ProMinent DULCOTEST CLO 1 User manual

DULCOTEST® Sensor for free chlorine
Type CLO 1 / CLO 2
Operating Manual
EN/DE/FR/ES
Part no. 986347 BA DT 101 05/09 EN/DE/FR/ES
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!
Technical changes reserved.

986347, 1, en_GB
© 2009
ProMinent Dosiertechnik Heidelberg GmbH
Im Schuhmachergewann 5-11
69123 Heidelberg
Telephone: [phone]
Fax: [phone]
email: [email protected]
Internet: www.prominent.com
2

Table of contents
1Introduction ............................................................................................................................ 8
1.1 Explanation of the Safety Information............................................................................ 8
1.2 Users' qualifications .................................................................................................... 10
1.3 General safety information .......................................................................................... 11
1.4 Correct and Proper Use............................................................................................... 12
1.5 Information in the event of an emergency ................................................................... 12
2 Functional Description .......................................................................................................... 13
2.1 Construction ................................................................................................................ 13
2.2 Measured variable ....................................................................................................... 13
2.3 Function ....................................................................................................................... 13
2.4 Construction of the sensor .......................................................................................... 15
3 Transport and Storage ......................................................................................................... 17
3.1 Storage ........................................................................................................................ 17
3.2 Transport...................................................................................................................... 17
4 Assembly .............................................................................................................................. 18
5Installation ............................................................................................................................ 21
6 Commissioning ..................................................................................................................... 22
6.1 Calibration ................................................................................................................... 22
7 Troubleshooting ................................................................................................................... 25
7.1 Troubleshooting ........................................................................................................... 25
7.2 Error ............................................................................................................................ 29
8 Maintenance and Repair ...................................................................................................... 31
8.1 Replacement intervals ................................................................................................. 31
8.2 Repair........................................................................................................................... 31
9 Decommissioning, Removal and Disposal ........................................................................... 32
10 Ordering Information ............................................................................................................ 33
11 Technical Specifications ....................................................................................................... 34
11.1 Observed regulations/standards (minimum requirement) ......................................... 34
11.2 Technical data ........................................................................................................... 34
11.3 Material data / Dimensions and weights .................................................................... 35
11.4 Flow ........................................................................................................................... 36
11.5 Electrical data ............................................................................................................ 36
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11.6 Temperature and climate .......................................................................................... 37
11.7 Rated gradient, drift and response time .................................................................... 37
12 Einleitung.............................................................................................................................. 38
12.1 Kennzeichnung der Sicherheitshinweise.................................................................... 38
12.2 Benutzer Qualifikation................................................................................................ 39
12.3 Allgemeine Sicherheitshinweise................................................................................. 40
12.4 Bestimmungsgemäße Verwendung........................................................................... 41
12.5 Angaben für den Notfall.............................................................................................. 41
13 Funktionsbeschreibung......................................................................................................... 42
13.1 Aufbau........................................................................................................................ 42
13.2 Messgröße................................................................................................................. 42
13.3 Funktion...................................................................................................................... 42
13.4 Aufbau des Sensors................................................................................................... 44
14 Transportieren und Lagern.................................................................................................... 46
14.1 Lagerung.................................................................................................................... 46
14.2 Transport.................................................................................................................... 46
15 Montieren.............................................................................................................................. 47
16 Installieren............................................................................................................................. 50
17 In Betrieb nehmen................................................................................................................. 52
17.1 Kalibrieren.................................................................................................................. 52
18 Fehler beheben..................................................................................................................... 55
18.1 Fehlersuche................................................................................................................ 55
18.2 Fehler......................................................................................................................... 59
19 Warten und Reparieren......................................................................................................... 61
19.1 Wechselintervalle....................................................................................................... 61
19.2 Reparieren.................................................................................................................. 61
20 Außerbetriebnahme, Abbau und Entsorgung........................................................................ 62
21 Bestellhinweise..................................................................................................................... 63
22 Technische Angaben............................................................................................................ 64
22.1 Eingehaltene Richtlinien/Normen (Mindestanforderung............................................. 64
22.2 Technische Daten...................................................................................................... 64
22.3 Werkstoffangaben / Maße und Gewichte................................................................... 65
22.4 Anströmung................................................................................................................ 66
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22.5 Elektrische Daten....................................................................................................... 66
22.6 Temperatur und Klima................................................................................................ 67
22.7 Nennsteilheit, Drift und Ansprechzeit......................................................................... 67
23 Introduction .......................................................................................................................... 68
23.1 Désignation des consignes de sécurité...................................................................... 68
23.2 Qualification des utilisateurs ...................................................................................... 70
23.3 Consignes générales de sécurité .............................................................................. 71
