ProMinent DULCOTROL Operating instructions

General Operating Instructions
Measuring/Control Stations DULCOTROL®
Cooling Water
ProMinent®
Please enter the Identcode of your device
DULCOTROL®cooling water ___ ___ ___ ___ ___ ___ ___ ___ ___ ___ ___ ___ ___ ___ ___ ___
These general operating instructions facilitate the installation and calibration of the measuring panel inclusive
of its individual component parts. All further processes such as for example the setting of specific limit and
control parameters are described in the individual operating instructions of the ProMinent®components.
The individual operating instructions are enclosed with the measuring/control station DULCOTROL®cooling water.
Part no. 986419 ProMinent Dosiertechnik GmbH ·69123 Heidelberg ·Germany BA DR 002 02/09 GB
These general operating instructions apply only in conjunction
with the individual operating instructions of all supplied individual components.
Please completely read through all operating instructions! Do not discard!
The operator shall be liable for any damage caused by installation or operating errors!
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ProMinent®
Page 2
Corporate information:
General Operating Instructions
Measuring/Control Stations DULCOTROL®Cooling Water
© ProMinent Dosiertechnik GmbH, 2008
ProMinent Dosiertechnik GmbH
Im Schuhmachergewann 5-11
69123 Heidelberg
Telephone: [phone]
Fax: [phone]
[email protected]
www.prominent.com
Technical changes reserved.
Corporate Information
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ProMinent®Page 3
Contents
Page
Identcode ................................................................................................................ 8
General User Information ........................................................................................ 11
1 Safety Chapter ....................................................................................................... 12
1.1 Identification of the Notes on Safety ....................................................................... 12
1.2 General Notes on Safety ......................................................................................... 12
1.3 Information for Emergencies ................................................................................... 13
1.4 Proper Use .............................................................................................................. 14
1.5 Qualification of the Personnel ................................................................................. 14
2 Storage and Transport .......................................................................................... 14
3 About this Product ................................................................................................ 15
3.1 DULCOTROL®Cooling Water ................................................................................. 15
4 Overview of Measuring Stations .......................................................................... 15
4.1 DULCOTROL®Measuring/Control Station with Fitting and In-line Probe DLG III.... 15
4.2 DULCOTROL®Measuring/Control Station with Fitting and T-Piece ....................... 16
4.3 DULCOTROL®Measuring/Control Station, Installation Diagram............................. 17
5 Mounting / Installation .......................................................................................... 17
5.1 Mounting (mechanical) ............................................................................................ 17
5.1.1 Measuring Station ................................................................................................... 18
5.1.2 Accessories ............................................................................................................. 19
5.2 Installation (hydraulic) .............................................................................................. 20
5.2.1 DULCOTROL®Measuring/Control Station .............................................................. 20
5.3 Installation of DULCOTROL®Measuring/Control Station (electrical) ....................... 20
5.3.1 Measuring Panel ...................................................................................................... 21
5.3.2 Sample Water Pump ............................................................................................... 21
