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.

3
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.

5
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).

6
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

7
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).

8
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

9
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

11
2.5.2 Hydraulic connections Oxiperm Pro (OCD-162-30, -60)
Fig. 6 Oxiperm Pro (OCD-162-30, -60) hydraulic connections
For nominal width of hose connections, see section 6. Technical data.
2.5.3 Device connections
The Oxiperm Pro has connections for the following:
• dilution water hose at the solenoid valve (fig. 5and fig. 6,
pos. 26)
• hoses for both suction lances on the suction side of the
chemical pumps (fig. 5, pos. 5b and 6b)
• dosing line from the dosing pump to the injection unit at the
main line or to the flow control instrument in the mixing
module or to the external batch tank. (fig. 5and fig. 6, pos. 14)
• hose at the drain cock of the reservoir tank (only installed for
flushing and ventilation) (fig. 5, pos. 8b).
2.5.4 External dosing pump connection
If the system has been supplied without a dosing pump, the
dosing line of an external dosing pump is connected to the
reservoir tank.
2.5.5 Measuring cell connections
The measuring cell is hydraulically connected to the main line.
After dosing, the ClO2concentration, temperature and pH/ORP
value of the sample water are measured in the measuring cell.
The measuring cell has connections for the following:
• hose from the sample-water bleeding point to the measuring
cell
• hose from the measuring cell to the drain.
See the installation and operating instructions for the measuring
cell.
2.5.6 Measuring module connections
The measuring module is hydraulically connected to the main
line.
The measuring module has connections for the following:
• hose from tapping sleeve 1 to the measuring module and
hose from the measuring module to tapping sleeve 2 at the
main line.
See the installation and operating instructions for the measuring
module.
2.5.7 Mixing module connections
The mixing module is hydraulically connected to the main line and
the Oxiperm Pro.
The mixing module has connections for the following:
• dosing line from the Oxiperm Pro dosing pump to the
injection unit in the mixing module.
• hose from tapping sleeve 1 to the mixing module and hose
from the mixing module to tapping sleeve 2 at the main line.
See the installation and operating instructions for the mixing
module.
TM04 0953 1509
8b
6b
14
26
5b
6b
14
OCD-162-30 OCD-162-60
8b
5b

12
2.6 Power supply connections and electronic
connections
The Oxiperm Pro disinfection system is equipped with an
electronic control system from Grundfos Alldos.
See section 2.8 Control and display elements, fig. 8.
The control system has connections for the following:
• power supply cable to the main switch
• cable from the water flow meter or flow meter
• cable from external batch tank to level control, if necessary
• cables for measuring cell AQC-D1 or AQC-D6, if necessary:
– measuring electrode, from the counter-electrode
– sample-water deficiency sensor
– Pt100 sensor
– pH electrode, if necessary (for pH or ORP) (AQC-D1 only)
– cleaning motor (AQC-D1 only)
• or the cables from the measuring module, if necessary:
– measuring electrode and counter-electrode
– water deficiency sensor
– Pt100 sensor
• or the cable from the mixing module, if necessary:
– flow controller.
For additional connections, see the separate service instructions,
sections 4. Installation and 4.6 Connecting the electronic
components.
2.7 Operating modes
During commissioning, the disinfection system is set up
according to the application. When switched on and the ClO2
production is started, system operation is fully automatic using
menu commands.
For ClO2production, two operating modes can be set:
• continuous operation ("continuous" mode)
• dosing once ("once" mode).
• external batch tank (operation mode "ext. batch").
Dosing is controlled automatically by the controller. In manual
operation, the controller can be switched off. See section
5.14 Emergency stop.
Other functions in manual operation can only be used with the
service code.
2.8 Control and display elements
Fig. 7 The display and control panel
2.8.1 Using the control panel
2.8.2 Using the display
Once the system is started, the following display level appears in
the display:
Fig. 8 Display level after starting the system
The header indicates the status (here: no process started). For
symbols and numbers for relays, see the table below.
Press [OK] to access the MAIN MENU:
During operation, press [Esc] to access the display level.
TM03 6900 4506
Buttons and LEDs Functions
[Esc] button Cancels command, exits menu
[Up] button Selects the previous menu item or sets
a higher numerical value
[Down] button Selects the next menu item or sets a
lower numerical value
[OK] button Confirms the menu selection
[Cal] button Calibration
[Man] button Manual operation
"Alarm" LED Alarm (red)
"Caution" LED Warning (yellow)
"Cal" LED Calibration (yellow)
"Man" LED Manual operation (yellow)
TM03 6901 4506
MAIN MENU
PROCESS
CONTROLLER
ALARM
SERVICE
SETUP
MAINTENANCE
54321

