ProMinent DULCOTROL DWCa Assembly And Operating Instructions Manual Download Page 24

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5.3 Installation Diagram for DULCOTROL

Measuring and Control Station

Schematic diagram of the components of a

DULCOTROL

measuring and control station, installed outside of

the measuring plate, in the order shown here, see original ProMi‐

nent accessories. The accessories illustrated are required

depending on the application.

NOTICE!
The installation sequence is binding and to be

adhered to.

10.

A2106

Fig. 3: Installation diagram

Components:

1 Stopcock (supplied on site)

2 Process line

3 Heat exchanger (supplied on site)

4 Temperature control with shut-off valve. Not

included in the scope of delivery but necessary on

site at media temperatures of > 45 °C

5 Dirt filter (optional for pressure reducer) (to be pro‐

vided on site)

6 Pressure reducer (only operate with dirt filter) (to

be provided on site)

7 Dirt filter (optional via ID code)

8 Measuring plate

9 Free flow

10 Sample water pump "vonTaine" (to be provided

on site)

Overview of the measuring point

Summary of Contents for DULCOTROL DWCa

Page 1: ... in the oper ating instructions for the individual components These operating instructions are only valid if used in conjunction with the operating instructions for the individual components which can be found on the manufacturer s homepage EN Part no 984397 Version BA DR 014 12 19 EN Please carefully read these operating instructions before use Do not discard The operator shall be liable for any ...

Page 2: ...formation includes detailed descriptions of the haz ardous situation see Ä Chapter 2 1 Labelling of Warning Informa tion on page 9 The following symbols are used to highlight instructions links lists results and other elements in this document Tab 1 More symbols Symbol Description Action step by step Outcome of an action Links to elements or sections of these instructions or other applicable docum...

Page 3: ...e DGMa with Sensors 30 7 2 Electrical Installation of the Sensors 31 7 3 Adjusting the Flow Sensor Switching Point 32 8 Installing sensors in the bypass fitting DLG III IV 33 8 1 Fitting the DLG with sensors 34 8 2 Hydraulic Installation 35 8 3 Electrical Installation of the Sensors 35 8 4 Starting Up the DLG 37 9 Electrically and hydraulically assembling and installing the measuring points 38 9 1...

Page 4: ...efining metering and control processes 64 12 1 5 Calibrating conductive conductivity sensor parameter adjustment 65 13 Commissioning the Compact Controller for Inductive Con ductivity 66 13 1 Measured variables 66 14 Configuration of the controllers 68 14 1 Configuration of the Compact Controllers DCCa 68 14 2 Configuring the diaLog controller DACb 68 15 Calibrating the controller diaLog DACb 70 1...

Page 5: ...oning Less Than 4 Weeks 124 19 2 Temporary Decommissioning Longer Than 4 Weeks 124 19 3 Final decommissioning 125 20 Technical data and operating parameters 126 20 1 Flow and operational test of flow control 128 21 Spare parts and accessories 129 21 1 Spare parts 129 21 2 Accessories 134 22 EU Declaration of Conformity 135 23 Index 136 Table of contents 5 ...

Page 6: ...d pH 7 H Hot water to max 65 C at max 2 bar measured variables C1 P0 R0 L0 only Channel 1 measured variable 1 C0 Free chlorine pH 8 C1 Free chlorine pH 8 and or contaminated water G0 Total chlorine free and combined chlorine P0 pH R0 ORP D0 Chlorine dioxide I0 Chlorite L0 Conductivity Z0 Ozone F0 Fluoride pH min 5 5 pH max 8 5 H0 Hydrogen peroxide A0 Peracetic acid X0 Dissolved oxygen Channel 2 me...

Page 7: ...n the main plate but available in a separate construction Data logger 1 Data logger with measured value display on SD card Hardware extension 1 Protective RC circuit for output relay Sensor equipment 0 With sensors 1 Without sensors Design 0 Plate mounted with ProMinent logo B Assembly kit without plate with ProMinent logo Sample water preparation 0 none 1 with filter not for measured variable D0 ...

Page 8: ...es other languages are available A third measured variable can be retrofitted on site if the DGMa is fitted an additional module is avail able With the DLGIII An amperometric measured variable and up to two measured variables with PG13 5 connector are possible Identity code ordering system for DULCOTROL measuring and control panels 8 ...

Page 9: ...t will result in fatal or very serious injuries WARNING Nature and source of the danger Possible consequence Fatal or very serious inju ries Measure to be taken to avoid this danger Denotes a possibly hazardous situation If the situation is disregarded it could result in fatal or very serious injuries CAUTION Nature and source of the danger Possible consequence Slight or minor injuries Material da...

Page 10: ...installed to take appropriate measures to ensure that the failure of the meas uring plate or of individual components of the measuring plate do not have a damaging effect on the entire process and or the overall system These measures can include for example Redundant design of the measuring and con trol station Connection of an appropriate alarm device to the measuring plate and or the controller ...

Page 11: ...at the seals are sitting correctly after closing the housing of the pump controller or terminal box We fundamentally recommend the use of appro priate residual current circuit breakers RCCB or other residual current devices RCD providing they can be installed sensibly and professionally within the electrical installation Please adhere to all national standards and regulations WARNING Danger from h...

Page 12: ...osing can occur during the run in period WARNING Operating error Unauthorised access Possible consequence Fatal or very serious inju ries Measure Ensure that there can be no unau thorised access to the unit Ensure that the unit is only operated by ade quately qualified and technically expert per sonnel Please also observe the operating instructions for controllers and fittings and any other units ...

Page 13: ...stance List in the product catalogue or at www prominent com Take appropriate measures to ensure that there is no danger to personnel products or equipment in the event of hydraulic leaks An appropriate measure might include a sufficiently large floor drain Indoors or protective covering Protect the DULCOTROL measuring control sta tion from direct sunlight and other UV sources The unit is only int...

Page 14: ...e technical data and specifications provided in these operating instructions and in the operating instructions for the individual components n You are obliged to observe the information contained in the operating instructions at the different phases of the device s service life such as assembly installation etc n Do not use the unit outdoors n All other uses or a modification of the unit are only ...

Page 15: ...orised distribution partner Trained qualified per sonnel A trained qualified employee is deemed to be a person who is able to assess the tasks assigned to him and recognize possible hazards based on his training knowledge and experience as well as knowledge of pertinent regula tions A trained qualified employee must be able to perform the tasks assigned to him independently with the assistance of ...

