10000C Service manual
Contents
1. 18 4 2 3 Removing the diaphragms from the dosing pump 19 4 2 4 Valves for suction pulsation damper eese 21 4 2 5 Servicing the suction injector pp 22 4 2 6 H2O PUM Paernas De ie erste redatto ees 24 5 Tests every 24 months cesses 25 5 1 iron c 25 5 2 Irapeller COUriter arret rte tee eee rere He Eee ec iet oderit 25 Sc M20 oT o 25 5 4 Solution container for ClO2 os 26 Tests every 5 years eeeeeeseeeeeeeee eene nennen nennen nnn nnne nnn nnns 27 Starts p 28 7 1 Selecting the installation and operating mode ssssss 29 7 2 Checking the limit contacts of the flow meter pp 29 7 2 1 Limit contacts for 164 4000 C RN 30 7 2 2 Limit contacts for 164 6000 C 30 7 2 8 Limit contacts for 164 7500 C Ne 30 7 2 4 Limit contacts for 164 10000 CN 31 7 3 Start up mode filling the reactor with water pp 31 7 4 Filing the water container 33 7 5 Deaerating and setting the H2O pump pp 35 7 6 X Deaerating and setting the pump for HCI NaCIO 2 36 7 7 Deaerating and setting the bypass line pps 39 7 8 Deaerating the line for the suction injector pp 39 4 BE gt THINK gt INNOVATE gt V2 0 Oxiperm 164C 4 10 kg Service en 1 General 1 1 Spare parts set ti NOTE In accordance with the regulations for the prevention of accidents GUV 8 15 and VGB 65 192. Replacing valves from the bypass line e Replace valve DN20 Pos 220 and valve DN20 Pos 1000 Replacing the valve in the predilution line e Replace valve DN20 Pos 220 i n WV LL TLUI mm En HC nas 3 aa LIE 1 SEE im Ll Ur m2 bs Cf 18 BE THINK INNOVATE V2 0 Oxiperm 164C 4 10 kg Service en 4 2 3 Removing the diaphragms from the dosing pump Removing the diaphragm Loosen the connection screws on the suction side and pressure side Loosen the four dosing head screws e Remove the dosing head and unscrew the diaphragm in an anticlockwise direction Assembly e Insert the intermediate ring in such a way that the relief hole is facing downwards e Screw in diaphragm e Switch on pump briefly until the diaphragm reaches the back dead point e Carefully fit the dosing head and gradually tighten the screws in a diagonal sequence so that the dosing head is not damaged e Deaerate the pump i GD J fh INS ON 15 710138 V2 0 BE THINK INNOVATE gt 19 e GRUNDFOS ALLDOS Oxiperm 164C 4 10 kg Service en Spare parts set for dosing heads M251 M252 Order No 553 253 6 Pos Part No Designation
3. 53 650 001 Bypass pump 230V all 53 650 005 Bypass pump 115V all 15 710138 V2 0 BE THINK INNOVATE 25 e GRUNDFOS 27 ALLDOS Oxiperm 164C 4 10 kg Service en 5 4 Solution container for CI02 Replacing the absorption filter Spare parts H4 Pos Part No Designation 430 12 5733 Float PVC 164 4000C to 10000C 440 12 4736 Change over contact164 4000C to 10000C 450 12 3768 320 Absorption filter 164 4000C to 10000C 530 12 4908 410 Float switch 164 4000C to 10000C 26 BE gt THINK gt INNOVATE gt V2 0 Oxiperm 164C 4 10 kg Service en 6 Tests every 5 years eo NOTE For this test we recommend replacing the following components Replacing the dosing pump for HCI NaCIO2 15 710138 V2 0 BE THINK INNOVATE gt 27 e GRUNDFOS ALLDOS Oxiperm 164C 4 10 kg Service en 7 Start up CAUTION During start up of Oxiperm C164 installations with concentrated chemicals the following start up procedure must be observed 1 Selecting the installation and operating mode 2 Checking the limit contacts of the flow meter 3 Start up mode filling the reactor with water 4 Filling the water run down tank 5 Deaeration and setting of the pump for H20 6 Deaeration and setting of pumps for HCI NaClOg 7 Deaerating the bypass line and setting the bypass water quantity
4. Ti p pin D TE UTE FSH CS FSH H u U jl CJ UNE esi Sais FSi E WV EE emt y z gt L ae m FSL L 1 D Ed mi Vallo g Hoe NaClO S Ho BE THINK INNOVATE gt 29 15 710138 V2 0 Mw GRUNDFOS ALLDOS Oxiperm 164C 4 10 kg Service en 7 2 1 Limit contacts for 164 4000 C 7 2 2 Limit contacts for 164 6000 C 7 2 3 Limit contacts for 164 7500 C Flow meter Pos MIN contact Flow meter Pos MAX contact MIN contact Flow meter Pos MAX contact MIN contact Flow meter Pos MAX contact MIN contact Flow meter Pos MIN contact Flow meter Pos MAX contact MIN contact Flow meter Pos MAX contact MIN contact Flow meter Pos MAX contact MIN contact Flow meter Pos MIN contact Flow meter Pos MAX contact MIN contact Flow meter Pos MAX contact MIN contact Flow meter Pos MAX contact MIN contact 1 850 2 26 22 3 26 22 4 155 120 1 1400 2 39 34 3 39 34 4 230 190 1 1800 2 48 43 3 48 43 4 290 240 H20 Bypass water l h NaClo2 Vh h HCI V h Vh H20 Dilution of hydrochloride acid h h H20 Bypass water l h NaClo2 h Vh HCI Vh h H20 Dilution of hydrochloride acid h V h H20 Bypass water V h NaClo2 h h HCI yh Vh H20 Dilution of hydrochloride acid Vh h
