ProMinent DULCOTEST DO 3-mA-20 ppm User manual

DULCOTEST® sensors for dissolved oxygen
Type: DO 3-mA-20 ppm
Assembly and operating instructions
A2613
EN
Target group: Instructed person982373 BA DT 061 12/18 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.

General non-discriminatory approach In order to make it easier to read, this docu‐
ment uses the male form in grammatical struc‐
tures but with an implied neutral sense. It is
aimed equally at both men and women. We
kindly ask female readers for their under‐
standing in this simplification of the text.
Supplementary information
Please read the supplementary information in its entirety.
Information
This provides important information relating to the correct operation of the unit or is intended
to make your work easier.
Warning information
Warning information includes detailed descriptions of the hazardous situation, see
Ä Chapter 2.1
‘Labelling of Warning Information’ on page 8 .
The following symbols are used to highlight instructions, links, lists, results and other elements in
this document:
Tab. 1: More symbols
Symbol Description
Action, step by step.
⇨Outcome of an action.
Links to elements or sections of these instructions or other applicable docu‐
ments.
nList without set order.
[Button] Display element (e.g. indicators).
Operating element (e.g. button, switch).
Supplemental directives
2

Symbol Description
‘Display /GUI’ Screen elements (e.g. buttons, assignment of function keys).
CODE Presentation of software elements and/or texts.
Supplemental directives
3

Table of contents
1 Function.................................................................................................................................. 5
1.1 Measuring principle........................................................................................................ 5
1.2 Construction and function............................................................................................... 6
1.3 Scope of delivery............................................................................................................ 7
2 Safety...................................................................................................................................... 8
2.1 Labelling of Warning Information.................................................................................... 8
2.2 User qualification.......................................................................................................... 10
2.3 General safety information........................................................................................... 11
2.4 Intended use................................................................................................................. 11
3 How to store and transport the sensor.................................................................................. 12
3.1 Storage......................................................................................................................... 12
3.2 Transport...................................................................................................................... 12
4 Assembly and installation...................................................................................................... 13
4.1 Installation on a PVC immersion tube.......................................................................... 14
4.2 Installation in the bypass fitting DGMa......................................................................... 15
4.3 Installation in bypass fitting DLG III.............................................................................. 16
4.4 Electrical connection.................................................................................................... 18
5 Preparation for the measurement......................................................................................... 20
6Calibration with the DULCOMETER ® DACb........................................................................ 21
6.1 Calibration on air.......................................................................................................... 21
6.2 Calibration in water using a reference measurement................................................... 21
6.3 Calibrating the zero point............................................................................................. 21
7 Maintenance and troubleshooting......................................................................................... 22
7.1 Dismantling the sensor................................................................................................. 22
7.2 Replacing the sensor cap............................................................................................. 22
7.3 Cleaning....................................................................................................................... 23
7.4 Troubleshooting............................................................................................................ 23
8 Disposal of used parts........................................................................................................... 24
9 Parts and accessories........................................................................................................... 25
10 Technical data....................................................................................................................... 26
10.1 Standards and regulations complied with................................................................... 27
11 Index..................................................................................................................................... 28
Table of contents
4

1 Function
The DULCOTEST® sensor, type DO 3, is used
for measurement of the partial pressure of dis‐
solved oxygen and the measured variables
derived from this:
nOxygen concentration in aqueous liquids
in mg/l or ppm,
nDegree of oxygen saturation in aqueous
liquids in %
The sensor type DO 3 is used for measurement
of the concentration of dissolved oxygen in
fresh water and salt water. The applications
specifically include
nThe control and monitoring of aeration pro‐
cesses in clarification plants,
nMonitoring of fish farming facilities
nThe aeration of raw water in water works
nAssessment of the quality of surface
water.
All wetted materials are suitable for fresh water
and salt water.
1.1 Measuring principle
The sensor type DO 3 is based on the optical
measurement of a fluorescence beam. The flu‐
orescence beam is weakened depending on
the partial pressure of the oxygen in the water.
The measurement is done in pulsed mode, with
the relaxation time of the fluorescence beam
being determined.
Function
5