23.4 Utilisation conforme à l’usage prévu.......................................................................... 72
23.5 Informations en cas d'urgence .................................................................................. 72
24 Description de fonctionnement ............................................................................................. 73
24.1 Structure .................................................................................................................... 73
24.2 Grandeur de mesure ................................................................................................. 73
24.3 Fonction ..................................................................................................................... 73
24.4 Structure de la sonde ................................................................................................ 75
25 Transport et stockage .......................................................................................................... 77
25.1 Stockage ................................................................................................................... 77
25.2 Transport.................................................................................................................... 77
26 Montage ............................................................................................................................... 78
27 Installation ............................................................................................................................ 81
28 Mise en service .................................................................................................................... 83
28.1 Étalonnage ................................................................................................................ 83
29 Élimination de défauts .......................................................................................................... 86
29.1 Recherche des erreurs .............................................................................................. 86
29.2 Défaut ........................................................................................................................ 91
30 Entretien et réparations ........................................................................................................ 93
30.1 Intervalle de remplacement ....................................................................................... 93
30.2 Réparations................................................................................................................ 93
31 Mise hors service, démontage et élimination ....................................................................... 94
32 Informations de commande .................................................................................................. 95
33 Informations techniques ....................................................................................................... 96
33.1 Directive/Normes respectées (exigence minimale) ................................................... 96
33.2 Caractéristiques techniques ...................................................................................... 96
33.3 Matériaux / Dimensions et poids ............................................................................... 97
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33.4 Débit d'alimentation ................................................................................................... 98
33.5 Caractéristiques électriques ...................................................................................... 98
33.6 Température et climat ............................................................................................... 99
33.7 Pente nominale, dérive et temps de réponse ............................................................ 99
34 Introducción ........................................................................................................................ 100
34.1 Señalización de las indicaciones de seguridad........................................................ 100
34.2 Cualificación del usuario ......................................................................................... 102
34.3 Indicaciones generales de seguridad ...................................................................... 103
34.4 Uso conforme a lo prescrito..................................................................................... 104
34.5 Indicaciones en casos de emergencia .................................................................... 104
35 Descripción del funcionamiento ......................................................................................... 105
35.1 Montaje .................................................................................................................... 105
35.2 Magnitud de medida ................................................................................................ 105
35.3 Función .................................................................................................................... 105
35.4 Montaje del sensor .................................................................................................. 107
36 Transporte y almacenamiento ............................................................................................ 109
36.1 Almacenamiento ...................................................................................................... 109
36.2 Transporte................................................................................................................ 109
37 Montaje .............................................................................................................................. 110
38 Instalación .......................................................................................................................... 113
39 Puesta en marcha .............................................................................................................. 115
39.1 Calibración .............................................................................................................. 116
40 Eliminación de fallos .......................................................................................................... 118
40.1 Localización de fallos .............................................................................................. 118
40.2 Fallo ......................................................................................................................... 123
41 Mantenimiento y reparación ............................................................................................... 125
41.1 Intervalos de cambio ............................................................................................... 125
41.2 Reparación............................................................................................................... 125
42 Período fuera de servicio, desmontaje y eliminación ......................................................... 126
43 Indicaciones para el pedido ............................................................................................... 127
44 Información técnica ............................................................................................................ 128
44.1 Directivas/normas aplicadas (requisitos mínimos) .................................................. 128
44.2 Datos técnicos ......................................................................................................... 128
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44.3 Datos de los materiales / Dimensiones y pesos ...................................................... 129
44.4 Caudal ..................................................................................................................... 130
44.5 Datos eléctricos ....................................................................................................... 130
44.6 Temperatura y clima ................................................................................................ 131
44.7 Pendiente nominal, variación y tiempo de reacción ................................................ 131
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1 Introduction
These operating instructions provide information
on the technical data and functions of the product
DULCOTEST ® Sensor for free chlorine,
Type CLO 1 / CLO 2
1.1 Explanation of the Safety
Information
Introduction
These operating instructions provide information
on the technical data and functions of the
product. These operating instructions provide
detailed safety information and are provided as
clear step-by-step instructions.
The safety information and notes are categorised
according to the following scheme. A number of
different symbols are used to denote different
situations. The symbols shown here serve only
as examples.
DANGER!
Nature and source of the danger
Consequence: Fatal or very serious inju‐
ries.
Measure to be taken to avoid this danger.
Danger!
–Denotes an immediate threatening
danger. If this is disregarded, it will
result in fatal or very serious injuries.
WARNING!
Nature and source of the danger
Possible consequence: Fatal or very
serious injuries.
Measure to be taken to avoid this danger.
Warning!
–Denotes a possibly hazardous situa‐
tion. If this is disregarded, it could result
in fatal or very serious injuries.
CAUTION!
Nature and source of the danger
Possible consequence: Slight or minor inju‐
ries. Material damage.
Measure to be taken to avoid this danger.
Caution!
–Denotes a possibly hazardous situa‐
tion. If this is disregarded, it could result
in slight or minor injuries. May also be
used as a warning about material
damage.
Introduction
8