13
Fig. 9 PROCESS RUNNING display level
Fig. 9: 1-5, see table below:
• 6 = water temperature
•7=ClO
2concentration
• 8 = pH value in the sample water.
2.9 Access codes
When the system is ready for operation, the MAIN MENU cannot
be accessed without a code request.
Two different access authorisations/security levels are assigned
for all submenus. Each code automatically enables the levels
below it too.
•User code: By default, all user menus can initially be
accessed without a code request.
(When the menu selection has been confirmed using [OK], a
code request is not displayed.)
Once the user has entered his/her own user code (MAIN
MENU - SETUP - CHANGE CODE), the code request
appears before any user submenu can be accessed. The
modified user code must only allow access for trained users
with appropriate technical training and experience. Access is
enabled for 60 minutes after entry.
•Service code: This code is reserved for trained Grundfos
Alldos service engineers. Access is enabled for 30 minutes
after entry. The service code is necessary for commissioning.
See section 5.8.2 Changing the user code.
TM03 6922 4506
Message in the
display level Meaning of the message
PROCESS
RUNNING ClO2production is active.
1
Headers
PROCESS
STOP ClO2production has been
stopped by an alarm.
PROCESS
ABORTION
ClO2production has been
aborted by a menu command or
alarm.
FLUSHING Flushing is started automatically
or manually.
1
Relay for solenoid valve.
Display:
White number on a black
background: relay active.
Black number on a white
background: relay not active.
2
Relays
2Relay for HCl pump:
display as for 1.
3Relay for NaClO2pump:
display as for 1.
4Alarm relay:
display as for 1.
5Warning relay:
display as for 1.
Symbol for relay for the pulse
pause controller.
3
Symbol
Symbol for relay stop for the
pulse pause controller.
.........
24,5 °C
pH 7,35
5
4
3
2
1
0,23 mg/l
1
2
6
74/3
5
8
PROCESS RUNNING
6
6
Symbol for continuous controller.
Box with plotted line.
The height of the line is
proportional to the actuating
variable (ClO2dosing volume):
Line not visible:
Actuating variable = 0 %.
Line fills the entire box:
Actuating variable = 100 %.
4
Symbol
Symbol for continuous controller
stop and external controller stop
due to an alarm.
White box with a diagonal line
through it.
Symbol for external disturbance
value input (input value of the
disturbance variable, for water
flow meter: pulses, for flow
meter: mA).
Box with plotted triangle.
The black fill is proportional to
the flow (the greater the fill, the
greater the flow, 0-100 %).
(Only visible if proportional or
combined controller is
configured.)
5
Symbol
Message in the
display level Meaning of the message

14
2.10 User menu structure
Users can view certain submenus in the display and can also
modify certain values.
2.10.1 Finding user menus
In the following tables, the first column indicates whether users
can access a submenu:
• without a code (0)
• with the user code (A).
Users can access the following submenus from the MAIN MENU
(without a code or with the user code):
User menu
Note
All software menus can be selected from the
MAIN MENU using the [Up] and [Down] buttons
and accessed using [OK].
Press [Esc] to return to the previous menu level.
For operating instructions for each menu, see
section 5. Operation.
Code Main menu Submenu 1 Submenu 2 Submenu 3 Submenu 4 Submenu 5
A
Main menu
Process
Start Start Start ClO2
production?
ABack
AAbortion Abortion Abort ClO2
production?
ABack
A
Operation
continuous
Aonce
A ext. batch
0
Service
Process
Status Display:
Process status
0 List of events
0
ClO2production
Cycles
0
Chemicals
HCl/NaClO2
since 14.09.2006
HCl (l)
NaClO2(l)
reset
0Age of ClO2 (mm:ss)
0Maintenance
AFlushing Start
AAbortion
0
Measurement
ClO2
Measured value
0CalData/logbook
0 Temperature °C or °F
Measured value
0pH or ORP Measured value
0CalData/logbook
0ClO
2controller Display:
Controller setting
0
Water flow meter
1.00 - 100.00 pulses/
sec.
(Note 5*)
50 pulses/sec., 50 %*
(or: 5 mA, 25 %)
0Testdisplay
Program version
A
Setup
Language
Deutsch
A English
A (all listed)
A
Date/time
Date
ATime
A Daylight sav. t. Begin, end, time shift
(± x hours), off
ACode function Change
A Delete
A Display Contrast 50 %
0