Page 16: ... includes all rinsing pro cesses in the food and beverage industry which aim to clean and disinfect pipework vessels and machinery and or highly contaminated process or industrial process water With the DULCOTROL DWC product range a distinction is made between the following types of waste water n Waste water clear n Waste water with solid particle fraction turbid n Waste water with fluoride fracti...

Page 17: ... mV mA measuring input with Profibus DPV1 1103487 DACBW006VA4000B1101000 Extended expansion unit 2x Conductive conductivity temperature with Profibus DPV1 1103488 DACBW006L34000B1101000 Basic expansion unit measured variable mV mA measuring input with LAN web server 1103489 DACBW006VA4000E1101000 Extended expansion unit 2x Conductive conductivity temperature with LAN web server 1103490 DACBW006L34...

Page 18: ...e 1 CDE 2 mA 0 5 ppm 792930 Chlorine dioxide temperature corrected 2 CDR 1 mA 2 ppm 1033393 Chlorite 1 2 CLT 1 mA 0 5 ppm 1021596 Conductivity conductive 1 LFTK 1 DE 1002822 Conductivity inductive 2 ICT 5 1095248 Ozone 1 2 OZE 3 mA 2 ppm 792957 Fluoride temperature corrected 1 2 FLEP 010 SE FLEP 0100 SE 1028279 Reference electrode REFP SE 1018458 Pt 100 SE 305063 Transmitter 4 20 mA FPV1 1028280 H...

Page 19: ...corrected 4 5 7 FLEP 010 SE FLEP 0100 SE 1028279 Transmitter 4 20 mA FP 100 V1 1031331 Reference electrode REFP SE 1018458 Conductivity inductive 4 5 6 7 ICT 1 1023244 Total chlorine 4 5 BCR 1 mA 2 ppm 1040115 Free chlorine 4 5 CBR 1 mA 2 ppm 1038015 Free chlorine H CLO 2 mA 2 ppm 1033878 Hydrogen peroxide 4 5 H2O2 sensor PEROX H2 10 P 792976 PEROX transducer V2 1047979 Pt 100 SE temperature senso...

Page 20: ...including the hoses using clean pure water Store and transport the system in its original packaging Also protect the packaged systems against damp exposure to chemicals and mechanical effects Please also observe the operating instructions for fittings and other units such as sensors fil ters metering pumps Storage temperature 5 55 C Air humidity 90 relative humidity non condensing Humidity None Av...

Page 21: ...ntrol for inserting the sensors A filter can optionally be fitted on the sample water input Various stopcocks enable the flow to be stopped or adjusted and the system bled The stopcocks are labelled on the plate The bypass fitting contains a potential equalisation pin stainless steel pin for reference potential equalisation of the liquid enabling measurements with potential equalisation Electrical...

Page 22: ...ng on the design of the measuring plate 6 Stopcock flow adjustment device 7 Stopcock 8 Filter 9 Potential equalisation pin The DULCOTROL measuring and control station with a modular bypass fitting flow sensor DLG III or DLG IV is optimised for turbid waste water and industrial process water and consists of 1 or 2 controllers 1 4 sensors and the bypass fitting DLG III 1 3 sensors or DLG IV 4 sensor...

Page 23: ...ntial equalisation Electrically wire the potential equalisation pin to the controller if necessary The bypass fitting has a sampling tap for extracting a sample of water or for draining the bypass fitting The power supply to all electrically operated components is pro vided via a terminal box with manually operated switches Overview of the measuring point 23 ...

Page 24: ...adhered to 1 2 3 4 5 6 7 8 9 10 A2106 Fig 3 Installation diagram Components 1 Stopcock supplied on site 2 Process line 3 Heat exchanger supplied on site 4 Temperature control with shut off valve Not included in the scope of delivery but necessary on site at media temperatures of 45 C 5 Dirt filter optional for pressure reducer to be pro vided on site 6 Pressure reducer only operate with dirt filte...

Page 25: ...nsure that the failure of the meas uring plate or of individual components of the measuring plate do not have a damaging effect on the entire process and or the overall system These measures can include for example Redundant design of the measuring and con trol station Connection of an appropriate alarm device to the measuring plate and or the controller The alarm relay on the controller could be ...

Page 26: ...ng the feed chemicals Should the float of the flow module become stuck due to dirt the DULCOTROL measuring control station can over meter A filter may be required depending on the type and quality of the sample water Should the circulating pump not pump the DULCOTROL measuring control station can over meter Lock the controller via the potential free con tact of the circulating pump In the event of...

Page 27: ...e observed Fig 4 Drilling template The selection of the measuring plate depends on the bypass fitting used and the number of controllers used The following applies in principle n with 1 controller Size 1 n with 2 controllers Size 2 Labelling 1 controller 2 controllers A 745 mm 800 mm B 595 mm 800 mm C 705 mm 760 mm D 555 mm 760 mm Secure the DULCOTROL measuring control station as close as possible...

Page 28: ...Hexagonal nut 6 1 2 Accessories Fit any accessories supplied such as heat exchanger sample water pump pressure reducer or filter in accordance with their operating instructions upstream of the DULCOTROL measuring control station in the direction of flow The installation sequence is binding and to be adhered to Supplied with accessories Assembling the measuring point 28 ...

Page 29: ...indings The system operator is responsible for ensuring that these safety data sheets are available and that they are kept up to date as well as for producing an associated hazard assessment for the worksta tions affected CAUTION Observe the maximum permissible operating parameters for the entire installation e g pres sure temperature flow In this respect consider the lowest maximum permissible op...

Page 30: ...rwise extend Requirement The sensor is filled with electrolyte and the dia phragm cap is screwed on tightly Accessories Mounting kit part number 815079 Refer to the operating instructions for the respec tive sensor 1 Remove the upper blanking plug from a 25 mm module 2 Push the O ring 4 first then the assembly washer 5 onto the sensor 3 from below 3 Push the holding bolt 1 from above onto the sens...

Page 31: ...ensor to an alarm device as per the table Terminal Contact 1 NC 2 Root C 3 N O Technical data for the reed switch potential free n Switching power max 3 W n Switching voltage max 42 V protective low voltage SELV n Switching current max 0 25 A 7 Bring approx 5 cm of the cable into the flow sensor and tighten the clamping screw on the M12 threaded connector 8 Push the top part of the sensor fully in...