5.4 Mounting of the Sensors ......................................................................................... 21
5.5 Hydraulic Test Run after Installation ........................................................................ 21
5.6 Installation of the Sensor (electrical) ....................................................................... 22
6 Commissioning of the Sensors ............................................................................ 22
6.1 Setting of the Flow Meter Switching Point .............................................................. 23
6.2 Running-In Period ................................................................................................... 23
7 Device Overview / Controls D1C / D2C General ................................................. 24
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ProMinent®
Page 4
Contents
8 Measuring Parameters........................................................................................... 25
8.1 Measuring Parameter Free Chlorine .................................................................... 25
8.1.1 DULCOMETER®D1C Measured Variable Chlorine, Setting and Operation............. 25
8.1.2 DULCOTEST®CLE Chlorine Sensor for Free Chlorine, Commissioning.................. 28
8.1.2.1 DULCOTEST®CLE Chlorine Sensor for Free Chlorine, Assembly........................... 28
8.1.2.2 DULCOTEST®CLE Chlorine Sensor for Free Chlorine, Electrical Installation.......... 28
8.1.2.3 DULCOTEST®CLE Chlorine Sensor for Free Chlorine, Running-In......................... 29
8.1.2.4 DULCOTEST®CLE Chlorine Sensor for Free Chlorine, Calibration ......................... 29
8.1.3 DULCOMETER®D1C and DULCOTEST®CLE Chlorine Sensor for Free Chlorine,
Troubleshooting ....................................................................................................... 31
8.1.4 DULCOMETER®D1C Measured Variable Chlorine and DULCOTEST®CLE
Chlorine Sensor, Maintenance ................................................................................ 33
8.2 Measuring Parameter Ozone ................................................................................ 34
8.2.1 DULCOMETER®D1C Measured Variable Ozone, Setting and Operation................ 34
8.2.2 DULCOTEST®OZE Ozone Sensor, Commissioning ................................................ 37
8.2.2.1 DULCOTEST®OZE Ozone Sensor for Ozone, Assembly ........................................ 37
8.2.2.2 DULCOTEST®OZE Ozone Sensor, Electrical Installation ........................................ 38
8.2.2.3 DULCOTEST®OZE Ozone Sensor, Running-In........................................................ 38
8.2.2.4 DULCOTEST®OZE Ozone Sensor, Calibration........................................................ 39
8.2.3 DULCOMETER®D1C and DULCOTEST®OZE Ozone Sensor for Ozone,
Troubleshooting ....................................................................................................... 41
8.2.4 DULCOMETER®D1C Measured Variable Ozon and DULCOTEST®OZE Ozone
Sensor for Ozone, Maintenance............................................................................... 43
8.3 Measuring Parameter H2O2................................................................................... 45
8.3.1 DULCOMETER®D1C Measured Variable H2O2, Setting and Operation .................. 45
8.3.2 DULCOTEST®PER Sensor for Hydrogen Peroxide, Commissioning ...................... 48
8.3.2.1 DULCOTEST®PER Sensor for Hydrogen Peroxide, Assembly................................ 48
8.3.2.2 DULCOTEST®PER Sensor for Hydrogen Peroxide, Electrical Installation ............. 49
8.3.2.3 DULCOTEST®PER Sensor for Hydrogen Peroxide, Running-In.............................. 50
8.3.2.4 DULCOTEST®PER Sensor for Hydrogen Peroxide, Calibration.............................. 50
8.3.3 DULCOMETER®D1C and DULCOTEST®PER Sensor for Hydrogen Peroxide,
Troubleshooting ....................................................................................................... 52
8.3.4 DULCOMETER®D1C Measured Variable H2O2and DULCOTEST®PER Sensor
for Hydrogen Peroxide, Maintenance....................................................................... 54
8.4 Measuring Parameter Chlorine Dioxide Sensor CDP ........................................ 56
8.4.1 DULCOMETER®D1C Measured Variable Chlorine Dioxide Setting and Operation. 56