15
Notes to table:
Note 4*:
• The ALARM settings are only available when
MEASUREMENT has been enabled (using the service code).
• The alarm relay is activated in case previously set alarm
values for chlorine dioxide are exceeded or not reached, the
maximum dosing time is exceeded, and in case of a fault.
Note 5*:
• The WATER FLOW METER submenu only appears if a
WATER FLOW METER is enabled (using the service code).
• When connecting a contact water meter, the pulse rate and
the maximum flow are entered during commissioning. The
control system thus calculates the number of pulses per
second. This value corresponds 100 % to the disturbance
variable as a control parameter.
• When connecting a flow meter, the measuring range of the
incoming current signal is entered during commissioning. This
is used as the basis for a control parameter.
Users can view the current input value of the water flow meter or
flow meter as well as the pulses/second or value in mA and the
calculation in percent. See section 5.9.3 Displaying the current
input value for the water flow meter (not applicable for Group 3
applications).
The value is also displayed if the defined input values are
exceeded or not reached (a water flow meter malfunction is
visible here).
A
Main menu Alarm
(Note 4*)
ClO2alarm values
Alarm off
A
Alarm on
Alarm value1
0.15 mg/l
Upward
violation or
downward viol.
AAlarm value 2
0.70 mg/l
Upward
violation or
downward viol.
AHysteresis
0.01
AAlarm delay
0 sec.
A Dos. time monit. Off/On
A
Calibration
Chlorine dioxide
Cal. meas. value
A Cal. result Slope µA, mg/l
A Cal. cycle On/Off
A
pH
Cal. meas. value Grundfos, DIN/Nist, other
ACal.result
Slope µA, mg/l
asym. mV
A Cal. cycle On/Off
A
ORP
Cal. meas. value
A Cal. result Asym. mV
A Cal. cycle On/Off
HB Manual
operation ClO2controller On/Off
Code Main menu Submenu 1 Submenu 2 Submenu 3 Submenu 4 Submenu 5

16
3. Transport and packaging
3.1 Unpacking the device(s)
Number of packing units: 1 box.
Procedure:
1. Unpack the device.
2. Unpack the cover.
3. Unpack the measuring cell, if supplied.
4. Unpack the extension modules, supplied.
5. Retain the original packaging in order to return the device for
servicing.
6. Check the device(s) for transport damage (especially hoses
and lines).
3.2 Measures in case of transport damage
In case of transport damage:
1. Pack the device in its original packaging.
2. Inform the forwarder of the transport damage.
3. Return the device to the supplier.
4. Installation
Installation is described in detail in the separate service
instructions.
This subsection can be used by operators to plan installation.
4.1 Planning installation
4.1.1 Preparing the installation location (customer)
The operator must ensure that all the conditions listed below for
structurally and technically safe and optimum operation of the
system are met prior to commencing installation.
An installation location must be provided that fulfils the following:
• It is protected from the sun, frost-proof, well-ventilated and
has sufficient lighting (the system must not be installed
outdoors).
• It meets the conditions specified in section 6. Technical data
regarding air temperature, humidity, permissible component
operating temperature and dilution water quality.
• It has concrete walls and floors, which enable the OCD-162-5,
-10 system to be wall-mounted (minimum wall thickness of
10 cm for the mounting screws) or the OCD-162-30, -60
system to be floor-mounted.
• It has a power supply connection. See section 6. Technical
data.
• It has access to the main water line.
• It has a connection for dilution water of drinking water quality
in accordance with TrinkwV 2001.
• It has a floor drain for washing away chemicals and a drain
(tank) for sample water.
• It has a separate storage room for empty and full chemical
containers.
• It is isolated from other areas with regard to fire protection.
• It is secured against unauthorised access and meets the
regulations for the prevention of accidents.
• It is not in permanent use by personnel (maximum stay: two
hours).
Warning
Increased risk of damage to equipment and
personal injury as a result of operating faults due
to transport damage.
Do not shake, crush or drop the box. Open the
packaging carefully.
Do not use a sharp or pointed blade.
Carefully remove the device from the box.
Do not bend the hoses and cables.
Box Dimensions L x W x H
[mm] Contents Weight gross / net
1 900 x 900 x
518 Device with
cover,
hoses,
screws,
accessories
OCD-162-5: 30 kg / 26 kg
OCD-162-10: 32 kg / 28 kg
1 766 x 558 x
1813
OCD-162-30-D: 80 kg / 70 kg
OCD-162-30-P: 79 kg / 69 kg
1 766 x 558 x
1813
OCD-162-60-D: 100 kg / 85
kg
OCD-162-60-P: 99 kg / 84 kg
Warning
Risk of fire and corrosion due to incorrect
storage of chemicals. Do not store hydrochloric
acid and sodium chlorite near grease, flammable
or oxidising substances, oils, acids or salts.
Obtain approval for storing chemicals.
Operator’s checklist – preparing for installation
See section 6. Technical data Done
1. Read the installation and operating instructions for
Oxiperm Pro and for the dosing pumps DMI 208,
DDI 209, DMX 221 or DDI 222, if applicable, as
well as for the multi-function valve, the measuring
cell and the extension module, if used. Store the
manuals in a dry place in the installation location.
2. Measure the pressure and temperature in the
dilution water line and in the main water line.
3. Measure the room temperature and humidity.
4. Obtain official approval for storing chemicals, if
necessary.
5. Purchase accessories. See section 8. Operator’s
accessory list.
6. Fit a tapping sleeve for the dilution water supply in
the drinking water line.
7. Fit a tapping clamp for the injection unit in the main
line.
8. Install a protective pipe for the dosing line, if
necessary.
At the main line:
9. Fit a tapping sleeve for sample water extraction, if
necessary.
10. Fit tapping sleeves for the measuring or mixing
module, if used.
11. Provide protective clothing in the room in
accordance with the regulations for the prevention
of accidents (German GUV-V D05).
12. Display a "No fires, naked flames or smoking"
warning sign. Display all warning signs provided.