Page 32: ...Switching Point Task The flow sensor should switch when the flow falls the flow sensor is connected as an N C Term 1 Term 2 NC C 1 Use the ball valve to adjust the flow to 50 l h 2 Hold the flow sensor in place and loosen the mounting clip a little 3 Press the float down to 40 l h using the flow sensor ð The connected alarm device should switch off 4 Hold the flow sensor in this position and tight...

Page 33: ...indings The system operator is responsible for ensuring that these safety data sheets are available and that they are kept up to date as well as for producing an associated hazard assessment for the worksta tions affected CAUTION Observe the maximum permissible operating parameters for the entire installation e g pres sure temperature flow In this respect consider the lowest maximum permissible op...

Page 34: ...by the sensor manufacturer Never use a tool to install sensors with a glass shaft With sensors with a glass shaft this can cause tension in the glass shaft which could irrep arably damage the sensor 2 Manually screw the sensor back into the in line probe housing until leak tight Sensors with 25 mm You can only fit sensors with 25 mm e g chlorine sensor type CLE 3 with the corre sponding mounting k...

Page 35: ...to the O ring 4 4 Insert the sensor into the in line probe housing 5 Screw the sensor with the threaded sleeve 1 to the in line probe housing until liquid tight 8 2 Hydraulic Installation Free flow Make sure that there is no overpressure 1 bar and also no negative pressure at the outlet of the DLG Overpressure damages the DLG Negative pressure damages the sensors fitted 1 Use the hose connection s...

Page 36: ... sensor and tighten the clamping screw on the M12 threaded connector 8 Push the top part of the sensor fully into the housing and tighten it carefully in a clockwise direction until it can go no further ensuring that the nibs of the bayonet fixing do not break off 1 Turn the top part of the sensor a quarter turn counter clock wise and remove it 2 Loosen the clamping screw on the M12 threaded conne...

Page 37: ... a visual display and does not replace the electrical flow control with measuring and control functions You can adjust the inlet side of the flow of the DLG III using the regulating tap The working range is reached when the white ball is visible in the ball cage Electrical installation of the ORP and pH sensor Installing sensors in the bypass fitting DLG III IV 37 ...

Page 38: ...uring plate is installed to take appropriate measures to ensure that the failure of the meas uring plate or of individual components of the measuring plate do not have a damaging effect on the entire process and or the overall system These measures can include for example Redundant design of the measuring and con trol station Connection of an appropriate alarm device to the measuring plate and or ...

Page 39: ...r and or terminal box If the housing of the controller and or terminal box is ruptured or obviously damaged immedi ately switch off the system and have it repaired Only carry out set up maintenance repair and service work when the system is shut down and the electrical power disconnected Calibration and maintenance work on the sen sors represents an exception to this This can also be done when the...

Page 40: ...f the measuring and control station The cable ends of the connecting lines of the sensors are labelled according to the measured vari able Please also observe the operating instructions for the controllers and fittings and any other units such as sensors sample water pumps The cable ends of the connecting lines of the sensors are labelled according to the measured variable The cable ends are label...

Page 41: ...l Temperature Temperature PT PT Fluoride Fluoride FLE F 1 Install a mains cable on the terminal box 2 Wire up all inputs and outputs not yet connected as per the wiring diagrams Electrically and hydraulically assembling and installing the measuring points 41 ...

Page 42: ...odule C Module A Main board mA signal Coaxial Optional Coaxial A residual current circuit breaker 30 mA or another suitable measure is recommended Main switch with housing Fig 10 Wiring diagram measuring plate Electrically and hydraulically assembling and installing the measuring points 42 ...

Page 43: ...other suitable measure is recommended Main switch with housing Sample water error Module A Main board Magnetic stirrer supplied loose Coaxial 88_02 401_00_37 4A A2913 Fig 11 Wiring diagram for measuring plate complete fluoride Electrically and hydraulically assembling and installing the measuring points 43 ...

Page 44: ...uitable measure is recommended Main switch with housing Sample water error Module C Module A Main board Conductive conductivity Optional Temperature Coaxial 88_02 401_00_37 4A A2912 Fig 12 Wiring diagram for measuring plate Conductive conductivity Electrically and hydraulically assembling and installing the measuring points 44 ...

Page 45: ...rent circuit breaker 30 mA or another suitable measure is recommended Main switch with housing Sample water error mA signal Coaxial Module C Module A Main board Temperature Fig 13 Wiring diagram for measuring plate Inductive conductivity Electrically and hydraulically assembling and installing the measuring points 45 ...

Page 46: ...the stop over the nozzle 3 4 Tighten the union nut 5 5 Pull on the hose 6 and tighten up the union nut 5 1 Connector 2 Seal 3 Nozzle 4 Clamp ring 5 Union nut 6 Hose line NOTICE Decoupling the measuring plate from oscillations vibrations etc Put in place appropriate measures to decouple the measuring plate and on site pipework from oscilla tions vibrations load bending stress etc which can be trans...

Page 47: ...ovided for the addi tional operational components outside of the plate when hydrauli cally connecting them After successful installation a hydraulic test run of the DULCOTROL measuring control station is essential n Check the sampling tap Make sure that the sampling tap is closed otherwise sample water will escape n Check all threaded connectors prior to initial commissioning n Open the stopcock b...

Page 48: ... operator is responsible for ensuring that these safety data sheets are available and that they are kept up to date as well as for producing an associated hazard assessment for the worksta tions affected CAUTION The sampling tap must be closed otherwise sample water can escape The sample water should be free from air bub bles to ensure reliable measurement and con trol Should the sample water carr...

Page 49: ...structions supplied for the respective controller fitted 7 The operating instructions supplied for the respective sensor fitted provide detailed information on commissioning the sen sors 10 2 Sampling from the Bypass Fitting Bleeding of the DLG Remove sufficient sample water before taking a sample to fully bleed the measuring point with measuring and control stations fitted with DLG bypass fitting...

Page 50: ...ted Refer to the operating instructions for the photometer DT2C Calibration instructions Regularly check and calibrate the sensor Please note the applicable national guidelines The sensor needs to have run in prior to initial cali bration Observe the controller operating instructions Perform 2 point calibration during initial commis sioning 2 point calibration needs to be carried out less reg ular...