8.4.2 DULCOTEST®CDP Chlorine Dioxide Sensor, Commissioning................................ 59
8.4.2.1 DULCOTEST®CDP Chlorine Dioxide Sensor, Assembly ....................................... 59
8.4.2.2 DULCOTEST®CDP Chlorine Dioxide Sensor, Installation ....................................... 60
8.4.2.3 DULCOTEST®CDP Chlorine Dioxide Sensor, Running-In ...................................... 60
8.4.2.4 DULCOTEST®CDP Chlorine Dioxide Sensor, Calibration ....................................... 61
8.4.3 DULCOMETER®D1C and DULCOTEST®CDP Chlorine Dioxide Sensor,
Troubleshooting ....................................................................................................... 63
8.4.4 DULCOMETER®D1C Measured Variable Chlordioxid and DULCOTEST®CDP
Chlorine Dioxide Sensor, Maintenance ................................................................... 65
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Contents
8.5 Measuring Parameter Redox/ORP ...................................................................... 66
8.5.1 DULCOMETER®D1C Measured Variable Redox/ORP, Setting and Operation ....... 66
8.5.2 DULCOTEST®Sensor for Redox/ORP, Commissioning........................................... 69
8.5.2.1 DULCOTEST®Sensor for Redox/ORP, Assembly ................................................... 69
8.5.2.2 DULCOTEST®Sensor for Redox/ORP, Electrical Installation................................... 69
8.5.2.3 DULCOTEST®Sensor for Redox/ORP, Running-In ................................................. 69
8.5.2.4 DULCOTEST®Sensor for Redox/ORP, Calibration ................................................. 69
8.5.3
DULCOMETER®D1C and DULCOTEST®Sensor for Redox/ORP,
Troubleshooting
....................................................................................................... 70
8.5.4 DULCOMETER®D1C Measured Variable Redox/ORP and DULCOTEST®
Sensor for Redox/ORP, Maintenance....................................................................... 71
8.6 Measuring Parameter pH ...................................................................................... 72
8.6.1 DULCOMETER®D1C Measured Variable pH, Setting and Operation .................... 72
8.6.2 DULCOTEST®PHEP or PHER Sensor for pH, Commissioning .............................. 76
8.6.2.1 DULCOTEST®PHEP or PHER Sensor for pH, Assembly ........................................ 76
8.6.2.2 DULCOTEST®PHEP or PHER Sensor for pH, Electrical Installation ...................... 76
8.6.2.3 DULCOTEST®PHEP or PHER Sensor for pH, Running-In ...................................... 76
8.6.2.4 DULCOTEST®PHEP or PHER Sensor for pH, Calibration....................................... 76
8.6.3 DULCOMETER®D1C and DULCOTEST®PHEP or PHER Sensor for pH,
Troubleshooting ....................................................................................................... 78
8.6.4 DULCOMETER®D1C Measured Variable pH and DULCOTEST®PHEP or PHER
Sensor for pH, Maintenance ................................................................................... 79
8.7 Measuring Parameter Inductive Conductivity ..................................................... 80
8.7.1 DULCOMETER®D1C Measured Variable Inductive Conductivity,
Setting and Operation .............................................................................................. 80
8.7.2 DULCOTEST®ICT 2 Inductive Conductivity Sensor, Commissioning .................... 83
8.7.2.1 DULCOTEST®ICT 2 Inductive Conductivity Sensor, Assembly .............................. 83
8.7.2.2 DULCOTEST®ICT 2 Inductive Conductivity Sensor, Electrical Installation ............ 83
8.7.2.3 DULCOTEST®ICT 2 Inductive Conductivity Sensor, Running-In ............................ 84
8.7.2.4 DULCOTEST®ICT 2 Inductive Conductivity Sensor, Calibration ............................ 84
8.7.3 DULCOMETER®D1C Measured Variable Inductive Conductivity and
DULCOTEST®ICT 2 Inductive Conductivity Sensor, Troubleshooting .................... 89
8.7.4 DULCOMETER®D1C Measured Variable Inductive Conductivity and
DULCOTEST®ICT 2 Inductive Conductivity Sensor, Maintenance ......................... 89
8.8 Measuring Parameter Total Chlorine.................................................................... 90
8.8.1 DULCOMETER®D1C Measured Variable Chlorine, Setting and Operation ............ 90
8.8.2 DULCOTEST®CTE Sensor for Total Chlorine, Commissioning .............................. 93
