GRUNDFOS ALLDOS Oxiperm Pro OCD-162 User manual

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

2
Declaration of Conformity
We Grundfos Alldos declare under our sole responsibility that the
products Oxiperm®Pro, to which this declaration relates, are in conformity
with the Council Directives on the approximation of the laws of the EC
Member States relating to
— Machinery (98/37/EC).
— Electrical equipment designed for use within certain voltage limits
(73/23/EC).
— Electromagnetic compatibility (89/336/EC).
The following harmonised standards have been applied:
EN 292-1: 1991
EN 292-2: 1991 + A1: 1995
Safety of machines, parts 1 and 2
EN 61010-1: 2002 Electrical equipment for
measurement, control and laboratory
use – EMC requirements – Part 1:
General requirements
EN 954-1: 1996 Safety-related parts of machinery
control systems
EN 1050: 1996 Principles for risk assessment
EN 61326-1: 2006 class B
EN 61000-3-2: 2006
EN 61000-3-3: 2006
Interference emission
EN 61326-1: 2006 industrial
locations
Electrical equipment for
measurement, control and laboratory
use – EMC requirements – Part 1:
General requirements
EN 809: 1998 Pumps and pump units for fluids/
liquids – Safety specifications.
The complete technical documentation, including operating instructions, is
available.
Pfinztal, 1st September 2009
W. Schwald
Managing Director
Ulrich Stemick
Technical Director
Any modification made to the Oxiperm Pro disinfection system without our
approval will invalidate this declaration.

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CONTENTS
Page
1. General safety instructions 3
1.1 Purpose of these operating instructions 3
1.2 Symbols used in this document 3
1.3 Users/target groups 4
1.4 Obligations of the operator 4
1.5 Maintenance and service personnel 4
1.6 Correct usage 4
1.7 Inappropriate usage 4
1.8 Safety and monitoring equipment 5
1.9 Chemicals 5
2. Product description 6
2.1 Application examples 6
2.2 Functional principle 7
2.3 Components of the standard device 8
2.4 System peripheral devices and accessories 9
2.5 Hydraulic connections 10
2.6 Power supply connections and electronic
connections 12
2.7 Operating modes 12
2.8 Control and display elements 12
2.9 Access codes 13
2.10 User menu structure 14
3. Transport and packaging 16
3.1 Unpacking the device(s) 16
3.2 Measures in case of transport damage 16
4. Installation 16
4.1 Planning installation 16
5. Operation 17
5.1 Switching on the system 17
5.2 Changing operating mode 18
5.3 Starting operation 18
5.4 Interrupting operation 18
5.5 Continuing operation after an interruption 18
5.6 Flushing 19
5.7 Manually ventilating the dosing pump 21
5.8 Modifying setup 21
5.9 Monitoring the production and dosing process 23
5.10 Changing alarm settings 29
5.11 Changing chemical containers 30
5.12 Fault finding 31
5.13 Calibration 36
5.14 Emergency stop 39
5.15 Switching off the system 39
6. Technical data 40
6.1 Technical data 40
7. Applicable standards and directives 44
8. Operator’s accessory list 44
9. Dimensional sketch OCD-162-5, -10 45
10. Photos 47
11. Disposal 49
1. General safety instructions
1.1 Purpose of these operating instructions
The Grundfos Alldos Oxiperm Pro disinfection system is a state-
of-the-art solution, which complies with recognised safety
regulations.
Conformity with applicable standards, directives and laws has
been verified.
For a list of applicable standards and directives, see section
7. Applicable standards and directives.
Nevertheless, certain risks which cannot be prevented by the
manufacturer are associated with the use of the system.
Purpose of this manual:
• Inform users of optimum use of the system.
• Warn users of possible residual risks when using the system
correctly, and identify measures that should be taken to avoid
damage.
• Caution users against obvious misuse or inappropriate use of
the system and inform them of the necessary care that must
be taken when operating the system.
For installation, maintenance, servicing and dismantling
information, please see the separate service instructions.
1.2 Symbols used in this document
Information about possible residual risks can be found:
• on warning signs located at the installation site
• at the beginning of each section in this manual
• immediately before steps associated with a residual risk.
Warning
These operating instructions are also available
on www.Grundfosalldos.com.
Before operating the Oxiperm Pro system, read
these operating instructions.
Warning
If these safety instructions are not observed, it
may result in personal injury!
Caution
If these safety instructions are not observed, it
may result in malfunction or damage to the
equipment!
Note
Notes or instructions that make the job easier
and ensure safe operation.