Page 51: ...ill with the standard solution Make sure that the stirrer rod is in the cup 6 Fit the filled cup 7 Fit the wall bracket and magnetic stirrer 8 Switch on the magnetic stirrer 9 Perform calibration as described in the operating instructions for the controller 2 point calibration Fill the cup with the second standard solu tion if required Perform calibration as described in the oper ating instruction...

Page 52: ... will find the operating instructions for the ProMinent compo nents on the manufacturer s homepage 11 1 Operating concept 11 1 1 Display and keys A1035 1 Fig 17 Operating cross 1 Active keys are displayed in black in the display inactive keys in grey The following path is shown as an example Continuous display or Calibrate or Slope Continuous display Calibrate Slope A1036 Fig 18 A display change i...

Page 53: ...ent of an error with the status ERROR the backlight of the display changes from white to red This makes it easier for the operator to react to an error A2438 Fig 19 Example of a continuous display when used with one measuring channel e g pH A2439 7 55 7 20 0 50 0 30 25 15 2 1 Fig 20 Example of a continuous display when used with two measuring channels e g pH chlorine If you are using 3 measuring c...

Page 54: ...ing 3 measuring channels you can use or to dis play the overall view of the measuring channels as the fourth view see A2441 7 55 0 30 635 mV ORP Kanal 1 Kanal 2 Kanal 3 Fig 22 Example of a continuous display when used with 3 meas uring channels e g pH chlorine ORP and the display of all 3 measuring channels User interface of the controllers 54 ...

Page 55: ...he desired param eter 3 You can adjust the desired value in the setting menu using the four arrow keys and then save it using ð Range error If you enter a value that is outside the possible setting range the message Range error appears after has been pressed Pressing or returns you to the value to be set The controller returns to the menu once has been pressed Cancelling the setting process Pressi...

Page 56: ...ontroller s setting menus Enables direct access to the controller s calibration menu from the continuous display Start Stop of the controller s control and metering function from any display To increase a displayed number value and to jump upwards in the operating menu Confirmation in the setting menu Moves the cursor to the right Confirmation in the continuous display Displays further information...

Page 57: ...cess the controller indicates all errors and warn ings The pending alarm messages can be selected and if required acknowledged confirmed If you acknowledge an error the alarm relay activates and the backlight switches back to white light In the bottom part of the display the error or warning mes sage that has occurred remains displayed such as Error 01 until the cause has been cleared In the event...

Page 58: ...l 11 1 6 Measured variables and measuring inputs Measured variable Measuring input Modul type pH mV Temperature mV ORP mV mV VA VV mV mA measuring input or mV mV measuring input pH mA ORP mA mA general Bromine Chlorine Chlorine dioxide Chlorite Fluoride Oxygen Ozone Peracetic acid Hydrogen peroxide Conductivity mA Temperature mA mA VA AA mV mA measuring input or mA mA measuring input Conductivity ...

Page 59: ...cursor one place to the right 5 OK key To apply confirm or save a displayed value or status or To confirm an alarm 6 DOWN key To decrease a displayed numerical value and move down in the operating menu 7 MENU key To access the controller s operating menu 8 STOP START key Starts and stops the control and metering function 9 ESC key Moves one level back in the operating menu without storing or chang...

Page 60: ...of the value to be entered 2 Enter the values using the and keys 3 The value entered is transferred to the memory 4 Cancelling the input of values without saving the entered value The original value is retained 11 2 3 Adjusting display contrast If the DULCOMETER Compact Controller is set to continuous display you can set the contrast of the LCD display By pressing the key you can adjust the LCD di...

Page 61: ...te all measured variables which is why the second line of the continuous display therefore displays infor mation about temperature compensation and the reference tem perature The setpoint is displayed in the Information menu Use the key to switch between the controller s measured varia bles ConI RES TDS and SAL in the continuous display Depending on the measured variable set the settings of variab...

Page 62: ...isplay currently shown to the selection menu for this information display Use to move directly back to the information display 11 2 6 Password Access to the setting menu can be restricted by a password The controller is delivered with the password 5000 The controller is set up with the pre set password 5000 so that access is possible to all menus A1863 MENU MENU DEVICE OUTPUT INPUT DEVICE PASSWORD...

Page 63: ...suring and metering is only pos sible if the sensor is working perfectly It is imperative that you adhere to the run in periods of the sensor Calculate the run in period when planning com missioning It may take a whole working day to run in the sensor Refer to the sensor s operating instructions After mechanical and electrical installation the controller must be integrated into the measuring point...

Page 64: ...splay to match the ambient conditions at your installation location 12 1 3 Resetting the operating language Resetting the operating language In the event that a foreign and hence incompre hensible operating language has been set the controller can be reset to the basic setting This is implemented by the simultaneous pressing of the and keys If you no longer know whereabouts you are in the operator...

Page 65: ...alibration there is an option to dry the conductivity sensor A dry conductivity sensor can be successfully recalibrated to the sensor parameters If Sensor not dry continues to be displayed despite the conduc tivity sensor having been dried then you will have to wait some time until the controller has detected the sensor as dry Once you have selected the sensor type the prompt automatically appears...

Page 66: ...red variable set the settings of variables are changed or the variables are hidden completely in the INPUT Ø TCOMP menu and in the LIMIT menu Symbol displayed in the controller s display ConI Units of measurement μS cm mS cm S cm The measuring range is automatically detected and switched by the controller Physical variable specific electrical conductivity K Only this measured variable and the corr...

Page 67: ... 1 000 Default 0 640 Temperature compensation is always linear on the TDS display with a reference temperature of 25 C Symbol displayed in the controller s display SAL units g kg Physical variable Mass of salts in one kg of water given in PSU practical salinity units The salinity is derived from the conductivity measured with a specified non linear temperature compensation and a reference conducti...

Page 68: ...Ca is factory configured to the application based measuring range You have to adjust the outputs of the Compact controller DCCa in line with the requirements of your application refer ring to the operating instructions for the controller Presetting inductive conductivity 0 1000 mS cm conduc tive conductivity 0 20 mS cm 14 2 Configuring the diaLog controller DACb Only when measuring conductivity Wh...

