ProMinent DULCOTEST CLO 1 User manual

DULCOTEST® Sensor for free chlorine
Type CLO 1 / CLO 2
Assembly and operating instructions
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.
The latest version of the operating instructions are available on our homepage.

Overall Table of Contents
EN DULCOTEST® Sensor for free chlorine Type CLO 1 / CLO 2 ............................... 6
1 Introduction ....................................................................................................... 9
1.1 Explanation of the safety information............................................................. 9
1.2 Users' qualifications ..................................................................................... 11
1.3 General safety information .......................................................................... 12
1.4 Correct and Proper Use............................................................................... 13
1.5 Information in the event of an emergency ................................................... 13
2 Functional Description .................................................................................... 14
2.1 Construction ................................................................................................ 14
2.2 Measured variable ....................................................................................... 14
2.3 Function ....................................................................................................... 15
2.4 Construction of the sensor .......................................................................... 16
3 Transport and Storage ................................................................................... 18
3.1 Storage ........................................................................................................ 18
3.2 Transport...................................................................................................... 18
4 Assembly ........................................................................................................ 19
5 Installation ...................................................................................................... 22
6 Commissioning ............................................................................................... 24
6.1 Calibration ................................................................................................... 24
7 Troubleshooting .............................................................................................. 27
7.1 Troubleshooting ........................................................................................... 27
7.2 Error ............................................................................................................ 31
8 Maintenance and Repair ................................................................................ 33
8.1 Replacement intervals ................................................................................. 33
8.2 Repair........................................................................................................... 33
9 Decommissioning, Removal and Disposal ..................................................... 34
10 Ordering Information .................................................................................... 35
11 Technical Specifications ............................................................................... 36
11.1 Observed regulations/standards (minimum requirement) ......................... 36
11.2 Technical data ........................................................................................... 36
11.3 Material data / Dimensions and weights .................................................... 37
11.4 Flow ........................................................................................................... 38
11.5 Electrical data ............................................................................................ 38
11.6 Temperature and climate .......................................................................... 38
11.7 Rated gradient, drift and response time .................................................... 39
Overall Table of Contents
2

DE DULCOTEST® Sensor für freies Chlor Typ CLO 1 / CLO 2.................................. 42
1 Einleitung......................................................................................................... 45
1.1 Kennzeichnung der Sicherheitshinweise...................................................... 45
1.2 Benutzer Qualifikation.................................................................................. 47
1.3 Allgemeine Sicherheitshinweise................................................................... 48
1.4 Bestimmungsgemäße Verwendung............................................................. 49
1.5 Angaben für den Notfall................................................................................ 49
2 Funktionsbeschreibung................................................................................... 50
2.1 Aufbau.......................................................................................................... 50
2.2 Messgröße................................................................................................... 50
2.3 Funktion........................................................................................................ 51
2.4 Aufbau des Sensors..................................................................................... 52
3 Transportieren und Lagern.............................................................................. 54
3.1 Lagerung...................................................................................................... 54
3.2 Transport...................................................................................................... 54
4 Montieren........................................................................................................ 55
5 Installieren....................................................................................................... 58
6 In Betrieb nehmen........................................................................................... 60
6.1 Kalibrieren.................................................................................................... 60
7 Fehler beheben............................................................................................... 63
7.1 Fehlersuche.................................................................................................. 63
7.2 Fehler........................................................................................................... 67
8 Warten und Reparieren................................................................................... 69
8.1 Wechselintervalle......................................................................................... 69
8.2 Reparieren.................................................................................................... 69
9 Außerbetriebnahme, Abbau und Entsorgung.................................................. 70
10 Bestellhinweise.............................................................................................. 71
11 Technische Angaben..................................................................................... 72
11.1 Eingehaltene Richtlinien/Normen (Mindestanforderung............................. 72
11.2 Technische Daten...................................................................................... 72
11.3 Werkstoffangaben / Maße und Gewichte................................................... 73
11.4 Anströmung................................................................................................ 74
11.5 Elektrische Daten....................................................................................... 74
11.6 Temperatur und Klima................................................................................ 74
11.7 Nennsteilheit, Drift und Ansprechzeit......................................................... 75
Overall Table of Contents
3