5. 8 Deaerating the suction injector line 9 Filling the overflow system on the solution container CAUTION Before the installation is run with chemicals the reactor must be filled with water The installation must not be run with chemicals if there is air in the reactor NOTE The stroke length of the dosing pumps are factory set and may be different depending on the size of the installation When the dosing pump is calibrated loosen the locking screw under the stroke adjustment button and if necessary adjust the dosing pump to the required consumption data Then tighten the locking screw again to avoid any unwanted stroke adjustment NOTE During the calibration of the dosing pumps for HCI and NaCIOs5 the setting is reduced by approximately 10 15 e g setting 50 calibration at 35 40 in order to perform the first calibration The dosing pumps are then adjusted to the correct consumption data depending on the local pressure NOTE The start up operation can only be carried out by authorised and qualified personnel Guidelines Dueto current regulations forthe prevention of accidents chlorine dioxide installations can only be started up once they have been inspected by an expert to ensure it is in its proper condition Priorto any subsequent start up the chlorine dioxide installations mustbe inspected by an expert This inspection must be repeated every 6 to 12 months in accordance with regulations 28 BE THINK g
6. and the setting of the water volume for predilution and bypass Here the performance of the dosing pumps for HCI and NaCIO2 is checked and also the quantities of water that are used to predilute HCI and the bypass water for the solution container Settings see table j RR e Checking the dosing pump for HCI on the measuring tube pos 1 4 adjust the dosing pump if necessary pos 3 right hand wheel e Checking the dosing pump for NaCIO2 on the measuring tube pos 2 4 adjust the dosing pump if necessary pos 3 left hand wheel e Checking the water quantity to predilute HCI on the measuring tube pos 5 4 adjust if necessary using the ball valve pos 5 7 e Checking the bypass water volume on the measuring tube pos 4 3 adjust is necessary using the ball valve pos 4 5 CIO System generation Consumption of Dilution water requirement for bypass system Op pressure performance components Bypass Prelim dilution Suction from Total NaCIO2 HCI with 3 g l for mm wl solution E water a RR mw m m ww ec e ese n 9 399 6s ae zw er or wm os e x s 15 710138 V2 0 BE gt THINK gt INNOVATE gt 11 e GRUNDFOS 24 ALLDOS Oxiperm 164C 4 10 kg Service en 3 7 Float in the solution container Here the float and the guide pipe are checked for contamination e Check float
7. be replaced Label Part No Designation Installation 12 6029 300 Warning label all 12 6028 410 HCI label all 12 6028 400 NaClO2 label all 3 4 Relay connection for control system Here all relay connections are checked To check on the display switch to service mode test mode relay The following relays can be checked Dosing pump NaCIO2 HCI Bypass line solenoid valve Suction of solution container solenoid valve Electrically isolated output Auto Manual Electrically isolated output error messages Electrically isolated output pre empty signals Electrically isolated output dry run batch container Rinsing line solenoid valve Pump for H2O 3 5 Suction injector for the solution container Here the operation suction ability of the suction injector is checked Remove vacuum hose above suction injector Switch to Service operation Deaeration mode on the display Switch to the Bypass line menu e Press the F2 key to activate or deactivate the suction operation Apply a piece of paper to check the suction ability of the suction injector If there is no suction the following points should be checked e Counterpressure of the pipe line after the suction injector the pressure may be too high e Nozzle and diffuser are clogged Clean components 10 BE THINK gt INNOVATE V2 0 Oxiperm 164C 4 10 kg Service en 3 6 Checking the dosing flow of the pumps for HCI Nacl02
8. pipe lines and reactor Here the installation is flushed with demineralised water or in part with process water Rinsing the dosing pump and lines for HCI and NaClO2 e Switch to Service operation Deaeration mode on the display e Switch to Pump NaCIO2 HCl menu e Activate dosing pump The dosing pump is runs under time control and switches off after approximately 3 minutes NOTE The dosing pump and time control can be stopped at any time by pressing the ESC key NOTE If the suction pulsation damper is emptied before the time control switches off the dosing pump this process should be stopped by pressing the ESC key The pulsation damper should then be filled again with demineralised water To rinse the dosing pump or pipe lines for HCI or NaCIO2 requires approximately 3 4 fillings of the suction pulsation damper e Deactivate the dosing pump time controlled or ESC key Rinsing the reactor e Switch to Service operation Deaeration mode on the display e Switch to the Bypass line menu e Press the F3 key to activate or deactivate the rinsing operation The reactor is now flushed with water NOTE The rinsing process remains active until the water level in the solution container batch container reaches MAX contact The solution container should then be dosed again or emptied If it is emptied the solution in the container should be neutralised Once the MAX contact is reached deactivate the rinsing