4
1.3 Users/target groups
Users are persons who are responsible for operating and
monitoring the Oxiperm Pro disinfection system at the
installation location. The system may only be operated by trained
and qualified personnel. Personnel must have appropriate
technical knowledge and be familiar with the basic principles of
measuring and control technology.
1.3.1 Obligations of the users
The users’ obligations:
• Read this manual before operating the Oxiperm Pro
disinfection system.
• Be trained by qualified personnel from Grundfos Alldos in the
operation of the system.
• Observe the recognised regulations governing safety in the
workplace and accident prevention.
• Wear appropriate protective clothing in accordance with
national regulations for the prevention of accidents when
operating the system and handling chemicals
(German GUV-V D05).
• Keep secret the user code for the operating software.
1.3.2 User workstation
The Oxiperm Pro disinfection system is electronically controlled.
Users and service personnel operate the system via a display
with control and display elements. See section 2.8 Control and
display elements.
1.4 Obligations of the operator
The owner of the building or the operator of the Oxiperm Pro
disinfection system is responsible for the following:
• Consider this manual to be part of the product and ensure
that it is kept clearly accessible in the immediate vicinity of
the system for the entire service life of the system.
• Meet the installation requirements specified by the
manufacturer (required water connections and fittings,
environmental conditions, electrical connection, protective
tube for dosing line (if necessary), audible or optical warning
device for alarm messages (if necessary)). See section
4.1 Planning installation.
• Ensure that water lines and fixings are regularly checked,
serviced and maintained.
• Obtain official approval for storing chemicals, if necessary.
• Instruct users in the operation of the system.
• Ensure that the labels supplied by the manufacturer with the
system are clearly displayed in the installation location. For
illustration, see section 10. Photos.
• Provide the user code for the operating software only to users
who have received appropriate technical training.
• Ensure that the regulations for the prevention of accidents are
observed in the installation location (German GUV-V D05
regulation for the prevention of accidents, "Chlorination of
Water" dated January 1997).
• Provide all users and service personnel with protective
clothing in accordance with GUV-V D05 (face mask, gloves,
protective apron).
• If the system has been ordered without a dosing pump, the
operator must provide an external dosing pump prior to
installation. This may only be connected to the Oxiperm Pro
disinfection system by authorised and qualified personnel
from Grundfos Alldos.
1.5 Maintenance and service personnel
The system may only be maintained and serviced by authorised
service personnel from Grundfos Alldos.
1.6 Correct usage
The Oxiperm Pro disinfection system is used to mix a diluted
chlorine dioxide solution from 7.5 % sodium chlorite and 9 %
hydrochloric acid. In accordance with the conditions described in
this manual, it is used to dose the chlorine dioxide solution
produced continuously or non-continuously into the (drinking)
water line of a building or to introduce it into a swimming pool,
process water, wastewater or other industrial system for water
disinfection.
1.7 Inappropriate usage
Applications other than those listed in section 1.6 Correct usage
are not in accordance with the intended use and are not
permitted. The manufacturer, Grundfos Alldos, accepts no liability
for any damage resulting from incorrect use.
The system comprises state-of-the-art components and has
undergone safety-related testing.
Warning
Unauthorised structural modifications to the
system may result in serious damage to
equipment and personal injury.
It is forbidden to dismantle, modify, change the
structure of, bridge, remove, bypass or disable
components, including safety equipment.