NOTICE!
Nature and source of the danger
Damage to the product or its surroundings.
Measure to be taken to avoid this danger.
Note!
–Denotes a possibly damaging situa‐
tion. If this is disregarded, the product
or an object in its vicinity could be
damaged.
Type of information
Hints on use and additional information.
Source of the information. Additional meas‐
ures.
Information!
– Denotes hints on use and other useful
information. It does not indicate a
hazardous or damaging situation.
Introduction
9

1.2 Users' qualifications
WARNING!
Danger of injury with inadequately qualified personnel!
If inadequately qualified personnel work on the sensor, this could result in dangers that could
cause serious injuries and material damage.
–All work on the unit should therefore only be conducted by qualified personnel.
–Keep unqualified personnel away.
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 that could result from improper behaviour,
as well as having been instructed in the required protective equip‐
ment and protective measures.
Trained user A trained user is a person who fulfills the requirements made of an
instructed person and who has also received additional training
specific to the system from ProMinent or another authorised distri‐
bution partner.
Technical experts A technical expert is deemed to be a person who is able to assess
the tasks assigned to him and recognize possible hazards based
on his/her technical training and experience, as well as knowledge
of pertinent regulations.
Trained qualified personnel A qualified employee is deemed to be a person who is able to
assess the tasks assigned to him and recognize possible hazards
based on his/her training, knowledge and experience, as well as
knowledge of pertinent regulations. The assessment of a
person's technical training can also be based on several years of
work in the relevant field.
Electrician Electricians are deemed to be people, who are able to complete
work on electrical systems and recognize and avoid possible
hazards independently based on his/her technical training and
experience, as well as knowledge of pertinent standards and regu‐
lations.
Electricians should be specifically trained for the working environ‐
ment in which they are employed and know the relevant standards
and regulations.
Introduction
10

Training Definition
Electricians must comply with the provisions of the applicable stat‐
utory directives on accident prevention.
Customer Service department Customer Service department refers to service technicians, who
have received proven training and have been authorised by ProM‐
inent to work on the system.
Note for the system operator
The pertinent accident prevention regulations, as well as all other generally acknowledged safety
regulations, must be adhered to!
1.3 General safety information
WARNING!
Unauthorised access!
Possible consequence: Fatal or very
serious injuries
–Measure: Ensure that there can be no
unauthorised access to the unit
–The sensor may only be fitted,
installed, serviced and operated by
personnel trained for this
CAUTION!
Functional limitations
Possible consequence: Slight or minor inju‐
ries, material damage
–Check the sensor regularly for dirt and
impurities
–Check the membrane cap regularly for
air bubbles adhering to it
–Observe all applicable national regula‐
tions relating to maintenance, service
and calibration intervals.
Introduction
11

