DULCOTROLAssembly and operating instructions DWCa

DULCOTROL® DWCaAssembly and operating instructions

A1999

DULCOTROL® ___ ___ ___ ___ ___ ___ ___ ___ ___ ___ ___ ___ ___ ___ ___ ___Please enter the identity code of your device here.These operating instructions will allow you to install and calibrate the measuring plate with your individual components. Allother required measures are described in the operating instructions for the individual components. These operating instruc‐tions are only valid if used in conjunction with the operating instructions for the individual components.

EN

Part no. 984397 BA DR 008 06/15 EN

Please carefully read these operating instructions before use. · Do not discard.The operator shall be liable for any damage caused by installation or operating errors.

The latest version of the operating instructions are available on our homepage.

In order to make it easier to read, this document uses the maleform in grammatical structures but with an implied neutral sense. Itis aimed equally at both men and women. We kindly ask femalereaders for their understanding in this simplification of the text.

Please read the supplementary information in its entirety.Information

This provides important information relating to the cor‐rect operation of the unit or is intended to make yourwork easier.

Safety InformationThe safety information includes detailed descriptions of the haz‐ardous situation, see Ä Chapter 2.1 ‘Explanation of the safetyinformation’ on page 9The following symbols are used to highlight instructions, links, lists,results and other elements in this document:

More symbols

Symbol Description

Action, step by step

⇨ Outcome of an action

Links to elements or sections of these instructions or other applicable documents

n List without set order

[Button] Display element (e.g. indicators)Operating element (e.g. button, switch)

‘Display /GUI’ Screen elements (e.g. buttons, assignment of function keys)

CODE Presentation of software elements and/or texts

General non-discriminatory approach

Supplementary information

Supplemental instructions

2

Table of contents1 Identity Code Ordering System for DULCOTROL® Meas‐

uring and Control Plates....................................................... 62 Safety and Responsibility...................................................... 9

2.1 Explanation of the safety information............................ 92.2 General Safety Information......................................... 102.3 Information in the Event of an Emergency.................. 142.4 Intended Use.............................................................. 142.5 Users' qualifications.................................................... 15

3 About This Product............................................................. 163.1 DULCOTROL® Measuring and Control Stations........ 16

4 Storage and Transport........................................................ 195 Overview of the Measuring Station..................................... 20

5.1 DULCOTROL® Measuring and Control Station withBypass Fitting DGMa.................................................. 20

5.2 DULCOTROL® Measuring and Control Station withBypass Fitting DLG III................................................. 21

5.3 DULCOTROL® Measuring and Control Station withPipework..................................................................... 23

5.4 Installation Diagram for DULCOTROL® Measuringand Control Station..................................................... 24

6 Assembly of the Measuring Point ...................................... 256.1 Assembly (Mechanical)............................................... 256.1.1 Measuring Point....................................................... 276.1.2 Accessories............................................................. 28

7 Installing Sensors in the Bypass Fitting DGMa................... 297.1 Fitting the DGMa with Sensors................................... 297.2 Electrical Installation of the Sensors........................... 307.3 Adjusting the Flow Sensor Switching Point................ 32

8 Installing Sensors in the Bypass Fitting DLG III/IV............. 338.1 Fitting the DLG with Sensors...................................... 348.2 Hydraulic Installation................................................... 368.3 Electrical Installation of the Sensors........................... 368.4 Starting Up the DLG................................................... 37

9 Installing Sensors in the Bypass Fitting with Pipework ...... 389.1 Fitting the Pipework with Sensors............................... 389.2 Electrical Installation of the Sensors........................... 409.3 Hydraulic Installation, Bypass Fitting with Pipework... 419.4 Starting Up the Bypass Fitting with Pipework............. 41

10 Electrically and Hydraulically Assembling and Installingthe Measuring Points.......................................................... 4210.1 Electrical Installation of the Measuring and Control

Station....................................................................... 4310.1.1 Wiring Diagram for DACa and Measuring Plate.... 4510.1.2 Wiring Diagram for DACa and Measuring Plate -

Fluoride.................................................................. 4810.1.3 Wiring Diagram for DACa, DCC and Measuring

Plate - Waste Water............................................... 5010.2 Hydraulic Test Run after Installation......................... 53

Table of contents

3

11 Starting-up Sensors............................................................ 5511.1 Preparation of Sensors............................................. 5511.2 Sampling from the Bypass Fitting............................. 5611.3 Calibrating the Sensors............................................ 5611.4 Calibrating the Fluoride Sensor................................ 5711.5 Removing and Fitting the Bypass Fitting Cup for

Calibration................................................................. 5812 Controllers' User Interface.................................................. 59

12.1 Operating Concept.................................................... 5912.1.1 Functions of the keys ............................................ 6212.1.2 Changes the set operating language..................... 6312.1.3 Acknowledge fault or warning message ............... 6312.1.4 Key Lock ............................................................... 6412.2 Operating Diagram for Measured Variable: Conduc‐

tive Conductivity........................................................ 6512.2.1 Overview of equipment/Operating elements.......... 6512.2.2 Entering values...................................................... 6612.2.3 Adjusting display contrast...................................... 6612.2.4 Continuous display................................................ 6712.2.5 Information display................................................. 6712.2.6 Password............................................................... 6812.3 Operating Diagram for Measured Variable: Inductive

Conductivity.............................................................. 6912.3.1 Overview of equipment/Operating elements.......... 6912.3.2 Entering values...................................................... 7012.3.3 Adjusting display contrast...................................... 7012.3.4 Continuous display................................................ 7112.3.5 Information display................................................. 7112.3.6 Password............................................................... 72

13 Commissioning the Controller diaLog DACa...................... 7313.1 Commissioning......................................................... 7313.1.1 Switch-on behaviour during commissioning.......... 7313.1.2 Adjusting the backlight and contrast of the con‐

troller display.......................................................... 7413.1.3 Resetting the operating language.......................... 7413.1.4 Defining metering and control processes.............. 74

14 Commissioning the Compact Controller for ConductiveConductivity........................................................................ 7614.1 Measured variables.................................................. 76

15 Commissioning the Compact Controller for Inductive Con‐ductivity............................................................................... 7815.1 Measured variables.................................................. 78

16 Configuration of the Controllers.......................................... 8016.1 Configuration of the Compact Controllers DCCa...... 8016.2 Configuration of the diaLog Controller DACa........... 80

17 Calibrating the Controller diaLog DACa.............................. 8217.1 Calibration................................................................. 8217.1.1 Calibrating the pH sensor...................................... 8317.1.2 Calibrating the ORP Sensor.................................. 9517.1.3 Calibrating the Fluoride Sensor............................. 9917.1.4 Calibrating Amperometric Sensors...................... 104

Table of contents

4

17.1.5 Calibrating Oxygen Sensors................................ 11017.1.6 Measured value [mA general] calibration............ 11817.1.7 Calibrating conductivity........................................ 11817.1.8 Calibrating temperature....................................... 120

18 Calibrating the Compact Controller for Conductive Con‐ductivity............................................................................. 12118.1 Calibrating [CAL] the conductivity sensor .............. 12118.1.1 Calibration of the cell constant............................. 12218.1.2 Calibration of the temperature coefficient............ 124

19 Calibrating the Compact Controller for Inductive Conduc‐tivity................................................................................... 12719.1 Calibrating [CAL] the conductivity sensor .............. 12719.1.1 Calibration of the cell constant............................. 12819.1.2 Calibration of the temperature coefficient............ 13019.1.3 Calibration of the zero point................................. 132

20 Maintenance..................................................................... 13520.1 DGMa: Replacing the Modules............................... 13620.2 Flushing the Bypass Fitting with Pipework............. 138

21 Troubleshooting................................................................ 14022 Decommissioning and Disposal........................................ 142

22.1 Temporary Decommissioning (Less Than 4Weeks).................................................................... 142

22.2 Temporary Decommissioning (Longer Than 4Weeks).................................................................... 142

22.3 Final Decommissioning........................................... 14323 Technical Data and Operating Parameters....................... 144

23.1 Flow and Operational Test of Flow Control............ 14524 Spare Parts and Accessories............................................ 147

24.1 Spare Parts............................................................. 14724.2 Accessories............................................................ 155

25 EC Declaration of Conformity .......................................... 15626 Index................................................................................. 157

Table of contents

5

1 Identity Code Ordering System for DULCOTROL® Measuringand Control Plates

Identity code ordering system for DULCOTROL® measuring and control plates

DWCa DULCOTROL measuring and control system

Application

P Potable water (1 or 2 for "water to be measured")

W Waste water (4, 5, 6 or 7 for "water to be measured")

Water to be measured

1 Potable water / product water, T< 45 °C

2 Rinsing water / industrial water / process water, T< 45 °C

Cooling water (planned for the future)

4 Clear waste water

5 Waste water with solid particle fraction, turbid

6 Waste water with solid particle fraction, containing sludge (sensors directly in the pipe, nofilter)

7 Waste water with fluoride and pH < 7

Channel 1, measured variable 1

C0 Free chlorine < pH 8

C1 Free chlorine > pH 8 and stable

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, measured variable 2 (optional)

00 none

C0 Free chlorine < pH 8

C1 Free chlorine pH value > 8.0 and stable

G0 Total chlorine (free and combined chlorine)

P0 pH

R0 ORP

D0 Chlorine dioxide

I0 Chlorite

Identity Code Ordering System for DULCOTROL® Measuring and Control Plates

6


L0 Conductivity

Z0 Ozone

F0 Fluoride

H0 Hydrogen peroxide

A0 Peracetic acid

X0 Dissolved oxygen

Measurement - Control

0 All measured variables can be measured

9 All measured variables bidirectionally controllable

Communication interface

0 none

4 PROFIBUS-DP

6 LAN interface

Data logger

0 none

1 Data logger with measured value display on SD card

Hardware extension

0 none

1 Protective RC circuit for output relay

Sensor equipment

0 With sensors

1 Without sensors

Design

0 Plate-mounted with ProMinent Logo

(M) Modified design

Sample water preparation

0 none

1 with filter (not with waste water = 6)

Approvals

01 CE (Standard)

Documentation language*

EN German

EN English

FR French

IT Italian

NL Dutch

ES Spanish


7


PL Polish

SV Swedish

HU Hungarian

PT Portuguese

CS Czech

* All EU languages + other languages are available.


8

2 Safety and Responsibility2.1 Explanation of the safety information

These operating instructions provide information on the technicaldata and functions of the product. These operating instructions pro‐vide detailed safety information and are provided as clear step-by-step instructions.The safety information and notes are categorised according to thefollowing scheme. A number of different symbols are used todenote different situations. The symbols shown here serve only asexamples.

DANGER!Nature and source of the dangerConsequence: Fatal or very serious injuries.Measure to be taken to avoid this dangerDanger!– Denotes an immediate threatening danger. If this is

disregarded, it will result in fatal or very seriousinjuries.

WARNING!Nature and source of the dangerPossible consequence: Fatal or very serious injuries.Measure to be taken to avoid this dangerWarning!– Denotes a possibly hazardous situation. If this is

disregarded, it could result in fatal or very seriousinjuries.

CAUTION!Nature and source of the dangerPossible consequence: Slight or minor injuries, mate‐rial damage.Measure to be taken to avoid this dangerCaution!– Denotes a possibly hazardous situation. If this is

disregarded, it could result in slight or minor inju‐ries. May also be used as a warning about materialdamage.

Introduction

Safety and Responsibility

9

NOTICE!Nature and source of the dangerDamage to the product or its surroundingsMeasure to be taken to avoid this dangerNote!– Denotes a possibly damaging situation. If this is

disregarded, the product or an object in its vicinitycould be damaged.

Type of informationHints on use and additional informationSource of the information, additional measuresInformation!– Denotes hints on use and other useful information.

It does not indicate a hazardous or damaging sit‐uation.

2.2 General Safety Information

WARNING!Failure of the control and impact on the processCause: If the controller or other parts of the measuringplate fail, then the process, in the bypass of which themeasuring plate is working, will no longer be measuredand regulated.Possible consequence: Fatal or very serious injuries.The process, in the bypass of which the measuringplate is working, will become out of control and couldcause harmful reactions.Measure: It is the responsibility of the operator and/ormanufacturer of the entire system in which the meas‐uring plate is installed to take appropriate measures toensure that the failure of the measuring plate or of indi‐vidual components of the measuring plate do not havea damaging effect on the entire process and/or theoverall system.These measures can include, for example:– Redundant design of the measuring and control

station.– Connection of an appropriate alarm device to the

measuring plate and/or the controller.– The alarm relay on the controller could be set to

[fail save] and be evaluated as an overall alarm forthe process.

– Installation of additional safety systems from activeor passive system components, with the purposeof making the technical systems safer for operatorsand users.


10

WARNING!Operation in areas with an explosive atmospherePossibility of an explosionDo not operate the systems in areas where there is arisk of explosion. The system is not intended for opera‐tion in areas at risk from explosion. The system itselfdoes not present a risk of explosion.

WARNING!Pumping flammable mediaPossible consequence: Fatal or very serious injuries.Pumping flammable media is not permitted. Observethe material safety data sheet for the medium.

WARNING!Live partsPossible consequence: Fatal or very serious injuries.Measures:– Disconnect the system from the power supply

before opening the housing of a component.– If the housing of the pump, controller, terminal box

or other components is broken, ruptured or obvi‐ously damaged, immediately switch off the systemand arrange for its repair.

– Only carry out set-up / maintenance / repair andservice work when the system is shut down andthe electrical power disconnected. Calibration andmaintenance work on the sensors represents anexception to this. This work can be carried outwhile the system is live. Please also observe theinformation in the operating instructions for thesensors and controllers.

– Check that the seals are sitting correctly afterclosing the housing of the pump, controller or ter‐minal box

We fundamentally recommend the use of appropriateresidual current circuit breakers (RCCB) or otherresidual current devices (RCD) providing they can beinstalled sensibly and professionally within the elec‐trical installation. Please adhere to all national stand‐ards and regulations.


11

WARNING!Danger from hazardous substances!Possible consequence: Fatal or very serious injuries.Please ensure when handling hazardous substancesthat you have read the latest safety data sheets pro‐vided by the manufacture of the hazardous substance.The actions required are described in the safety datasheet. Check the safety data sheet regularly andreplace, if necessary, as the hazard potential of a sub‐stance can be re-evaluated at any time based on newfindings.The system operator is responsible for ensuring thatthese safety data sheets are available and that theyare kept up to date, as well as for producing an associ‐ated hazard assessment for the workstations affected.

WARNING!Unexpected start-upPossible consequence: Fatal or very serious injuries.

– Unexpected start-up of the DULCOTROL® meas‐uring/control station after failure or malfunction ofthe control/power supply or as a deliberate actiondue to a control process.

– Danger due to unexpected actions of the systems.– Disconnect the DULCOTROL® measuring/control

station from the power supply in the event of mal‐function/failure of the control or power supply.

– When the system is switched on after an interrup‐tion to the power supply and/or after a long periodof operation without feed chemical, make allow‐ance for the run in periods of the sensor. Limit themaximum capacity of the metering pump so that nodangerous overdosing can occur during the run inperiod.

WARNING!Operating error / Unauthorised accessPossible consequence: Fatal or very serious injuries.– Measure: Ensure that there can be no unauthor‐

ised access to the unit.– Ensure that the unit is only operated by adequately

qualified and technically expert personnel.– Please also observe the operating instructions for

controllers and fittings and any other units, such assensors, sample water pumps ...

– The operator is responsible for ensuring that per‐sonnel are qualified.


12

WARNING!Lightning strike on outdoor installationsDanger due to overvoltage resulting from a lightingstrike on outdoor installations, which are connected tothe DULCOTROL® measuring/control station.Measures:

– Do not use the DULCOTROL® measuring/controlstation directly or indirectly outdoors.

– Ensure there is sufficient earthing potential wheninstalling electrical components.

WARNING!Effects of chemicals in the event of a leakPossible consequence: Fatal or very serious injuries.– Measure: Make sure that the system is installed

correctly and regularly check it for leak-tightness,wear and the brittleness of hoses and connectorsand lines caused by the effects of chemicals.

– Ensure that the unit is only operated by adequatelyqualified and technically expert personnel.

– Please also observe the operating instructions forcontrollers and fittings and any other units, such assensors, sample water pumps ...

– The operator is responsible for ensuring that per‐sonnel are qualified.

NOTICE!Hydraulic leaksBear in mind the material resistance of all wettedmaterials of all units (see for example the ProMinentResistance List in the product catalogue or atwww.prominent.com)Take appropriate measures to ensure that there is nodanger to personnel, products or equipment in theevent of hydraulic leaks. An appropriate measuremight include a sufficiently large floor drain.

Indoors or protective coveringProtect the DULCOTROL® measuring/control stationfrom direct sunlight and other UV sourcesThe unit is only intended for use indoors. When usingoutdoors, provide a protective housing to offer protec‐tion against the weather, lighting and the sun's rays(UV radiation) etc.


13

2.3 Information in the Event of an Emergencyn Electrical emergency: Switch off the DULCOTROL® measuring/

control station via the main switch or at the position specifiedby the operator.

n Hydraulic emergency: Hydraulically isolate the DULCOTROL®

measuring/control station via the ball valve(s), if necessary,observing the instructions in the material safety data sheet forthe feed chemical.

2.4 Intended Usen The unit is only intended for measuring or controlling a meas‐

uring parameter in aqueous media, within the measuring rangeof the sensors used and in accordance with the identity codeand specifications on the unit's nameplate.

n Compare the identity code on the nameplate with the identitycode in the overview and the applications stated there.Ä further information on page 6

n The unit is not intended for measuring or regulating gaseous orsolid media.

n Only use the unit in accordance with the technical data andspecifications provided in these operating instructions and inthe operating instructions for the individual components!

n You are obliged to observe the information contained in theoperating instructions at the different phases of the device'sservice 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 permitted

with the written authorisation of the manufacturer.n Only allow adequately qualified personnel to operate the unit,

see Ä Chapter 2.5 ‘Users' qualifications’ on page 15. The oper‐ator of the unit is responsible for ensuring that personnel arequalified.


14

2.5 Users' qualifications

WARNING!Danger of injury with inadequately qualified personnel!The operator of the plant / device is responsible forensuring that the qualifications are fulfilled.If inadequately qualified personnel work on the unit orloiter in the hazard zone of the unit, this could result indangers that could cause serious injuries and materialdamage.– All work on the unit should therefore only be con‐

ducted by qualified personnel.– Unqualified personnel should be kept away from

the hazard zone

Training Definition

Instructed personnel An instructed person is deemed to be a person who has been instructed and,if required, trained in the tasks assigned to him/her and possible dangers thatcould result from improper behaviour, as well as having been instructed in therequired protective equipment and protective measures.

Trained user A trained user is a person who fulfils the requirements made of an instructedperson and who has also received additional training specific to the systemfrom ProMinent or another authorised distribution partner.