Page 69: ...e factory configuration You have to adjust the outputs of the diaLog controller DACb in line with the requirements of your application referring to the oper ating instructions for the controller You will find the operating instructions for the controller on the manufacturer s homepage Configuration of the controllers 69 ...

Page 70: ...vice and controller must be calibrated with sensors and or with output signals from meas uring devices that do not require calibration or where calibration is performed in the sensor meas uring device The relevant information for this is contained in the respective operating instructions for the sensor or measuring device Cancelling the calibration process with ESC ESC can be used to cancel an ong...

Page 71: ...d reproducibility The calibration interval can vary between daily and every few months Tab 7 Valid calibration values Evaluation Zero point Slope Good 30 mV 30 mV 55 mV pH 62 mV pH Acceptable 60 mV 30 mV 40 mV pH 55 mV pH 30 mV 60 mV 62 mV pH 65 mV pH If you measure the pH with potential equalisation set the Potential equalisation procedure as a parameter when selecting the measured variable as a ...

Page 72: ...sor with 2 point cali bration The pH sensor remains in the sample medium and you should calibrate a sample of the medium to be measured against an external comparison measurement Perform the comparison measurement using an electrochemical method Deviations of up to 0 5 pH units can occur using the phenol red method photometer Calibration solely using a pH 7 buffer This only calibrates the zero poi...

Page 73: ...what extent the sensor signal fluctuates during calibration At the start of calibra tion the waiting time for stabilisation of the measured value is 30 seconds during this waiting time Please wait flashes in the dis play You cannot continue with calibration during this waiting time If the pH sensor is cold e g 10 C then the pH sensor responds slowly and you have to wait a few minutes until the sen...

Page 74: ...the key has been pressed 15 1 1 1 Selecting the Calibration Process for pH To calibrate the controller there are three available calibration pro cesses n 2 point n Sample 1 point n Data input 1 Continuous display ð The Calibration menu is displayed you may need to select Channel 1 or Channel 2 depending on the measuring channel on which the pH measurement is per formed Selecting the calibration pr...

Page 75: ...ss 4 Use the arrow keys to select the calibration process and press 5 Continue with ð You can now start your chosen calibration process 15 1 1 2 2 Point Calibration of the pH Sensor CAL Correct sensor operation Correct measuring and metering is only pos sible if the sensor is working perfectly Refer to the sensor s operating instructions 2 point calibration is strongly recommended and is preferabl...

Page 76: ...olution at temper atures other than 25 C are printed in a table on the label of the buffer bottle Select the available buffer CAL pH Buffer manufacturer Calibration process A1512 Manual Buffer detection 2 point Manual Buffer value 1 Buffer value 2 Buffer temperature ProMinent pH 7 pH 4 Buffer temperature 25 0 C Fig 36 Example Display in CAL Setup Used buffer Dispose of the used buffer solution For...

Page 77: ... Do not move the sensor cable during calibra tion as this can lead to signal variations ð Calibration is running Please wait flashes Sensor voltage Sensor calibration in buffer 1 A1017 Buffer temperature Stability acceptable good Continue with CAL Fig 38 Display of the sensor stability achieved 5 The range acceptable good very good is displayed ð The black part of the horizontal bar indicates the ...

Page 78: ...variations ð Calibration is running Please wait flashes Sensor voltage Sensor calibration in buffer 2 A1018 Buffer temperature Stability acceptable good Continue with CAL Fig 39 Display of the sensor stability achieved 12 The range acceptable good very good is displayed ð The black part of the horizontal bar indicates the deter mined range 13 As soon as the black bar appears the display changes fr...

Page 79: ...fore it can be reused for calibration Carry over the result of the calibration into the controller memory by pressing ð The controller shows the continuous display again and operates with the results of the calibration 15 1 1 3 pH sensor calibration CAL with an external sample 1 point Measuring and control behaviour of the controller during calibration During calibration the actuating outputs are ...

Page 80: ...constant uniform mV signal this cannot be detected using the calibra tion method with an external sample With the cali bration method with two buffers e g pH 7 and pH 4 this becomes apparent if the pH sensor does not detect any changes in the pH value The calibration method with an external sample should only be used with installations where there is poor access to the pH sensor and the identical ...

Page 81: ...ng the Sample method 3 Press 4 Use the arrow keys to enter the pH value you have deter mined in the controller 5 Press 6 Accept the pH value by pressing ð All the values of the calibration result are shown in the display Incorrect calibration An error message appears if the result of the cali bration lies outside the specified tolerance limits In this case the current calibration is not applied Ch...

Page 82: ...Measuring and control behaviour of the controller during calibration During calibration the actuating outputs are deacti vated Exception a basic load or a manual control variable has been set This remains active The measured value output standard signal output mA is frozen corresponding to its settings in the mA output menu When calibration testing has been completed suc cessfully all of the error...

Page 83: ...and press ð The Enter window appears 3 Use the arrow keys to enter the values of your sensor and press 4 Continue with Incorrect calibration An error message appears if the result of the cali bration lies outside the specified tolerance limits In this case the current calibration is not carried over Check the prerequisites for calibration and elimi nate the error Then repeat calibration 5 Carry ov...

Page 84: ...he calibration process appears 4 Using the arrow keys select the required menu item Calibration process and press ð The input window appears 5 Use the arrow keys to select the calibration process and press 6 Continue with ð You can now start your chosen calibration process 15 1 2 2 1 point calibration of ORP sensor CAL Correct sensor operation Correct measuring and metering is only pos sible if th...

Page 85: ...signal output mA is frozen corresponding to its settings in the mA output menu When calibration testing has been completed suc cessfully all of the error checks relating to the measured value are restarted The controller saves all the determined data for zero point and slope upon a successful calibration Buffer used Dispose of the used buffer solution For more infor mation refer to the buffer solu...

Page 86: ... is acceptable good continue with CAL 0 1 mV very good Fig 48 Display of the sensor stability achieved 3 The acceptable good very good range is displayed ð The black part of the horizontal bar indicates the range detected 4 Continue with CAL ORP Offset Buffer value A1030 Accept with CAL 165 mV 0 0 mV Fig 49 Adjusting the buffer value 5 Press and use the four arrow keys to adjust the mV value of th...

Page 87: ... mV can be set and thus compensated If the ORP sensor deviates by more than 40 mV from the reference value then it must be checked in accordance with the requirements of the sensor operating instruc tions Measuring and control behaviour of the controller during calibration During calibration the actuating outputs are deacti vated Exception a basic load or a manual control variable has been set Thi...