CAUTION!
Prerequisites for operation
Possible consequence: Slight or minor inju‐
ries, material damage
–The sensor may only be used in flow
gauges that ensure the correct flow
parameters.
–There must be a free outlet or at most
a counter pressure of 1 bar at the outlet
of the flow gauge. The maximum oper‐
ating pressure of the respective single
components must be observed.
–The sensor's voltage supply may not
be interrupted
–Following longer interruptions to the
voltage supply (> 2 h), allow the sensor
to run-in again and recalibrate it
1.4 Correct and Proper Use
NOTICE!
Correct and Proper Use
–The sensor may only be used to deter‐
mine and regulate concentrations of
free chlorine
–The sensor may not be used in
conjunction with organic chlorine
compounds, such as trichloroisocya‐
nuric acid, or stabilisers, such as
cyanuric acid
–Any other uses or modifications to the
system are prohibited
–The sensor is not a safety component
1.5 Information in the event of an
emergency
nIn the event of an emergency, switch off the
controller
nIf liquid exits from the flow gauge housing
then close the shut-off valves provided by
the customer at their inlets and outlets
nObserve the safety instructions of the plant
operator before opening the flow gauge
housing
nIn case of proven over-metering, destroy the
excess chlorine using a suitable reducing
agent (e.g. hydrogen peroxide or sodium
sulphite)
Introduction
12

2 Functional Description
Brief functional description
The DULCOTEST® Sensor for free chlorine CLO
1 / CLO 2 is an amperometric three-electrode
sensor without a membrane. The
DULCOTEST® Sensor for free chlorine CLO 1 /
CLO 2 can be used to determine the concentra‐
tion of free chlorine in water.
The DULCOTEST® Sensor for free chlorine CLO
1 / CLO 2 measures the content of hypochlorous
acid (HOCl) in water.
Typical applications:
nchlorination of swimming bath water (CLO
1)
nchlorination of drinking water (CLO 1)
ncombating legionella in house water instal‐
lations up to 70 °C (CLO 2)
The sensor signal depends on the conductivity of
the sample medium.
The sensor signal is flow-dependent. The rate of
flow in the DGMA module must therefore be kept
constant at ± 5 l/h.
2.1 Construction
The DULCOTEST® Sensor for free chlorine CLO
1 / CLO 2 is an open, three-electrode sensor
without a membrane. It comprises a sensor cap
and the sensor shaft. The electrolyte-filled
sensor cap constitutes the reference system.
The ring-shaped reference electrode in the
measuring chamber is above the electrolyte and
contacts with the working electrode (cathode)
and the counter electrode (anode).
Both electrodes on the sensor shaft are
immersed in the measuring (sample) water. The
amplifier electronics are located in the sensor
shaft. The electrical connection is above this.
The temperature sensor for temperature
compensation is incorporated in the lower part of
the sensor shaft .
2.2 Measured variable
CAUTION!
Oxidising agent
Possible consequence: Slight or minor inju‐
ries, material damage
If there are additional oxidising agents in the
sample medium such as, e.g. chlorine
dioxide, ozone or chloramine then these are
also detected by the sensor. In other
words, the sensor is not specifically cali‐
brated for chlorine but detects all oxidising
agents in the sample media.
This should be considered when configuring
the process to prevent incorrect measure‐
ment and concomitant incorrect metering.
Free chlorine (HOCI, OCI -, Cl 2 ). Free chlorine
is the sum of chlorine gas (Cl 2 ), hypochlorous
acid (HOCI) and hypochlorite (OCI -).
2.3 Function
Gold wires with a diameter of 2 mm are used as
the working electrode (cathode) and counter
electrode (anode); a silver ring coated with a
layer of silver halide is used as reference elec‐
trode. After the sensor has been electrically
connected to the controller, a potentiostat is used
to ensure there is a constant polarisation voltage
for the required electrode reaction on the working
electrode, independent of the current flow. The
current flow (depolarisation current) produced,
Functional Description
13

which under constant conditions is proportional
to the concentration of the hypochlorous acid, is
converted into a standard output signal (4...20
mA) by the sensor electronics and is displayed
by the measuring device/control device.
The photometric DPD-I method is used to cali‐
brate the DULCOTEST® sensor for free chlorine
CLO 1 / CLO 2.
Functional Description
14