Trained qualified per‐sonnel

A qualified employee is deemed to be a person who is able to assess thetasks assigned to him and recognize possible hazards based on his/hertraining, knowledge and experience, as well as knowledge of pertinent regula‐tions. The assessment of a person's technical training can also be based onseveral years of work in the relevant field.

Electrician Electricians are deemed to be people, who are able to complete work on elec‐trical systems and recognize and avoid possible hazards independently basedon his/her technical training and experience, as well as knowledge of pertinentstandards and regulations.Electricians should be specifically trained for the working environment inwhich the are employed and know the relevant standards and regulations.Electricians must comply with the provisions of the applicable statutory direc‐tives on accident prevention.

Customer Service depart‐ment

Customer Service department refers to service technicians, who havereceived proven training and have been authorised by ProMinent to work onthe system.

Note for the system operatorThe pertinent accident prevention regulations, as wellas all other generally acknowledged safety regulations,must be adhered to!


15

3 About This Product3.1 DULCOTROL® Measuring and Control Stations

DULCOTROL® measuring and control stations are online processmeasuring/control stations mounted on a PE-plate installed in aprocess water bypass. One or two measured variables can bemeasured or regulated depending on the design ordered. Thesensor types and measuring fittings are coordinated to the samplewater specified.

With the DULCOTROL® DWCa product range, the term "samplewater" is defined as follows:n Potable/product water treatment: water similar to potable

water, as is the case in the production of potable water but alsoin the production of beverages or food.

n Rinsing/process/industrial water: this includes all rinsingprocess in the food and beverage industry, which aim to cleanand disinfect pipework, vessels and machinery and/or highlycontaminated process or industrial process water.

With the DULCOTROL® DWCa product range, a distinction ismade between the following types of waste water:n Waste water, clearn Waste water with solid particle fraction, turbidn Waste water with solid particle fraction, containing sludgen Waste water with fluoride content, clear or turbid, pH < 7The power supply to all electrically operated components is pro‐vided via a terminal box with manually operated switches.

Check the scope of delivery against the delivery note and identitycode.

The operating instructions for the components below also applywhere these components form part of the scope of delivery of themeasuring plate supplied.

Scope of delivery

Further applicable documents (oper‐ating instructions)

About This Product

16

diaLog DACa controller

Hardware design: Identity code for the diaLog DACa con‐troller:

1-channel device without RC, without data logger DACa PA 6 1 0 0 0 0 0 0 0 01 0

1-channel device with RC, without data logger DACa PA 6 1 0 0 0 0 0 0 1 01 0

2-channel device without RC, without data logger DACa PA 6 1 4 0 0 0 0 0 0 01 0

2-channel device with RC, without data logger DACa PA 6 1 4 0 0 0 0 0 1 01 0

1-channel device without RC, with data logger DACa PA 6 1 0 0 0 0 0 1 0 01 0

1-channel device with RC, with data logger DACa PA 6 1 0 0 0 0 0 1 1 01 0

2-channel device without RC, with data logger DACa PA 6 1 4 0 0 0 0 1 0 01 0

2-channel device with RC, with data logger DACa PA 6 1 4 0 0 0 0 1 1 01 0

1-channel device, PROFIBUS® DP DACa PA 6 1 0 0 0 0 4 0 0 01 0

2-channel device, PROFIBUS® DP DACa PA 6 1 4 0 0 0 4 0 0 01 0

1-channel device with RC, PROFIBUS® DP DACa PA 6 1 0 0 0 0 4 0 1 01 0

2-channel device with RC, PROFIBUS® DP DACa PA 6 1 4 0 0 0 4 0 1 01 0

1-channel device, PROFIBUS® DP, with data logger DACa PA 6 1 0 0 0 0 4 1 0 01 0

1-channel device with RC, PROFIBUS® DP, with data logger DACa PA 6 1 0 0 0 0 4 1 1 01 0

2-channel device, PROFIBUS® DP, with data logger DACa PA 6 1 4 0 0 0 4 1 0 01 0

2-channel device with RC, PROFIBUS® DP, with data logger DACa PA 6 1 4 0 0 0 4 1 1 01 0

Compact controller

Hardware design: Identity code for the Compact controller:

Compact controller for conductive conductivity DCCaW006L30010

Compact controller for inductive conductivity DDCaW006L60010

About This Product

17

Sensors

Measured variable Water to be measured Sensor type Order number

Free chlorine with a pHvalue < 8

1 CLE 3-mA-0.5 ppm 792927

Free chlorine with a pHvalue > 8

1 CBR 1-mA-0.5 ppm 1038016

Free chlorine 2 CBR 1-mA-2 ppm 1038015

Total chlorine 1 CTE 1-mA-0.5 ppm 740686

Total chlorine 2 BCR 1-mA-2 ppm 1040115

pH 1 1 PHEP 112 SE 150041

pH 2 PHER 112 SE 1001586

ORP 1 RHEP-Pt-SE 150094

ORP 2 RHER-Pt-SE 1002534

ORP combined with ozone:R0 Z0

1/2 RHEP-Au-SE 1003875

Chlorine dioxide 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 1 1023244

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

Hydrogen peroxide 1 PER 1-mA-200 ppm 1022509

Hydrogen peroxide 2 PER 1-mA-2000 ppm 1022510

Peracetic acid 1 PAA 1-mA-200 ppm 1022506

Peracetic acid 2 PAA 1-mA-2000 ppm 1022507

Dissolved oxygen 1/2 DO 1-mA-20 ppm 1020532

Temperature 1/2 Pt 100 SE 305063

About This Product

18

4 Storage and Transport

CAUTION!Danger of material damageThe device can be damaged by incorrect or improperstorage or transportation!– The unit should only be stored or transported in a

well packaged state - preferably in its originalpackaging.

– The packaged unit should also only be stored ortransported in accordance with the stipulatedstorage conditions.

– The packaged unit should be protected from mois‐ture and the ingress of chemicals.

Packaging materialDispose of packaging material in an environmentallyresponsible way. All packaging components carry thecorresponding recycling code .

CAUTION!– Prior to storage or transport, ensure that the

system is free from feed chemical and water– Flush out the wetted components including the

hoses using clean pure water– Store and transport the system in its original pack‐

aging– 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, filters,metering pumps ...

Storage temperature: + 5 ... 55 °CAir humidity: < 90 % relative humidity, non-condensingHumidity: None. Avoid rain and condensation.Other: No dust, no direct sunlight.

NOTICE!If the system is stored as an assembly with other com‐ponents, then the storage and transport conditionsshould be appropriate for the component with the leastresistance to external influences.

There is no limit to the storage period if no sensors are fitted.

The transport weight depends on the configuration of the meas‐uring plate and is between 8 ... 13 kg.

Ambient conditions for storage andtransport

Storage period

Transport weight

Storage and Transport

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5 Overview of the Measuring Station5.1 DULCOTROL® Measuring and Control Station with Bypass Fitting DGMa

A2020

1.2.

3.

4.

5.

6.

7.

8.

9.

Fig. 1: Bypass fitting DGMa1. Controller2. Main switch3. Flow control4. Bypass fitting DGMa5. Stopcock

6. Sampling tap7. Potential equalisation pin8. Stopcock / flow adjustment9. Filter

The DULCOTROL® measuring and control station with a modularbypass fitting, type flow sensor DGMa, is optimised for clear waterand consists of 1 or 2 controllers, 1 ... 4 sensors and the bypassfitting DGMa with integral flow control, for inserting the sensors. Afilter can optionally be fitted on the sample water input. Variousstopcocks enable the flow to be stopped or adjusted and thesystem bled. The stopcocks are labelled on the plate.

The bypass fitting contains a potential equalisation pin (stainlesssteel pin) for reference potential equalisation of the liquid, enablingmeasurements with potential equalisation. Electrically wire thepotential equalisation pin to the controller, if necessary.The bypass fitting has a sampling tap for extracting a sample ofwater 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 Station

20

5.2 DULCOTROL® Measuring and Control Station with Bypass Fitting DLG III

A2014

1.2.

3.

4.

5.

6.

2a.

5a.

7.

8.

9.

Fig. 2: Bypass fitting DLG III1. Controller2. Terminal box with main switch (depending on

the design of the measuring plate)2a. Main switch (depending on the design of the

measuring plate)3. Sampling tap4. Sensor5. Bypass fitting DLG with magnetic stirrer

(depending on the design of the measuringplate)

5a. Bypass fitting DLG with drain valve (dependingon the design of the measuring plate)

6. Stopcock/flow adjustment device7. Stopcock8. Filter9. Potential equalisation pin

The DULCOTROL® measuring and control station with a modularbypass fitting, flow sensor DLG III or DLG IV, is optimised for turbidwaste water and industrial process water and consists of 1 or 2controllers, 1 ... 4 sensors and the bypass fitting DLG III (1 ... 3sensors) or DLG IV (4 sensors) with integrated flow control. A filtercan optionally be fitted on the sample water input. Various stop‐cocks enable the flow to be stopped or adjusted and the systembled. The stopcocks are labelled on the plate.


21

The bypass fitting contains a potential equalisation pin (stainlesssteel pin) for reference potential equalisation of the liquid, enablingmeasurements with potential equalisation. Electrically wire thepotential equalisation pin to the controller, if necessary.The bypass fitting has a sampling tap for extracting a sample ofwater 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.


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5.3 DULCOTROL® Measuring and Control Station with Pipework

A2019

1. 2.

3.

4.

5.

6.

7.

8.9.

10.

Fig. 3: Pipework for ICT / O2 / pH / ORP1. Controllers2. Terminal box with master switch3. Pipework4. Flow control5. Stopcock / flow adjustment6. Flushing connector7. Stopcock8. Potential equalisation pin9. Stopcock10. Sampling tap

The DULCOTROL® measuring and control station with pipework isoptimised for waste water containing sludge and consists of 1 or 2controllers, 1 ... 4 sensors and pipework with integrated flow con‐trol, for fitting the sensors using an appropriate adapter. Variousstopcocks enable the flow to be stopped or adjusted and thesystem bled. The stopcocks are labelled on the plate.The pipework contains a potential equalisation pin (stainless steelpin) for reference potential equalisation of the liquid, enablingmeasurements with potential equalisation. Electrically wire thepotential equalisation pin to the controller, if necessary.The pipework has a sampling tap for extracting a sample of wateror for draining the bypass fitting.The power supply to all electrically operated components is pro‐vided via a terminal box with manually operated switches.


23

5.4 Installation Diagram for DULCOTROL® Measuring and Control StationSchematic diagram of the components of aDULCOTROL® measuring and control station, installed outside ofthe measuring plate, in the order shown here, see original ProMi‐nent accessories. The accessories illustrated are requireddepending on the application.

NOTICE!The installation sequence is binding and to be adheredto.

1.2.

3. 4. 5. 6.

7.8.

9.10.

A2106

Fig. 4: Installation diagram

Components:

1 Stopcock (supplied on site) 2 Process line

3 Heat exchanger (supplied on site) 4 Temperature control with shut-off valve. Notincluded in the scope of delivery but necessary onsite 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) (tobe provided on site)

7 Dirt filter (optional via ID code) 8 Measuring plate

9 Free flow 10 Sample water pump "vonTaine" (to be providedon site)


24

6 Assembly of the Measuring Pointn User qualification, mechanical installation: trained qualified per‐

sonnel, see Ä Chapter 2.5 ‘Users' qualifications’ on page 15






CAUTION!– Please also observe the operating instructions for

fittings and any other units, such as sensors,sample water pumps ... !

6.1 Assembly (Mechanical)

WARNING!– Live parts.– Bear in mind any concealed installations when

drilling holes to secure theDULCOTROL® measuring/control station.

Assembly of the Measuring Point

25

CAUTION!– Remove any water from the

DULCOTROL® measuring/control station and thesupplied components before assembly if feedchemicals are being used, which should not comeinto contact with water.

– Fix the DULCOTROL® measuring/control stationperpendicular and upright on a wall or a stablemounting system. Pay attention to the load-bearingcapacity of the wall or the mounting system.

– Ensure that theDULCOTROL® measuring/control station is easilyaccessible.

CAUTION!Possibility of over-metering the feed chemicals.– Should the float of the flow module become stuck

due to dirt, theDULCOTROL® measuring/control station can over-meter.

– A filter may be required depending on the type andquality of the sample water.

– Should the circulating pump not pump, theDULCOTROL® measuring/control station can over-meter.

– Lock the controller via the potential-free contact ofthe circulating pump. In the event of the circulatingpump being "OFF", theDULCOTROL® measuring/control station switchesto ‘PAUSE’ via the controller's pause input.

– Alternatively the metering pumps can be switchedin such a way that they only work together with thecirculating pumps.


26

6.1.1 Measuring PointSelect the mounting height so that:n The controller's LCD display can be easily readn The controller lid can still be parked in the "Park position"n There is still space for maintenance work underneath the

bypass fittingn There is sufficient room outside of the plate to fit accessoriesComply with the following drilling dimensions depending on thesize of the plate:

Fig. 5: Drilling templateThe selection of the measuring plate depends on the bypass fittingused and the number of controllers used.The following applies in principle:n With DGMa or DLGIII/IV: size 1n With 2 controllers: size 2n With pipework: size 3

Size 1 2 3

A 595 800 1000

B 745 800 800

C 555 760 960

D 705 760 760

Secure the DULCOTROL® measuring/control station, as close aspossible to the point of injection using hanger bolts. Leave an ade‐quate gap from the wall for the cables on the back of the plate.


27

10 mm

1 23 434

A2107

Fig. 6: Hanger bolt1. Rawlplug (design depending on the substrate and in line with

the stipulations of the rawlplug manufacturer)2. Hanger bolt3. Washer4. Hexagonal nut

6.1.2 AccessoriesFit any accessories supplied, such as heat exchanger, samplewater pump, pressure reducer or filter, in accordance with theiroperating instructions upstream of theDULCOTROL® measuring/control station (in the direction of flow).

The installation sequence is binding and to be adheredto.

Supplied with accessories:


28

7 Installing Sensors in the Bypass Fitting DGMan User qualification, mechanical installation: trained qualified per‐

sonnel, see Ä Chapter 2.5 ‘Users' qualifications’ on page 15n User qualification, hydraulic installation: trained qualified per‐

sonnel, see Ä Chapter 2.5 ‘Users' qualifications’ on page 15n User qualification, electrical installation: Electrical technician,

see Ä Chapter 2.5 ‘Users' qualifications’ on page 15


CAUTION!– Observe the maximum permissible operating

parameters for the entire installation (e.g. pres‐sure, temperature, flow).

– In this respect, consider the lowest maximum per‐missible operating parameters for the parts of theDULCOTROL® measuring/control station and theintegrated sensors; see their operating instruc‐tions.

– Please also observe the operating instructions forany other units, such as sensors, sample waterpumps ...

– Bear in mind the direction of flow of the samplewater.

– Do not exceed the maximum operating pressure.– Fit an appropriate pressure reducer if unavoidable.– Danger due to pressurised media. Before working

on the hydraulic part of theDULCOTROL® measuring/control station, ensurein a controlled manner that this part is at atmos‐pheric pressure using the sampling tap.

– Wear safety goggles.

7.1 Fitting the DGMa with Sensors1. Remove the upper blanking plug from a module2. With pH/ORP sensors: remove the sensor from its transport

protection container.

Fitting sensor with PG 13.5 connector:

Installing Sensors in the Bypass Fitting DGMa

29

3. Screw in the sensor.

With the DULCOTEST® Perox sensor, screw the flow resisterof an in-line probe housing module into the module frombelow

Sensitive sensors are not ready mounted but suppliedloose with the measuring plate in their original pack‐aging.Push the sensor slowly into the in-line probe housing,as the sensor diaphragm can otherwise extend

RequirementThe sensor is filled with electrolyte and the diaphragmcap is screwed on tightly.Accessories: Mounting kit, part number 815079.Refer to the operating instructions for the respectivesensor.

1. Remove the upper blanking plug from a 25-mm module2. Push the O-ring (4) first, then the assembly washer (5) onto

the sensor (3) from below3. Push the holding bolt (1) from above onto the sensor (3)4. Carefully push the sensor (3) into the module5. Tighten the holding bolt (1)6. Carefully push the flow resister (6) down into the module

7.2 Electrical Installation of the SensorsThe bypass fitting can be fitted with different sensors. All the dif‐ferent types of sensors listed here can be fitted but do not have tobe.

Amperometric sensors withØ = 25 mm

4

2

1

3

5

6A1247

Fig. 7: Fitting the sensors


30

Only wire protective low voltage (SELV in accordancewith EN 60335-1) to the flow sensor.The cable needs to have a diameter of 4 mm, so thatthe cable connector achieves degree of protection IP65.

1. Hold the top part of the flow sensor and turn it a quarter-turncounter-clockwise (bayonet fitting).

2. Loosen the clamping screw on the M12 threaded connectorand feed the cable through the alarm device

3. Remove 2 cm from the cable sheath4. Isolate the ends of the wires5. Fit the cable end sleeves6. Connect the flow sensor 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 Wn 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 andtighten the clamping screw on the M12 threaded connector

8. Push the top part of the sensor fully into the housing andtighten it carefully in a clockwise direction until it can go nofurther, ensuring that the nibs of the bayonet fixing do notbreak 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 connectorand feed through the measuring line from the control device

3. Strip the cable ends, fit the cable ends with cable endsleeves (⌀ max = 0.5 mm2) and connect the cable ends to the2-wire connector: 1 = plus, 2 = minus

4. Insert approx. 5 cm of the measuring line into the sensor5. Tighten the clamping screw on the threaded connector6. Push the top part of the sensor right into the sensor shaft and

tighten it clockwise up to the stop

Electrical installation of the flowsensor

Electrical installation of the ampero‐metric sensors

A0102

Fig. 8: 2-wire connection


31

Screw the measuring line coming from the controller onto therespective sensor.

7.3 Adjusting the Flow Sensor Switching Point

Task:The flow sensor should switch when the flow falls; theflow 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/h2. Hold the flow sensor in place and loosen the mounting clip a

little3. 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 tighten the mountingclip

5. Lower the flow for test purposes

ð The alarm device should switch off

6. Check the threaded connector for leak-tightness

Electrical installation of the ORP andpH sensor


32

8 Installing Sensors in the Bypass Fitting DLG III/IVn User qualification, mechanical installation: trained qualified per‐













Installing Sensors in the Bypass Fitting DLG III/IV

33

8.1 Fitting the DLG with Sensors

Shaft diameter < 12 mmYou can fit sensors with a shaft diameter of up to 14mm. It is essential that you fit an O-ring with a clampdisc to seal sensors with a shaft diameter of < 12 mm.

Use an Allen key (width 10 mm) for dismantling toensure that the blanking threaded connector is notdamaged.

