60 l tank
T003 Suction line 2.5 m for 200 l tank
T005 Suction line 5 m for 30/60 l tank
T006 Suction line 5 m for 200 l tank
Housing suction Code Description
A03 Housing suction DN20, 230 V 50/60 Hz
A04 Housing suction DN20, 115 V 50/60 Hz
A02 Without housing suction (standard version)
Reactor check valves Code Description
R003 System back-pressure less than 3 bar (standard version)
R004 System back-pressure greater than 3 bar
Bus systems Code Description
L000 Profibus DP module
L001 Ethernet-TCP/IP module
Interface Code Description
K000 RS 232 interface
K001 RS 422/485 interface
Selection of display language Code Description
N000 German
N001 English (standard version)
N002 French
N003 Spanish
N004 Italian

20 15.710010-V5.0
Oxiperm 164 150-2500 g en
5.3 Mode of Operation of System
When starting the compact system in normal mode, the solenoid valve (item 3.1)
opens up, and dilution water flows to the mixer (item 5), see Fig. in Section 5.1.
The flow of dilution water is monitored by an impeller flowmeter (item 3.2).
The two dosing pumps (items 1.1 and 2.1) supply 33% hydrochloric acid and 24.5%
sodium chlorite solution respectively into the reactor (item 4.1), where the dilution
water pump (item 10) dilutes the 33% hydrochloric acid before the two chemicals
react. The flow quantities of the chemicals and the dilution water are monitored by
the dosing controllers (items 1.3, 2.3 and 10.2).
The reaction between sodium chlorite and hydrochloric acid results in a chlorine
dioxide solution with a concentration of 20 g / l in the reactor (4.1). The dwell time
in the reactor is approx. 10 minutes.
In the subsequent mixer, this solution is diluted down to a concentration of max.
3,3 g ClO2/ l depending on the system size and performance setting, and passed
on to the injector.
The system is switched off immediately if one of the dosing controllers or the
impeller flowmeters detects a low flow.
WARNING Chlorine dioxide is a toxic gas.
Hydrochloric acid and sodium chlorite are highly
corrosive chemicals which must be handled properly.
Installation and operating personnel must therefore be
acquainted with the regulations concerning the handling
of chlorine dioxide, hydrochloric acid and sodium
chlorite.
In Germany, the accident prevention regulations UVV
of April 1979 are applicable.
Protection units should be provided in addition, such as
e.g. separate protection troughs for the hydrochloric
acid and sodium chlorite tanks, and protective clothing
for operators.
Furthermore, the specified warning signs, danger
information and first aid information must be positioned
at the specified points.
NOTE A set of warning signs for the chlorine dioxide system
in accordance with the specifications is available under
Order No. 515-662.
You can find further general information for operation of
a chlorine dioxide system in:
Accident prevention regulations: "Chlorination of
water" (VGB 65 or GUV 8.15) (German)
Carl Heymanns Verlag, Cologne
Directive on dangerous working materials
(ArbeitsstoffV) in latest edition (German)
DIN 19617 "Sodium chlorite solution for water
treatment; technical conditions of delivery" (German)
DIN 19610 "Hydrochloric acid for water treatment"
(German)
"Chlorine dioxide for water treatment"
DVGW directive, worksheet W 224 (German)
!