9. 10 kg Service en LS LA L3 4 2 Bee I i a Eu j d d 2al 3 1 2 V2 0 BE gt THINK gt INNOVATE gt 34 Oxiperm 164C 4 10 kg Service en 7 5 Deaerating and setting the H20 pump Deaeration To deaerate the rotary pump pos 5 2 screen on page 53 the water container pos 5 1 must be filled with water e Close the ball valve pos 5 7 dilution water line and then open it slightly turn approximately 45 to the left Switch to Service operation Deaeration H20 pump menu also see Section 7 8 1 Display indicator 2 H2O pump OFF target XXX I h actual YYY l h 1 limit XX TXX 96 gt e Press the F2 key to activate the H2O pump display indicator lt ON gt e Place the deaeration hose pos 5 10 in a separate container to collect the leaking water e Open the ball valve pos 5 9 to deaerate the H2O pump The pump
10. 2 the safety of the chlorine dioxide systems must be checked by an expert on a regular basis and at least once a year and before each start up These checks can be carried out by the service centre within the framework of a 6 month or annual maintenance check Before any maintenance work is carried out i e if parts and gaskets are replaced the whole installation must be flushed with water When maintenance work is carried out all remains of chemicals must be removed When working with acids or lyes ensure that the necessary protective clothing is worn Maintenance and repair work may only be carried out by authorised qualified personnel Each spare parts set includes the following parts Spare parts set for the dosing pump diaphragms valves O rings Spare parts set for suction pulsation damper valves Spare parts set for valves Spare parts set for the suction injector of the batch container Ball check valve O rings for Bypass line DN20 impeller counter circulating pump 2 Preparing the installation for maintenance For maintenance work which involves replacing components the dosing pumps for HCI and NaCIO2 and the reactor must be flushed with demineralised water and the bypass line with process water in order to avoid direct contact with chemical residues o NOTE Any remaining CIO2 solution in the batch container should be dosed before the dry run contact MIN MIN or empty the batch container over the eva
11. 30 BE gt THINK gt INNOVATE V2 0 Oxiperm 164C 4 10 kg Service en 7 2 4 Limit contacts for 164 10000 C Flow meter Pos 1 H20 Bypass water MIN contact 2500 l h Flow meter Pos 2 NaClo2 MAX contact 65 Vh MIN contact 60 Vh Flow meter Pos 3 HCI MAX contact 65 Vh MIN contact 60 Vh Flow meter Pos 4 H20 Dilution of hydrochloride acid MAX contact 390 l h MIN contact 330 l h 7 3 Start up mode filling the reactor with water V 0 WARNING Before the installation is run with chemicals the reactor must be filled with water Switch to Service operation Deaeration Bypass line menu also see Section 7 8 1 Display indicator Deaeration 1 Bypass OFF 2 Suction OFF 3 Rinsing OFF NOTE The filling process is only complete once the solution container has been filled twice to MAX contact e Use the F3 key to activate the solenoid valve for the rinsing process Display indicator lt ON gt e Use the F3 key to deactivate the solenoid valve for the rinsing process Display indicator OFF if the water level has reached the MAX contact in the solution container see diagram e Use the evacuation ball valve Pos 1 to completely empty the solution container so that no water is left in it or use the dosing pump to pump the water out of the solution container After it has been emptied close the ball valve again 15 710138 V2 0 BE THINK INNOVATE 9 31 v
12. 4 10 kg Service en 4 2 5 Servicing the suction injector In the case of water which has a high deposit content deposits can change the nozzle ratio of the injector in such a way that it causes a drop in performance during suction In this case the nozzle must be cleaned V ATTENTION Do not use sharp objects to clean the nozzles Hydrochloride acid has proven to be the most suitable cleaning agent Observe the regulations when using hydrochloric acid 160 gt 20 E j 210 ALL LIU m lt ZZ R L gt 60 p EA 7 260 ml 280 0 20 20 7 K Spare parts set Order No 553 1033 Pos Part No Designation Installation 20 52 153 2 O ring Viton 164 4000C to 10000C 60 12 779 4 Seat PTFE 164 4000C to 10000C 70 52 139 O ring Viton 164 4000C to 10000C 120 12 778 4 Piston PTFE 164 4000C to 10000C 130 12 312 4 Diaphragm FEP 164 4000C to 10000C 160 52 164 O ring Viton 164 4000C to 10000C 180 52 107 1 O ring Viton 164 4000C to 10000C 390 12 312 4 Diaphragm FEP 164 4000C to 10000C 400 12 1770 400 Diaphragm Viton 164 4000C to 10000C 25 BE gt THINK gt INNOVATE gt V2 0 Oxiperm 164C 4 10 kg Service en Checking the diaphragm non return If the diaphragm non return is leaking the seat and piston must be checked and replaced i