1. Use the Allen key to unscrew a blanking threaded connectorout of the top of the in-line probe housing

NOTICE!Always read the assembly instructions provided by thesensor manufacturerNever use a tool to install sensors with a glass shaft.With sensors with a glass shaft, this can cause tensionin the glass shaft, which could irreparably damage thesensor.

2. Screw the sensor manually back into the in-line probehousing until leak-tight

Sensors with ⌀ = 25 mmYou can only fit sensors with ⌀ = 25 mm (e.g. chlorinesensor type CLE 3) with the corresponding mountingkit (Accessories, part number 815079).


Amperometric sensors withØ = 25 mm


34

A0645

1.

2.

3.

4.

5.

Fig. 9: Amperometric sensor1. Threaded sleeve2. Clamp disc3. Sensor4. O-ring5. Washer

RequirementThe sensor is filled with electrolyte and the diaphragmcap is screwed on tightly.Accessories: Mounting kit, part number 815079.Refer to the operating instructions for the respectivesensor.

1. Unscrew a large blanking threaded connector out of the topof the in-line probe housing

Blanking threaded connectorKeep the blanking threaded connector. You canuse the blanking threaded connector to resealthe in-line probe housing at a later stage. Youcan then operate the in-line probe housingwithout a sensor.

2. Push the O-ring (4) from below over the sensor (3) up to theclamp disc (2)

3. Push the washer (5) from below over the sensor up to the O-ring (4)

4. Insert the sensor into the in-line probe housing5. Screw the sensor with the threaded sleeve (1) to the in-line

probe housing until liquid-tight


35

8.2 Hydraulic Installation

Free flowMake sure that there is no overpressure > 1 bar andalso no negative pressure at the outlet of the DLG.Overpressure damages the DLG. Negative pressuredamages the sensors fitted.

1. Use the hose connection set 8/5 mm (DLG III A) to seal thesample water line or as an adhesive connection betweenPVC-U pipe d16 and the adhesive connection d16

2. If fitted: Seal the backflushing line (inner diameter of the hose4 - 6 mm)






Terminal Contact

1 NC

2 Root (C)

3 N/O







36







8.4 Starting Up the DLG

Flow controlThe ball in the ball cage of the DLG III is only a visualdisplay and does not replace the electrical flow controlwith measuring and control functions.

You can adjust the inlet side of the flow of the DLG III using theregulating tap. The working range is reached when the white ball isvisible in the ball cage.


A0102




37

9 Installing Sensors in the Bypass Fitting with Pipeworkn User qualification, mechanical installation: trained qualified per‐













9.1 Fitting the Pipework with Sensors1. Remove the upper blanking plug from a module2. With pH/ORP sensors: remove the sensor from its transport

protection container.3. Screw in the sensor.


Installing Sensors in the Bypass Fitting with Pipework

38

Sensor insertThe sensor insert is factory-inserted into the oxygensensor and no longer needs to be fitted on site.

2.

3.4. 1.

A1284

Fig. 11: Construction of the sensor DO 11. Bracket for the sensor insert2. Sensor diaphragm3. Transmitter4. Sensor insert

Do not remove the silicone paste on the rear of thesensor insert.The silicone paste protects the electrical contacts fromshort-circuiting, even if any water enters their environ‐ment.The bracket for the sensor insert has a bayonet seal.Loosen and tighten the bracket for the sensor insert.

1. If you have not yet done so: Dismantle the transmitter andinsert the sensor insert.

2. Insert the sensor insert into the transmitter, positioning thesensor insert with the two pins into the corresponding holeson the underside of the transmitter.

A1289

Fig. 12: Positioning the sensor insert on the DO 13. Screw the bracket for the sensor insert until the bayonet seal

snaps into place on the transmitter.4. Fit the sensor in the pipe.

Assembling sensor DO 1


39






Terminal Contact

1 NC

2 Root (C)

3 N/O










40





9.3 Hydraulic Installation, Bypass Fitting with Pipework

Free flowMake sure that the system pressure specified on thenameplate is not exceeded and that there is no nega‐tive pressure.

Adhering the sample water linesThe manufacturer's specification for the different mate‐rials, such as pipes, adhesive, straight unions etc., isessential for the design of the adhesive.

Glue the sample water lines provided on site with the straightunions of the bypass fitting. Refer to the drawing for sizing.

9.4 Starting Up the Bypass Fitting with Pipework

Flow controlAdjust the flow control.

You can adjust the flow of the bypass fitting with the pipework onthe ball valves. Adjust the flow so that the sensors have a sufficientflow. Refer to the operating instructions for the sensors for the"Flow" setpoint.

A0102




41

10 Electrically and Hydraulically Assembling and Installing theMeasuring Points

n User qualification, mechanical installation: trained qualified per‐sonnel, see Ä Chapter 2.5 ‘Users' qualifications’ on page 15

n User qualification, hydraulic installation: trained qualified per‐sonnel, see Ä Chapter 2.5 ‘Users' qualifications’ on page 15

n User qualification, electrical installation: Electrical technician,see Ä Chapter 2.5 ‘Users' qualifications’ on page 15








NOTICE!Strain relief and decoupling of all connectionsProvide all components with suitable strain relief,decouplings and/or other protection devices to avoiddamage to connections, like pipework, cables etc.between the measuring plate and the place of installa‐tion.

Electrically and Hydraulically Assembling and Installing the Measuring Points

42

10.1 Electrical Installation of the Measuring and Control Station

WARNING!Live partsPossible consequence: Fatal or very serious injuries.Measures:– Switch off the system until de-energised before

opening the housing of the controller and/or ter‐minal box.

– If the housing of the controller and/or terminal boxis ruptured or obviously damaged, immediatelyswitch off the system and have it repaired.

– Only carry out set-up / maintenance / repair andservice work when the system is shut down andthe electrical power disconnected. Calibration andmaintenance work on the sensors represents anexception to this. This can also be done when thesystem is live. Please also observe the informationin the operating instructions for the sensors andcontroller.

– Check that the seals are sitting correctly afterclosing the housing of the controller and/or ter‐minal box.


CAUTION!Defective control by defective measured valuesCause: Electrical faults are coupled into the control cir‐cuit via the sample medium.Consequence: Defective control by defective meas‐ured values. The measuring fault can lead to anuncontrolled control circuit.Measure: Do not fit any sources of EMC interferenceinto the water circulation system and close to thesystem.Perform regular comparative measurements with agalvanically isolated measuring device.Provide for potential separation of the power supplyfrom the measuring device to the power circuit of thevoltage to be measured or a potential separation in themeasuring signal path.Connect the system to its own power supply, ifneeded.Fit a power repeater, if needed.

Note the electrical connection values on the nameplate of themeasuring and control station. The cable ends of the connectinglines of the sensors are labelled according to the measured vari‐able.


43


The cable ends of the connecting lines of the sensors are labelledaccording to the measured variable. The cable ends are labelledby a cable marker defined as follows for the respective measuredvariables:

Measured variable Controller label Sensor type Cable label

pH pH PHES P

ORP Redox/ORP RHES R

Conductive conductivity Conductivity LFTK1 Pre-installed

Inductive conductivity Conductivity ICT Pre-installed

Chlorine CL CLE, CTE CL

Bromine Br BCR BR

Chlorine dioxide CLO2 CDE, CDP CD

Chlorite Chlorite CLT CT

Ozone O3 OZE OZ

Peracetic acid PES/PAA PAA PA

Hydrogen peroxide H2O2 PER PE

Dissolved oxygen O2 DO1 Pre-installed

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.

Measuring plate


44

10.1.1 Wiring Diagram for DACa and Measuring Plate

Hau

ptsc

halte

r und

Geh

äuse

Mes

swas

serfe

hler

Optional

A2094

Fig. 14: Wiring diagram for measuring plate, complete


45

Kunde Messplatte Regler

Drahtbrücke

mV-Sensor Eingang

mV-Sensor Eingang

Messwasserfehler

Digitaler Kontakteingang 1


A2093

Pause

Messwasserfehler

Pumpe 1, heben

Pumpe 2, senken

Messwert Kanal *

Messwert Kanal *

mV-Sensor Eingang

mV-Sensor Eingang

Optional weiteremA-Sensoren

Temperatursensor optional

Impulsfrequenzausgang 1


Normsignal-Ausgang 1


Drahtbrücke

optional

Sensor-Eingang

X0 Schirm erden!






Niveau in Behälter 1Pause halten / Aus

Pause halten / AusNiveau in Behälter 2


Pumpe 3, heben

Pumpe 4, senken

Leistungsrelais 1

Leistungsrelais 2

Alarmrelais

Netzanschluss

Klemmenkasten

Grenzwert * + Kanal *


Hauptbaugruppe

Erweiterungsbaugruppe (O

ptional)

Fig. 15: Wiring diagram for DACa


46

Kund

eM

essp

latte

Reg

ler

Nor

msi

gnal

-Aus

gang

Optional

Net

zans

chlu

ss

Mes

swer

t Kan

al 1

Paus

e

Pum

pe 1

heb

en /

senk

en

SCH

IRM

A2127

Fig. 16: Wiring diagram for DACa, conductivity, optional


47

10.1.2 Wiring Diagram for DACa and Measuring Plate - Fluoride

Kund

e (b

ause

its)

Hau

ptsc

halte

r + G

ehäu

se

Mes

swas

serfe

hler

Mag

net-

Rüh

rer

(lose

Bei

stel

lung

)

A2097

OPTIONAL

Fig. 17: Wiring diagram for measuring plate, complete, fluoride


48


Drahtbrücke

mV-Sensor Eingang

mV-Sensor Eingang

Messwasserfehler






Drahtbrücke







Netzanschluss

Leistungsrelais 1

Leistungsrelais 2

Klemmenkasten


Pause

Messwasserfehler

Pumpe 1, heben

Pumpe 2, senken

Messwert Kanal *

Messwert Kanal *

mV-Sensor Eingang

mA-Sensor Eingang

Niveau in Behälter 1 / Pause halten / Aus

Niveau in Behälter 2 / Pause halten / Aus

Niveau in Behälter 3 / Pause halten / AusPumpe 3, heben

Pumpe 4, senken


Hauptbaugruppe


ptional)

A2095

Fig. 18: Wiring diagram for DACa, fluoride


49

10.1.3 Wiring Diagram for DACa, DCC and Measuring Plate - Waste Water

Klemmenkasten

Hauptschalter

Netzteil

Netzfilter optional

Mes

swas

serfe

hler

Optional

Opt

iona

l

A2101

Fig. 19: Wiring diagram for measuring plate, complete, waste water


50


Optional weiteremA-Sensoren

Temperatursensoroptional

mV-Sensor Eingang

mA-Sensor Eingang

Pause

Messwasserfehler

Pumpe 1, heben

Pumpe 2, senken

Messwert Kanal *

Messwert Kanal *

mV-Sensor Eingang

mA-Sensor Eingang

Niveau in Behälter 1Pause halten / Aus



Pumpe 3, heben

Pumpe 4, senken



Netzanschluss

Leistungsrelais 1

Leistungsrelais 2









Normsignal-Ausgang 2,



Klemmenkasten A2098

Sensor-Eingang Option

Option

Hauptbaugruppe


ptional)

Fig. 20: Wiring diagram for DACa, waste water


51

Netzfilter optional!

Klemmenkasten

Netzanschluss

Normsignal-Ausgang

Pause

Messwert Kanal 1

Pumpe 1 heben / senken

Optional


Messw

asserfehler 88_02-401_00_38-4A

A2099

Fig. 21: Wiring diagram for DCC, power supply, flow meter, waste water


52

10.2 Hydraulic Test Run after Installation

CAUTION!Warning of escaping feed chemicalFeed chemical can escape in the event that the hoselines are incorrectly installed.– Only use original hoses with the specified hose

dimensions.– Avoid reducing the hose sizes.

Permissible operating conditionsThe values for the permissible hydraulic operating con‐ditions are given on the nameplate.

1. Cut off the ends of the hoses (6) so that they are straight.2. Unscrew the union nut (5) and push over the hose together

with the clamp ring (4).3. Push the hose end (6) up to 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 Connector2 Seal3 Nozzle4 Clamp ring5 Union nut6 Hose line

NOTICE!Decoupling the measuring plate from oscillations,vibrations etc.Put in place appropriate measures to decouple themeasuring plate and on-site pipework from oscillations,vibrations, load, bending stress etc., which can betransmitted by the glued pipes onto the measuringplate. The operator is responsible for selecting theappropriate measures.

If not yet fitted: Fitting the hose lines

1

3

2

4

5

6

P_MAZ_0041_SW

Fig. 22: Installing the hose line

Hydraulic installation, bypass fittingwith pipework


53

Free flowMake sure that the system pressure specified on thenameplate is not exceeded and that there is no nega‐tive pressure.

Adhering the sample water linesThe manufacturer's specification for the different mate‐rials, such as pipes, adhesive, straight unions etc., isessential for the design of the adhesive.

1.

A2124

Fig. 23: Bypass fitting straight union (1)Glue the sample water lines provided on site with the straightunions of the bypass fitting. Refer to the drawing for sizing.

Pay attention to the operating instructions provided for the addi‐tional operational components outside of the plate when hydrauli‐cally connecting them.

After successful installation, a hydraulic test run of theDULCOTROL® 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/ball valve on the inlet and outlet side.n Check the system for leak-tightness. Do not allow any liquids to

escape.Should liquid escape: check the system and repair the leak.

Connect the additional hydraulic com‐ponents outside of the plate (optional)


54

11 Starting-up Sensorsn User qualification: trained user, see Ä Chapter 2.5 ‘Users'

qualifications’ on page 15

WARNING!Sensor run-in periodsThis can result in hazardous incorrect metering.– Correct measuring and metering is only possible if

the sensor is working perfectly– Observe the sensor operating instructions– Calibrate the sensor after commissioning


CAUTION!– The sampling tap must be closed, otherwise

sample water can escape.– The sample water should be free from air bubbles

to ensure reliable measurement and control.Should the sample water carry air with it as a resultof the process, then suitable means must be usedto separate out the air.


Maximum permissible operating pressure: 1 bar at maximum 45 °Cor see Ä ‘Permissible operating pressures’ on page 144

11.1 Preparation of Sensors1. Tighten all threaded connectors and check that the threaded

connectors are leak-tight.2. Check the positions of all shut-off valves. The position of the

shut-off valves has to guarantee that theDULCOTROL® measuring/control station is tight and thatthere is a flow of sample water.

3. Plug the mains plug into the sockets provided and switch onthe mains voltage.

Starting-up Sensors

55

4. Check the operating conditions, as described in the operatinginstructions for the sensors, as follows:n Flown Pressuren Temperaturen pHn Concentration of feed chemicalAdjust these values so that the values are within the sensor'sspecification.

5. To condition the amperometric sensors, make sure that thereis electrical power to the sensors, that there is a flow ofchemical to be measured and that the appropriate run inperiod given in the operating instructions for the sensor hasexpired.

ð The sensor signal should be stable in terms of time afterconditioning.Only then can the measuring point be calibrated. Theoperating conditions have to remain as constant as pos‐sible during this.

6. Calibrate the measuring points, as described in the operatinginstructions supplied for the respective controller fitted.

7. The operating instructions supplied for the respective sensorfitted provide detailed information on commissioning the sen‐sors.

11.2 Sampling from the Bypass Fitting

Bleeding of the DLGRemove sufficient sample water before taking asample to fully bleed the measuring point with meas‐uring and control stations fitted with DLG bypass fit‐ting. There should be no air in the bypass fitting duringsampling.

Sampling for calibrationWhen taking a sample to calibrate a sensor, makesure that sufficient sample water is removed beforesampling in order to rule out particles of dirt, foreignbodies etc. in the actual sample. Properly dispose ofthe sample water that is removed.

The sampling points are labelled on the measuring and controlplate. The extraction of sample water is only permitted at thesesampling points. The extraction of sample water at other points onthe measuring and control station can lead to incorrect results, forinstance during calibration.

11.3 Calibrating the SensorsAll sensors are calibrated, as described in the operating instruc‐tions for the controllers and sensors fitted. Any sample required istaken at the sampling points labelled on the measuring plate, seeÄ Chapter 11.2 ‘Sampling from the Bypass Fitting’ on page 56.

Starting-up Sensors

56

11.4 Calibrating the Fluoride SensorThere is a fundamental distinction between 1-point calibration and2-point calibration. 1-point calibration is performed using astandard solution with e.g. 1 ppm fluoride for calibration. 2-pointcalibration is performed using two standard solutions, which haveto be more than 1 ppm apart (minimum value 0.5 ppm).There are two options for calibrating a fluoride sensor:n Calibration with a photometer DT2C (order number: 1039316)n Calibration with a standard solutionThe fluoride sensor is calibrated, as described in the operatinginstructions for the controller and sensors fitted.

Refer to the operating instructions for the photometer DT2C.

Calibration instructionsRegularly check and calibrate the sensor.Please note the applicable national guidelines.The sensor needs to have run in prior to initial calibra‐tion.Observe the controller operating instructions.Perform 2-point calibration during initial commis‐sioning.2-point calibration needs to be carried out less regu‐larly than 1-point calibration.

The standard solution has to be evenly stirred with a magneticstirrer during calibration.Use a standard solution with a conductivity of> 1000 μS/cm(e.g. 1g/litre Na2SO4 solution) to accelerate potentialadjustment. The two standard solutions have to be more than 1ppm apart (minimum value 0.5 ppm) to calibrate the slope (2-pointcalibration).1. Immerse the sensor, the reference electrode and the Pt 100

(if fitted) into the standard solution for calibration2. Perform calibration in line with the controller's specification,

referring to the operating instructions for the controller.

Calibration with a photometer DT2C

Calibration with a standard solution

Starting-up Sensors

57

11.5 Removing and Fitting the Bypass Fitting Cup for Calibration

A2114

1. 2.

3.

4.

5.

Fig. 24: Removing and fitting the bypass fitting cup for calibration1. Ball valve, inlet side2. Ball valve, outlet side3. Cup with stirrer rod inserted4. Magnetic stirrer5. Wall bracket1. Close the ball valves (1 and 2).2. Remove the magnetic stirrer (4).3. Remove the wall bracket (5).4. Remove the container (3).5. Empty the cup and fill 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 instructions for the controller.

10. Complete calibration, as described in the operating instruc‐tions for the controller.

11. Open the ball valves (1 and 2).

ð The fluoride sensor is now calibrated.

Starting-up Sensors

58

12 Controllers' User InterfaceOne or two controllers with different user interfaces can be fitted,depending on the selection using the identity code, on theDULCOTROL® measuring and control station. These user inter‐faces are described here and facilitate basic tasks on the control‐lers. All other tasks, such as configuring the inputs and outputsetc., are described in the detailed operating instructions for theProMinent® components.

12.1 Operating Concept

A1035

1.