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1.8 Safety and monitoring equipment
The Oxiperm Pro disinfection system is fitted with the following
safety and monitoring equipment:
• cover on the system frame
• two collecting trays for the two chemical containers
(accessories)
• safety/multi-function valve at the dosing pump
• solenoid valve at the dilution water inlet
• volumetric accumulator and activated carbon filter for ClO2
gas that escapes from the reaction tank
• alarm functions in the control system.
1.9 Chemicals
1.9.1 Chlorine dioxide concentration
In the reaction tank of the Oxiperm Pro disinfection system,
diluted sodium chlorite and diluted hydrochloric acid are mixed to
create a chlorine dioxide concentration of approximately 2 g per
litre of water. The system doses the diluted chlorine dioxide
solution according to the disinfection requirement into the main
line to be disinfected. According to the German drinking water
ordinance (TrinkwV 2001), the chlorine dioxide concentration in
drinking water must not exceed a maximum of 0.4 mg per litre of
water.
The following safety instructions must be observed:
1.9.2 Storing chemicals
• Chemicals must be stored in the appropriately marked
original plastic containers (20 to 33 litres).
• Do not store chemicals near grease, flammable substances,
oils, oxidising substances, acids or salts.
• Empty and full containers must be kept closed, especially in
areas where national regulations for the prevention of
accidents apply to storage (German GUV-V D05).
1.9.3 Procedure in case of an emergency
The general safety regulations and regulations for the procedure
in case of an emergency as specified in EN 12671: 2007 (D)
apply.
Actions in case of an emergency:
• Ventilate the installation location immediately.
• Wear protective clothing (safety goggles, gloves, respirator
and/or self-contained breathing apparatus, protective apron).
• Implement initial help measures:
– In case of contact with the eyes, rinse immediately with
plenty of water for at least 15 minutes. Consult a doctor.
– In case of contact with the skin, wash immediately with
plenty of water. Remove all contaminated clothing.
– In case gas is inhaled, move the casualty to a source of
fresh air. Avoid taking deep breaths. Consult a doctor (look
out for a racing pulse, as vasodilating treatment may be
required).
• Spillages:
– In case of contact with clothing, remove the clothing
immediately and wash with plenty of water. Chemical
spillages in buildings must be washed away with water.
• Firefighting:
– Aqueous solutions of chlorine dioxide are not directly
flammable. Extinguish the surrounding fire with water,
preferably using a fire sprinkler system to dilute the
ambient gas. Inform the fire brigade of the installed
production capacity and any harmful starting substances
that are being stored (precursor substances) so that
precautions can be taken regarding possible risks.
For emergency phone numbers, see the acceptance report.
Warning
Risk of explosion when using chemicals in too
high a concentration.
Only use sodium chlorite in a diluted
concentration of 7.5 % by weight in accordance
with DIN EN 938.
Only use hydrochloric acid in a diluted
concentration of 9.0 % by weight in accordance
with DIN EN 939.
The safety data sheets from the supplier must be
observed.
Warning
Risk of explosion and serious damage to
equipment and personal injury as a result of
operating faults due to confusing the chemical
containers or suction lances.
Do not confuse the containers.
Observe the red and blue markings on chemical
pumps, suction lances and chemical containers:
Red = HCl, blue = NaClO2.
Warning
Risk of burns when skin and clothing come into
contact with sodium chlorite and hydrochloric
acid.
Affected skin and clothing must be washed
immediately in water.
Warning
Risk of irritation to eyes, respiratory system and
skin if chlorine dioxide is inhaled.
When changing the chemical containers, wear
protective clothing in accordance with
regulations for the prevention of accidents
(German GUV-V D05, "Chlorination of Water"
dated January 1997).