13. 4 54 001 Flat gasket UNI blue 18 10 4700 351 Valve DN8 20 10 5805 400 Bead diaphragm TFM 1700 21 10 7400 351 Valve DN8 40 48 905 400 Leaflet 100 48 1104 403 Insert for spare parts set Spare parts set for dosing heads M253 Order No 553 292 6 Pos Part No Designation 4 54 001 Flat gasket UNI blue 20 10 4796 401 Bead diaphragm TFM 1610 53 52 141 O ring Viton 59 52 146 O ring Viton 60 10 6505 400 Valve seat PTFE 61 10 1838 Ball ceramics 100 48 1104 403 Insert for spare parts set 20 BE THINK INNOVATE gt V2 0 Oxiperm 164C 4 10 kg Service en 4 2 4 Valves for suction pulsation damper Replace valves DNB pos 130 14 pos 120 16 pos 100 16 and pos 110 14 O NOTE Observe mounting position flow direction rane oe r 3 Um un M0 TA MN E 20 16 16 P HCI TOI y W Le x a aa the 120 00 uy V J 1 RB T m u uo EL Spare parts set Order No 553 697 02 Pos Part No Designation Installation 100 1610 7400 351 Valve DN8 164 4000C to 10000C 110 1410 7400 351 Valve DN8 164 4000C to 10000C 120 1610 7400 351 Valve DN8 164 4000C to 10000C 130 1410 7400 351 Valve DN8 164 4000C to 10000C 15 710138 V2 0 BE gt THINK gt INNOVATE gt 21 e GRUNDFOS ALLDOS Oxiperm 164C
14. IO2 e Press F3 to switch to the Pump HCI NaCIO2 menu Display indicator Pump HCI NaCIO2 1 Pump OFF e Press F1 to activate the dosing pump for the chemicals If you press the F1 key the rotary pump is activated for the dilution water of the hydrochloric acid If the float body exceeds the MIN contact in the flow meter then the dosing pumpis activated for the chemicals For safety reasons the dosing pump HCI NaClO2 is always switched with the pump for the dilution water If the MAX MIN limits of the flow control for the dilution water are either exceeded or are below the limit values the installation switches off even though the F1 key is depressed An alarm message then appears on the display Flow control 1 2 impeller counter Flow control 2 flow meter e The dosing pump is deaerated correctly if the liquid flows through the flow meter without any bubbles 15 710138 V2 0 BE gt THINK INNOVATE gt 37 e GRUNDFOS ALLDOS Oxiperm 164C 4 10 kg Service en Setting the flow rate of HCI and NaCIO2 Before the calibration systems are filled with chemicals the existing water must be removed from the calibration system NOTE Only fill the calibration systems with chemicals if no water is left in the system e Open ball valves 1 6 and 2 6 e Set ball valves on the calibration system 1 2 3 and 2 2 3 to pos 3 deaeration function If there is no more water in the calibration systems e C
15. If the orifice is to be replaced the reactor should first of all be emptied using the evacuation ball valve 15 710138 V2 0 BE gt THINK INNOVATE gt 13 v GRUNDFOS ALLDOS Oxiperm 164C 4 10 kg Service en 4 Maintenance and tests every 12 months During these maintenance tests the following components are checked and if necessary cleaned or replaced 4 1 Tests Solenoid valves for bypass line rinsing line and suction injector See Section 3 1 Checking the pressure reducer or filter See Section 3 2 Check information signs See Section 3 3 Check relay connection for control system See Section 3 4 4 1 1 Solenoid valves or H20 pump H20 pump for predilution of hydrochloric acid See Section 3 8 Check float in the solution container See Section 3 7 Check flow limiter O rings of union pieces Here the operation and tightness of the solenoid valves or H2O pump is checked e NOTE Switch to Service operation Deaeration mode on the display Switch to the Bypass line menu Switch solenoid valves on to check the operation and tightness replace solenoid valves if necessary Switch to Service operation Deaeration on the display reset if necessary using the ESC key Switch to the H2O pump menu and activate pump The specified amount of water on the display must be within the set tolerances Check tightness of the H2O pump replace if necessary Check connection scre
16. Oxiperm 164C 4 10 kg Service en ev GRUNDFOS 24 ALLDOS Oxiperm C 164 Fully automatic chlorine dioxide processing plant 164 4000C 6000C 7500C 10000C Service manual 15 710138 V2 0 BE gt THINK INNOVATE gt e GRUNDFOS ALLDOS Oxiperm 164C 4 10 kg Service en Imprint Oxiperm C 164 Fully automatic chlorine dioxide processing plant 164 4000C 6000C 7500C 10000C Service manual Version 2 0 Issued by ALLDOS Eichler GmbH ReetzstraBe 85 76327 Pfinztal S llingen Postfach 1160 76317 Pfinztal Germany Tel 49 0 72 40 61 0 Fax 49 0 72 40 61 211 E Mail alldos de alldos com Internet http www alldos com 2008 by ALLDOS Eichler GmbH Subject to change without notice BE THINK INNOVATE V2 0 Oxiperm 164C 4 10 kg Service en Installation data o NOTE Please fill in this form following commissioning It will help you and your ALLDOS servicing partner to adjust the unit during subsequent corrections Owner Grundfos Alldos customer No Contract No Order No of unit Serial No of unit Put into service on Location of unit Used for Installation diagram 15 710138 V2 0 BE THINK INNOVATE gt 3 e GRUNDFOS 27 ALLDOS Oxiperm 164C 4 10 kg Service en Contents lug ge EDEN 2 Installation data as 3 Installation diagram aeree eene nen