Page 88: ...he Offset 2 Press and use the four arrow keys to adjust the mV value of the buffer you are using 3 Press 4 Transfer the result of the calibration into the controller memory by pressing ð The controller operates with the calibration results 15 1 3 Calibrating the Fluoride Sensor 15 1 3 1 Selection of the calibration process for fluoride To calibrate the controller there are two available calibratio...

Page 89: ...he sensor must be removed and refitted in the in line probe housing To do this observe the operating instructions of your in line probe housing Material required for calibration of fluoride sensors n Two test containers with calibrating solution Measuring and control behaviour of the controller during calibration During calibration the actuating outputs are deacti vated Exception a basic load or a...

Page 90: ...tinuous display 2 Using the arrow keys select Two point calibration 3 Then press CAL F Immerse sensor in buffer 1 Two point calibration A1038 Sensor value 2 50 ppm Sensor voltage 161 4 mV Start with CAL Fig 53 Fluoride sensor calibration CAL 4 Immerse the sensor in test container 1 with calibration solu tion When doing so gently move the sensor 5 Then press ð Calib in progress CAL F Two point cali...

Page 91: ...ibration lie out side the specified tolerance limits an error message appears In this case the current calibration will not be applied Check the prerequisites for the calibra tion and clear the error Then repeat the calibration 15 1 3 3 1 point fluoride sensor calibration CAL Correct sensor operation Correct measuring and metering is only pos sible if the sensor is working perfectly Observe the se...

Page 92: ...ro point and slope upon a successful calibration Used calibration solution Dispose of the used calibration solution For more information see calibration solution safety data sheet One test container with calibration solution are required for calibra tion 1 Press the key in the continuous display 2 Using the arrow keys select Single point calibration 3 Then press CAL F Immerse sensor in buffer Sing...

Page 93: ... case the current calibration will not be applied Check the prerequisites for the calibra tion and clear the error Then repeat the calibration 15 1 4 Calibration of Amperometric Sensors Calibration of Amperometric Sensors The calibration procedure for amperometric sen sors is the same for all amperometric measured variables The procedure for calibrating amperometric meas ured variables is describe...

Page 94: ...the sample water Replacing the diaphragm only delivers short term improvement It is important to prevent the occurrence of surfactants in the water If surfactants cannot be avoided then use an appropriate sensor for example sensor type CBR 15 1 4 1 Selecting the calibration process for amperometric measured variables There are two calibration processes available for calibrating the controller n Ca...

Page 95: ... testing has been completed suc cessfully all of the error checks relating to the measured value are restarted The controller saves all the determined data for zero point and slope upon a successful calibration The measured value frozen at the start of calibration is suggested as a reference value The reference value can be set using the arrow keys Calibration is only possible if the reference val...

Page 96: ...ncentration Latest sensor measured values 2 Take sample and continue with CAL Sensor current 1 Wait until meas values stable Fig 59 Reference value calibration shows the actual sensor values 4 Continue with CAL Cl A1045 Measured value upon sampling Change with OK Determine reference value continue with CAL Fig 60 Reference value calibration the sensor value is frozen here now take the sample and m...

Page 97: ...he error Then repeat calibra tion Permitted calibration range The permitted calibration range is 20 300 of the sensor s rated value Example of a shallow slope Blocking of the sensor membrane leads to a low slope low slope low sensor sensitivity Example of a steep slope Surfactants make the sensor membrane more permeable leading to a steeper slope steep slope high sensor sensi tivity 15 1 4 3 Calib...

Page 98: ... manual control variable has been set This remains active The measured value output standard signal output mA is frozen corresponding to its settings in the mA output menu When calibration testing has been completed suc cessfully all of the error checks relating to the measured value are restarted The controller saves all the determined data for zero point and slope upon a successful calibration N...

Page 99: ...rates with the results of the calibration Incorrect calibration Should the result of the calibration lie out side the specified tolerance limits an error message appears In this case the current calibration will not be applied Check the prerequisites for the calibra tion and clear the error Then repeat the calibration 15 1 5 Calibrating the oxygen sensor 15 1 5 1 Specify the calibration interval T...

Page 100: ...e measured value is not 102 2 SAT If the value is within the target range then you can extend the calibration interval Repeat this process monthly and determine from the results the optimum cali bration interval for your application Sensor manufacturer s calibration specifi cations When determining the calibration interval consider the sensor operating instruc tions as they may specify additional ...

Page 101: ...nductivity Higher than NNl 2 continue with CAL 1 Enter correcting value 300 m 0 0 mS cm 0 g l Fig 65 Correction variable values 4 Enter the current values for the correction variables Use OK to select the correction variable Use the arrow keys to enter the values 5 Use CAL to continue ð The display appears as follows CAL O2 A2853 Sensor current Concentration Latest sensor measured values 12 61 mA ...

Page 102: ...alibration is unsuccessful CAL O2 A2855 Before calibration Slope Calibration not possible Cancel with ESC After calibration A Zero point End with CAL i Fig 68 Unsuccessful calibration 11 n Use CAL to end n Press ESC to cancel 12 Check the sensor and installation once again and repeat the calibration procedure 15 1 5 2 2 Calibrating the slope using a reference measurement in water 1 Press the CAL k...

Page 103: ...K to select the calibration process Calibrate the slope using a reference measurement in water ð The display appears as follows CAL O2 A2857 Sensor current Concentration Latest sensor measured values 8 80 mA 7 67 ppm 2 Wait for the stability of the measured value 1 Sensor immersed in water Fig 70 Latest sensor measured values 4 Install the sensor in water 5 Wait for the stability of the measured v...

Page 104: ... 00 24 00 ppm 07 51 ppm Fig 72 Reference value 7 Continue with CAL 8 The display appears as follows if calibration is successful CAL O2 A2854 Before calibration Slope Calibration successful Cancel with ESC After calibration A Zero point End with CAL Fig 73 Successful calibration 9 n Use CAL to confirm n Press ESC to cancel 10 The display appears as follows if calibration is unsuccessful Calibratin...