8.8.2.1 DULCOTEST CTE Sensor for Total Chlorine, Assembly ......................................... 93
8.8.2.2 DULCOTEST®CTE Sensor for Total Chlorine, Electrical Installation ...................... 94
8.8.2.3 DULCOTEST®CTE Sensor for Total Chlorine, Running-In ...................................... 95
8.8.2.4 DULCOTEST®CTE Sensor for Total Chlorine, Calibration ...................................... 95
8.8.3 DULCOMETER®D1C and DULCOTEST®CTE Sensor for Total Chlorine,
Troubleshooting........................................................................................................ 97
8.8.4 DULCOMETER®D1C Measured Variable Chlorine and DULCOTEST®CTE
Sensor for Total Chlorine, Maintenance .................................................................. 100
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ProMinent®
Page 6
Contents
8.9 Measuring Parameter pH/Chlorine ...................................................................... 101
8.9.1 DULCOMETER®D2C Measured Variable pH/Chlorine, Setting and Operation ...... 101
8.9.2 DULCOTEST®CTE Sensor for Total Chlorine and DULCOTEST®Sensor
PHEP or PHER for pH, Commissioning .................................................................. 106
8.9.2.1 DULCOTEST®CTE Sensor for Total Chlorine and DULCOTEST®Sensor
PHEP or PHER for pH, Assembly ............................................................................ 106
8.9.2.2 DULCOTEST®CTE Sensor for Total Chlorine and DULCOTEST®Sensor
PHEP or PHER for pH, Electrical Installation .......................................................... 107
8.9.2.3 DULCOTEST®CTE Sensor for Total Chlorine and DULCOTEST®Sensor
PHEP or PHER for pH, Running-In .......................................................................... 108
8.9.2.4 DULCOTEST®CTE Sensor for Total Chlorine and DULCOTEST®Sensor
PHEP or PHER for pH, Calibration .......................................................................... 109
8.9.3 DULCOMETER®D2C, DULCOTEST®CTE Sensors for Total Chlorine and
DULCOTEST®Sensors PHEP or PHER for pH, Troubleshooting ............................ 112
8.9.4 DULCOMETER®D2C Measured Variable Chlorine, DULCOTEST®CTE
Sensor for Total Chlorine and DULCOTEST®Sensor PHEP or PHER for pH,
Maintenance ............................................................................................................ 113
8.10 Measuring Parameter pH/Redox (ORP) .............................................................. 114
8.10.1 DULCOMETER®D2C Measured Variable pH/Redox (ORP), Setting and
Operation ................................................................................................................. 114
8.10.2 DULCOTEST®Redox (ORP) Sensor RHER-Pt-SE and DULCOTEST®Sensor
PHEP or PHER for pH, Commissioning .................................................................. 119
8.10.2.1 DULCOTEST®Redox (ORP) Sensor RHER-Pt-SE and DULCOTEST®Sensor
PHEP or PHER for pH, Assembly ............................................................................ 119
8.10.2.2 DULCOTEST®Redox (ORP) Sensor RHER-Pt-SE and DULCOTEST®Sensor
PHEP or PHER for pH, Electrical Installation ........................................................... 119
8.10.2.3 DULCOTEST®Redox (ORP) Sensor RHER-Pt-SE and DULCOTEST®Sensor
PHEP or PHER for pH, Running-In........................................................................... 120
8.10.2.4 DULCOTEST®Redox (ORP) Sensor RHER-Pt-SE and DULCOTEST®Sensor
PHEP or PHER for pH, Calibration........................................................................... 120
8.10.3 DULCOMETER®D2C, DULCOTEST®Redox (ORP) Sensor RHER-Pt-SE and
DULCOTEST®Sensor PHEP or PHER for pH, Troubleshooting ............................. 122
8.10.4 DULCOMETER®D2C Measured Variable pH, Redox (ORP), DULCOTEST®Redox
(ORP) Sensor RHER-Pt-SE and DULCOTEST®Sensor PHEP or PHER for pH,
Maintenance ............................................................................................................ 123
8.11 Measuring Parameter pH/Chlorine Dioxide ........................................................ 124
8.11.1 DULCOMETER®D2C Measured Variable pH/Chlorine Dioxide, Setting and
Operation.................................................................................................................. 124
8.11.2 DULCOTEST®CDE Chlorine Dioxide Sensor and DULCOTEST®Sensor PHEP or