17. ass line Display indicator lt ON gt With the ball valve at pos 4 5 set the required quantity of bypass water setting data see Section 3 1 1 Power and consumption data Press the F1 key to deactivate the solenoid valve for the bypass line 7 8 Deaerating the line for the suction injector Switch to Service operation Deaeration Bypass line menu also see Section 7 8 1 NOTE Display indicator Deaeration 1 Bypass OFF 2 Suction OFF 3 Rinsing OFF Press the F2 key to activate the solenoid valve for the suction injector Display indicator lt ON gt If the counterpressure is too great in the outlet the suction capacity of the suction injector is reduced Checking the suction performance Remove the vacuum hose from the diaphragm non return of the suction injector Use your thumb to check the suction performance of the injector Reconnect the vacuum hose Press the F2 key to deactivate the solenoid valve for the suction injector display indicator lt OFF gt 15 710138 V2 0 BE gt THINK INNOVATE gt 39 e GRUNDFOS 4 1 ALLDOS Oxiperm 164C 4 10 kg Service en 40 BE gt THINK gt INNOVATE gt V2 0
18. ation and tightness replace solenoid valves if necessary Switch to Service operation Deaeration on the display reset if necessary using the ESC key Switch to the H20 pump menu and activate pump The specified amount of water on the display must be within the set tolerances Check tightness of the H2O pump replace if necessary Check connection screws and O rings pos 2 of the H2O pump replace if necessary Observe mounting position flow direction Switch off solenoid valves or H2O pump 24 BE gt THINK gt INNOVATE gt V2 0 Oxiperm 164C 4 10 kg Service en 5 Tests every 24 months NOTE For this test we recommend replacing the following components 5 1 Solenoid valves Bypass line with solenoid valve and flow limiter for the supply line of the run down tank H2O e Replacing the solenoid valve e Replacing the flow limiter 45 10245 3 4 Solenoid valve 230V 50Hz all 45 10249 3 4 Solenoid valve 115V 60Hz all 53 625 50 Flow limiter 5 l min 164 4000C 6000C 53 625 90 Flow limiter 9 l min 164 7500C 10000C 5 2 Impeller counter Impeller counter flow meter in the H20 line for the predilution of HCI o Replacing the impeller counter flow meter Part No Designation Installation 12 6010 1 Flow meter FHKU 100 all 5 3 H20 pump H2O pump for the water supply for the predilution of HCI Replacing the circulating pump Part No Designation Installation
19. cuation ball valve to neutralise the CIO2 solution 15 710138 V2 0 BE gt THINK gt INNOVATE gt 5 Mw GRUNDFOS ALLDOS Oxiperm 164C 4 10 kg Service en 2 1 Emptying the suction pulsation damper Here chemicals are emptied out of the suction pulsation damper WARNING Chemicals should be emptied separately WARNING Components with 33 hydrochloric acid and 24 5 sodium chloride must not be mixed together as a concentrated solution If undiluted components with 33 hydrochloric acid and 24 5 sodium chloride are an explosive solution concentration PIN gt B 2 1 1 1 2 2 Let AL 0 wd 3 Lr 16 12 1 2 Close ball valves pos 1 2 2 and 2 2 2 for the feed line of chemicals ai A a eed oes sn FY A laan KY t D JH gt E Place hose pos 1 7 in an empty container set ball valve above the suction pulsation damper pos 1 2 3 to Aeration screen 2 pos 3 an open the ball valve pos 1 6 The suction pulsation damper is now emptied 6 BE gt THINK gt INNOVATE gt V2 0 Oxiperm 164C 4 10 kg Service en Place hose pos 2 7 in a separate empty container set ball valve above the suction pulsation damper pos 2 2 3 to Aeration screen 2 pos 3 and open bal
20. f necessary e Switch off the installation and close the ball valve in the outlet so that when you open the diaphragm non return water cannot escape e Remove the vacuum hose from the non return valve loosen the screws and remove the upper part Replacing the diaphragm e Remove the diaphragm ring pos 80 and replace the 3 diaphragms replace the O rings pos 70 if necessary NOTE The Viton diaphragms are located between the FEP diaphragms Replacing the seat and piston e Remove the screw ring pos 50 and replace the seat pos 60 with the O ring pos 180 NOTE Observe mounting position e Replace the piston pos 120 in the upper part of the diaphragm non return Assembly of diaphragm non return e Push the diaphragm disk over the piston If it closes to easily tighten the screw ring pos 50 slightly e Mount upper part onto lower part NOTE If water escapes from the diaphragm non return when you open the isolating ball valve tighten the screw ring pos 50 again slightly e Connect vacuum hose 15 710138 V2 0 BE gt THINK INNOVATE gt 23 vy GRUNDFOS 24 ALLDOS Oxiperm 164C 4 10 kg Service en 4 2 6 H20 pump Here the operation and tightness of the solenoid valves or H2O pump is checked NOTE Switch to Service operation Deaeration mode on the display Switch to the Bypass line menu Switch solenoid valves on to check the oper