1.2 Construction and function
A sensor cap is screwed onto the optical window of the sensor type DO 3 integrated in the sensor
shaft. The sensor cap contains fluorescence dye immobilised on a carrier. A black protective cap is
attached to the sensor cap. The sensor has a 10-metre long fixed cable. The sensor can be
immersed under water. The sensor shaft has an Rp1” thread on the cable side. The adapter
included in the scope of delivery is screwed onto the thread to enable the sensor to be connected to
an immersion tube at an angle of 45°. The middle part of the sensor shaft has a groove for a clamp
disc. The clamp ring threaded connection is used to fix the sensor into a suitable ProMinent bypass
fitting. The sensor shaft contains a temperature sensor (Pt 1000). The temperature sensor is used
for internal temperature correction of the measuring signal. The temperature sensor is connected to
the measuring equipment. The sensor is factory calibrated. The temperature-corrected, calibrated
and galvanically isolated 4 ... 20 mA measuring signal leaves the sensor along 2 lines. The supply
voltage is also fed along the same lines (two-line technology).
A2646
4
3
2
1
5
Fig. 1: Construction of the sensor
1 Fixed cable, 10 metres
2 Rp1” thread
3 Sensor shaft with groove for the clamp disc
4 Sensor head area with protective cap
5 Clamp disc
Function
6

A2643
3
2
1
5
4
6
Fig. 2: Construction in the sensor head area
1 Groove for the clamp disc for connection to
the bypass fitting
2 Sensor shaft
3 O-ring
4 Sensor cap with fluorescence dye
5 Protective cap (bite protection for the appli‐
cation: fish farming)
6 Clamp disc
1.3 Scope of delivery
Please first check the scope of delivery of
sensor type DO 3, order number 1094609
n1 no. clamp disc,
n1 no. clamp disc, replacement,
n1 no. protective cap on the sensor head,
n1 no. adapter: with Rp1” thread, PVC-U,
n1 no. 45° angle, PVC, DN32,
n1 no. assembly and operating instructions.
Function
7

2 Safety
2.1 Labelling of Warning Infor‐
mation
Introduction
These operating instructions provide informa‐
tion on the technical data and functions of the
product. These operating instructions provide
detailed warning information and are provided
as clear step-by-step instructions.
The warning information and notes are categor‐
ised 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.
Description of hazard
– Denotes an immediate threatening
danger. If the situation 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.
– Denotes a possibly hazardous sit‐
uation. If the situation is disre‐
garded, 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.
– Denotes a possibly hazardous sit‐
uation. If the situation is disre‐
garded, it could result in slight or
minor injuries. May also be used
as a warning about material
damage.
Safety
8

NOTICE!
Nature and source of the danger
Damage to the product or its surround‐
ings.
Measure to be taken to avoid this
danger.
– Denotes a possibly damaging sit‐
uation. If the situation is disre‐
garded, 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
measures.
– Denotes hints on use and other
useful information. It does not indi‐
cate a hazardous or damaging sit‐
uation.
Safety
9

2.2 User qualification
WARNING!
Danger of injury with inadequately qualified personnel
The operator of the system / equipment is responsible for ensuring that the qualifications are
fulfilled.
If inadequately qualified personnel work on the unit or loiter in the hazard zone of the unit,
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.
– Unqualified personnel should be kept away from the hazard zone.
The pertinent accident prevention regulations, as well as all other generally acknowledged
safety regulations, must be adhered to.
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 and pos‐
sible dangers that could result from improper behaviour, as well as
having been instructed in the required protective equipment and protec‐
tive measures.
Trained user A trained user is a person who fulfils the requirements made of an
instructed person and who has also received additional training specific
to the system from the manufacturer or another authorised distribution
partner.
Trained, qualified per‐
sonnel
A trained, qualified employee is deemed to be a person who is able to
assess the tasks assigned to him and recognize possible hazards
based on his training, knowledge and experience, as well as knowledge
of pertinent regulations. A trained, qualified employee must be able to
perform the tasks assigned to him independently with the assistance of
drawing documentation and parts lists. The assessment of a person's
technical training can also be based on several years of work in the rel‐
evant field.
Safety
10