PHER for pH, Commissioning ................................................................................. 129
8.11.2.1 DULCOTEST®CDE Chlorine Dioxide Sensor and DULCOTEST®Sensor PHEP or
PHER for pH, Assembly .......................................................................................... 129
8.11.2.2 DULCOTEST®CDE Sensor and DULCOTEST®Sensor PHEP or PHER for pH,
Electrical Installation................................................................................................. 130
8.11.2.3 DULCOTEST®CDE Chlorine Dioxide Sensor and DULCOTEST®Sensor PHEP or
PHER for pH, Running-In ........................................................................................ 131
8.11.2.4 DULCOTEST®CDE Chlorine Dioxide Sensor and DULCOTEST®Sensor PHEP or
PHER for pH, Calibration ......................................................................................... 131
8.11.3 DULCOMETER®D2C, DULCOTEST®CDE Chlorine Dioxide Sensor and
DULCOTEST®Sensor PHEP or PHER for pH, Troubleshooting ............................. 134
8.11.4 DULCOMETER®D2C Measured Variable pH/Chlorine Dioxide,
DULCOTEST®CDE Chlorine Dioxide Sensor and DULCOTEST®Sensor PHEP or
PHER for pH, Maintenance ..................................................................................... 135
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ProMinent®Page 7
Contents
9 Settings of the Controllers D1C/D2C Deviating from the Data in the
D1C/D2C Operating Instructions (to be observed during repairs) ................... 136
9.1 Deviating Measuring Ranges.................................................................................... 136
9.2 Setting of the Pause Contact for Flow Monitoring .................................................. 137
10 Maintenance .......................................................................................................... 138
11 Troubleshooting...................................................................................................... 139
12 Decommissioning and Disposal .......................................................................... 140
12.1 Temporary or Long-Term Decommissioning ............................................................ 140
12.2 Final Decommissioning ............................................................................................ 140
13 Replacement Parts ................................................................................................ 140
14 List of Further Applicable Documents.................................................................. 141
15 EC Declaration of Conformity .............................................................................. 143
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ProMinent®
Page 8
Identcode
Identcode Measuring/Control Station DULCOTROL®Cooling Water –
One Measured Variable
CWCA Measured variable
L000 Conductivity
C000 Free chlorine (at pH-value < 8.0)
C001 Free chlorine (at pH value > 8.0 or unstable)
G000 Total chlorine (free+combined chlorine)
B000 Bromine organic (e.g. BCDMH, Stabrex)
B001 Free bromine (HOBr)
P000 pH
R000 ORP
D000 Chlorine dioxide (with temperature as correction variable)
Z000 Ozone
H000 Hydrogen peroxide
Water to be measured
1 Cooling water
Usage category
0 All measured variables measurable (L000: desalinate, blow down)
9 All measured variables two-way controllable
Power supply
A 230 V, 50/60 Hz
C 115 V, 50/60 Hz
Sensor equipment
0 With sensors
1 Without sensors
Version
0 With ProMinent logo
Sample water treatments
0None
1 With filter
2 With peristaltic pump
3 With filter and peristaltic pump
Accessories
0None
1 With pressure reducer
2 With heat exchanger
3 With sample water pump
4 With pressure reducer and heat exchanger
6 With heat exchanger and sample water pump
Language
DE German
EN English
FR French
IT Italian
NL Dutch
ES Spanish, not for H000
PL Polish, not for H000
SV Swedish, not for H000
HU Hungarian, not for H000
PT Portuguese, not for H000
CS Czech, not for H000
Approvals
1CE
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ProMinent®Page 9
Identcode
Identcode Measuring/Control Station DULCOTROL®Cooling Water –
Two Measured Variables
CWCA Measured variable
LC00 1. Conductivity / 2. free chlorine (at pH-value < 8.0)
LC01 1. Conductivity / 2. free chlorine (at pH value > 8.0 or unstable)
LG00 1. Conductivity / 2. total chlorine (free+combined chlorine)