Page 105: ...ration of the zero point is only needed for precise measure ments at the lower end of the measuring range 5 of the meas uring range CAL O2 A2860 Zero point Slope Last calibration 22 09 2019 14 22 33 4 00 mA 100 0 80 mA ppm Calibration of zero point Slope calibration by reference measurement in water Calibration of the slope in air Fig 75 Introduction Calibration of the zero point 1 Use OK to selec...

Page 106: ...until the signal is stable 3 Use CAL to accept 4 The display appears as follows if calibration is successful CAL O2 A2854 Before calibration Slope Calibration successful Cancel with ESC After calibration A Zero point End with CAL Fig 77 Successful calibration 5 n Use CAL to confirm n Press ESC to cancel 6 The display appears as follows if calibration is unsuccessful Calibrating the controller diaL...

Page 107: ...Exception a basic load or a manual control variable has been set This remains active The measured value output standard signal output mA is frozen corresponding to its settings in the mA output menu When calibration testing has been completed suc cessfully all of the error checks relating to the measured value are restarted The controller saves all the determined data for zero point and slope upon...

Page 108: ...output menu When calibration testing has been completed suc cessfully all of the error checks relating to the measured value are restarted The controller saves all the determined data for zero point and slope upon a successful calibration 15 1 8 1 Calibrating conductive conductivity sensor parameter adjustment NOTICE The sensor must be dry Do not allow the conductivity sensor to come into contact ...

Page 109: ...solution the conductivity of which is known Material Order number Conductivity calibration solution 1413 μS cm 250 ml 1027655 Conductivity calibration solution 1413 μS cm 1000 ml 1027656 Conductivity calibration solution 12 88 mS cm 250 ml 1027657 Conductivity calibration solution 12 88 mS cm 1000 ml 1027658 All parameters for the conductivity sensor are correctly entered in the Measurement menu i...

Page 110: ...o select the channel which should be calibrated 3 Then press ð You will see the display with the menu for selection of Cell constant or Temp coefficient 4 Use the arrow keys to select Temp coefficient 5 Continue with ð You will see the current data for the Temp coefficient 6 Continue with ð The sensor signal stability will be displayed the tem perature values relate to the temperature difference o...

Page 111: ...error checks relating to the measured value are restarted The controller saves all the determined data for zero point and slope upon a successful calibration You may need a manual measuring instrument for the temperature measured variable This manual instrument should measure and display sufficiently accurately to guarantee successful calibration 1 Press in the continuous display 2 Then press 3 Fo...

Page 112: ...ion is again incorrect refer to the information provided in the sensor operating instructions During calibration the controller sets the control outputs to 0 Exception If a basic load or a manual control variable has been set This remains active The mA standard signal output is frozen When calibration has been completed successfully all the error checks relating to the measured value are restarted...

Page 113: ... 3 Now dip the sensor into the calibration solution and gently move the sensor 4 Wait until the conductivity and temperature measured value has stabilised Press ð The conductivity value measured is displayed 5 Now use the or keys to set the conductivity value measured in accordance with the conductivity value speci fied on the calibration solution ð If calibration has been completed successfully t...

Page 114: ...tant and the error checks relating to the measured value are restarted The numerical setting range of the cell con stant is not limited 6 Press twice to return to the continuous display 1 Press and use the or key to move the cursor to INPUT Confirm with 2 Use the or key to move the cursor to CELLC Confirm with 3 Now use the or keys to adjust the precisely known or previously determined cell consta...

Page 115: ...ibration A1866 CAL CELLCONST CAL TEMPCOEFF CAL_T1 22 0 C CHANGE TEMP TCOEFF CAL TEMPCOEFF T2 32 0 C or CAL_T2 43 0 C CAL TEMPCOEFF TCOEFF 0 00 C CAL TEMPCOEFF CAL OLD CAL CONTINUE T2 12 0 C CAL CONTINUE WAIT CAL TEMPCOEFF T2 32 0 C or T2 12 0 C I II STABLE CAL_T2 43 0 C CAL TEMPCOEFF CAL CONTINUE ACCEPT III Fig 80 Calibration of the temperature coefficient I If the temperature change is greater th...

Page 116: ...mum Minimum temperature has been reached ACCEPT is displayed ð You can now terminate calibration To do so press CAL This process may take 10 20 minutes depending on the type of sensor 7 Use CAL to accept the temperature coefficient or ESC to discard it Display Meaning Status OK In order ΔTcal 20 C WRN Warning ΔTcal 10 C 20 C ERR Error ΔTcal 10 C ΔTcal Temperature difference of the calibration liqu...

Page 117: ...plication in which it is fitted 2 Rinse the sensor with clean water and dry it 3 Use the or key to move the cursor to ZERO and con firm with 4 Hold the sensor in the air Press 5 Wait for the process WAIT ð STABLE 10 sec The value displayed needs to be displayed stably for longer than 10 seconds Fluctuation 0 5 of the displayed value 6 Press 7 Press or Press if you wish to use the ZERO default valu...

Page 118: ...SET A1945 ERR Fig 82 Display of incorrect calibration 8 In the event of incorrect calibration press to retain the old calibration value and press to use the factory settings Calibrating the compact controller for inductive conductivity 118 ...

Page 119: ...of a component Immediately switch off the system and arrange for its repair if the housing of the pump con troller terminal box or other component etc is broken ruptured or obviously damaged Only carry out set up maintenance repair and service work when the system is shut down and the electrical power disconnected Calibration and maintenance work on the sen sors represents an exception to this Thi...

Page 120: ...r s instructions in the appendix Sensor Maintenance Refer to the oper ating instructions for the sensor Refer to the operating instructions for the sensor Bypass fitting DLG Unscrew the cup and clean the sensors According to the internal specifica tion of the system operator 17 2 DGMa Replacing the Modules WARNING Danger from hazardous substances Possible consequence Fatal or very serious inju rie...

Page 121: ...e modules point in the same direction Reposition the modules if they do not screw easily into each other The connection will otherwise become loose and will no longer be able to be loosened without damage Position the new module on the module block 10 Turn the module clockwise until it hangs vertically down wards 11 Fit the complete new module block 12 Close the drain nozzle and the sampling tap 1...

Page 122: ...cient functionality Check and as necessary repair the electrical power supply See wiring diagram and controller operating instructions Defective or incorrectly calibrated sensors Refer to the operating instructions for the sensor and controller Check and as necessary repair the electrical power supply See wiring diagram Power failure sensors in run in phase therefore faulty measure ment Stop the c...