21. for contamination visual check e Check the guide pipe for contamination visual check In the event of a fault due to contamination clean the guide pipe and float Before you remove the guide pipe dose or empty the NOTE eo solution in the container if present Pd Hh i H1 3 8 Pump for H20 predilution for HCI Here the operation of the H2O pump is checked for the predilution of hydrochloric acid H2O pump In the event of a fault the component must be NOTE eo replaced Spare pump 12 6443 400 Solenoid valve 230V 50Hz 12 6443 410 Solenoid valve 115V 60Hz BE gt THINK gt INNOVATE gt V2 0 12 Oxiperm 164C 4 10 kg Service en 3 9 Temperature Sensor For maintenance work the temperature sensor should be checked for damage or corrosion on the end of the sensor The temperature sensor is screwed into an orifice and therefore does not come into direct contact with the chlorine dioxide solution in the reactor e Unscrew the sensor from the orifice check it and then screw it back into the orifice WARNING If the union nut pos 80 13 is removed there is the danger that the contents of the reactor is released into the open Spare parts Pos Part No Designation 80 11 52 141 O ring Viton 80 12 12 6155 400 Orifice for sensor PTFE carbon 80 13 53 058 25 Union nut DN20 80 14 48 978 2 Temperature sensor e NOTE
22. is deaerated correctly if the dilution water flows without any bubbles in the measuring tube pos 5 4 e Close the ball valve pos 5 9 Setting the water quantity e Use the ball valve pos 5 7 to set the required quantity of dilution water see Section Power and consumption data e Press the F2 key to deactivate the H2O pump display indicator lt OFF gt e Press the Escape key to return to the Deaeration menu 15 710138 V2 0 BE THINK INNOVATE gt 35 v GRUNDFOS 24 ALLDOS Oxiperm 164C 4 10 kg Service en 7 6 Deaerating and setting the pump for HCI NaCIO2 o NOTE The dosing pump for HCI NaCIO2 is first of all deaerated using water o NOTE The dosing pump is time controlled during the deaeration process and then switches off automatically approximately 3 minutes runtime The deaeration process can be stopped at any time by pressing the Escape key V Yi X ite IN Filling the calibration system with water Close the ball valve 2 2 2 and 1 2 2 forthe supply of chemicals Place the hose 2 7 and 1 7 in a water container and open the ball valves 2 6 and 1 6 2 D ii 1 tamil I v ii E i 8H i e Turn the ball valve to position 1 white marking points in the direction of
23. l valve pos 2 6 The suction pulsation damper is now emptied WARNING Do not mix concentrated chemicals Use separate containers 2 2 Filling the suction pulsation dampers Here the suction pulsation dampers are filled with demineralised water in order to eventually flush the dosing pump and the dosing lines Suction pulsation damper for HCI Place hose pos 1 7 ina container which is filled with demineralised water set ball valve above the pulsation damper pos 1 2 3 to Suction screen 2 pos 1 open ball valve pos 1 6 and using the manual vacuum pump pos 1 2 1 suction the water in the pulsation damper Fill the pulsation damper to the top of the transparent tube Close ball valve pos 1 6 Set ball valve above the pulsation damper pos 1 2 3 to Closed screen 2 pos 2 Suction pulsation damper for NaCIO2 Place hose pos 2 7 in a container which is filled with demineralised water set ball valve above the pulsation damper pos 2 2 3 to Suction screen 2 pos 1 open ball valve pos 2 6 and using the manual vacuum pump pos 2 2 1 suction the water in the pulsation damper Fill the pulsation damper to the top of the transparent tube Close ball valve pos 2 6 Set the ball valve above the pulsation damper pos 2 2 3 to Closed screen 2 pos 2 15 710138 V2 0 BE gt THINK INNOVATE gt 7 Mw GRUNDFOS ALLDOS Oxiperm 164C 4 10 kg Service en 2 3 Rinsing the dosing pump
24. lose ball valves 1 6 and 2 6 e Set ball valves on the calibration system 1 2 3 and 2 2 3 to pos 2 closed e Open the ball valves 1 2 2 and 2 2 2 for the supply of chemicals The calibration systems can now be filled with chemicals NOTE The calibration systems are filled with chemicals in the same Way as they are filled with water Identical procedure e Press F1 to activate the dosing pump for the chemicals e Using the hand wheels on the pump set the required dosing flow via the relevantflow meter Setting data see Section 3 1 1 Powerand consumption data WARNING NaCIO2 is extremely temperature dependent i e depending on the ambient temperature gt or lt 20 C there is the possibility that the value set on the measuring tube does not match the calibration The display error on the measuring tube could in this case depending on the difference in temperature be in the range of 10 6 Irrespective of the temperature the dosing quantities for the chemicals must therefore be calibrated before the installation is switched on 38 BE THINK gt INNOVATE gt V2 0 Oxiperm 164C 4 10 kg Service en 7 1 Deaerating and setting the bypass line Switch to Service operation Deaeration Bypass line menu also see Section 7 8 1 display indicator lt OFF gt Display indicator Deaeration 1 Bypass OFF 2 Suction OFF 3 Rinsing OFF Press the F1 key to activate the solenoid valve for the byp