Fig. 25: Operating cross (1) / Active keys are displayed in [black] in the display; inactive keys in [grey].For example, the following path is presented:Continuous display ➨ ➨ or [calibrate] ➨ ➨ or [slope] ➨ ➨

Continuous display [Calibrate] [Slope]

A1036

Fig. 26: A display change is made within a sequence of actions.I. Continuous display 1II. Display 2III. Display 3IV. Display 4

The function of the keys is described in table Ä Chapter 12.1.1‘Functions of the keys ’ on page 62.➨ = describes as a symbol an action by the operator, that leads toa new possibility for an action.[Naming in the display] = square brackets contain the name thatappears with the identical wording in the controller display.

DACa

Controllers' User Interface

59

Additional information can be obtained via the key.

Illumination of the displayIn the case of an error with the status [ERROR], thebacklight of the display changes from ‘white’ to ‘red’ .This makes it easier for the operator to react to anerror.

Fig. 27: Example of the continuous display when used with ameasuring channel (e.g. pH)

A1177

7.557.20

0.50

0.3025

-15

Fig. 28: Example of the continuous display when used with twomeasuring channels (e.g. pH/chlorine)

No time-controlled menu itemsThe controller does not exit any menu items in a time-controlled manner, the controller remains in a menuitem until this menu item is exited by the user.

1. Select the desired parameter in the display using the keys or .

ð In front of the selected parameter there is an arrow tip,which marks the selected parameter.

2. Press

ð You are now in the setting menu for the desired param‐eter.

Setting of the various parameters inthe adjustable menus


60

3. You can adjust the desired value in the setting menu usingthe four arrow keys and then save it using the key

ðRange errorIf you enter a value that is outside the pos‐sible setting range, the message[range error] appears after pressing the key. By pressing or you return to thevalue to be set.

Once the key is pressed, the controller returns to themenu

Interrupting the setting processPressing the key returns to the menuwithout saving a value.


61

12.1.1 Functions of the keysFunctions of the keys

Key Function

Confirmation in the setting menu: Confirms and saves the input values.Confirmation in the continuous display: Displays all information about saved errors andwarnings.

Back to the continuous display or to the start of the respective setting menu, in which youare currently located.

Enables direct access to all of the controller'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 about the controllerinput and output values.

To decrease a displayed number value and to jump down in the operating menu.

Moves the cursor to the left.


62

12.1.2 Changes the set operating language1. Simultaneously press the keys and

ð The controller changes to the menu for setting the oper‐ating language.

A1482

Language 2

Language

German

Fig. 29: Menu for setting the operating language2. Now using keys and you can set the desired operating

language3. Confirm your selection by pressing the key

ð The controller changes back to the continuous displayand indicates the selected operating language.

12.1.3 Acknowledge fault or warning messageIf the controller recognises an error [Error], the control is stopped,the backlight switches to red lighting and the alarm relay is deacti‐vated. You can access the next value to be set by pressing the key. In this process, the controller indicates all errors and warn‐ings. The pending alarm messages can be selected and, ifrequired, acknowledged/confirmed. If you acknowledge an error,the alarm relay activates and the backlight switches back to whitelight. In the bottom part of the display, the error or warning mes‐sage that has occurred remains displayed, such as [Error 01], untilthe cause has been cleared.In the event of a warning, e.g. the controller signals that a sensorhas not been calibrated yet, further processing using the controlleris possible with or without acknowledgement of the message.In the event of an error message [Error], [e.g.] the controller signalsthat no sensor is connected, then after acknowledgement of themessage, no further processing is possible using the controller.You must now rectify the error - for this see the chapter on Diag‐nostics and Troubleshooting.


63

Fig. 30: Alarm message, controller stops control

12.1.4 Key LockThe controller has a key lock. If the key lock is activated, the keyscannot be pressed. The key lock can be activated or deactivatedby simultaneously pressing and . An activated key lock is indi‐cated by the symbol.


64

12.2 Operating Diagram for Measured Variable: Conductive Conductivity12.2.1 Overview of equipment/Operating elements

n User qualification: instructed user, see Ä Chapter 2.5 ‘Users'qualifications’ on page 15

A0291

Fig. 31: Overview of equipment/Operating elements

Function Description

1st respective measured vari‐able

Affix the measured variable label here

2. LCD display

3. UP key To increase a displayed numerical value and move up in the operatingmenu

4. INFO/RIGHT key Opens the information menu or moves the cursor one place to the right

5. OK key To apply, confirm or save a displayed value or status or To confirm analarm

6. DOWN key To decrease a displayed numerical value and move down in the operatingmenu

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 changingentries or valuesSwitches the measured variables in the continuous display.

10. CAL key To access the calibration selection menu (cell constant and temperaturecoefficient) and navigate within the calibration menu.


65


11. f-REL LED Shows the activated state of the f-relay

12. P-REL LED Shows the activated state of the P-relay

13. ERROR LED Indicates a controller error state. A text message is displayed simultane‐ously in the LCD display of the continuous display

12.2.2 Entering valuesDescribed by the example of entering setpoints in the Controlmenu.

※CONTROL

SET= 01.000A1634

Fig. 32: Entering values1. Use to select each position of the value to be entered.

You can also select and change the unit of thevalue to be entered.

2. Enter the values using the and keys3. : The value entered is transferred to the memory.4. : Cancelling the input of values without saving the entered

value. The original value is retained.

12.2.3 Adjusting display contrastIf the DULCOMETER® Compact Controller is set to ‘continuousdisplay’ , you can set the contrast of the LCD-display. By pressingthe key you can adjust the LCD display contrast so it is darker.By pressing the key you can adjust the LCD display contrast soit is lighter. Here each key press represents a contrast level. I.e.the key must be pressed once for each contrast level.


66

12.2.4 Continuous display

A1614

1

2

345

6

7 ConC µS/cm

Fig. 33: Continuous display1 Measured variable (switch using ESC), the fol‐

lowing are possible: [ConC], [RES], [TDS] and[SAL]

2 Reference temperature or temperature compen‐sation

3 Control variable

4 Possible error text: for example "Limit↓" (direc‐tion of limit value transgression e.g. value belowthe limit in this case)

5 Temperature (correction variable)6 Measured value (actual value)7 Operating status

The bottom line displays the current measuring temperature and atemperature manually entered. The temperature display cannot beswitched off.The temperature (measuring temperature or reference tempera‐ture) is needed to calculate all measured variables, which is whythe 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 [ConC], [RES], [TDS] and [SAL] in the continuous display.Depending on the measured variable set, the settings of variablesare changed or the variables are hidden completely in the[INPUT Ø TCOMP] menu and in the [LIMIT] menu.

12.2.5 Information displayThe most important parameters for each first-level menu item aredisplayed in the Information display.Use to access the Information display from the continuous dis‐play. Pressing again calls up the next Information display.Pressing calls up the continuous display again.

Switching between measured varia‐bles


67

A1615

ⒾLIMITSLIMIT↑= 0.020LIMIT↓= 0.010

SENSOR: LF1TEMP: auto

CABLE LEN: 3.00mP-REL: alarmmA OUT: meas val

ⒾCONTROLPUMP: dosing ↓

TYPE: PSET= 1.000mS/cm

Ⓘ INPUT

CONTACT: pause

Ⓘ OUTPUT

f-REL: dosing

Ⓘ INPUT_2ⒾLAST ERR.

ⒾVERSIONSSW-VER 01.00.00.00

SN 2366733289 (07)

mA Range↑ 88 minmA Range ↓ 136 min

BL-VER 03.02.02.01

TREF: lin 25.0 °C

CELLC: 1.0000cm-1

TCOEFF= 1.90%/°C

Ⓘ CAL

AUTORNG: 33

Fig. 34: Information displayUse to move from the information display currently shown to theselection menu for this information display.Use to move directly back to the information display.

12.2.6 PasswordAccess to the setting menu can be limited by a password. The con‐troller is delivered with the password ‘5000’ . The controller is setup with the pre-set password ‘5000’ so that access is possible toall menus.

A1616

MENU

≡MENU

DEVICEOUTPUTINPUT

※DEVICEPASSWORD: ****

※DEVICE

NEW PASSW. 5000=FREE

RESTART DEVICE... 5000FACTORY RESET

Fig. 35: Setting the password

Password Possible values

Factory setting Increment Lower value Upper value Remark

5000 1 0000 9999 5000 = [FREE]


68

12.3 Operating Diagram for Measured Variable: Inductive Conductivity12.3.1 Overview of equipment/Operating elements


A0291

Fig. 36: Overview of equipment/Operating elements


1st respective measured vari‐able

Affix the measured variable label here

2. LCD display

3. UP key To increase a displayed numerical value and move up in the operatingmenu

4. INFO/RIGHT key Opens the information menu or moves the cursor one place to the right

5. OK key To apply, confirm or save a displayed value or status or To confirm analarm

6. DOWN key To decrease a displayed numerical value and move down in the operatingmenu

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 changingentries or valuesSwitches the measured variables in the continuous display.

10. CAL key To access the calibration selection menu (cell constant and temperaturecoefficient) and navigate within the calibration menu.


69


11. f-REL LED Shows the activated state of the f-relay

12. P-REL LED Shows the activated state of the P-relay

13. ERROR LED Indicates a controller error state. A text message is displayed simultane‐ously in the LCD display of the continuous display

12.3.2 Entering valuesDescribed by the example of entering setpoints in the Controlmenu.

※CONTROL

SET= 01.000A1634

Fig. 37: Entering values1. Use to select each position of the value to be entered.

You can also select and change the unit of thevalue to be entered.

2. Enter the values using the and keys3. : The value entered is transferred to the memory.4. : Cancelling the input of values without saving the entered

value. The original value is retained.

12.3.3 Adjusting display contrastIf the DULCOMETER® Compact Controller is set to ‘continuousdisplay’ , you can set the contrast of the LCD-display. By pressingthe key you can adjust the LCD display contrast so it is darker.By pressing the key you can adjust the LCD display contrast soit is lighter. Here each key press represents a contrast level. I.e.the key must be pressed once for each contrast level.


70

12.3.4 Continuous display

A1861

1

2

345

6

7 ConI µS/cm

Fig. 38: Continuous display1 Measured variable (switch using [ESC]): the fol‐

lowing are possible: [ConI], [RES], [TDS] and[SAL]

2 Reference temperature or temperature compen‐sation

3 Control variable

4 Possible error text: for example [Limit↓] (direc‐tion of limit value transgression e.g. value belowthe limit in this case)

5 Temperature (correction variable)6 Measured value (actual value)7 Operating status

The bottom line displays the current measuring temperature and/ora temperature manually entered. The temperature display cannotbe switched off.The temperature (measuring temperature or reference tempera‐ture) is needed to calculate all measured variables, which is whythe 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 variablesare changed or the variables are hidden completely in the[INPUT Ø TCOMP] menu and in the [LIMIT] menu.

12.3.5 Information displayThe most important parameters for each first-level menu item aredisplayed in the information display.Use to access the information display from the continuous dis‐play. Pressing again calls up the next information display.Pressing calls up the continuous display again.



71

A1862

ⒾLIMITSLIMIT↑= 0.020LIMIT↓= 0.010

SENSOR: LF1TEMP: auto

CABLE LEN: 3.00mP-REL: alarmmA OUT: meas val

ⒾCONTROLPUMP: dosing ↓

TYPE: PSET= 1.000mS/cm

Ⓘ INPUT

CONTACT: pause

Ⓘ OUTPUT

f-REL: dosing

Ⓘ INPUT_2ⒾLAST ERR.

ⒾVERSIONSSW-VER 01.00.00.00

SN 2366733289 (07)

mA Range↑ 88 minmA Range ↓ 136 min

BL-VER 03.02.02.01

TREF: lin 25.0 °C

CELLC: 1.0000cm-1

TCOEFF= 1.90%/°C

Ⓘ CAL

AUTORNG: 65

Fig. 39: Information displayUse to move from the information display currently shown to theselection menu for this information display.Use to move directly back to the information display.

12.3.6 PasswordAccess to the setting menu can be restricted by a password. Thecontroller is delivered with the password ‘5000’ . The controller isset up with the pre-set password ‘5000’ so that access is possibleto all menus.

A1863

MENU

≡MENU

DEVICEOUTPUTINPUT

※DEVICEPASSWORD: ****

※DEVICE

NEW PASSW. 5000=FREE

RESTART DEVICE... 5000FACTORY RESET

Fig. 40: Setting the password

Password Possible values

Factory setting Increment Lower value Upper value Remark

5000 1 0000 9999 5000 = [FREE]


72

13 Commissioning the Controller diaLog DACa

Sample water faults and alarm relaysIf the sample water falls below the minimum flow vol‐umes (sample water fault), the controller DACaswitches to fault mode and control of both measuringchannels stops.The alarm relay is not factory-activated.

13.1 Commissioningn User qualification: trained user, see Ä Chapter 2.5 ‘Users'


WARNING!Sensor run-in periodThis can result in hazardous incorrect meteringTake into consideration the sensor's run-in periodduring commissioning:– There has to be adequate feed chemical in the

sample water for your application (e.g. 0.5 ppmchlorine)

– Correct measuring and metering is only possible ifthe sensor is working perfectly.

– It is imperative that you adhere to the sensor's run-in periods.

– Calculate the run in period when planning commis‐sioning.

– It may take a whole working day to run in thesensor.

– Refer to the sensor's operating instructions.

After mechanical and electrical installation, integrate the controllerinto the measuring point.

13.1.1 Switch-on behaviour during commissioning

Installation and function control– Check that all the connections have been made

correctly– Ensure that the supply voltage matches the

voltage indicated on the nameplate

1. Switch the supply voltage on2. The controller displays a menu in which you can set the lan‐

guage with which you wish to operate the controller

Switching On - First Steps

Commissioning the Controller diaLog DACa

73

3. Wait for the controller's module scan

Module scan

A1081

Base module

Expansion module

continue with <OK>

Softw. version: 01.00.00.00

Softw. version: 01.00.00.00

Auto continue in 10 sFig. 41: Module scan

ð The controller indicates the controller modules installedand identified.

4. Press

ð The controller now changes to its continuous display.From the continuous display, you can access all the con‐troller's functions using .

13.1.2 Adjusting the backlight and contrast of the controller displayContinuous display ➨ ➨ [Setup] ➨ [Device setup]➨ or

[Device configuration] ➨ [Backlight]Under this menu item you can set the brightness and contrast ofyour controller display to match the ambient conditions at yourinstallation location.

13.1.3 Resetting the operating language

Resetting the operating languageIn the event that a foreign and hence incomprehen‐sible operating language has been set, the controllercan be reset to the basic setting. This is implementedby the simultaneous pressing of the and keys.If you no longer know whereabouts you are in theoperator menu, you must press the key as often asnecessary until the continuous display becomes visibleagain.

13.1.4 Defining metering and control processesSet the controller once you have integrated it into the control cir‐cuit. Setting the controller adapts it to your process.Define the following parameters to set up a controller:n What type of a process is planned?n Which measured variables are there?


74

n Is there an in-line, batch or circulation process planned?n Should the controller operate as a one-way or two-way control?n Which control variables are there?n What control parameters are necessary?n What should the controller do in [HOLD]?n How should the actuators be controlled?n How should the mA-outputs be set?


75

14 Commissioning the Compact Controller for Conductive Con‐ductivity

n User qualification: trained user, see Ä Chapter 2.5 ‘Users'qualifications’ on page 15

WARNING!Sensor run in periodThis can result in dangerous incorrect meteringConsider the run in period of the sensor during com‐missioning:– Correct measuring and metering is only possible 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 commis‐

sioning.– It may take a whole working day to run-in the

sensor.– Observe the sensor operating instructions.

14.1 Measured variablesThe controller can process the following measured variables:n Conductive conductivity [ConC]n Resistance [RES]n TDS value [TDS]n Salinity [SAL]

Use the key to switch between the controller's measured varia‐bles [ConC], [RES], [TDS] and [SAL] in the continuous display.Depending on the measured variable set, the settings of variablesare 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: [ConC]Units of measurement: μS/cm, mS/cm , S/cm. The measuringrange is automatically detected and switched by the controller.Physical variable: specific electrical conductivity (K). Only thismeasured variable is emitted at the mA output, independently ofthe measured variable set on the controller. The setting of themeasured variable on the controller only affects the layout of thedisplay and not the output at the mA output.

Symbol displayed in the controller's display: [RES]Units of measurement: MΩcm, kΩcm, Ωcm, measuring range isautomatically detected and switched by the controllerPhysical variable: specific electrical resistance.Calculating the specific resistance: ρ (Tref) = 1/K (Tref)


Measured variable: conductive con‐ductivity [ConC]

Measured variable: Resistance [RES]

Commissioning the Compact Controller for Conductive Conductivity

76

Symbol displayed in the controller's display: [TDS] (total dissolvedsolids)Unit of measurement: ppm (mg/l)Physical variable: Total of all inorganic and organic substances dis‐solved in a solventDisplay range: 0 …. 2000 ppmTemperature range: 0 … 35 °C[TLIMIT↑]: ≤ 40 °CSetting the TDS value displayed: You can set a multiplicative factor[TDS] in the [INPUT] menu, with which the TDS value displayedcan be changed.Displayed TDS value [ppm] = К (25 °C) [uS/cm] * TDS factorSetting range of TDS factor: 0.400 … 1.000 (Default: 0.640)Temperature compensation is always linear with the TDS displaywith a reference temperature of 25 °C .

Symbol displayed in the controller's display: [SAL] units: ‰ (g/kg)Physical variable: Mass of salts in a kg of water given in PSU(practical salinity units).The salinity is derived from the conductivity measured, with aspecified non-linear temperature compensation and a referenceconductivity (KCL).Display range: 0 …. 70.0 ‰Temperature range: 0 … 35 °C[TLIMIT↑]: ≤ 35 °CThe salinity [SAL] is calculated based on the[Practical Salinity Scale 1978 (PSS-78)]

Measured variable: TDS value

Measured variable: Salinity (SAL)

Commissioning the Compact Controller for Conductive Conductivity

77

15 Commissioning the Compact Controller for Inductive Con‐ductivity

n User qualification: trained user, see Ä Chapter 2.5 ‘Users'qualifications’ on page 15

WARNING!Sensor run in periodThis can result in dangerous incorrect meteringConsider the run in period of the sensor during com‐missioning:– Correct measuring and metering is only possible 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 commis‐

sioning.– It may take a whole working day to run-in the

sensor.– Observe the sensor operating instructions.

15.1 Measured variablesThe controller can process the following measured variables:n Inductive conductivity [ConI]n Resistance [RES]n TDS value [TDS]n Salinity [SAL]

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 variablesare 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 measuringrange is automatically detected and switched by the controllerPhysical variable: specific electrical conductivity (K). Only thismeasured variable and the correction variable ‘Temperature’ areemitted at the mA output, independently of the measured variableset on the controller. The setting of the measured variable on thecontroller only affects the layout of the display and not the output atthe mA output.