Page 123: ...dy No sampling possible Negative pressure in the system Fully open inlet shut off valve adjust flow at the outlet shut off valve Leakage Pressure too high Fit a pressure reducer Leakage Repair leak Troubleshooting 123 ...

Page 124: ...late from the mains power supply Thoroughly rinse the sample water line with a suitable medium see material safety data sheet Please also observe the operating instructions for the controllers and fittings and any other units such as sensors sample water pumps Also necessary after brief decommissioning up to 12 h Observe the sensor operating instructions 19 1 Temporary Decommissioning Less Than 4 ...

Page 125: ...urer will take back decontaminated used devices pro viding they are covered by adequate postage Decontaminate the device before returning it for repair To do so remove all traces of hazardous substances Refer to the Material Safety Data Sheet for your feed chemical A current Declaration of Decontamination is available to download on the ProMinent website Please also observe the information on the ...

Page 126: ... Waste water with solid particle frac tion turbid Waste water with a low purity level with particles of dirt 1 mm floating bodies turbid and chemical pollution 7 Waste water with fluoride and pH 7 Waste water with a low purity level with small particles of dirt turbid appearance H Potable water rinsing water indus trial water process water clear waste water waste water with solids content for high...

Page 127: ...tion of the meas uring plate and lies between 8 13 kg Free flow No overpressure or negative pressure Make sure that there is no overpressure 1 bar and also no negative pressure at the outlet of the measuring plate Overpressure damages the bypass fitting Negative pressure damages the sensors fitted Use the stopcocks to adjust the pressure at the sample water inlet and outlet Route the pipework so t...

Page 128: ...the controller n the alarm relay e g horn Tab 12 Switching point of the flow control Sample water Designation Bypass fitting Nominal cross section mm Permissible flow l h Control switches off at l h 1 Potable water DGMa 4 20 60 20 2 and H Rinsing water DLG III 6 40 65 20 Industrial water Process water 4 and H Waste water clear DLG III 6 40 65 20 5 and H Waste water with solid par ticle fraction tu...

Page 129: ... 100 1 DACBW006L34000B1101000 1103488 100 1 DACBW006VA4000E1101000 1103489 100 1 DACBW006L34000E1101000 1103490 100 1 DACBW006VA4000G1101000 1103497 100 1 DACBW006L34000G1101000 1103498 101 1 DCCAP006L6001000 1044550 200 1 DGMA bypass fitting 1050374 201 1 Bypass fitting DLG III with backflushing 1050142 202 1 Bypass fitting DLG IV Dulcotrol 1050143 203 1 Filter 1050293 204 1 Fitting flow meter 10...

Page 130: ...m 792930 301 1 Chlorine sensor CLE 3 mA 0 5ppm 792927 301 1 Chlorine sensor CTE 1 mA 0 5ppm 740686 301 1 Chlorine sensor CLO 2 mA 2 ppm 1033878 302 1 Transmitter 4 20 mA FPV1 1028280 302 1 Transmitter 4 20 mA FP100 1031331 303 1 Conductivity sensor ICT5 1105778 304 1 Thermal switch 7760491 305 1 Oxygen sensor complete DO3 mA 50 ppm 1094609 500 1 Magnetic stirrer 790915 501 1 Magnetic stirring rod ...

Page 131: ...A2128 40124337 Fig 84 Measuring plate DWCa with filter and bypass fitting DGMa Measuring plate DWCa with filter and bypass fitting DGMa Spare parts and accessories 131 ...

Page 132: ...A2129 40124338 Fig 85 Measuring plate DWCa with filter and bypass fitting DLG Measuring plate DWCa with filter and bypass fitting DLG Spare parts and accessories 132 ...

Page 133: ...A2130 40124341 Fig 86 Measuring plate DWCa with filter bypass fitting DLG and stirrer Measuring plate DWCa with filter bypass fitting DLG and stirrer Spare parts and accessories 133 ...

Page 134: ...tivity 21 2 Accessories Tab 13 Photometer Component Order number Photometer DT1B 1039315 Photometer DT3B 1039317 Photometer DT4B 1039318 The scope of delivery of the photometer includes a transport case accessories cuvettes and reagents Measuring plate DWCa with filter DLG and sensor Spare parts and accessories 134 ...

Page 135: ...by us will invalidate this declaration Tab 14 Extract from the EU Declaration of Conformity Designation of the product DULCOTROL DWCa Product type DWCa _ _ _ _ _ _ _ _ _ _ _ 0 _ _ _ _ _ that is to say for installed systems Serial number see nameplate on the plate Relevant EU directives Low Voltage Directive 2014 35 EU EMC Directive 2014 30 EU Harmonised standards applied in particular EN 61010 1 2...

Page 136: ...p 63 D Data input 82 Decoupling 38 Defective control by incorrect measured values 40 Definition of sample water 126 Degree of protection IP 65 127 Designation of the product 135 Direction of flow 29 33 Drilling template 27 E Electrical data 126 Electrical installation of the amperometric sen sors 31 36 Electrical installation of the flow sensor 31 36 Electrical installation of the ORP and pH senso...

Page 137: ...do I adjust the display contrast 64 Question How do I calibrate the sensor s zero point 116 Question How does the controller operate 52 Question How does the key lock work 58 Question What ambient conditions need to be taken into consideration 20 Question What can be calibrated 112 Question What happens in the event of incor rect calibration 112 Question What information is made available in the c...

Page 138: ...interference 40 Standard signal outputs 95 98 Starting up the DLG 37 Storage 20 Strain relief 38 Sunlight 13 T Temperature data 127 Test container 1 with buffer solution 76 Test container 1 with fluoride calibration solution 89 91 Test container 2 with buffer solution 76 Test container 2 with fluoride calibration solution 89 Transport 20 U User qualification 15 UV sources 13 W Warning information ...

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Page 140: ...984397 1 en_GB 2019 ProMinent GmbH Im Schuhmachergewann 5 11 69123 Heidelberg Telephone 49 6221 842 0 Fax 49 6221 842 419 Email info prominent com Internet www prominent com ...

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Summary of Contents for DULCOTROL DWCa

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ProMinent DULCOTROL DWCa, Assembly And Operating Instructions Manual, Page: 24 / 140

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Summary of Contents for DULCOTROL DWCa

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