Training Definition
Electrical technician An electrical technician is able to complete work on electrical systems
and recognise and avoid possible dangers independently based on his
technical training and experience as well as knowledge of pertinent
standards and regulations. An electrical technician must be able to per‐
form the tasks assigned to him independently with the assistance of
drawing documentation, parts lists, terminal and circuit diagrams. The
electrical technician must be specifically trained for the working environ‐
ment in which the electrical technician is employed and be conversant
with the relevant standards and regulations.
Service The Service department refers to service technicians, who have
received proven training and have been authorised by the manufacturer
to work on the system.
2.3 General safety information
WARNING!
Danger from hazardous substances!
Possible consequence: Fatal or very
serious injuries.
Please ensure when handling haz‐
ardous substances that you have read
the latest safety data sheets provided
by the manufacture of the hazardous
substance. The actions required are
described in the safety data sheet.
Check the safety data sheet regularly
and replace, if necessary, as the
hazard potential of a substance can be
re-evaluated at any time based on new
findings.
The system operator is responsible for
ensuring that these safety data sheets
are available and that they are kept up
to date, as well as for producing an
associated hazard assessment for the
workstations affected.
The sensor contains a temperature sensor (Pt
1000). This temperature sensor should only be
used for temperature compensation of the
oxygen signal and not for control of the process
temperature.
Only use the sensor for the intended use and
when it is in perfect condition.
2.4 Intended use
The sensor type DO 3 is used for the measure‐
ment of the partial pressure of dissolved
oxygen and the measured variables derived
from this in the applications described in Ä Fur‐
ther information on page 5 :
nOxygen concentration in liquids in [ppm],
nOxygen saturation in [%].
No other uses are permitted.
Safety
11

3 How to store and transport the sensor
User qualification: instructed user Ä Chapter
2.2 ‘User qualification’ on page 10
NOTICE!
Original packaging
Damage to the product.
– Only transport, ship and store the
sensor in its original packaging.
3.1 Storage
Storage and transport temperature:
ncomplete sensor - 10 °C ... 60 °C.
Humidity: maximum 90% relative air humidity,
non-condensing.
Other: No dust, no direct sunlight.
3.2 Transport
The sensor should be transported in its original
packaging and in compliance with the permis‐
sible environmental conditions. No further spe‐
cial conditions have to be observed in relation
to transport.
How to store and transport the sensor
12

4 Assembly and installation
nUser qualification, mechanical installation:
trained and qualified personnel Ä Chapter
2.2 ‘User qualification’ on page 10
nUser qualification, electrical installation:
electrical technician Ä Chapter 2.2 ‘User
qualification’ on page 10
WARNING!
Danger from hazardous substances!
Possible consequence: Fatal or very
serious injuries.
Please ensure when handling haz‐
ardous substances that you have read
the latest safety data sheets provided
by the manufacture of the hazardous
substance. The actions required are
described in the safety data sheet.
Check the safety data sheet regularly
and replace, if necessary, as the
hazard potential of a substance can be
re-evaluated at any time based on new
findings.
The system operator is responsible for
ensuring that these safety data sheets
are available and that they are kept up
to date, as well as for producing an
associated hazard assessment for the
workstations affected.
When unpacking, check the sensor type DO 3
for any mechanical defects. Return any defec‐
tive sensors to your dealer or manufacturer in
their original packaging.
Assembly and installation
13

4.1 Installation on a PVC immersion tube
When using in the aeration tank of a clarification plant, make sure that the 45° angle piece is bonded
in when fitting the sensor to a PVC immersion tube. The measurement can only be done properly if
the sensor is immersed at an angle of 45° in the water to be measured.
1
2
A2650
Fig. 3: Adapter with Rp1” thread (2) with 45° angle, PVC, DN32 (1).
1. Use suitable adhesive to bond the 45° angle (PVC, DN32) to the adapter with an Rp1”
thread.
2. Push the sensor cable through the Rp1” threaded assembly.
3. Screw the sensor type DO 3 by turning the adapter onto the Rp1” thread.
CAUTION!
Do not allow the sensor cable to come into contact with the adhesive
Do not allow the sensor cable to come into contact with the adhesive as the adhesive will
attack and damage the insulation on the sensor cable.
4. Pull the sensor cable through the immersion tube.
5. Use suitable adhesive to bond the PVC adapter part to the immersion tube.
6. With non-fish farming installations: remove the sensor’s protective cap before installing it in
the process.
Assembly and installation
14