17
5. Operation
Fig. 10 PROCESS menu structure
This menu can be found:
• in the overview table in section 2.10.1 Finding user menus
• in the menu structure at the start of the section.
Use the display as follows:
The display menus are represented by tables in this manual. The
black header represents the menu and the lines below the
submenus.
Access a menu as follows:
Access the MAIN MENU by pressing [OK] in the display level.
In the MAIN MENU, use the [Up] or [Down] button to select the
menu, and access it by pressing [OK].
Exit a menu as follows:
Press [Esc] to return to the menu level above (this is automatic
for most menus).
Menu commands are specified as follows:
In this manual, for example:
1. MAIN MENU > PROCESS > [OK].
In the table that follows:
The black header contains PROCESS.
The text lines contain START, ABORTION and OPERATION.
2. LANGUAGE > [OK].
This means:
In the MAIN MENU, use the [Down] button to select the
PROCESS submenu, and access it by pressing [OK].
The PROCESS submenu appears in the display.
Use the [Down] button to select the LANGUAGE submenu, and
access it by pressing [OK].
The LANGUAGE submenu appears in the display.
5.1 Switching on the system
1. Open the stopcock for the dilution water (1b).
2. Switch on the main switch for the power supply.
The system starts. The following display level appears in the
display.
Fig. 11 Display level after switching on the system
The system is ready for operation.
3. Press [OK].
MAIN MENU appears in the display:
TM03 6903 4506
MAIN MENU
PROCESS
START ABORTION OPERATION
CONTINUOUS ONCE EXT. BATCH
Warning
The Oxiperm Pro disinfection system uses
chemicals. The system must only be operated by
authorised and qualified personnel.
TM03 6904 4506
MAIN MENU
PROCESS
CONTROLLER ClO2
ALARM
SERVICE
SETUP
MAINTENANCE
54321