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2. Product description
Fig. 1 The Oxiperm Pro – without cover and peripheral devices
The Grundfos Alldos Oxiperm Pro disinfection system is used to
produce and dose chlorine dioxide for the disinfection of drinking
water, process water, cooling water and wastewater.
The device itself consists of a plastic system frame, on which the
internal components are mounted. It is wall-mounted or installed
on the floor and covered by a plastic cover.
The chemicals are supplied from two original chemical
containers, which are located in two collecting trays directly under
the system (Oxiperm Pro systems up to 10 g/h) or in a separate
tray for each container next to the unit (Oxiperm Pro systems
with more than 10 g/h). A suction lance is inserted in each
container and is permanently connected to the corresponding
chemical pump in the device. The suction lance cables are used
to send "pre-empty" and "empty" signals to the control system.
The device is connected to two water lines:
• The drinking water line for supplying dilution water and
flushing water.
• The main water line to be disinfected, into which the final
ClO2solution is dosed.
2.1 Application examples
The Oxiperm Pro disinfection system can be used for two
different types of application:
Group 1: Disinfection of drinking water lines
• The flow rate of the water in the lines can fluctuate greatly
(peak times when water is used for bathing and cooking).
• The type and level of contamination in the water (disturbance
variables) are not known or are very varied.
• Examples: Drinking water lines in:
– hotels, multi-storey buildings
– schools, hospitals, nursing homes
– food and beverage plants
– small waterworks
– showers in gymnasiums and at swimming pools.
Group 2: Disinfection of industrial systems
• The water quantity in these systems is relatively constant.
• The type and level of contamination in the water
(disturbance variables) are measured and hardly ever
change.
• Examples:
– bottle cleaning plants in breweries
– industrial process water or wastewater systems
– cooling water systems.
Group 3: Shock disinfection
• Applications requiring large quantities of disinfectant in a
short time
•Example:
– cleaning of whirlpool baths
TM03 6914 4506
OCD-162-5, -10 OCD-162-30 OCD-162-60

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2.2 Functional principle
2.2.1 Production of chlorine dioxide
Chlorine dioxide is prepared in the reaction tank as follows:
Water, hydrochloric acid and then sodium chlorite are added until
a specific level is reached. During the reaction time, a diluted
ClO2solution is produced. The reaction vessel is then filled with
water. With a concentration of approximately 2 g of ClO2per litre
of water, the final solution flows (as a result of its own hydraulic
effect) through a pipe (overflow) located in the middle of the
reaction vessel into the reservoir tank below.
From the reservoir tank, the dosing pump doses the final ClO2
solution through to the injection unit, where it is dosed into the
main water line to be disinfected. See section 2.2.2 Flow-rate-
proportional dosing and 2.2.3 Setpoint-controlled dosing.
In "once" operation, the ClO2production stops.
In "continuous" or "ext. batch" operation, the chlorine dioxide
production starts from the beginning in the reaction tank after a
pause.
2.2.2 Flow-rate-proportional dosing
Suitable for group 1 applications – drinking water:
1. The control system is set to proportional controller.
2. A contact water meter or flow meter measures the water flow
rate in the main water line and continuously sends measured
values to the Oxiperm Pro control system.
3. The proportional controller calculates the required ClO2
dosing volume in proportion to the water flow rate in the main
line.
4. The proportional controller sends the corresponding output
signals to the dosing pump.
5. The dosing pump doses the corresponding quantity of the
ClO2solution from the reservoir tank into the main water line.
6. An optional measuring cell monitors the ClO2concentration in
the main line.
2.2.3 Setpoint-controlled dosing
Suitable for group 2 applications – industrial water:
1. The control system is set to setpoint controller. A setpoint for
the desired ClO2concentration in the main line is specified for
the setpoint controller.
2. A measuring cell monitors the ClO2concentration in the main
line.
3. The measuring cell continuously sends actual values for the
ClO2concentration to the control system of the disinfection
system.
4. The setpoint controller compares the incoming actual values
with the setpoint and based on the deviation calculates the
quantity of the ClO2solution (actuating variable) that is
required to achieve the desired concentration.
5. The setpoint controller sends output signals to the dosing
pump.
6. The dosing pump doses the corresponding quantity of the
ClO2solution from the reservoir tank into the main water line.
A combined controller is also available for applications with
setpoint controller and flow meter (see separate service
instructions).