ES Sensor de cloro libre DULCOTEST® Tipo CLO 1 / CLO 2 ................................... 79
1 Introducción .................................................................................................... 82
1.1 Señalización de las indicaciones de seguridad............................................ 82
1.2 Cualificación del usuario ............................................................................. 84
1.3 Indicaciones generales de seguridad .......................................................... 85
1.4 Uso conforme a lo prescrito......................................................................... 86
1.5 Indicaciones en casos de emergencia ........................................................ 86
2 Descripción del funcionamiento ..................................................................... 87
2.1 Montaje ........................................................................................................ 87
2.2 Magnitud de medida .................................................................................... 87
2.3 Función ........................................................................................................ 88
2.4 Montaje del sensor ...................................................................................... 89
3 Transporte y almacenamiento ........................................................................ 91
3.1 Almacenamiento .......................................................................................... 91
3.2 Transporte.................................................................................................... 91
4 Montaje ........................................................................................................... 92
5 Instalación ...................................................................................................... 95
6 Puesta en marcha .......................................................................................... 97
6.1 Calibración .................................................................................................. 98
7 Eliminación de fallos ..................................................................................... 100
7.1 Localización de fallos ................................................................................ 100
7.2 Fallo ........................................................................................................... 105
8 Mantenimiento y reparación ......................................................................... 107
8.1 Intervalos de cambio ................................................................................. 107
8.2 Reparación................................................................................................. 107
9 Período fuera de servicio, desmontaje y eliminación ................................... 108
10 Indicaciones para el pedido ........................................................................ 109
11 Información técnica .................................................................................... 110
11.1 Directivas/normas aplicadas (requisitos mínimos) .................................. 110
11.2 Datos técnicos ......................................................................................... 110
11.3 Datos de los materiales / Dimensiones y pesos ...................................... 111
11.4 Caudal ..................................................................................................... 112
11.5 Datos eléctricos ....................................................................................... 112
11.6 Temperatura y clima ................................................................................ 113
11.7 Pendiente nominal, variación y tiempo de reacción ................................ 113
Overall Table of Contents
4

FR Sonde DULCOTEST® pour le chlore libre Type CLO 1 / CLO 2 ........................ 116
1 Introduction ................................................................................................... 119
1.1 Désignation des consignes de sécurité...................................................... 119
1.2 Qualification des utilisateurs ...................................................................... 121
1.3 Consignes générales de sécurité .............................................................. 122
1.4 Utilisation conforme à l’usage prévu.......................................................... 123
1.5 Informations en cas d'urgence .................................................................. 123
2 Description de fonctionnement ..................................................................... 124
2.1 Structure .................................................................................................... 124
2.2 Grandeur de mesure ................................................................................. 124
2.3 Fonction ..................................................................................................... 125
2.4 Structure de la sonde ................................................................................ 126
3 Transport et stockage ................................................................................... 128
3.1 Stockage ................................................................................................... 128
3.2 Transport.................................................................................................... 128
4 Montage ....................................................................................................... 129
5 Installation .................................................................................................... 132
6 Mise en service ............................................................................................ 134
6.1 Étalonnage ................................................................................................ 135
7 Élimination de défauts .................................................................................. 137
7.1 Recherche des erreurs .............................................................................. 137
7.2 Défaut ........................................................................................................ 142
8 Entretien et réparations ................................................................................ 144
8.1 Intervalle de remplacement ....................................................................... 144
8.2 Réparations................................................................................................ 144
9 Mise hors service, démontage et élimination ............................................... 145
10 Informations de commande ........................................................................ 146
11 Informations techniques ............................................................................. 147
11.1 Directive/Normes respectées (exigence minimale) ................................. 147
11.2 Caractéristiques techniques .................................................................... 147
11.3 Matériaux / Dimensions et poids ............................................................. 148
11.4 Débit d'alimentation ................................................................................. 149
11.5 Caractéristiques électriques .................................................................... 149
11.6 Température et climat ............................................................................. 149
11.7 Pente nominale, dérive et temps de réponse .......................................... 150
Overall Table of Contents
5

DULCOTEST® Sensor for free chlorine
Type CLO 1 / CLO 2
Operating instructions
EN
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.
The latest version of the operating instructions are available on our homepage.

Table of contents
1 Introduction ............................................................................................................ 9
1.1 Explanation of the safety information............................................................. 9
1.2 Users' qualifications ..................................................................................... 11
1.3 General safety information .......................................................................... 12
1.4 Correct and Proper Use............................................................................... 13
1.5 Information in the event of an emergency ................................................... 13
2 Functional Description ......................................................................................... 14
2.1 Construction ................................................................................................ 14
2.2 Measured variable ....................................................................................... 14
2.3 Function ....................................................................................................... 15
2.4 Construction of the sensor .......................................................................... 16
3 Transport and Storage ......................................................................................... 18
3.1 Storage ........................................................................................................ 18
3.2 Transport...................................................................................................... 18
4 Assembly ............................................................................................................. 19
5 Installation ............................................................................................................ 22
6 Commissioning .................................................................................................... 24
6.1 Calibration ................................................................................................... 24
7 Troubleshooting ................................................................................................... 27
7.1 Troubleshooting ........................................................................................... 27
7.2 Error ............................................................................................................ 31
8 Maintenance and Repair ...................................................................................... 33
8.1 Replacement intervals ................................................................................. 33
8.2 Repair........................................................................................................... 33
9 Decommissioning, Removal and Disposal .......................................................... 34
10 Ordering Information ............................................................................................ 35
11 Technical Specifications ...................................................................................... 36
11.1 Observed regulations/standards (minimum requirement) ......................... 36
11.2 Technical data ........................................................................................... 36
11.3 Material data / Dimensions and weights .................................................... 37
11.4 Flow ........................................................................................................... 38
11.5 Electrical data ............................................................................................ 38
Table of contents
7