18
5.2 Changing operating mode
To specify whether just one batch of ClO2is to be prepared or
whether the production process should run continuously, proceed
as follows:
1. MAIN MENU > PROCESS > [OK].
2. OPERATION > [OK].
3. CONTINUOUS (or ONCE or EXT. BATCH) > [OK].
CONTINUOUS = continuous operation.
In the operation mode "continuous" or "ext. batch" a new
production process is started when the reaction tank is empty.
In the operation mode "once" the ClO2production stops, when
the reaction tank is empty.
5.3 Starting operation
5.3.1 Starting ClO2production
1. MAIN MENU > PROCESS > [OK].
2. START > [OK].
Cancel command:
3. BACK > [OK].
The display returns to the PROCESS submenu.
ClO2production is not started.
Execute command:
4. START > [OK].
5. Press [OK].
ClO2production starts. The display level appears.
Fig. 12 Display level during operation
Dosing does not have to be started. This is done automatically as
soon as the reservoir tank is filled.
5.4 Interrupting operation
5.4.1 Aborting ClO2production
1. Access the MAIN MENU by pressing [OK] in the display level.
2. MAIN MENU > PROCESS > [OK].
3. ABORTION > [OK].
Cancel command:
4. BACK > [OK].
The display returns to the PROCESS submenu.
Abort ClO2production:
5. ABORTION > [OK].
6. Press [OK].
The chemical pumps are stopped. To dilute the undefined
contents of the reaction tank, it is filled with water up to level 4
afterwards.
5.4.2 Aborting the dosing process
In order to stop the dosing pump, the controller must be switched
off in manual operation.
Switching off the controller in manual operation
1. Press [Man] (manual operation).
2. ClO2CONTROLLER > [OK].
3. (Controller) OFF > [OK].
See section 5.14 Emergency stop.
5.5 Continuing operation after an interruption
There are four ways in which operation can be interrupted:
•ABORTClO
2PRODUCTION menu command (and after the
CONTROLLER OFF command)
• fault with an alarm message
• an empty chemical container
• power failure with power supply interruption.
5.5.1 Continuing operation after aborting ClO2production
If the controller has been switched off in manual operation, switch
the controller on again in manual operation:
1. Press [Man] (manual operation).
2. ClO2CONTROLLER > [OK].
3. (Controller) ON > [OK].
See section 5.3.1 Starting ClO2production.
The system automatically carries out a flushing process.
The process and dosing then run in normal mode.
5.5.2 Continuing operation after removing a fault
Confirm the alarm message, if necessary.
The system automatically continues operating.
PROCESS
START
ABORTION
OPERATION
OPERATION
CONTINUOUS
ONCE
EXT. BATCH
PROCESS
START
ABORTION
OPERATION
START
START
BACK
START
START ClO2
PRODUCTION?
TM03 6905 4506
.........
24,5 °C
pH 7,35
54321
0,23 mg/l
PROCESS RUNNING
PROCESS
START
ABORTION
OPERATION
PROCESS
ABORTION
BACK
PROCESS
ABORT ClO2
PRODUCTION?

19
5.5.3 Continuing operation after changing a chemical
container
The system automatically continues operating.
5.5.4 Continuing operation after a power supply interruption
As soon as the power is restored, the system is switched on
again automatically.
If the reaction tank is full, the liquid is now in an undefined state.
It can contain too much hydrochloric acid or too little ClO2. The
control system uses the float switch in the reaction tank to
determine whether the reaction tank is empty or full and
continues operation accordingly:
1. Reaction tank part-filled or full, reservoir tank empty:
• If the reaction tank is full, it is filled up with water. The
undefined liquid is drained into the reservoir tank, and the
following alarm message is displayed: CHECK ClO2 BATCH.
– Drain the reservoir tank manually. See section
5.6.2 Manually draining the reservoir tank. (If it is not
emptied manually, the undefined liquid will be dosed.)
• The dosing pump is switched off when the reservoir tank is
empty.
2. Reaction tank empty, reservoir tank empty:
• In "continuous" mode, a new production process is started.
3. Reaction tank empty, reservoir tank part-filled or full:
• The finished batch is dosed (continues being dosed).
• In "continuous" or "ext. batch" mode, a new production
process is started.
4. Reaction tank part-filled or full, reservoir tank part-filled or full:
• The remaining batch is dosed into the reservoir tank.
• The reaction tank is filled up with water. The undefined liquid
remains in the reaction tank until the reservoir tank is empty.
Water is supplied to make the reaction tank overflow, and the
alarm message CHECK ClO2 BATCH is displayed.
– Drain the reservoir tank manually. (If it is not drained
manually, the undefined solution will be dosed.)
• In "continuous" mode, a new production cycle is started after
the reaction tank is empty.
5.6 Flushing
For automatic flushing, see section 5.5 Continuing operation after
an interruption.
Flushing using the FLUSHING menu command is useful for long
system downtimes.
During flushing, the system is flushed with water to remove any
chemical residue in the suction lines, pumps and reaction tanks.
Dilution water is used for flushing. However, the suction lances
must be removed from the chemical containers prior to flushing
and are placed in separate 10-litre buckets filled with drinking
water so that they can draw water in by suction.
Empty the reservoir tank manually at the drain cock prior to
flushing. If the reservoir tank is empty, the dosing pump is
switched off.
The reaction tank must be empty prior to flushing.
• Only start flushing if the ClO2production is not active
(the FLUSHING menu is also only visible in the display).
The flushing process can be stopped anytime using [Esc].
5.6.1 Preparing for flushing
1. Before using the FLUSHING menu command, have the
following to hand:
• empty 10-litre plastic bucket (1 bucket for OCD-162-005, -
010, -030 or 2 buckets for OCD-162-060)
• 11 x 8 mm PE hose for reservoir tank drain cock
• 20g (OCD-162-5), 40g (OCD-162-10), 120g (OCD-162-30),
240g (OCD-162-60) of ClO2breakdown substance sodium
thiosulfate Na2S2O3x 5 H2O
• two 10-litre buckets filled with water
• original screw plugs for the chemical containers.
2. Take the cover off the unit.
Warning
Risk of poisoning from ClO2gas.
Never mix NaClO2and HCl.
Never put suction lances in the same bucket.
Never insert suction lances in the wrong
container.
Observe the labels for HCl (red) and NaClO2
(blue) on chemical containers, pumps and
suction lances.
Warning
Risk of serious damage to equipment and
personal injury due to incorrect handling of
chemicals.
Before commencing work, put on protective
clothing (gloves, face mask, protective apron)
(German GUV-V D05).
Warning
Risk of burns from stray droplets when removing
the suction lance from the chemical container.
Take care that no stray droplets fall on skin,
clothing, shoes or the floor. Any stray droplets
on the container or in the collecting tray must be
immediately rinsed away with water.