Symbol displayed in the controller's display: [RES]Units of measurement: MΩcm, kΩcm, Ωcm. The measuring rangeis automatically detected and switched by the controllerPhysical variable: specific electrical resistance.Calculating the specific resistance: ρ (Tref) = 1/K (Tref)


Measured variable: Inductive conduc‐tivity [ConI]

Measured variable: Resistance [RES]

Commissioning the Compact Controller for Inductive Conductivity

78

Symbol displayed in the controller's display: [TDS] (total dissolvedsolids)Unit of measurement: ppm (mg/l)Physical variable: Total of all inorganic and organic substances dis‐solved in a solventDisplay range: 0 …. 2000 ppmTemperature range: 0 … 35 °C[TLIMIT↑]: ≤ 40 °CSetting the TDS value displayed: You can set a multiplicative factor[TDS] in the [INPUT] menu, with which the TDS value displayedcan be changed.Displayed TDS value [ppm] = К (25 °C) [uS/cm] * TDS factorSetting range of TDS factor: 0.400 … 1.000 (Default: 0.640)Temperature compensation is always linear on the TDS displaywith 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 aspecified non-linear temperature compensation and a referenceconductivity (KCL).Display range: 0 …. 70.0 ‰Temperature range: 0 … 35 °C[TLIMIT↑]: ≤ 35 °CThe salinity [SAL] is calculated based on the[Practical Salinity Scale 1978 (PSS-78)]

Measured variable: TDS value

Measured variable: Salinity (SAL)

Commissioning the Compact Controller for Inductive Conductivity

79

16 Configuration of the ControllersThe measured variables, sensor types and the measuring rangesof the sensors fitted are pre-set in the controllers when the meas‐uring and control station is delivered. The correct presettings arethe prerequisites for correct calibration of the measuring and con‐trol station. The operating instructions for the individual compo‐nents provide information on customer-specific adjustments

16.1 Configuration of the Compact Controllers DCCa

Archiving the settingsThe settings on the DCCa have to be manually docu‐mented and archived, as electronic archiving is notpossible with this unit.

Compact controller DCCa used as a transmitterThe Compact controller DCCa only works as a trans‐mitter and delivers an mA signal to the diaLog con‐troller DACa. The measuring range can only beadjusted and the conductivity sensor calibrated on theCompact controller DCCa. The output of the Compactcontroller DCCa is factory-configured to the applica‐tion-based measuring range.

You have to adjust the outputs of the Compact controllerDCCa 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.

16.2 Configuration of the diaLog Controller DACa

Only when measuring conductivityWhen measuring conductivity the compact controllerDCCa acts as a transmitter for the diaLog controllerDACa. The output of the compact controller DCCa isconnected to the input of the diaLog controller DACa.You therefore have to set the same measuring rangelimits on both units.

Configuration and archiving on an SD cardThe factory-set configuration of the diaLog controllerDACa is stored on an SD card. This SD card is locatedin the SD slot behind the interface cover carrying theSD logo. If necessary the configuration can be readfrom the SD card and the controller DACa can bereturned to its original factory configuration. You canalso save and secure your specific configuration.

Configuration of the Controllers

80

Additional SD cardSaving the user specific configuration on an additionalSD card. Do not overwrite the original SD card with thefactory configuration.

You have to adjust the outputs of the diaLog controller DACa inline with the requirements of your application, referring to the oper‐ating instructions for the controller.

Configuration of the Controllers

81

17 Calibrating the Controller diaLog DACa17.1 Calibration


Settings for [Channel 2]In its 2-channel version, the controller has two meas‐urement channels. This description for [Channel 1]applies correspondingly for the settings in [Channel 2].The procedure for making the settings for the channelin question is identical, however the parameters to beset may be different. Differences are pointed out andare also described.

Display tolerancesDisplay tolerances between the sensor and/or meas‐uring device and controller have to be calibrated withsensors and/or with output signals of measuringdevices that do not require calibration or where calibra‐tion is performed in the sensor/measuring device. Therelevant information for this is contained in the respec‐tive operating instructions for the sensor or measuringdevice.

Continuous display ➨ Menu ➨ or [Calibration] ➨ orContinuous display ➨

A1606

Channel 2Channel 1Please select channel

pH [mV]

CalibrationChlorine

Fig. 42: Please select channel

Calibrating the Controller diaLog DACa

82

CAL Cl

A1039

Zero pointSlope

Slope calibrationCalibration of zero point

4.00 mA

Last calibration 31.03. 2013 13:11:11100 %

Fig. 43: Display [Calibration] with the example of [Chlorine]

Calibrating measuring channel 1 and measuringchannel 2The calibration processes are identical for measuringchannel 1 and measuring channel 2. However, it isnecessary to calibrate each measuring channel sepa‐rately

17.1.1 Calibrating the pH sensorTo ensure a high level of measuring accuracy, adjust the pHsensor at set time intervals. This calibration interval seriouslydepends on the application of the pH sensor and on the requiredmeasurement accuracy and reproducibility. The calibration intervalcan vary between daily and every few months.

Valid calibration values

Assessment Zero point Slope

Very good -30 mV … +30 mV 56 mV/pH … 60 mV/pH

Good -45 mV … +45 mV 56 mV/pH … 61 mV/pH

Acceptable -60 mV … +60 mV 55 mV/pH … 62 mV/pH

If you measure the pH with potential equalisation, setthis [Potential equalisation] procedure as a parameterwhen selecting the measured variable as a parameter.

Calibrate the pH-sensor for the function: pH compen‐sation for chlorine measurementIt is mandatory that the pH measurement is alwayscalibrated first, followed by the chlorine measurement.Calibration of the chlorine measurement should alwaysfollow every further calibration of the pH measurement,otherwise the chlorine measurement will be inaccurate.


83

Select the calibration process prior to initial calibration. This selec‐tion is saved until you select a new process.n 2-point calibration: This is the recommended calibration

process because it evaluates the sensor characteristic data:asymmetric potential, slope and response speed. 2 buffer solu‐tions are needed for 2-point calibration, e.g. pH 7 and pH 4 ifsubsequent measurement is to be performed in an acidicmedium or pH 7 and pH 10, if subsequent measurement is tobe performed in an alkaline medium. The buffer gap should beat least 2 pH units.

n Samples (1-point) calibration: There are two options here.Samples (1-point) calibration is only recommended with reser‐vations. From time to time check the sensor with 2-point cali‐bration.– The pH sensor remains in the sample medium and you

should calibrate a sample of the medium to be measuredagainst an external comparison measurement. Perform thecomparison measurement using an electrochemicalmethod. Deviations of up to ± 0.5 pH units can occur usingthe phenol red method (photometer).

– Calibration solely using a pH 7 buffer. This only calibratesthe zero point. The sensor is not checked for an acceptableslope.

n Data input: With this calibration method, using a comparisonmeasuring device, determine in advance the characteristic dataof the pH sensor (asymmetry and slope) at standard tempera‐ture and enter this data into the controller. The comparativecalibration should not be more than one week old because thepH sensor's characteristic data changes if the data is saved forlonger.

Selecting the calibration process


84

Buffer temperatureAt temperatures that differ by 25 °C in the process,adjust the pH of the buffer solution by entering the ref‐erence values printed on the buffer solution bottle intothe controller prior to calibration.

Buffer temperature dependenciesAn incorrectly entered buffer temperature can lead toincorrect calibration.Each buffer has different temperature dependencies.You have various choices in terms of compensating forthese temperature dependencies, so that the controllercan correctly process the buffer temperature.– Buffer temperature [Manual]: Ensure that the buffer

temperature is identical for both buffers. Enter thebuffer temperature in the [CAL Setup] menu item inthe controller.

– Buffer temperature [Automatic]: Then immerse thetemperature sensor connected to the controllertogether with the pH sensor into the buffer. Wait fora sufficiently long period of time until the pH andtemperature sensor have recorded the buffer tem‐perature.

– Buffer temperature [Off]: this setting is not recom‐mended. Please use another setting.

The sensor stability information displayed during calibration,[acceptable], [good] and [very good], indicates to what extent thesensor signal fluctuates during calibration. At the start of calibra‐tion, the waiting time for stabilising of the measured value is 30seconds; 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 respondsslowly and you have to wait a few minutes until the sensor signalhas stabilised.The controller has no waiting time limit. You will see the actual[sensor voltage] in mV and can identify high fluctuations andassign influences to them, such as the movement of the sensorcable.Calibration is impossible if the sensor signal is very unsteady andthe sensor signal is disrupted by external influences, or if thesensor cable has a cable break or the coaxial cable is damp. Rec‐tify any fault or cable break.You can only continue with calibration once the signal bar hasreached the [acceptable] range and remains there or movestowards [good] or [very good]. Changes to the signal within theranges [acceptable], [good] and [very good] are permitted.The signal fluctuation width within the ranges is specified as fol‐lows:n first 30 seconds wait time, then evaluation of the sensor signal

– Acceptable: 0.5 mV/30s– Good: 0.3 mV/30s– Very good: 0.1mV/30s

Buffer temperature dependencies


85

CAL pH

Asymmetry

Buffer 2:

A1019

Zero point

Slope% Slope

Accept with <CAL>

Buffer 1:

Calibr.param. for 25 °C

Fig. 44: Display of the calibration result

CAL pHAsymmetry in mV

Sensor quality

A1481Slope in mV/pH

acceptable

good

good

55 56 57 58 59 60 61 62

-60 -30 0 30 60

Fig. 45: Displayed after the key has been pressed

17.1.1.1 Selecting the Calibration Process for pHTo calibrate the controller there are three available calibration pro‐cesses:n 2-pointn Sample (1-point)n Data input1. Continuous display ➨

ð The Calibration menu is displayed, you may need toselect [Channel 1] or [Channel 2], depending on themeasuring channel on which the pH measurement is per‐formed.



86

2. Press

CAL pH

Buffer manufacturer

Calibration process

A1025

Off

Buffer detection

2 point

requirement

Buffer value 1Buffer value 2

Buffer temperature

ProMinentpH 7pH 4

Fig. 46: Selecting the calibration processð The menu for selecting the calibration process appears.

3. Use the arrow keys to select the required menu item andpress

ð The input window appears and you can make the neces‐sary settings for your process

4. Use the arrow keys to select the calibration process andpress

5. Continue with

ð You can now start your chosen calibration process.

17.1.1.2 2-point pH sensor calibration (CAL)

Correct sensor operation– Correct measuring and metering is only possible if

the sensor is working perfectly– Refer to the sensor's operating instructions– 2-point calibration is strongly recommended and is

preferable to other methods– Remove the sensor from the in-line probe housing

and re-fit it for calibration. To do this, refer to theoperating instructions for your in-line probehousing


87

Determining buffer detectionThere are 2 methods of buffer detection with 2-pointcalibration.[Requirement]: you have to select 2 buffers from the 4possible buffer sets for this. Adhere to the selectedorder, e.g. buffer value 1: pH 7 and buffer value 2: pH4 for calibration.– ProMinent® (pH 4; 7; 9; 10)– NBS/DIN 19266 (pH 1; 4; 7, ; 9)– DIN 19267 (pH 1;4; 7; 9; 13)– Merck + Riedel® (pH 2; 4; 7; 9; 12)The buffer sets vary with regard to their pH values andtemperature dependencies configured in the controller.The pH values for the different temperatures are alsoprinted on the buffer containers.[Manual]: enter the buffer value with the associatedtemperature into the controller.– The pH values of the buffer solution at tempera‐

tures that deviate from 25 °C are displayed in atable on the label of the buffer bottle.

Select the buffer you require.

CAL pH

Buffer manufacturer

Calibration process

A1512

Manual

Buffer detection

2 point

Manual

Buffer value 1Buffer value 2

Buffer temperature

ProMinentpH 7pH 4

Buffer temperature 25.0 °CFig. 47: Example: Display in[CAL Setup]

Buffer usedDispose of the used buffer solution. For more informa‐tion: refer to the buffer solution safety data sheet.

Valid calibration valuesValid calibration:– Zero point -60mV…+60 mV– Slope 55 mV/pH…62 mV/pH

You need two test containers with buffer solution for calibration.The pH values of the buffer solutions should be at least 2 pHvalues apart. Thoroughly rinse the sensor with water whenchanging the buffer solution.Continuous display ➨


88

CAL pHLast calibration

A1016

Zero pointSlope

Calibration processCAL setup

continue with <CAL>

14:26:07

7,00 pH

2 point

56.64mV/pH 06/04/2013

Fig. 48: pH sensor calibration (CAL)1. Then press 2. Rinse the sensor thoroughly with water before drying with a

cloth (pad dry, don't rub)3. Immerse the sensor in test container 1 containing buffer solu‐

tion (e.g. pH 7). When doing so, move the sensor gently4. Continue with

ð Calibration is running . [Please wait!] flashes.

CAL pHSensor voltageSensor calibration in buffer 1

A1017

Buffer temperatureThe stability is:

acceptable good

continue with <CAL>

25.0 °C0.1 mV

very good

Fig. 49: Display of the sensor stability achieved5. The [acceptable / good / very good] range is displayed

ð The black part of the horizontal bar indicates the rangedetected.

6. Continue with 7. [Buffer detection] e.g. [Manual]: Press and set the buffer

value for buffer 1 to the value of the buffer you are using withthe four arrow keys. Confirm the input of the value with

8. Remove the sensor from the buffer solution, rinse thoroughlyin water and then dry with a cloth (pad dry, don't rub!)

9. Continue with 10. Immerse the sensor in test container 2 containing buffer solu‐

tion (e.g. pH 4). When doing so, move the sensor gently11. Continue with



89

CAL pHSensor voltageSensor calibration in buffer 2

A1018

Buffer temperatureThe stability is:

acceptable good

continue with <CAL>

25.0 °C173 mV

very good



13. Continue with 14. [Buffer detection] [Manual]: Press and set the buffer value

for buffer 2 to the value of the buffer you are using with thefour arrow keys. Confirm input of the value by pressing

15. Continue with

CAL pH

Asymmetry

Buffer 2:

A1019

Zero point

Slope% Slope

Accept with <CAL>

Buffer 1:

Calibr.param. for 25 °C

Fig. 51: Display of the calibration result16.

Incorrect calibrationAn error message appears should the result ofthe calibration lie outside the specified tolerancelimits. In this case the current calibration will notbe applied.Check the prerequisites for calibration and clearthe error. Then repeat calibration.

Transfer the result of the calibration into the controllermemory by pressing

ð The controller displays the continuous display again andoperates with the results of the calibration.


90

17.1.1.3 pH sensor calibration (CAL) with an external sample (1-point)

Measuring and control behaviour of the controllerduring calibrationDuring calibration the actuating outputs are deacti‐vated. Exception: a basic load or a manual control vari‐able has been set. This remains active. The measuredvalue output [standard signal output mA] is frozen, cor‐responding to its settings in the mA output menu.When calibration/testing has been completed success‐fully, all of the error checks relating to the measuredvalue are restarted. The controller saves all the deter‐mined data for zero point and slope upon a successfulcalibration.

NOTICE!Poor sensor operation and fluctuating pH valuesduring the processThe calibration method with an external sample has anumber of disadvantages compared with the buffersolution calibration method. If the pH value fluctuatessignificantly during the process, then the pH value maychange by a variable amount in the period betweensampling, sample measurement and entry of the pHvalue into the controller. This could mean that the pHvalue entered into the controller does not correspondto the actual pH value in the process. Consequentlythe result is a linear displacement of the pH valueacross the entire measuring range.If the pH sensor no longer reacts to changes in the pHvalue and only gives out a constant uniform mV signal,this cannot be detected using the calibration methodwith an external sample. With the calibration methodwith two buffers (e.g. pH 7 and pH 4), this becomesapparent if the pH sensor does not detect any changesin the pH value.The calibration method with an external sample shouldonly be used with installations where there is pooraccess to the pH sensor and the identical or very uni‐form pH values are used in the process. In addition thepH sensor should be regularly serviced or replaced.

Correct sensor operation– Correct measuring, control and metering is only

possible if the sensor is working perfectly– Refer to the sensor's operating instructions


Evaluation Zero point Slope


Good -45 mV … +45 mV 56 mV/pH … 61 mV/pH



91

Continuous display ➨

CAL pH

Calibration process

A1023

Zero pointSlope

Last calibration

CAL setup

continue with <CAL>

06/05/2013 14:26:07

Sample (1-point)Buffer temperature Manual

Fig. 52: pH sensor calibration (CAL)1. Continue with 2. Take a water sample at the in-line probe housing and, using

a suitable method (measuring strips, hand measuring instru‐ment), measure the pH value of the sample

CAL pH

Change with <OK>A1022

2) Determine pH value

pH value

continue with <CAL>

1) Take sample

Fig. 53: Instructions for determining the pH value using the[Sample] method3. Press 4. Use the arrow keys to enter the pH value you have deter‐

mined in the controller5. Press 6. Accept the pH value by pressing

ð All the values of the calibration result are shown in thedisplay.


92

Incorrect calibrationAn error message appears if the result of the calibra‐tion lies outside the specified tolerance limits. In thiscase, the current calibration is not applied.Check the prerequisites for calibration and clear theerror. Then repeat calibration.

7. Transfer the result of the calibration into the controllermemory by pressing


17.1.1.4 Calibration of the pH Sensor (CAL) by [Data Input]

Data inputUsing the[Calibration of the pH sensor (CAL) by data input] cali‐bration method, the sensor's known data is enteredinto the controller. Calibration by data input is only asaccurate and reliable as the method with which thedata was determined.The sensor data must have been determined in real-time. The more up-to-date the sensor data is, the morereliable is this calibration method.


the sensor is working perfectly– Refer to the sensor's operating instructions



Evaluation Zero point Slope


Good -45 mV … +45 mV 56 mV/pH … 60,5 mV/pH




93

CAL pH

Calibration process Data input

A1024

Zero pointSlope

Last calibration

CAL setup

continue with <CAL>

16:47:327,00 pH

59.16 mV/pH

06/05/2013

Fig. 54: pH sensor calibration (CAL)1. Continue with

CAL pH

6.88 pH

Slope at 25.0 °C

A1026

or

-58.07 mV/pH

continue with <CAL>

Asymmetry at 25.0 °C

Zero point at 25.0 °C

-6.4 mV

Fig. 55: Selection of the settable parameters2. Use the arrow keys to select the required menu item and

press

ð The entry window appears.

3. Enter the values for your sensor using the arrow keys andpress

4. Continue with

Incorrect calibrationAn error message appears if the result of the calibra‐tion lies outside the specified tolerance limits. In thiscase, the current calibration is not applied.Check the prerequisites for calibration and clear theerror. Then repeat calibration.