11.6 Temperature and climate .......................................................................... 38
11.7 Rated gradient, drift and response time .................................................... 39
12 Index..................................................................................................................... 40
Table of contents
8

1 Introduction
These operating instructions provide infor‐
mation 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 infor‐
mation on the technical data and functions
of the product. These operating instruc‐
tions provide detailed safety information
and are provided as clear step-by-step
instructions.
The safety information and notes are cate‐
gorised 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
injuries.
Measure to be taken to avoid this
danger
Danger!
– Denotes an immediate threat‐
ening danger. If this is disre‐
garded, 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 sit‐
uation. 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 injuries, material damage.
Measure to be taken to avoid this
danger
Caution!
– Denotes a possibly hazardous sit‐
uation. If this is disregarded, it
could result in slight or minor inju‐
ries. May also be used as a
warning about material damage.
Introduction
9

NOTICE!
Nature and source of the danger
Damage to the product or its sur‐
roundings
Measure to be taken to avoid this
danger
Note!
– Denotes a possibly damaging sit‐
uation. If this is disregarded, the
product or an object in its vicinity
could be damaged.
Type of information
Hints on use and additional informa‐
tion
Source of the information, additional
measures
Information!
– Denotes hints on use and other
useful information. It does not
indicate a hazardous or dam‐
aging situation.
Introduction
10

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 equipment and pro‐
tective 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 distribution partner.
Technical experts A technical expert is deemed to be a person who is able
to assess the tasks assigned to him and recognize pos‐
sible hazards based on his/her technical training and
experience, as well as knowledge of pertinent regula‐
tions.
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 regu‐
lations. The assessment of a person's technical training
can also be based on several years of work in the rele‐
vant field.
Introduction
11

Training Definition
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 regulations.
Electricians should be specifically trained for the working
environment in which they are employed and know the
relevant standards and regulations.
Electricians must comply with the provisions of the appli‐
cable statutory directives on accident prevention.
Customer Service depart‐
ment Customer Service department refers to service techni‐
cians, who have received proven training and have been
authorised by ProMinent to work on the system.
Note for the system operator
The pertinent accident prevention regulations, as well as all other generally acknowl‐
edged 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 injuries, material damage
– Check the sensor regularly for dirt
and impurities
– Check the membrane cap regu‐
larly for air bubbles adhering to it
– Observe all applicable national
regulations relating to mainte‐
nance, service and calibration
intervals.
Introduction
12

CAUTION!
Prerequisites for operation
Possible consequence: Slight or
minor injuries, material damage
– The sensor may only be used in
flow gauges that ensure the cor‐
rect 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 operating pressure
of the respective single compo‐
nents 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
determine and regulate concen‐
trations of free chlorine
– The sensor may not be used in
conjunction with organic chlorine
compounds, such as trichloroiso‐
cyanuric acid, or stabilisers, such
as cyanuric acid
– Any other uses or modifications
to the system are prohibited
– The sensor is not a safety com‐
ponent
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 sul‐
phite)
Introduction
13

2 Functional Description
Brief functional description
The DULCOTEST® Sensor for free
chlorine CLO 1 / CLO 2 is an ampero‐
metric three-electrode sensor without a
membrane. The DULCOTEST® Sensor for
free chlorine CLO 1 / CLO 2 can be used
to determine the concentration 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
installations up to 70 °C (CLO 2)
The sensor signal depends on the con‐
ductivity 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 electro‐
lyte and contacts with the working elec‐
trode (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 injuries, 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 calibrated for chlorine
but detects all oxidising agents in the
sample media.
This should be considered when con‐
figuring the process to prevent incor‐
rect measurement and concomitant
incorrect metering.
Free chlorine (HOCI, OCI -, Cl 2 ). Free
chlorine is the sum of chlorine gas (Cl 2 ),
hypochlorous acid (HOCI) and hypo‐
chlorite (OCI -).
Functional Description
14

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 electrode. 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 (depo‐
larisation current) produced, 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/con‐
trol device.
The photometric DPD-I method is used to
calibrate the DULCOTEST® sensor for
free chlorine CLO 1 / CLO 2.
Functional Description
15

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
16

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
17

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 electro‐
lytes in their original packaging: see label
on the bottle
Maximum storage period of the sensor in
its original packaging and normal atmos‐
phere: 3 years
3.2 Transport
The sensor should be transported in its
original packaging and in compliance with
the permissible environmental conditions.
No further special conditions have to be
observed in relation to transport.
Transport and Storage
18

4 Assembly
nUsers' qualifications: trained qualified
personnel, see Ä Chapter 1.2 ‘Users'
qualifications ’ on page 11
Electrolyte filling
NOTICE!
Perform the following work over a sink
After this, carefully re-close the elec‐
trolyte bottle. Unclosed electrolyte
bottles may severely limit the storage
period of the electrolytes.
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
19

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)
Assembly
20