20
5.6.2 Manually draining the reservoir tank
1. Place the two 10-litre buckets filled with water to the right and
left of the chemical containers.
2. Untwist the cover on the suction lance for the NaClO2
container, remove the suction lance and place it in one of the
buckets of water.
3. Screw the original screw cover onto the chemical container.
4. Untwist the cover on the suction lance for the HCl container,
remove the suction lance, and place it in the other bucket of
water.
5. Screw the original screw cover onto the chemical container.
6. Fill the empty bucket with 1 litre of water and 20 g (OCD-162-
5), 40 g (OCD-162-10) or 120 g (OCD-162-30) of ClO2
breakdown substance and place it to the left of the system.
For OCD-162-60: fill two empty buckets with 1 litre of water
each and 120 g of ClO2breakdown substance and place
them next to the system.
7. Remove the cover from the device.
8. Connect the hose (PE or PVC) to the reservoir tank drain
cock, and place the other end in the bucket. Open the outlet
valve.
9. Empty the contents of the reservoir tank (OCD-162-5: around
1 litre, OCD-162-10: around 1.8 litres, OCD-162-30: around
6.5 litres or OCD-162-60: around 13.0 litres) into the
bucket(s).
10. When the reservoir tank is empty, close the outlet valve.
When the reservoir tank is empty, the dosing pump is switched
off. When the reservoir tank is filled with a new batch, the dosing
pump is switched on again.
5.6.3 Starting flushing
1. MAIN MENU > SERVICE > [OK].
2. PROCESS > [OK].
3. FLUSHING > [OK].
Start flushing:
4. START > [OK].
5. Press [OK].
6. Press [OK] if the lances are already in the water.
7. Press [OK], if the reservoir tank is already empty.
See section 5.6.2 Manually draining the reservoir tank.
8. Press [OK], if the drain cock is already closed.
9. Flushing starts. The flushing process automatically runs
twice.
Fig. 13 Flushing process
10. Dilution water is filled up in the reaction tank until the level
reaches K1.
11. The HCl pump runs for two minutes.
12. The NaClO2pump runs for two minutes.
13. Dilution water is filled up until the reaction tank’s highest level
K4 is reached and it overflows into the reservoir tank.
The following message is displayed:
At the end of flushing, the following message is displayed:
This message disappears after one minute.
14. If the reaction tank is empty, the process starts again with
step 8.
After two flushing processes, the following message is displayed:
15. Confirm using [OK].
FLUSHING
START SYSTEM
FLUSHING?
FLUSHING
PUT SUCTION LANCE IN
WATER
FLUSHING
DRAIN RESERVOIR TANK
FLUSHING
CLOSE DRAIN COCK
TM04 0855 0908
H2OHCl pump,
2 min.
NaClO2pump,
2 min.
DRAIN RESERVOIR
TANK
END
START
H2O
PLEASE WAIT
2x
FLUSHING
FLUSHING IS RUNNING
FLUSHING
PLEASE WAIT!
FLUSHING
SYSTEM FLUSHING IS
FINISHED