5. Transfer the result of the calibration into the controllermemory by pressing



94

17.1.2 Calibrating the ORP Sensor17.1.2.1 Selecting the calibration process for ORP

There are two calibration processes available for calibrating thecontroller:n 1-point (with buffer solution)n Data input1. Continuous display ➨

CAL ORP

Pot. equalisationCalibration process

A1027

No

0.0 mVOffsetLast calibration

CAL setup

13:26:1111/04/2013

continue with <CAL>

1 point

Fig. 56: [ORP] calibration menuð The calibration menu is displayed.

2. Use to select the Setup menu or start calibration bypressing

3. [CAL Setup]: Press

ð The menu for selecting the 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 andpress

6. Continue with


17.1.2.2 1-point calibration of ORP sensor (CAL)


the sensor is working perfectly– Refer to the sensor's operating instructions– Remove the sensor from the in-line probe housing





95

ORP sensor calibrationThe ORP sensor cannot be calibrated. Only an[OFFSET] deviation of magnitude ± 40 mV can be setand thus compensated. If the ORP sensor deviates bymore than ± 40 mV from the reference value, then itmust be checked in accordance with the requirementsof the sensor operating instructions.


Buffer usedDispose of the used buffer solution. For more informa‐tion: refer to the buffer solution safety data sheet.

You need one test container with a buffer solution for calibration.Continuous display ➨

CAL ORP

Pot. equalisationCalibration process

A1027

No

0.0 mVOffsetLast calibration

CAL setup

13:26:1111/04/2013

continue with <CAL>

1 point

Fig. 57: 1-point calibration of ORP sensor (CAL)1. Continue with


96

CAL ORP

A1028

Immerse sensor in buffer

continue with <CAL>

Fig. 58: 1-point calibration of ORP sensor (CAL)2. Carry out the instructions and then press


CAL ORPSensor voltageSensor calibration in buffer

A1029

The stability is:

acceptable good

continue with <CAL>

0.1 mV

very good



4. Continue with

CAL ORP

Offset

Buffer value

A1030Accept with <CAL>

165 mV

0.0 mV

Fig. 60: Adjusting the buffer value5. Press and use the four arrow keys to adjust the mV value

of the buffer you are using


97

6. Press 7. Transfer the result of the calibration into the controller

memory by pressing

ð The controller operates with the calibration results.

17.1.2.3 Calibration data for ORP sensor (CAL)


the sensor is working perfectly– Refer to the sensor's operating instructions– Remove the sensor from the in-line probe housing


ORP sensor calibrationThe ORP sensor cannot be calibrated. Only an‘OFFSET’ deviation of magnitude ± 40 mV can be setand thus compensated. If the ORP sensor deviates bymore than ± 40 mV from the reference value, then itmust be checked in accordance with the requirementsof the sensor operating instructions.



98


CAL ORP

CAL setup

A1032

Offset21.05.2013 14:59:56

continue with <CAL>

Calibration process

Last calibration0.0 mV

Data input offset

Fig. 61: Data input, ORP sensor calibration (CAL)1. Continue with

CAL ORPOffset

A1033Accept with <CAL>

0.1 mV

Fig. 62: Adjusting the [Offset]2. Press and use the four arrow keys to adjust the mV value

of the buffer you are using3. Press 4. Transfer the result of the calibration into the controller

memory by pressing

ð The controller operates with the calibration results.

17.1.3 Calibrating the Fluoride Sensor17.1.3.1 Selection of the calibration process for fluoride

To calibrate the controller there are two available calibration pro‐cesses:n 1 pointn 2 point


99

1. Continuous display ➨

CAL F-

A1037

-59.16 mV/decSlope

1 ppm = 185.0 mV 16:51:18

Single point calibration

11:11:1111/11/2011

100 % 11/11/2011

Two point calibration

Fig. 63: Calibration menu [Fluoride]ð The calibration menu is displayed.

2. Using the arrow keys select the desired menu item. Press the key

ð You can now start the selected calibration process.

17.1.3.2 2-point fluoride sensor calibration (CAL)


the sensor is working perfectly– Observe the sensor operating instructions– The carrying out of a 2-point calibration is strongly

recommended and is to be preferred to othermethods

– For calibration the sensor must be removed andrefitted in the in-line probe housing. To do this,observe the operating instructions of your in-lineprobe housing

Material required for calibration of fluoride sensors:n Two test containers with calibrating solution


Calibration process selection


100

Used calibration solutionDispose of the used calibration solution. For moreinformation: see calibration solution safety data sheet.

Two test containers with a calibration solution are required for cali‐bration. The fluoride content of the calibrating solutions should beat least 0.5 ppm F- apart from each other. The sensor should berinsed thoroughly with fluoride-free water when changing the cali‐brating solution.1. Press the key in the continuous display.2. Using the arrow keys select [Two point calibration]3. Then press

CAL F-Immerse sensor in buffer 1Two point calibration

A1038

Sensor value 2.50 ppm

Sensor voltage 161.4 mV

Start with <CAL>

Fig. 64: Fluoride sensor calibration (CAL)4. Immerse the sensor in test container 1 with calibration solu‐

tion. When doing so gently move the sensor5. Then press

ð [Calib. in progress] .

CAL F-Two point calibration

A1040


Change with <OK>

continue with <CAL>

Fig. 65: Fluoride sensor calibration (CAL)6. Then press to change the ppm value or press to con‐

tinue with the calibration7. Then press


101

CAL F-

Immerse sensor in buffer 2Two point calibration

A1041

Sensor valueSensor voltage

Start with <CAL>

4.88 ppm144.2 mV




10. Then press to adjust the ppm value or press to con‐tinue with the calibration

11. Then press 12. Import the result of the calibration into the controller memory

by pressing the key


Incorrect calibrationShould the result of the calibration lie outsidethe specified tolerance limits, an error mes‐sage appears. In this case the current cali‐bration will not be applied.Check the prerequisites for the calibrationand clear the error. Then repeat the calibra‐tion

17.1.3.3 1-point fluoride sensor calibration (CAL)


the sensor is working perfectly– Observe the sensor operating instructions– The carrying out of a 2-point calibration is strongly

recommended and is to be preferred to othermethods

– For calibration the sensor must be removed andrefitted in the in-line probe housing. To do this,observe the operating instructions of your in-lineprobe housing


102

Material required for calibration of fluoride sensors:n One test container with calibration solution


Used calibration solutionDispose of the used calibration solution. For moreinformation: 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 bufferSingle point calibration

A1042


Sensor voltage 161.4 mV

Start with <CAL>





103

CAL F-Single point calibration

A1043


Change with <OK>

continue with <CAL>

Fig. 68: Fluoride sensor calibration (CAL)6. Then press to change the ppm value or press to con‐

tinue with the calibration7. Then press 8. Import the result of the calibration into the controller memory

by pressing the key



17.1.4 Calibrating Amperometric Sensors

Calibrating Amperometric SensorsThe process for calibrating amperometric sensors isidentical with all amperometric measured variables.The process for calibrating amperometric measuredvariables is described throughout based on the meas‐ured variable chlorine [Cl]. All other measured varia‐bles require the same process as the measured vari‐able chlorine [Cl].The following measured variables can be calibratedusing the process described here:– Chlorine– Chlorine dioxide– Bromine– Chlorite– Ozone– Peracetic acid (PES)– H2O2


104

Calibration combining pH and chlorineIt is imperative that you always calibrate the pH meas‐urement first before the chlorine measurement. Thechlorine measurement always needs to be calibratedany further time the pH measurement is calibrated.Otherwise the chlorine measurement will be inaccu‐rate.

17.1.4.1 Selecting the calibration process for amperometric measured variablesThere are two calibration processes available for calibrating thecontroller:n Calibrating the slopen Calibrating the zero point1. Continuous display ➨

CAL Cl

A1039

Zero pointSlope

Slope calibrationCalibration of zero point

4.00 mA

Last calibration 31.03. 2013 13:11:11100 %

Fig. 69: [Chlorine] calibration menuð The calibration menu is displayed.

2. Use the arrow keys to select the chosen menu item. Press




105

17.1.4.2 Calibrating the slope

CAUTION!Correct sensor operation / Run-in periodDamage to the product or its surroundings– Correct measuring and metering is only possible if

the sensor is working perfectly– Please read the operating manual for the sensor– Please also read the operating manuals for the fit‐

tings and other components used– It is imperative that the run in periods of the sen‐

sors are adhered to– The run in periods should be allowed for when

planning commissioning– It may take an entire working day to run in the

sensor


The measured value frozen at the start of calibration is suggestedas a reference value. The reference value can be set using thearrow keys. Calibration is only possible if the reference value is ≥ 2% of the measuring range of the sensor.

NOTICE!Prerequisites for correct calibration of the sensor slope– The reference method needed is used, depending

on the feed chemical used (e.g. DPD 1 for freechlorine).

– The run-in period for the sensor has been com‐plied with; refer to the operating instructions for thesensor.

– There is permitted and constant flow at the in-lineprobe housing

– There is temperature balance between the sensorand the sample water

– There is a constant pH value in the permittedrange

Material required for calibration of amperometric sensors:n A reference method suitable for the measured variable in ques‐

tion


106

Remove sample water directly at the measuring point and deter‐mine the content of the feed chemical in the sample water in [ppm]using an appropriate reference method (e.g. DPD, titration etc.).Enter this value into the controller as follows:1. Press in the continuous display.2. Use the arrow keys to select [Slope calibration]3. Continue with

CAL Cl

A1044

Concentration

Latest sensor measured values

2) Take sample and continue with <CAL>

Sensor current

1) Wait until meas values stable

Fig. 70: Reference value calibration shows the actual sensorvalues4. Continue with

CAL Cl

A1045

Measured value upon sampling

Change with <OK>

Determine reference value

continue with <CAL>

Fig. 71: Reference value calibration, the sensor value is frozenhere; now take the sample and measure using DPD, for example5. Then press to adjust the ppm value or press to con‐

tinue with the calibration


107

CAL Cl

A1047

Calibration successfulSlope

continue with <CAL>

Zero point

Fig. 72: Calibrating the reference value6. Transfer the result of the calibration into the controller

memory by pressing


Incorrect calibrationAn error message appears if the result of thecalibration lies outside the specified tolerancelimits. In this case, the current calibration isnot applied.Check the prerequisites for calibration andclear the error. Then repeat calibration

Permitted calibration rangeThe permitted calibration range is 20 ... 300% of thesensor's rated value.Example of a shallow slope: Blocking of the sensormembrane leads to a low slope (low slope = lowsensor sensitivity)Example of a steep slope: Surfactants make thesensor membrane more permeable, leading to asteeper slope (steep slope = high sensor sensitivity)

17.1.4.3 Calibration of zero point

Necessity for calibrating the zero pointCalibration of the zero point is not generally necessary.A calibration of the zero point is only necessary if thesensor is operated at the lower limit of the measuringrange or if the 0.5 ppm sensor version is used.


108





planning commissioning– It may take a whole working day to run-in the

sensor


NOTICE!Prerequisites for a correct calibration of the sensorzero point– The run in period for the sensor has been adhered

to– There is permitted and constant flow at the in-line

probe housing– There is temperature balance between the sensor

and the sample water– There is a constant pH value in the permitted

range

1. Press the key in the continuous display.2. Using the arrow keys select the [Zero point]3. Then press


109

CAL Cl

A1046

Accept with <CAL>

Zero point

Range

Fig. 73: Calibration of zero point4. Then press

CAL Cl

A1048

continue with <CAL>

Zero pointSlope

Calibration successful

Fig. 74: Calibration of zero point5. Import the result of the calibration into the controller memory

by pressing the key



17.1.5 Calibrating Oxygen SensorsThe calibration interval depends heavily on:n the applicationn the installation location of the sensor

Specifying the calibration interval


110

If you wish to calibrate a sensor for a special application and/or aspecial installation location, then you can determine the calibrationintervals using the following method. Check the sensor, e.g. onemonth after commissioning:1. Remove the sensor from the medium2. Clean the outside of the sensor with a damp cloth3. Then gently dry the sensor membrane for example using a

paper towel4. After 20 minutes measure the oxygen saturation index in the

air5. Protect the sensor from external influences, such as sunlight

and wind

ð Now decide depending on the expected result:

Amperometric sensor: Calibrate the sensor if the meas‐ured value is not 102 ± 2 %SAT.If the value is within the setpoint range, then you canextend the calibration interval. Repeat this processmonthly and determine the optimum calibration intervalfor your application from the results.

Calibration specifications of the sensor man‐ufacturerWhen determining the calibration interval,also take into consideration the operatinginstructions for the sensor, which may offeradditional and/or different calibration inter‐vals.

17.1.5.1 Selection of the calibration process for the measured variable O2

To calibrate the controller there are three available calibration pro‐cesses:n automaticn DO valuen Zero point1. Continuous display ➨

CAL DO

A1049

Zero point

Slope

DO valueZero point

automatic

Fig. 75: Calibration menu [DO]ð The calibration menu is displayed.

Calibration process selection


111

2. Using the arrow keys select the desired menu item. Press the key

ð You can now start the selected calibration process.

17.1.5.2 Selection of the calibration process for the measured variable DO






sensor


1. Press the key in the continuous display.2. Using the arrow keys select [automatic]3. Then press


112

CAL DO

A1074

Air temperature

Water temp.

continue with <CAL>

Air pressure

Adjusting the concentration

higher than Sea levelRelat. humiditySalinity of the Water

Fig. 76: Selection of the calibration process for the measured vari‐able DO4. Then press to adjust the values or press to continue

with the calibration

CAL DO

A1075

Sensor head up

continue with <CAL>

Minimum waiting time 5 minTime: XX.XX min

Fig. 77: Selection of the calibration process for the measured vari‐able DO5. Hold the DO sensor head up in the ambient air.

ð The calibration takes place. The elapsed time is dis‐played. The minimum waiting time for a correct calibra‐tion is 5 minutes

6. Press the key to import the result of the calibration into thememory of the controller

ð The controller changes back to the continuous displayand operates with the results of the calibration.



113

17.1.5.3 Zero point calibration for the measured variable DO






sensor


1. Press the key in the continuous display.2. Using the arrow keys select [Zero point]3. Then press

CAL DO

A1074

Air temperature

Water temp.

continue with <CAL>

Air pressure



Fig. 78: Zero point calibration for the measured variable DO4. Then press to adjust the values or press to continue



114

CAL DO

A1079

Range

Accept with <CAL>

Zero point

Fig. 79: Zero point calibration for the measured variable DO5. Then press

CAL DO

A1080

Zero point

continue with <CAL>

Slope


Fig. 80: Zero point calibration for the measured variable DO6. Press the key to import the result of the calibration into the

memory of the controller

ð The controller changes back to the continuous displayand operates with the results of the calibration.The controller displays the continuous display again andoperates with the results of the calibration.



115

17.1.5.4 DO value calibration for the measured variable DO






sensor


1. Press the key in the continuous display.2. Using the arrow keys select [DO value]3. Then press

CAL DO

A1074

Air temperature

Water temp.

continue with <CAL>

Air pressure



Fig. 81: DO value calibration for the measured variable DO4. Then press to adjust the values or press to continue



116

CAL DO

A1076

DPD value

Start with <CAL>


Sensor current 8.03 mA

Fig. 82: DO value calibration for the measured variable DO5. Then press

CAL DO

A1077

1) Take sample

Change with <OK>

7.04 ppm

continue with <CAL>

2) Determine DPD value

Fig. 83: DO value calibration for the measured variable DO6. Take a water sample and determine the DPD value with a

suitable measuring instrument.7. Then press to adjust the values or press to continue



117

CAL DO

A1078


Zero point

continue with <CAL>

Slope

Fig. 84: DO value calibration for the measured variable DO8. Import the result of the calibration into the controller memory

by pressing the key



17.1.6 Measured value [mA general] calibration

Measured value [mA general] calibrationThe measured value [mA general] cannot be cali‐brated, this menu item is shown ‘greyed out’ and hasno purpose.

17.1.7 Calibrating conductivity



118

You may need a manual measuring instrument for the conductivitymeasured variable. This manual instrument should measure anddisplay sufficiently accurately to guarantee successful calibration.1. Press in the continuous display.2. Use the arrow keys to select [Calibrate slope]3. Then press 4. Follow the instructions in the controller display and perform

calibration5. Then press 6. Then press to adjust the µS/cm value or press to con‐

tinue with calibration

CAL Cl

A1047

Calibration successfulSlope

continue with <CAL>

Zero point

Fig. 85: Calibrating the reference value7. Import the result of the calibration into the controller memory

by pressing

ð The controller shows the continuous display again andoperates with the results of the calibration.

Incorrect calibrationAn error message appears if the result of thecalibration lies outside the specified tolerancelimits. In this case the current calibration isnot carried over.Check the prerequisites for calibration andeliminate the error. Then repeat calibration.


119

17.1.8 Calibrating temperature


You may need a manual measuring instrument for the temperaturemeasured variable. This manual instrument should measure anddisplay sufficiently accurately to guarantee successful calibration.1. Press in the continuous display.2. Then press 3. Follow the instructions in the controller display and perform

calibration4. Then press 5. Then press to adjust the value or press to continue with

calibration6. Import the result of the calibration into the controller memory

by pressing

ð The controller shows the continuous display again andoperates with the results of the calibration.

Incorrect calibrationAn error message appears if the result of thecalibration lies outside the specified tolerancelimits. In this case the current calibration isnot carried over.Check the prerequisites for calibration andeliminate the error. Then repeat calibration.


120

18 Calibrating the Compact Controller for Conductive Conduc‐tivity

18.1 Calibrating [CAL] the conductivity sensorThe following calibration functions are available depending on thetype of sensor:n Calibration of the cell constantn Calibration of the temperature coefficient


the sensor is working perfectly– Observe the operating instructions for the sensor

Incorrect calibrationAn error message ‘ERR’ appears if the result of thecalibration lies outside the specified tolerance limits. Inthis case the current calibration is not applied.Check the prerequisites for calibration and clear theerror. Then repeat calibrationIn the event of repeated calibration failure, observe thenotes given 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 beenset. This remains active. The mA standard signal output is frozen.When calibration has been completed successfully, all of the errorchecks relating to the measured value are restarted. The controllersaves the data determined for the cell constant and temperaturecoefficient when the calibration is successful.The conductivity sensors can be calibrated using 3 differentmethods. The cell constant is adjusted directly or indirectly in allmethods:n Calibration compared to a reference solutionn Calibration compared to a reference measurement (e.g.

manual measuring device)n Calibration by entering a precisely known or determined cell

constant

Calibrating the Compact Controller for Conductive Conductivity

121

18.1.1 Calibration of the cell constant

A1625

CALCELLCONST

CAL CELLCONST

TCoeffCAL 1.90%/°C

COND= 43,2µS/cm @25°C

CAL=CONTINUE

TCOEFF

CAL CELLCONST

CAL_T= 155.0 °C

COND=

CAL CELLCONST@25°C

043,975 µS/cm

CELLCCAL CELLCONST

1.0000cm-1 OK

CAL=ACCEPT

Fig. 86: Calibration of the cell constant1. Press and move the cursor using the or key to

[CELLCONST] and confirm with .2. Enter the temperature coefficient of the calibration solution.