LB00 1. Conductivity / 2. bromine organic (e.g. BCDMH, Stabrex
LB01 1. Conductivity / 2. free bromine (HOBr)
LD00 1. Conductivity / 2. chlorine dioxide (with temperature as correction variable)
LZ00 1. Conductivity / 2. ozone
LR00 1. Conductivity / 2. ORP
LP00 1. Conductivity / 2. pH
CP00 1. Free chlorine / 2. pH (at pH-value < 8.0)
CP01 1. Free chlorine / 2. pH (at pH-value > 8.0)
GP00 1. Total chlorine / 2. pH (free+combined chlorine or chlorine measurement for pH value > 8.0
BP00 1. Bromine organic / 2. pH
BP01 1. Free bromine (HOBr) / 2. pH
DP00 1. Chlorine dioxide / 2. pH (with temperature as correction variable)
HP00 1. Hydrogen peroxide / 2. pH
RP00 1. ORP / 2. pH
Water to be measured
1 Cooling water
Usage category
0 All measured variables measurable (Lx0x: desalinate, blow down)
1 1st measured variable = conductivity: desalinate (blow down), others two-way controllable, 2nd measured variable only
measurable
2 2nd measured variable two-way controllable, 1st measured variable = conductivity: desalinate (blow down), others only
measurable
3 Both measured variable one-way controllable with two-channel controller D2C (CP00, CP01, GP00, RP00, DP00)
9 All measured variables two-way controllable
Power supply
A 230 V, 50/60 Hz
C 115 V, 50/60 Hz
Sensor equipment
0 With sensors
1 Without sensors
Version
0 With ProMinent logo
1 Without ProMinent logo
Sample water treatments
0None
1 With filter
2 With peristaltic pump
3 With filter and peristaltic pump
Accessories
0None
1 With pressure reducer
2 With heat exchanger
3 With sample water pump
4 With pressure reducer and heat exchanger
6 With heat exchanger and sample water pump
Language
DE German
EN English
FR French
IT Italian
NL Dutch
ES Spanish, not for H in HP00
PL Polish, not for H in HP00
SV Swedish, not for H in HP00
HU Hungarian, not for H in HP00
PT Portuguese, not for H in HP00
CS Czech, not for H in HP00
Approvals
1CE
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ProMinent®
Page 10
Identcode
Identcode Measuring/Control Station DULCOTROL®Cooling Water –
Three Measured Variables
CWCA Measured variable
LCP0 1. Conductivity / 2. free chlorine / 3. pH (at pH-value < 8.0)
LCP1 1. Conductivity / 2. free chlorine / 3. pH (at pH value > 8.0 or unstable)
LGP0 1. Conductivity / 2. total chlorine (free+combined chlorine) / 3. pH
LBP0 1. Conductivity / 2. bromine organic (e.g. BCDMH, Stabrex) / 3. pH
LBP1 1. Conductivity / 2. free bromine (HOBr) / 3. pH
LDP0 1. Conductivity / 2. chlorine dioxide (with temperature as correction variable) / 3. pH
LZP0 1. Conductivity / 2. ozone / 3. pH
LHP0 1. Conductivity / 2. hydrogen peroxide / 3. pH
Water to be measured
1 Cooling water
Usage category
0 All measured variables measurable (Lxxx: desalinate, blow down)
4 1st measured variable = conductivity: Demineralisation, 2nd +3rd measured variable only measurable
5 2nd measured variable two-way controllable, 1st measured variable = conductivity: desalinate, blow down, 3rd measured
variable only measurable
6 1st measured variable = conductivity: desalinate (blow down), 2nd + 3rd measured variable one-way controllable with two-
channel controller D2C (only LCP0/LGP0/LDP0)
7 1st measured variable = conductivity: desalinate (blow down), 2nd + 3rd measured variable two-way controllable
9 All measured variables two-way controllable
Power supply
A 230 V, 50/60 Hz
C 115 V, 50/60 Hz
Sensor equipment
0 With sensors
1 Without sensors
Version
0 With ProMinent logo
Sample water treatments
0None
1 With filter
2 With peristaltic pump
3 With filter and peristaltic pump
Accessories
0None
1 With pressure reducer
2 With heat exchanger
3 With sample water pump
4 With pressure reducer and heat exchanger
6 With heat exchanger and sample water pump
Language
DE German
EN English
FR French
IT Italian
NL Dutch
ES Spanish, not for H in LHP0
PL Polish, not for H in LHP0
SV Swedish, not for H in LHP0
HU Hungarian, not for H in LHP0
PT Portuguese, not for H in LHP0
CS Czech, not for H in LHP0
Approvals
1CE
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ProMinent®Page 11
General User Information
General User Information
Please read through the following user guidelines! Familiarity with these points ensures optimum
use of the operating instructions.
Key points in the text are indicated as follows:
• Enumerations
Hints
Working guidelines:
NOTE
A note is to facilitate your work.
Notes on safety are identified by pictographs.