2.4 Construction of the sensor
1
2
3
4
5
6
7
8
9
10
11
Fig. 1: Exploded view of the sensor CLO
Position number Description
1 Opening for M12 cable connector
2 Top section
3 O-ring seal
4 2-lead connection
5 Sensor shaft
Functional Description
15

Position number Description
6 O-ring seal
7 Working electrode and counter electrode
8 Tubular seal and air vent opening
9 Sensor cap
10 Reference electrode
11 Clamping disc
Functional Description
16

3 Transport and Storage
NOTICE!
Original packaging
Damage to the product
–Only transport, ship and store the
sensor in its original packaging
–Retain the packaging in its entirety
including the polystyrene inserts
NOTICE!
Maximum storage period
Damage to the product
If the sensor is stored for a long period of
time, return it to ProMinent for checking or
servicing. Otherwise the safe operation and
measuring accuracy of the sensor can no
longer be guaranteed.
3.1 Storage
Permissible ambient temperature: +5 °C to +50
°C
Humidity: maximum 90 % relative air humidity,
non-condensing
Other: no dust, no direct sunlight
Maximum storage period of the electrolytes in
their original packaging: see label on the bottle
Maximum storage period of the sensor in its orig‐
inal packaging and normal atmosphere: 3 years
3.2 Transport
The sensor should be transported in its original
packaging and in compliance with the permis‐
sible environmental conditions. No further
special conditions have to be observed in relation
to transport.
Transport and Storage
17

4 Assembly
nUsers' qualifications: trained qualified
personnel, see Ä Chapter 1.2 “Users' qual‐
ifications ” on page 10
Electrolyte filling
NOTICE!
Perform the following work over a sink
After this, carefully re-close the electrolyte
bottle. Unclosed electrolyte bottles may
severely limit the storage period of the elec‐
trolytes.
1. Remove the red end cap and cut off the
top end of the spout with a knife.
2. Screw the sensor cap (1) and the sensor
cap protector (2) off from the sensor shaft
A0107
1
2
Fig. 2: Sensor cap (1) with sensor cap protector
(2)
3. With the sensor cap protector plugged
on, place the sensor cap onto a working
surface
ðThe sensor cap protector seals the
bottom of the sensor cap.
Assembly
18

4. Fill the sensor cap (4) to the brim with
electrolyte (3) taking care to avoid
bubbles
A0108
3
4
Fig. 3: Sensor cap (4) with electrolyte (3)
5. Place the sensor shaft (5) vertically onto
the sensor cap (7) filled with electrolyte
(6) and turn until the thread catches
A0126
5
6
7
Fig. 4: Sensor shaft (5) with electrolyte (6) and
sensor cap (7)
6. Turn the sensor cap manually until it
stops. No gap must be visible between
the sensor cap and the sensor shaft
ðExcess electrolyte (8) exits from the
openings when screwing together.
A0127
8
Fig. 5: Electrolyte (8) exits
7. Remove sensor cap protector (11)
8. Rinse the leaked electrolyte (10) from the
sensor (9) and from your fingers under
running water
A0128
9
10
11
Fig. 6: Remove sensor cap protector (11)
ðThere should be no air in the sensor
cap and the electrolyte. If the meas‐
uring results are unclear during
operation then the sensor cap must
be re-filled. If the problem persists
then the sensor must be regener‐
ated by ProMinent.
Assembly
19

9. Free the two gold electrodes on the face
side of the sensor body from any
remaining electrolyte using a soft, mois‐
tened paper towel
10. Fit the sensor as described in the oper‐
ating manual for the flow gauge .
Assembly
20