25. ne menu also see Section 7 8 1 Display indicator Deaeration 1 Bypass OFF 2 Suction OFF 3 Rinsing OFF e Close ball valve pos 4 5 bypass line see screen on page 51 Open ball valve pos 5 6 filling line for water container NOTE The ball valve pos 5 6 must be always be open when E the installation is running so that the water container is always filled e Press the F1 key to activate the bypass solenoid valve pos 4 2 The water run down tank is filled when water flows through the bypass line of the installation i e the bypass solenoid valve is active The water run down tank is filled by means of the float valve which stops the water supply as soon as the water container is full e Press the F1 key to deactivate the bypass solenoid valve pos 4 2 15 710138 V2 0 BE THINK INNOVATE gt 33 GRUNDFOS ALLDOS Oxiperm 164C 4
26. nen nennt nnn 3 1 G neral aseene a sane tne ncessn tg tenn ci encase suse a a a 5 1 1 Spare DAMS Set yAn isean a a rE US TEE eniri 5 2 Preparing the installation for maintenance ee 5 2 1 Emptying the suction pulsation damper pp 6 2 2 Filling the suction pulsation dampers Nt 7 2 3 Rinsing the dosing pump pipe lines and reactor pp 8 3 Tests every 6 months saannnnunnunnnennnnnnnnnnnnnunnnnnnnnnnnnnnnnnnnnnn nnne nnmnnn nanana 9 3 1 Checking the solenoid valves pp 9 3 2 Checking the pressure reducer or filter pp 9 3 3 Check information signs ssssseeeeeeeeemeeenne 10 3 4 Relay connection for control system pp 10 3 5 Suction injector for the solution container ppp 10 3 6 Checking the dosing flow of the pumps for HCI NaCIO2 and the setting of the water volume for predilution and bypass 11 3 7 Float in the solution container 12 3 8 Pump for H2O predilution for HCI pp 12 3 9 Termiperat re Sensor e ete eric re AS EROR RAUS E EREDE PIERDE 13 4 Maintenance and tests every 12 months eese 14 4 1 TES S 14 4 1 1 Solenoid valves or H2O pump ppp 14 4 2 Flow litter x rette n eter Eee Ere esee orte 15 4 1 3 O rings of union pieces pp 15 4 2 MalINt NnaAMGe err 16 4 2 1 Reactor valves and valves for rinsing line 16 4 2 2 Ball checks of bypass line and of predilution line
27. os Pos Pos Pos Do not interchange valves 271 1 Check back valve DN8 for supply of NaCIO2 271 2 Check back valve DN8 for supply of HCI 220 1 Check back valve DN20 for dilution water 220 2 Check back valve DN20 for rinsing line 321 1 Evacuation ball valve 321 2 Isolating ball valve reactor 321 3 Isolating ball valve NaCIO2 321 4 Isolating ball valve HCI 322 Isolating ball valve reactor 490 Orifice for bypass water line 492 Flat gasket Part No 54 142 980 Orifice for predilution H2O 16 BE gt THINK gt INNOVATE gt V2 0 Oxiperm 164C 4 10 kg Service en Replacing the valves e Once the reactor has been rinsed close ball valves pos 321 2 pos 321 3 Pos 321 4 and pos 322 e Replace valves DN8 pos 271 1 pos 271 2 and valves DN20 pos 220 1 Pos 220 2 e Before the installation starts up open ball valves pos 321 1 pos 321 3 Pos 321 4 and pos 322 ax 1 nats elit EIS ets ur Tj Bs 15 710138 V2 0 BE THINK INNOVATE gt 17 Mw GRUNDFOS 27 ALLDOS Oxiperm 164C 4 10 kg Service en 4 2 2 Ball checks of bypass line and of predilution line e NOTE i NOTE During these maintenance tests the valves must be fully replaced Observe mounting position flow direction
28. process All lines and even the reactor are now flushed with water BE THINK gt INNOVATE gt V2 0 Oxiperm 164C 4 10 kg Service en 3 Tests every 6 months During these tests the following functions or components are checked and if necessary cleaned or replaced 3 1 Checking the solenoid valves Here the function of existing solenoid valves is checked e Solenoid valves of the bypass line e Solenoid valves for the rinsing line e Solenoid valves for suction of batch container NOTE If a solenoid valve is faulty it must be replaced Spare valves 45 10245 3 4 Solenoid valve 230V 50Hz 45 10249 3 4 Solenoid valve 115V 60Hz 3 2 Checking the pressure reducer or filter Here the operation of the pressure reducer and the condition of the filter are checked e Check the pressure adjustment e Check the filter clean if necessary NOTE In the event of a fault the component must be eo replaced Part No Designation Installation 53 600 1 Pressure reducer 1 164 4000C 164 6000C 53 600 11 4 Pressure reducer 1 1 4 164 7500C 164 10000C 15 710138 V2 0 BE gt THINK gt INNOVATE gt 9 e GRUNDFOS ALLDOS Oxiperm 164C 4 10 kg Service en 3 3 Check information signs Here the legibility of all system signs or labels is checked e Warning label e HCl label on dosing pump e NaClO2 label on dosing pump NOTE If the labels are illegible or damaged they must