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ProMinent®
Page 12
Safety Chapter
1 Safety Chapter
1.1 Identification of the Notes on Safety
The following terms are used in the present operating instructions to indicate the various severity
levels of the danger:
DANGER
Characterizes a possibly hazardous situation. There is a danger of death or serious injuries
if these notes are disregarded.
WARNING
Characterizes a possibly hazardous situation. Your life is in danger and there is a danger of
serious injury or death if these notes are disregarded!
CAUTION
Characterizes a possibly hazardous situation. There is a danger of slight or minor injury or
damage to property if these notes are disregarded.
NOTE
A note provides important notes for the correct functioning of the unit or is to facilitate
your work.
The following warning signs are used in the present operating instructions to indicate different
types of the danger:
Warning of danger area
Warning of hazardous electrical voltage
Warning of caustic substances
Warning of hot surfaces
Warning of unexpected start
1.2 General Notes on Safety
WARNING
• Live parts!
• Disconnect from mains plug before opening the housing.
• De-energise damaged, defective or manipulated units by disconnecting the mains plug.
WARNING
• Hot surfaces!
• Risk of burning at the surfaces of the measuring station.
• For sample water > 55 °C, a temperature monitor with solenoid valve has to be installed
to protect the DULCOTROL®measuring/control station. The temperature monitor is not
included in the scope of delivery and must be installed by the customer.
• Suitable measures must be taken to prevent that nobody gets into contact with hot
surfaces.
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ProMinent®Page 13
Safety Chapter
WARNING
• Hazardous substances!
• Hazards from contact, inhalation or other contamination with/by substances or media!
• Observe the safety data sheet of the used substance/media.
• The operator of the DULCOTROL®measuring/control station is responsible for the fact
that the safety data sheets are available and up-to-date.
WARNING
• Unexpected start of the DULCOTROL®measuring/control station after failure, malfunc-
tion of the control/voltage supply or as intended action because of a control process!
• Hazards from unexpected actions of the stations!
• In case of malfunction/failure of the control or voltage supply, the DULCOTROL®meas-
uring/control station is to be disconnected from the voltage supply. For further informa-
tion see the operating instructions of the DULCOMETER®D1C units and sensors.
WARNING
• Operating error!
• Hazards from operating errors!
• The DULCOTROL®measuring/control stations may only be operated by sufficiently
qualified and trained personnel.
WARNING
• Electrical hazards from lightning!
• Hazards from overvoltage because of lightning stroke into external installations which
are connected to the DULCOTROL®measuring/control station.
• Do neither directly nor indirectly use the DULCOTROL®measuring/control station for
use in the open.
• Provide for sufficient potential to ground when installing electrical components.
NOTE
• Protect the DULCOTROL®measuring/control stations against unauthorised access!
• Please also read the operating instructions of the controllers and fittings and any other
existing assemblies such as sensors, sample water pump … !
• Please observe the resistance of the materials of all assemblies in contact with
the media. (see e.g. the ProMinent resistance list in the product catalogue or at
www.prominent.com.)!
• Protect the DULCOTROL®measuring/control station against direct exposure to the sun
and other UV sources!
• Please observe the basic rules of ergonomic principles!
1.3 Information for Emergencies
• Electrical emergency: Switch off the DULCOTROL®measuring/control station via the mains
switch, at the terminal box or at the place specified by the operator!
• Hydraulical emergency: Close the DULCOTROL®measuring/control station at the inlet- or
outlet-side ball valve, observe the safety data sheet of the medium!
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1.4 Proper Use
• The DULCOTROL®measuring/control stations are only designed to measure or control liquid
metering media in accordance with the Identcode feature specified on the rating plate of the
measuring/control station.
• The DULCOTROL®measuring/control stations are not designed to meter or control gaseous or
solid media.
• The DULCOTROL®measuring/control stations may only be used in compliance with the
technical data and specifications stated in these operating instructions and the operating
instructions of the individual components!
• You are obliged to observe the information in the operating instructions on the various life
phases of the DULCOTROL®measuring/control stations (such as assembly, installation, …)!
• The DULCOTROL®measuring/control stations may not be used for applications in the open.