4.2 Installation in the bypass fitting DGMa
You will need a mounting kit, order number 791818.
1
2
3
A2654
Fig. 4: Installation in the bypass fitting
1 Mounting for the clamp disc
2 Protective rubber cap
3 Clamp disc
1. Remove the black protective rubber cap (2) by pulling off by turning it clockwise. Make sure
that you do not loosen the sensor cap.
2. Fit the sensor as described in the operating instructions for the bypass fitting. Only use the
mounting kit, order number 791818, for installation, which is not included in the scope of
delivery. Unlike the description, guide the parts of the mounting kit from below over the posi‐
tion of the mounting (1) for the clamp disc (3). Then insert the clamp disc seal (3) into the
mounting (1).
Assembly and installation
15

4.3 Installation in bypass fitting DLG III
You will need a mounting kit, order number 815079.
1
2
3
A2654
Fig. 5: Installation in the bypass fitting
1 Mounting for the clamp disc
2 Protective rubber cap
3 Clamp disc
Assembly and installation
16

1. Remove the black protective rubber cap (2) by pulling off by turning it clockwise. Make sure
that you do not loosen the sensor cap.
A0645
1
2
3
4
5
6
Fig. 6: Installation in the bypass fitting
1. Threaded sleeve
2. Clamp disc
3. Sensor
4. O-ring
5. Washer
6. Bypass fitting
2. Fit the sensor as described in the operating instructions for the bypass fitting. Only use the
mounting kit, order number 815079, for installation, which is not included in the scope of
delivery.
Unlike the description, guide the parts of the mounting kit from below over the position of the
mounting for the clamp disc (1). Then insert the clamp disc seal (3) into the mounting (1).
Assembly and installation
17

4.4 Electrical connection
WARNING!
Danger from electrical voltage and short circuiting.
Insulate any unused leads to prevent short circuiting and this damage to the sensor.
Only use the fitted temperature sensor to monitor the conditions of use of sensor type DO 3 and not
to control a process temperature
Tab. 2: Electrical connection
Cable colour Assignment and function
Red 4 ... 20 mA loop, polarity, “+"
Brown 4 ... 20 mA loop, polarity,"-"
White Service, with heat shrink hose
Pink Service, with heat shrink hose
Black Shielding, with heat shrink hose
Grey Pt 1000
Blue Pt 1000
Assembly and installation
18

EMC-polluted environment
Connect the cable shield to ground or earth in EMC-polluted environments to improve inter‐
ference resistance and signal quality.
The galvanically isolated 4 ... 20 mA interface enables sensor type DO 3 with 2 lines to be con‐
nected directly to a controller, PLC Programmable Logic Controller, data recorder, display unit or
process control systems with an analogue input. The power supply (VDC 18 ... 30 V) is fed by the
red line (plus) and the brown line (minus). The lines also carry the measuring signal.
In the factory setting, the 4 ... 20 mA interface is configured with a measuring range of 0 ... 200%.
1
2
A2614
4
3
Fig. 7: Wiring example
I. Sensor
II. Measuring unit, PLC Programmable Logic
Controller etc.
1 Brown (minus)
2 Red (plus)
3 Grey (Pt 1000)
4 Blue (Pt 1000)
Assembly and installation
19

5 Preparation for the measurement
User qualification: instructed user Ä Chapter
2.2 ‘User qualification’ on page 10
Prepare the sensor for the measurement:
1. Make sure that the sensor cap is fitted
tightly to the sensor shaft and the O-ring
between the shaft and cap is undam‐
aged.
2. Make sure that the sensor is inserted.
3. Ensure that the sensor is electrically
wired, as described in chapter .
ðAssuming identical temperatures
between the medium and sensor,
the sensor signal will stabilise in a
few minutes. In the event of a
higher temperature difference
between the sensor and the meas‐
ured water, stabilisation can take
up to 30 minutes.
Preparation for the measurement
20