29. t INNOVATE V2 0 Oxiperm 164C 4 10 kg Service en The operation and servicing of chlorine dioxide installations and the use of chemicals is only permitted to those who are qualified to use them It goes without saying that these persons reliably fulfil their tasks 3 See regulations for the prevention of accidents GUV 8 15 and VBG 65 Chlorination of water This is why a start up is only carried out by trained personnel with the relevant documentation 7 1 Selecting the installation and operating mode The installation size and mode are defined in the Installation selection menu Press Escape on the control panel to interrupt entry at any time eo NOTE The preset installation size flashes in the installation type menu reselect the installation size if necessary See Section 7 6 1 Installation type Oxiperm C 164 chlorine dioxide installations can be used in two different modes 1 Auto Manual LI Bus control o NOTE The preset mode is displayed flashing select a new mode if necessary See Section 7 6 2 Operating mode 7 2 Checking the limit contacts of the flow meter Before start up check the limit contacts of the individual flow meters and adjust if necessary The MAX and MIN limits are different depending on the size of the installation 1 2 3 fi f _ p
30. the manual vacuum pump e Using the manual vacuum pump pos 2 2 1 or pos 1 2 1 suction liquid into the calibration system Fill the calibration system by approximately 50 80 96 e Once it is filled turn the ball valve to position 2 the calibration system is closed white marking points to the front 36 BE gt THINK gt INNOVATE gt V2 0 Oxiperm 164C 4 10 kg Service en 2 The ball valves pos 2 2 3 and pos 1 2 3 directly above the calibration systems are set facing forward upon delivery i e the calibration system is closed see screen below pos 2 NOTE If there is not sufficient water in the calibration system for the deaeration process the calibration systems have to be filled with water again until the water flows through the flow meter without any bubbles NOTE Mirror inverted arrangement of the calibration systems but nevertheless using the same procedure as for the filling white marking points towards the vacuum pump and calibration white marking points towards the deaeration valve NOTE The calibration systems must be closed whilst the installation is running automatic or manual operation or bus control Deaerating the dosing pump HCI NaCIO2 From the main menu press the F3 key to switch to the Service operation menu scroll within the main menu if necessary e Press F1 to switch to the Deaeration menu Display indicator Deaeration 1 Bypass line 2 H20 pump 3 Pump HCI NaC
31. ws and O rings pos 2 of the H2O pump replace if necessary Observe mounting position flow direction Switch off solenoid valves or H2O pump 14 BE gt THINK gt INNOVATE gt V2 0 Oxiperm 164C 4 10 kg Service en 4 1 2 Flow limiter Here the tightness of the flow limiter is checked The flow limiter is at the rear of the installation and supplies the run down tank for the predilution of HCI with water Check tightness of flow limiter replace flat gaskets Replace pos 910 7 o NOTE Observe mounting position flow direction J 4 1 3 O rings of union pieces Here the tightness of all union pieces is checked e Replace O rings if leaking 15 710138 V2 0 BE THINK INNOVATE gt 15 e GRUNDFOS 27 ALLDOS Oxiperm 164C 4 10 kg Service en 4 2 Maintenance Reactor valves and valves for rinsing line Ball checks in the bypass line Dosing pump for NaCIO2 HCI Valves for suction pulsation damper Suction injector H20 pump 4 2 1 Reactor valves and valves for rinsing line o NOTE During these maintenance tests the reactor valves must be fully replaced Spare parts set Valves Order No Designation Installation 553 697 01 Valves DN8 valves DN20 164 4000C to 164 10000C NOTE The reactor valves are not identical to the valves of the eo dosing pumps Pos Pos Pos Pos Pos Pos Pos Pos P
32. y GRUNDFOS ALLDOS Oxiperm 164C 4 10 kg Service en NOTE Press the Escape key to return to the Deaeration menu Repeat the rinsing process a second time i e activate by pressing the F3 Use the F3 key to deactivate the solenoid valve for the rinsing process Display indicator lt OFF gt if the water level has reached the MAX contact in the solution container see diagram Use the evacuation ball valve Pos 1 to completely empty the solution container so that no water is left in it or use the dosing pump to pump the water out of the solution container After it has been emptied close the ball gt Gee It is important to run the rinsing process twice in order to make sure that the no air is left in the reactor before it is used with chemicals and also that any air bubbles which may accumulate either between or in the ceramic rings have been completely removed 32 BE THINK INNOVATE gt V2 0 Oxiperm 164C 4 10 kg Service en 7 4 Filling the water container In order to ensure that the installations start up properly the bypass water line must be deaerated each time it is commissioned at the same time the water run down tank is filled for the dilution water Switch to Service operation Deaeration Bypass li
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