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2.3 Components of the standard device
Fig. 2 Components of the Oxiperm Pro standard device (here: OCD-162-5, -10)
2.3.1 External parts
See the photos in section 10. Photos.
2.3.2 Internal components
TM03 6897 4506
blue red
Pos. Components
1a Water line for supplying dilution water and flushing
water (via solenoid valve in the device)
1b Bleeding point for dilution water with stopcock
3
Chemical container for NaClO2(diluted concentration
of 7.5 % by volume) with suction lance and collecting
tray
4Chemical container for HCl (diluted concentration of
9 % by volume) with suction lance and collecting tray
11 Main water line to be disinfected
12 Flow meter (or contact water meter)
14 Dosing line
15 Injection unit for dosing the ClO2
18 Measuring cell for checking the chlorine dioxide
concentration in the main line (optional)
19 Power supply connection
Pos. Components
2Solenoid valve for supplying dilution water and
flushing water
5 Chemical pump for sodium chlorite (pump 2)
6 Chemical pump for hydrochloric acid (pump 1)
7 Reaction tank with float switch
8Chlorine dioxide reservoir tank with float switch and
drain cock (bottom left)
9 Volumetric accumulator for ClO2gas
10 Activated carbon filter for ClO2gas
13 Dosing pump with multi-function valve
16 Measuring water pipe
17 Measuring water extraction point
20 Electronic control system with measured-value sensor
for check measurements
21 Display with control and display elements

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2.4 System peripheral devices and accessories
Fig. 3 Complete Oxiperm Pro OCD-162-5, -10 system with measuring cell and without extension module
Fig. 4 Complete Oxiperm Pro OCD-162-30, -60 system with measuring cell and without extension module
TM03 6918 4506
red
blue
TM03 0875 1509
17
1a
14
1b 19
15
23
26
12
24
25
16 18
17
11
Pos. Components
1a Water line for supplying dilution water and flushing water
(via solenoid valve in the device)
1b Bleeding point for dilution water with stopcock
3Chemical container for NaClO2(diluted concentration of
7.5 % by volume) with suction lance and collecting tray
4Chemical container for HCl (diluted concentration of 9 %
by volume) with suction lance and collecting tray
11 Main water line to be disinfected
12 Flow meter (or contact water meter)
14 Dosing line
15 Injection unit for dosing the ClO2
16 Hose for sample-water bleeding
17 Sample-water bleeding point
18 Measuring cell
19 Power supply connection/main switch
23 Connection cable for measuring cell
24 Sample-water drain
25 Connection cable for cleaning motor
26 Hose for dilution water
Pos. Components

10
2.4.1 Accessories for the dilution water line (not included)
• Stopcock (ball valve)
• Tapping sleeve for dilution water bleeding (optional) (if
necessary, with double nipple and connection piece for hose)
• Hose with connection to solenoid valve.
Stopcock and tapping sleeve are not required if the bypass mixing
module with dilution water connection has been selected.
2.4.2 Accessories for the main water line (not included)
• Contact water meter or fitted flow meter (in case of a new
water line, water flow meter that provides signals or
ultrasound flow meter).
• Tapping sleeve for the injection unit (optional).
• Protective tube for the dosing line, installed from the dosing
pump to the injection unit (optional).
• Grundfos Alldos DIT photometer (measures ClO2
concentration after dosing) (optional).
• Sample-water filter (in case of insufficient water quality).
2.4.3 Measuring cell (optional)
• Measuring cell
• Tapping sleeve for sample-water bleeding at the main line
(not included)
• Hose from the sample-water bleeding point to the measuring
cell
• Hose from the measuring cell to the sample-water drain.
2.4.4 Extension modules (optional)
The standard system can be extended using modules:
• measuring cell for cold and hot water (main water up to 50 °C,
pressure 4 bar) for connection to the Oxiperm Pro.
• measuring module for cold and hot water (main water up to
70 °C, pressure 8 bar) for connection to the Oxiperm Pro.
• bypass mixing module for cold and hot water for connection
to the Oxiperm Pro (separate instructions).
2.5 Hydraulic connections
2.5.1 Hydraulic connections Oxiperm Pro (OCD-162-5, -10)
Fig. 5 Oxiperm Pro (OCD-162-5, -10) hydraulic connections
Note
In case of fluctuating flow rates in the main water
flow, the use of a bypass mixing module is
recommended in order to optimise mixing and
reduce the risk of corrosion.
TM03 6899 4506
8b
6b
14
26
5b