The temperature coefficient of the calibration sol‐ution is specified on the storage tank for the cali‐bration solution. ProMinent's calibration solutionhas a temperature coefficient of 2% /K.

Confirm with .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 enter the conductivity value measured using the , or keys, in accordance with the conductivity value specified

on the calibration solution.

ð If calibration has been completed successfully, the con‐troller stores the determined values for the cell constantand the error checks relating to the measured value arerestarted. The numerical setting range of the cell con‐stant is not limited.

6. Press twice to return to the continuous display.

Calibration compared to a calibrationsolution


122

Temperature coefficient of the measuring solutionThe temperature coefficient of the measuring solutionhas to be known.

1. Press , leaving the sensor in the application in which thesensor is fitted.

2. Move the cursor using the or key to [CELLCONST] andconfirm with .

3. Enter the temperature coefficient of the measuring solution.Confirm with .

4. Press .


5. Now enter the conductivity value displayed using the , or keys, in accordance with the reference value measured.



1. Press and move the cursor using the or key to[INPUT]Confirm with .

2. Move the cursor using the or key to [CELLC].Confirm with .

3. Now adjust the precisely known or previously determined cellconstant using the , or keys.Confirm with .


Sensor status

Display Meaning Status

[OK] In order Cell constant = 0.005 / 15.0

[WRN] Warning none

[ERR] Error Cell constant < 0.005 or cell constant > 15

Calibration compared with a referencemeasurement (e.g. manual measuringdevice)

Calibration by entering a preciselyknown cell constant


123

18.1.2 Calibration of the temperature coefficient

Conductivity sensors with temperature elementYou can only calibrate the temperature coefficient withconductivity sensors with a temperature elements,because it is impossible to calculate the temperaturecoefficient without measuring the temperature.

Temperature changeIt is recommended that the temperature is changed byno more than 0.5 °C per minute, or with a temperaturechange of e.g.10°C you will need to wait for a min‐imum of 20 minutes before calibration.


124

A1626

CALCELLCONST

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%/°CCAL TEMPCOEFF

CAL=OLD

CAL=CONTINUE

T2 < 12.0 °C

CAL=CONTINUE

WAITCAL TEMPCOEFF

T2 > 32.0 °C orT2 < 12.0 °C

I.

II.STABLE ?

CAL_T2= 43.0 °C

CAL TEMPCOEFF

CAL=CONTINUE

ACCEPT ?

III.

Fig. 87: Calibration of the temperature coefficientI. If the temperature change is greater than 2°C,

the note changes to [WAIT]II. If the temperature is within the specified range,

the note changes to [STABLE]III. When a stable final temperature has been

reached, the note changes to [ACCEPT?] Cali‐bration can now be terminated manually.

1. Calibrate at the first calibration temperature calibration tem‐perature; this calibration temperature should be close to theselected reference temperature.

2. Press [CAL] to accept the first calibration point. At the sametime the temperature ranges for the second temperaturevalue are given.

3. Note: [CHANGE TEMP], now immerse the sensor in thesame liquid with the second calibration temperature (min‐imum temperature difference ± 10°C)

4. If the measured temperature has changed by more than2°C , [WAIT] displayed.


125

5. If the temperature has changed by more than 10°C,[STABLE?] is displayed, and you can now terminate calibra‐tion if the displayed temperature value no longer changes. Todo so, press [CAL].

6. When the Maximum/Minimum temperature has beenreached, [ACCEPT?] is displayed

ð You can now terminate calibration. To do so, press[CAL].

This process may take 10 ... 20 minutesdepending on the type of sensor.

7. Use [CAL] to accept the temperature coefficient or [ESC] todiscard it


[OK] In order ΔTkal > 20 °C

[WRN] Warning ΔTkal = 10 °C…20 °C

[ERR] Error ΔTkal < 10 °C

ΔTkal = Temperature difference of the calibration liquids

Sensor status


126

19 Calibrating the Compact Controller for Inductive Conductivity19.1 Calibrating [CAL] the conductivity sensor

The following calibration functions are available depending on thetype of sensor:n Calibration of the cell constantn Calibration of the temperature coefficientn Calibration of the zero point


the sensor is working perfectly– Refer to the operating instructions for the sensor

Incorrect calibrationAn error message ‘ERR’ appears if the result of thecalibration lies outside the specified tolerance limits. Inthis case the current calibration is not applied.Check the prerequisites for calibration and clear theerror. Then repeat calibrationIn the event of repeated calibration failure, refer to theinformation given 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 beenset. This remains active. The mA standard signal output is frozen.When calibration has been completed successfully, all the errorchecks relating to the measured value are restarted. The controllersaves the data determined for the cell constant and temperaturecoefficient when calibration is successful.The conductivity sensors can be calibrated using 3 differentmethods. The cell constant is adjusted directly or indirectly with allmethods:n Calibration compared to a reference solutionn Calibration compared to a reference measurement (e.g.

manual measuring device)n Calibration by entering a precisely known or determined cell

constant

Calibrating the Compact Controller for Inductive Conductivity

127

19.1.1 Calibration of the cell constant

A1865

CALCELLCONST

CAL CELLCONST

TCoeffCAL 1.90%/°C

COND= 43,2µS/cm @25°C

CAL=CONTINUE

ZERO

CAL CELLCONST

CAL_T= 155.0 °C

COND=

CAL CELLCONST@25°C

043,975 µS/cm

CELLCCAL CELLCONST

1.0000cm-1 OK

CAL=ACCEPT

TCOEFF

Fig. 88: Calibration of the cell constant1. Press and use the or key to move the cursor to

[CELLCONST] and confirm with .2. Enter the temperature coefficient of the calibration solution.

The temperature coefficient of the calibration sol‐ution is specified on the storage tank for the cali‐bration solution.

Confirm with .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 .


5. Now use the , or keys to set the conductivity valuemeasured, in accordance with the conductivity value speci‐fied on the calibration solution.



Calibration compared to a calibrationsolution


128

Temperature coefficient of the measuring solutionThe temperature coefficient of the measuring solutionhas to be known.

1. Press , leaving the sensor in the application in which thesensor is fitted.

2. Use or key to move the cursor to [CELLCONST] andconfirm with .

3. Enter the temperature coefficient of the measuring solution.Confirm with .

4. Press .


5. Now use the , or keys to enter the conductivity valuedisplayed, in accordance with the reference value measured.



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 knownor previously determined cell constant.Confirm with .


Sensor status


[OK] In order Cell constant = 0.005 / 99.9

[WRN] Warning none

[ERR] Error Cell constant < 0.005 or cell constant > 100

Calibration compared with a referencemeasurement (e.g. manual measuringdevice)

Calibration by entering a preciselyknown cell constant


129

19.1.2 Calibration of the temperature coefficient

Conductivity sensors with temperature elementYou can only calibrate the temperature coefficient withconductivity sensors with a temperature element,because it is impossible to calculate the temperaturecoefficient without measuring the temperature.

Temperature changeIt is recommended that the temperature is changed byno more than 0.5 °C per minute, or with a temperaturechange of e.g. 10 °C you will need to wait for a min‐imum of 20 minutes before calibration.


130

A1866

CALCELLCONST

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%/°CCAL TEMPCOEFF

CAL=OLD

CAL=CONTINUE

T2 < 12.0 °C

CAL=CONTINUE

WAITCAL TEMPCOEFF

T2 > 32.0 °C orT2 < 12.0 °C

I.

II.STABLE ?

CAL_T2= 43.0 °C

CAL TEMPCOEFF

CAL=CONTINUE

ACCEPT ?

III.

Fig. 89: Calibration of the temperature coefficientI. If the temperature change is greater than 2°C,

the message changes to [WAIT]II. If the temperature is within the specified range,

the message changes to [STABLE ?]III. When a stable final temperature has been

reached, the message changes to [ACCEPT?].Calibration can now be terminated manually.

1. Calibrate at the first calibration temperature calibration tem‐perature; this calibration temperature should be close to theselected reference temperature.

2. Press [CAL] to accept the first calibration point. At the sametime the temperature ranges for the second temperaturevalue are given.

3. Important note: [CHANGE TEMP], now immerse the sensorin the same liquid with the second calibration temperature(minimum temperature difference ± 10 °C)

4. If the measured temperature has changed by more than2 °C, [WAIT] is displayed.


131

5. If the temperature has changed by more than 10 °C,[STABLE?] is displayed, and you can now terminate calibra‐tion if the displayed temperature value no longer changes(fluctuation < 0.3% of the value displayed). To do so, press[CAL].

6. When the Maximum/Minimum temperature has beenreached, [ACCEPT?] is displayed

ð You can now terminate calibration. To do so, press[CAL].

This process may take 10 ... 20 minutesdepending on the type of sensor.

7. Use [CAL] to accept the temperature coefficient or [ESC] todiscard it


[OK] In order [ΔTcal] > 20 °C

[WRN] Warning [ΔTcal] = 10 °C…20 °C

[ERR] Error [ΔTcal] < 10 °C

[ΔTcal] = Temperature difference of the calibration liquids

19.1.3 Calibration of the zero point

Dry the sensor and keep it free from electromagneticfieldsIf the zero point of the sensor is to be calibrated, it isnecessary to remove, rinse and dry the sensor beforecalibration. No electromagnetic fields can influence thesensor as these electromagnetic fields could distortcalibration. Keep devices that transmit radiation farfrom the sensor, such as mobile phones, WLANrouters, sources of high voltage, transformers etc.

Sensor status


132

A1942

CALCELLCONST

CAL ZEROPut LF-Sensor in airCAL=ACCEPT

ZERO

CAL ZEROSENSOR= 762.µS

CAL=ACCEPT

ZERO = 710.793 µS CAL ZERO

CAL=ACCEPT OK=RESET

TCOEFF

STABLE (10 sec)?

Fig. 90: Calibrating the zero point / The [CAL] [ZERO] default value corresponds to the default value of thesensor selected.

Zero point calibration limits

Sensor Value

ICT1 65 uS

ICT2 4 uS

CLS52 4 uS

Manual 50 uS

1. Press , removing the sensor from the application in which itis 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 bedisplayed 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 value and thenpress .

ð The new value for the zero point is carried over into thememory and the controller shows the continuous displayagain.

Calibrating the zero point


133

ZERO = 373.793 µS CAL ZERO

CAL=OLD OK=RESET A1945

ERR

Fig. 91: Display of incorrect calibration8. In the event of incorrect calibration, press to retain the old

calibration value and press to use the factory settings.


134

20 Maintenance


WARNING!Live partsPossible consequence: Fatal or very serious injuries.Measures:– Disconnect the system from the power supply

before opening the housing of a component.– If the housing of the pump, controller, terminal box

or other component is broken, ruptured or obvi‐ously damaged, immediately switch off the systemand arrange for its repair.

– Only carry out set-up / maintenance / repair andservice work when the system is shut down andthe electrical power disconnected. Calibration andmaintenance work on the sensors represents anexception to this. This work can be carried outwhile the system is live. Please also observe theinformation in the operating instructions for thesensors and controllers.

– Check that the seals are sitting correctly afterclosing the housing of the pump, controller or ter‐minal box




–

Maintenance

135

These parts of the DULCOTROL® measuring/control stationrequire the following maintenance:

Part Maintenance Frequency

With continuous flow through the installation

Parts through which sample waterflows

Check for leaks According to the internal specifica‐tion of the system operator

Flow control Test the flow controln Record the flow valuen Lower the flow - the controller

should switch to "Pause"n Readjust the recorded flow

value.

With a flushed and depressurised installation

Sample water pump See operating instructions in theappendix

See operating instructions in theappendix

Filter Clean, if not possible replace car‐tridge

As necessary, depending on thedegree of dirt in the sample water.

V82 pressure reducer See manufacturer's instructions inthe appendix

See manufacturer's instructions inthe appendix

Honeywell pressure reducer See manufacturer's instructions inthe appendix

See manufacturer's instructions inthe appendix

Sensor Maintenance: See the sensoroperating instructions

See the sensor operating instruc‐tions

Bypass fitting DLG Unscrew the cup and clean thesensors

According to the internal specifica‐tion of the system operator

20.1 DGMa: Replacing the Modules


1. Close the ball valve in the feed of the in-line probe housing2. Close the shut-off valve in the outlet of the in-line probe

housing

Maintenance

136

3. Unscrew the sensors and store the sensors as described inthe operating instructions for the sensors

4. Remove all hoses from the in-line probe housing5. Unscrew all modules and loosen the modules from the

holding clips6. Drain the modules7. Loosen the module to be replaced from the module block8. Check whether all O-rings are correctly fitted

270 °

I. III.II. A1249

Fig. 92: Replacing/adding modulesI. Position (front view)II. Turn clockwise (side view)III. Finished (front view)

9.Make sure that all the arrows on the modulespoint in the same direction.Reposition the modules if they do not screweasily into each other.The connection will otherwise become loose andwill no longer be able to be loosened withoutdamage.

Position the new module on the module block10. Turn the module clockwise until it hangs vertically down‐

wards11. Fit the complete new module block12. Close the drain nozzle and the sampling tap13. Screw in the sensors and calibrate if necessary, referring to

the operating instructions for the sensors14. Fit all hoses on the in-line probe housing15. Open the ball valve a little and check the leak-tightness of the

corresponding module before fully opening the ball valve16. Adjust the flow

Maintenance

137

20.2 Flushing the Bypass Fitting with PipeworkWhen do you have to flush the fitting? You have to flush the fittingwhen:n There is insufficient flown The sensors deliver incorrect measured values caused by con‐

taminationn For decontamination purposes before maintenancen Preventative maintenance.

1.

2.3.

A2113

Fig. 93: Flushing the bypass fitting with pipework1. Rinsing water inlet2. Rinsing and sample water outlet3. Sample water input

Maintenance

138

Nameplate / System pressureSet the system pressure stated on the nameplateduring flushing but do not exceed it. Use a pressurereducer if necessary.Do not allow sample water to enter the flushing pipefeed. Take appropriate self-sealing technical measuresto prevent backwashing.

1. Make sure that the waste water line is sufficiently large in thedirection of the flushing and sample water outlet (2) to enablethe rinsing water to drain away properly.

2. Make sure that the rinsing and sample water outlet is fullyopen.

3. Close the sample water inlet (3).4. Open the rinsing water inlet (1).

ð The bypass fitting with pipework is flushed.

5. Close the rinsing water inlet (1).6. Open the sample water inlet (3).

ð The bypass fitting with pipework is flushed and onceagain operational.

7. Check the flow and use the ball valves (1 and 3) to adjust theflow if necessary.

Maintenance

139

21 Troubleshooting


controllers and fittings and any other units, such assensors, sample water pumps ... !

– Adhere to the material safety data sheets for themedia used in your process!

NOTICE!– With terminal boxes: A wiring diagram is enclosed

in the documentation for the DULCOTROL® meas‐uring/control station.

Fault Cause Remedy

No or insufficient sample waterflow(Flow meter shows no or too low aflow)

Filter blocked Clean or replace the filter. Seemanufacturer's documentation

Sample water pumps not workingor working incorrectly

Check and, as necessary, repairthe electrical power supply. Seewiring diagram.

Mechanical causes: See manufac‐turer's documentation

Blockage of the pipework system Check the pipework system andclean as necessary

Defective metering and controlperformance

Controller with no or without suffi‐cient functionality

Check and, as necessary, repairthe electrical power supply. Seewiring diagram and controlleroperating instructions

Defective or incorrectly calibratedsensors

Refer to the operating instructionsfor the sensor and controller

Check and, as necessary, repairthe electrical power supply. Seewiring diagram

Power failure, sensors in run inphase, therefore faulty measure‐ment

Stop the control and observe therun in period for the sensors

Incorrect composition and/or con‐centration of the feed chemical

Adhere to the material safety datasheets for the media used in yourprocess! Check the quality and/orquantity of the feed chemical andcorrect as necessary

Incorrect allocation of the feedchemical

Check the feed chemical alloca‐tion and correct as necessary

Measuring errors Air in the system Bleed the system

Temperature outside of the speci‐fication

Install heat exchanger upstreamof the measuring point

Changed process parameters,e.g. water quality

Check the suitability of the sen‐sors

Pressure too high Fit a pressure reducer

Troubleshooting

140

Fault Cause Remedy

No sampling possible Negative pressure in the system Fully open inlet shut-off valve,adjust flow at the outlet shut-offvalve.

Leakage Pressure too high Fit a pressure reducer

Leakage Repair leak

Troubleshooting

141

22 Decommissioning and Disposal


CAUTION!– Only allow an electrical technician to disconnect

the measuring plate from the mains/power supply.– Thoroughly rinse the sample water line with a suit‐

able medium (see material safety data sheet).– Please also observe the operating instructions for


– Also necessary after brief decommissioning (up to12 h): Observe the sensor operating instructions.

22.1 Temporary Decommissioning (Less Than 4 Weeks)



With temporary decommissioning. Close the ball valves sothat the sensors remain surrounded by the sample water.

22.2 Temporary Decommissioning (Longer Than 4 Weeks)



Unscrew the sensors and store the sensors properly, asdescribed in the operating instructions for the sensors.

Decommissioning and Disposal

142

22.3 Final Decommissioningn User qualification: instructed user, see Ä Chapter 2.5 ‘Users'




– The electrolyte of the sensors can be corrosive.– Capture any escaping electrolyte. Wear suitable

safety gloves and glasses, referring to the materialsafety data sheet for the electrolyte.

– Dispose of waste water in an environmentally-friendly manner.

NOTICE!Regulations governing the disposal of used parts– Note the current national regulations and legal

standards which apply in your country

The manufacturer will take back decontaminated used units pro‐viding they are covered by adequate postage.Decontaminate the unit before returning it for repair. To do so,remove all traces of hazardous substances. Refer to the MaterialSafety Data Sheet for your feed chemical.A current Declaration of Decontamination is available to downloadon the ProMinent website. Please also observe the information onthe current Declaration of Decontamination.

Decommissioning and Disposal

143

23 Technical Data and Operating Parameters

Application Type Sample water Operating pressure

Potable water (P) C0, C1, D0, I0, Z0, F0, H0, X0 1 1 bar at 45 °C

Potable water (P) G0, A0 1 3 bar at 45 °C

Potable water (P) P0, R0, L0 1 6 bar at 45 °C

Waste water (W) C0, C1, D0, I0, Z0, F0, H0, X0 2, 4, 5, 7 1 bar at 45 °C

Waste water (W) G0, A0 2, 4, 5, 7 3 bar at 45 °C

Waste water (W) X0 6 1 bar at 45 °C

Waste water (W) P0, R0, L0 6 6 bar at 45 °C

Water to be measured Description Definition

1 Potable water Drinking water in accordance with theGerman Drinking Water Ordinance.

2 Rinsing water Process water with a low purity level (withsmall particles of dirt, turbid appearance)

Process water

Industrial process water

4 Clear waste water Waste water with a low purity level (withsmall particles of dirt and chemical pollu‐tion)

5 Waste water with solid particle frac‐tion, turbid

Waste water with a low purity level (withparticles of dirt < 1 mm, floating bodies,turbid and chemical pollution)

6 Waste water with solid particle frac‐tion, containing sludge

Municipal waste water with coarse impuri‐ties; industrial waste water (from thepaper or metal industry), max. permittedparticles of dirt 3 mm and chemical pollu‐tion

7 Waste water with fluoride and pH < 7 Waste water with a low purity level (withsmall particles of dirt, turbid appearance)

Refer to the specifications for the series components

Refer to the specifications for the series components. The pipe‐work in the bypass is made of PVC fittings.

The electrical components have a wide-voltage power supply andcan be operated at 100 ... 230 VAC, 50/60 Hz.Electrical connection:n 100 … 230 V 50/60 Hzn 0.7 … 0.3 An 35 W

Permissible operating pressures

Definition of "sample water"

Accuracy

Material specifications/Manufacturingprocesses/Chemical resistance

Electrical data

Technical Data and Operating Parameters

144

Ambient temperature: +5 … +50°CMedium temperature: max. sample water temperature 45 °CMedium temperature: max. sample water temperature 35 °C (withfluoride)

Air humidity: max. 90 % relative air humidity, non-condensing.

Degree of protection: IP 65

The transport weight depends on the configuration of the meas‐uring plate and is between 8 ... 13 kg.

Free flow / No overpressure or negative pressureMake sure that there is no overpressure > 1 bar andalso no negative pressure at the outlet of the meas‐uring plate. Overpressure damages the bypass fitting.Negative pressure damages the sensors fitted. Usethe stopcocks to adjust the pressure at the samplewater inlet and outlet. Route the pipework so that thesample water can drain unimpeded.

23.1 Flow and Operational Test of Flow ControlSet the ranges of the reed switch on the flow control DGMa and/orDLG to Minimum and Maximum, switching the DACa from Opera‐tion to Pause when doing soCheck:n The wiring to the controller is correctn The switching function of the flow sensorn The correct configuration of the controllern The alarm relay (e.g. horn)

Switching point of the flow control

Water to bemeasured

Description Bypass fitting Nominal crosssectionmm

Permissible flowl/h

Control switchesoffat l/h

1 Potable water DGMa 4 20 … 60 < 20

2 Rinsing water DLG III 6 40 … 65 < 20

Process water

Industrialprocess water

4 Waste water,clear

DLG III 6 40 … 65 < 20

Temperature data

Climate

Protection against contact andhumidity (IP)

Transport weight


145

Water to bemeasured

Description Bypass fitting Nominal crosssectionmm

Permissible flowl/h

Control switchesoffat l/h

5 Waste waterwith solid par‐ticle fraction,turbid

DLG III 6 40 … 65 < 20

7 Waste waterwith fluorideand pH < 7

DLG III 6 40 … 65 < 20


146

24 Spare Parts and Accessories24.1 Spare Parts

Please also observe the lists in the operating instructions for con‐trollers and fittings and any other units, such as sensors, samplewater pumps ... ! In addition, spare parts can be purchased fromour Service department.The replacement diaLog DACa controller is supplied with a defaultconfiguration. When commissioning the diaLog DACa controller,the previous configuration of the old controller can be transferredusing the SD card.

Position number Quantity Description Part number

100 1 DACAPA61000000001000 1048190

100 1 DACAPA61000000101000 1048191

100 1 DACAPA61400000001000 1048192

100 1 DACAPA61400000101000 1048193

101 1 DCCAP006L3001000 1044468

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 1050292

300 1 Fluoride sensor, FLEP-010/0100-SE 1028279

300 1 ORP sensor, REFP-SE 1018458

300 1 pH sensor, PHEF -012-SE 1010511

300 1 ORP sensor RHEP-Au-SE 1003875

300 1 Conductivity sensor, LFTK 1 DE 1002822

300 1 ORP sensor RHER-Pt-SE 1002534

300 1 pH sensor, PHEP -112 SE 1001586

300 1 ORP sensor RHEX-Pt-SE 305097

300 1 pH sensor PHEX -112 SE 305096

300 1 Temperature sensor, Pt-100-SE 305063

300 1 ORP sensor, RHEP-Pt-SE 150094

300 1 pH sensor, PHEP-112-SE 150041

301 1 Bromine sensor, BCR 1-mA- 1040115

301 1 Chlorine sensor, CBR 1-mA- 1038016

301 1 Chlorine sensor, CBR 1-mA- 1038015

301 1 Chlorine dioxide sensor CDR 1-mA-2 ppm 1033393

301 1 Hydrogen peroxide sensor, PER 1-mA-50 ppm 1030511

301 1 Hydrogen peroxide sensor, PER 1-mA-2000 p 1022510

Spare Parts and Accessories

147

Position number Quantity Description Part number

301 1 Hydrogen peroxide sensor, PER 1-mA-200 pp 1022509

301 1 PES sensor, PAA 1-mA-2000 p 1022507

301 1 PES sensor, PAA 1-mA-200 pp 1022506

301 1 Chlorite sensor, CLT 1-mA-0.5 ppm 1021596

301 1 Ozone sensor, OZE 3-mA- 2 ppm 792957

301 1 ClO2 sensor, CDE 2-mA-0.5ppm 792930

301 1 Chlorine sensor, CLE 3-mA-0.5ppm 792927

301 1 Chlorine sensor, CTE 1-mA-0.5ppm 740686

302 1 Transmitter, 4 ... 20 mA, FPV1 1028280

302 1 Transmitter, 4 ... 20 mA, FP100 1031331

303 1 Conductivity sensor ICT1 1023244

304 1 Thermal switch 7760491

305 1 Oxygen sensor, fully assembled 1031715

500 1 Magnetic stirrer 790915

501 * 1 Magnetic stirring rod, 15x6, PRFE 790917

502 * 1 SD card, industrial 732483

503 * 1 Coaxial cable, 0.8 m, SN 6, open end 1006410

504 * 1 Control cable, LiYY, 2 x 0.25 mm2 725122

505 * 1 Cable, complete, LFTK, 3 m, screened 1046012

506 * 1 Cable, control cable, 5 m, SN 6, open end 1003208

507 * 1 Filter element, FL-5-10 1031210

508 * 1 Filter element, FL-5-100 1031211


148

A2128

40124337

Fig. 94: Measuring plate DWCa with DGMA and filter

Measuring plate DWCa with DGMAand filter


149

A2129

40124338

Fig. 95: Measuring plate DWCa with DLG III and filter

Measuring plate DWCa with DLG IIIand filter


150

A2130

40124341

Fig. 96: Measuring plate DWCa with DLG III, filter and stirrer

Measuring plate DWCa with DLG III,filter and stirrer


151

40124390A2131

Fig. 97: Measuring plate DWCa with ICT/pH/RH/Temperature

Measuring plate DWCa with ICT/pH/RH/Temperature


152

A2133

40130341

Fig. 98: Measuring plate DWCa with oxygen measurement for potable water

Measuring plate DWCa with oxygenmeasurement for potable water


153

A2134

40124458

Fig. 99: Measuring plate DWCa with filter, DLG and ICT

Measuring plate DWCa with filter,DLG and ICT


154

A213540124467

Fig. 100: Measuring plate DWCa with O2/ICT/pH/ORP

24.2 AccessoriesPhotometer

Component Order number

Photometer DT1B 1039315

Photometer DT2C 1039316



The scope of delivery of the photometer includes a transport case, accessories, cuvettes and reagents.

Measuring plate DWCa with O2/ICT/pH/ORP


155

25 EC Declaration of ConformityWe,n ProMinent GmbHn Im Schuhmachergewann 5 - 11n D - 69123 Heidelberg,hereby declare that the product specified in the following, complieswith the relevant basic health and safety requirements of the ECDirective, on the basis of its functional concept and design and inthe version distributed by us. Any modification to the product notapproved by us will invalidate this declaration.

Extract from the EC Declaration of Conformity

Designation of the product: DULCOTROL® DWCa

Product type: DWCa _ _ _ _ _ _ _ _ _ _ _ 0 _ _ _ _ _

Serial number: see nameplate on the unit

Relevant EC directives: Low Voltage Directive 2006/95/ECEC EMC Directive (2004/108/EC)

Harmonised standards applied,in particular:

EN 61010-1: 2010EN 61326 - 1: 2013, Class A, industrial sector

Date: 15.05.2015

The EC Declaration of Conformity is available to download on ourhomepage.

EC Declaration of Conformity

156

26 IndexAAccuracy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144Action, step by step . . . . . . . . . . . . . . . . . . . . . . . . 2Actuating outputs . . . . . . . . . . . . 109, 112, 114, 116Air humidity . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145Alarm equipment . . . . . . . . . . . . . . . . . . . 11, 25, 42Alarm relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73Ambient temperature . . . . . . . . . . . . . . . . . . . . . 145Applied harmonised standards . . . . . . . . . . . . . 156Archiving the settings . . . . . . . . . . . . . . . . . . . . . 80Area at risk from explosion . . . . . . . . . . . . . . . . . 11Assembly height . . . . . . . . . . . . . . . . . . . . . . . . . 27

BBacklight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74Ball valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14Brightness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74Bypass fitting . . . . . . . . . . . . . . . . . . . . . . . . . 20, 22

CCable marker . . . . . . . . . . . . . . . . . . . . . . . . . . . 44Calibrating Amperometric measured Variables . 104Calibrating Chlorine . . . . . . . . . . . . . . . . . . . . . . 104Calibrating the "Conductivity" measured variable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118

Calibrating the "Temperature" measured vari‐able . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120Calibrating the zero point . . . . . . . . . . . . . . . . . 106Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82Calibration solution . . . . . . . . . . . . . . . . . . . . . . . 57Chemical resistance . . . . . . . . . . . . . . . . . . . . . 144Circulating pump . . . . . . . . . . . . . . . . . . . . . . . . . 26Climate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145Concealed installations . . . . . . . . . . . . . . . . . . . . 26Contamination . . . . . . . . . . . . . . . . . . . . . . . . . . . 12Contrast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74Contrast setting . . . . . . . . . . . . . . . . . . . . . . . 66, 70Control outputs . . . . . . . . . . . . . . . . . . . . . . . . . 106Control stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

DData input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93Decoupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42Defective control by defective measured values . 43Definition of "sample water" . . . . . . . . . . . . . . . . 144Degree of protection: IP 65 . . . . . . . . . . . . . . . . 145Designation of the product . . . . . . . . . . . . . . . . 156Direction of flow . . . . . . . . . . . . . . . . . . . . 29, 33, 38Drilling template . . . . . . . . . . . . . . . . . . . . . . . . . 27

EElectrical data . . . . . . . . . . . . . . . . . . . . . . . . . . 144Electrical installation of the amperometric sen‐sors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31, 37, 40Electrical installation of the flow sensor . . 31, 36, 40Electrical installation of the ORP and pH sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32, 37, 41

Emergency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

FFailure of the control and impact on the process. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11, 25, 42

Fitting sensors with screw thread PG 13.5 . . 34, 38Fitting sensors with shaft diameter 25 mm (onlyDLG III A or B) . . . . . . . . . . . . . . . . . . . . . . . . . . 35Flammable media . . . . . . . . . . . . . . . . . . . . . . . . 11Flushing the bypass fitting with pipework . . . . . 138Function of the keys . . . . . . . . . . . . . . . . . . . . . . 59Further applicable documents . . . . . . . . . . . . . . . 16

GGalvanically isolated measuring device . . . . . . . . 43General non-discriminatory approach . . . . . . . . . . 2Guard plate (IP) . . . . . . . . . . . . . . . . . . . . . . . . . 145

HHanger bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28Hydraulic leaks . . . . . . . . . . . . . . . . . . . . . . . . . . 13Hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . 53

IIn-line probe housing . . . . . . . . . . . . . . . . . . . . . . 23Incorrect metering . . . . . . . . . . . . . . . . . . . . . . . . 55Indoors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13Installation diagram . . . . . . . . . . . . . . . . . . . . . . . 24Installation diagram for accessories . . . . . . . . . . 28

KKey Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

LLanguage settings . . . . . . . . . . . . . . . . . . . . . . . . 63Life phases . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14Lightning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13Links to elements or sections of these instruc‐tions or other applicable documents . . . . . . . . . . . 2Live parts . . . . . . . . . . . . . . . . . . . . . . . . . . . 11, 43

MMains switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43Manufacturing processes . . . . . . . . . . . . . . . . . 144Material specifications . . . . . . . . . . . . . . . . . . . . 144Maximum operating pressure . . . . . . . . . . . . . . 144Measuring plate . . . . . . . . . . . . . . . . . . . . . . . . . 44Medium temperature . . . . . . . . . . . . . . . . . . . . . 145Metering pumps . . . . . . . . . . . . . . . . . . . . . . . . . 26Moisture protection (IP) . . . . . . . . . . . . . . . . . . . 145More symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2Mounting system . . . . . . . . . . . . . . . . . . . . . . . . . 26

NNon-discriminatory approach . . . . . . . . . . . . . . . . 2

OOperating Concept . . . . . . . . . . . . . . . . . . . . . . . 59Operating elements . . . . . . . . . . . . . . . . . . . . 65, 69Operating errors . . . . . . . . . . . . . . . . . . . . . . . . . 13Operating language . . . . . . . . . . . . . . . . . . . . 63, 74Operating pressure . . . . . . . . . . . . . . . . . . . . . . 144Outdoor applications . . . . . . . . . . . . . . . . . . . . . . 14Overview of equipment . . . . . . . . . . . . . . . . . 65, 69

Index

157

PParked position . . . . . . . . . . . . . . . . . . . . . . . . . . 27PE plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16Permissible operating pressures . . . . . . . . . . . . 144pH calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . 83Pipework . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23Poor sensor operation and fluctuating pH valuesduring the process . . . . . . . . . . . . . . . . . . . . . . . . 91Potential adjustment . . . . . . . . . . . . . . . . . . . . . . 57Potential equalisation pin . . . . . . . . . . . . . 20, 21, 23Potential separation of the power supply . . . . . . . 43Power repeater . . . . . . . . . . . . . . . . . . . . . . . . . . 43Protective housing . . . . . . . . . . . . . . . . . . . . . . . . 13

QQualification . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14Question: Are there disadvantages with pH cali‐bration with an external sample? . . . . . . . . . . . . . 91Question: How are the device and sensor cali‐brated? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121Question: How are the unit and sensor cali‐brated? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127Question: How can I reset the operating lan‐guage? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74Question: How can I set or change the operatinglanguage? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63Question: How can I store and transport theproduct? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19Question: How do I adjust the display bright‐ness? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74Question: How do I adjust the display contrast? . 74Question: How do I calibrate the sensor's zeropoint? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132Question: How does the controller operate? . . . . 59Question: How does the key lock work? . . . . . . . 64Question: What ambient conditions need to betaken into consideration? . . . . . . . . . . . . . . . . . . 19Question: What can be calibrated? . . . . . . 121, 127Question: What happens in the event of incor‐rect calibration? . . . . . . . . . . . . . . . . . . . . . 121, 127Question: What information is made available inthe continuous display? . . . . . . . . . . . . . . . . . 67, 71Question: What information is made available inthe info display? . . . . . . . . . . . . . . . . . . . . . . 68, 72Question: What type of buffer solutions do Ineed for a fluoride calibration? . . . . . . . . . 101, 103Question: What type of buffer solutions do Ineed for pH calibration? . . . . . . . . . . . . . . . . . . . 88Question: Which calibration process can youuse to calibrate amperometric measured varia‐bles? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105Question: Which calibration process can youuse to calibrate the DO measured variable? . . . 111Question: Which calibration process can youuse to calibrate the fluoride value? . . . . . . . . . . 100Question: Which calibration process can youuse to calibrate the ORP value? . . . . . . . . . . . . . 95

Question: Which calibration process can youuse to calibrate the pH value? . . . . . . . . . . . . . . . 86Question: Which values render pH calibrationvalid? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

RRecycling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19Redundant design . . . . . . . . . . . . . . . . . . 11, 25, 42Regulating tap . . . . . . . . . . . . . . . . . . . . . . . . . . . 37Relevant EC directives . . . . . . . . . . . . . . . . . . . 156Remove and refit the fluoride sensor in the in-line probe housing . . . . . . . . . . . . . . . . . . . 100, 102Remove and refit the pH sensor in the in-lineprobe housing . . . . . . . . . . . . . . . . . . . . . . . . . . . 87Residual current circuit breaker (RCCB) . . . . . . . 11Residual current devices (RCD) . . . . . . . . . . . . . 11Resistance list . . . . . . . . . . . . . . . . . . . . . . . . . . . 13Risks of explosion . . . . . . . . . . . . . . . . . . . . . . . . 11Run in periods . . . . . . . . . . 106, 109, 112, 114, 116

SSafety data sheet . . . . . . . . . . . . . . . . . . . . . . . . 55Safety goggles . . . . . . . . . . . . . . . . . . . . 29, 33, 38Safety information . . . . . . . . . . . . . . . . . . . . . . . . . 9Sample water fault . . . . . . . . . . . . . . . . . . . . . . . 73Sample water temperature . . . . . . . . . . . . . . . . 145Sampling tap . . . . . . . . . . . . . . . . . . . . . . . . . 22, 23Scope of delivery . . . . . . . . . . . . . . . . . . . . . . . . . 16Sensor function . . . . . . . . . 106, 109, 112, 114, 116Serial number . . . . . . . . . . . . . . . . . . . . . . . . . . 156Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147Sources of EMC interference . . . . . . . . . . . . . . . 43Standard signal outputs . . . 106, 109, 112, 114, 116Starting up the DLG . . . . . . . . . . . . . . . . . . . . . . 37Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19Strain relief . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42Sunlight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

TTemperature data . . . . . . . . . . . . . . . . . . . . . . . 145Test container 1 with buffer solution . . . . . . . . . . 88Test container 1 with fluoride calibration solution. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100, 102

Test container 2 with buffer solution . . . . . . . . . . 88Test container 2 with fluoride calibration solution. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100

Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

UUsers' qualifications . . . . . . . . . . . . . . . . . . . . . . 15UV sources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

ZZERO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133Zero point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133Zero point calibration . . . . . . . . . 109, 112, 114, 116

Index

158

159

984397, 1, en_GB

© 2015

ProMinent GmbHIm Schuhmachergewann 5 - 1169123 Heidelberg, GermanyTelephone: +49 (6221) 842-0Fax: +49 (6221) 842-419Email: [email protected]: www.prominent.com

Documents

DULCOTROLAssembly and operating instructions DWCa