• All other uses or modifications of the DULCOTROL®measuring/control stations require the
prior written consent of ProMinent Dosiertechnik GmbH, Heidelberg, Germany.
• The DULCOTROL®measuring/control stations may only be operated by sufficiently qualified
personnel (see table below). The operator of the DULCOTROL®measuring/control station is
responsible for the qualification of the personnel.
1.5 Qualification of the Personnel
Safety Chapter / Storage and Transport
Tasks Qualification
Mounting, installation, hydraulical Qualified employee
Installation, electrical Qualified employee
Commissioning Trained user
Maintenance Trained person
Troubleshooting Qualified employee
Disposal Trained person
2 Storage and Transport
CAUTION
• Before storing or transporting, the DULCOTROL®measuring/control stations must be
free from metering media and water!
• Only transport and store the DULCOTROL®measuring/control station in its original
packaging!
• Protect the packaged DULCOTROL®measuring/control station also against moisture
and exposure to chemicals and mechanical influences!
• Please also read the operating instructions of the controllers and fittings and any other
existing assemblies such as sensors, sample water pump … !
Environmental conditions for storage and transport of
measuring panel without sensors
Temperature 5 ... 50 °C
Relative humidity < 95 % relative humidity, non-condensing
Sensors Store and transport the sensors within the sensor-specific parameters. For information on the
individual cases, please see the documentation for the individual sensors.
NOTE
If the DULCOTROL®measuring/control stations are stored together with the sensors as an
assembly, the storage and transport conditions should be adjusted to the component part
with the lowest resistance to external influences!
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ProMinent®Page 15
3 About this Product
3.1 DULCOTROL®Cooling Water
DULCOTROL®measuring/control stations are complete and compact online process measuring/
control stations mounted on a PE panel which are installed into a process water bypass.
1-3 measured variables can be configured on one single panel specific to the sample water. The
measuring devices can be equipped with a measuring function and numerous control functions
as required.
Optionally, a compatible filter, pressure reducer, heat exchanger, and/or a sample water pump
can be ordered for sample water conditioning.
Measurement panels from two controllers onward include a terminal box for a safe electrical
connection. All connecting cables are routed in a cable conduit.
Scope of delivery Check the scope of delivery based on the delivery note and the Identcode!
4 Overview of Measuring Stations
4.1 DULCOTROL®Measuring/Control Station with Fitting and In-line
Probe DLG III
About this Product / Overview of Measuring Stations
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Overview of Measuring Stations
The measuring panel DULCOTROL®measuring/control station with fitting and in-line probe
DLG III is produced in a customer-specific configuration. It consists of at least one D1C control-
ler, a sensor and the in-line probe DLG III. On the occasion of the first order and depending on
the customer’s needs it can be extended by further components which are greyed out here. In
case of more than one controller, a terminal box is added for the electrical installation.
Optionally, a compatible filter, pressure reducer, heat exchanger, and/or a sample water pump
can be ordered for sample water conditioning.
4.2 DULCOTROL®Measuring/Control Station with Fitting and T-Piece
The measuring panel DULCOTROL®measuring/control station with fitting and T-piece is pro-
duced in a customer-specific configuration. It consists of at least one D1C controller, a sensor
and the fitting with a T-piece. On the occasion of the first order and depending on the customer’s
needs it can be extended by further components which are greyed out here. In case of more than
one controller, a terminal box is added for the electrical installation.
Optionally, a compatible filter, pressure reducer, heat exchanger, and/or a sample water pump
can be ordered for sample water conditioning.
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ProMinent®Page 17
Components:
1 Sample water pump “vonTaine”
2 Heat exchanger
3 Pressure reducer
4 Dirt filter
5 Measuring panel
6 Free outlet
7 Process line
8 Shut-off valve
9 Temperature monitor with shut-off valve
Not included in delivery scope, to be installed by the customer at
media temperatures > 55 °C
Overview of Measuring Stations / Mounting/Installation
4.3 DULCOTROL®Measuring/Control Station, Installation Diagram
Diagram of the components of a DULCOTROL®measuring/control station which are installed
beyond the measuring panel.
5 Mounting / Installation
CAUTION
Please also read the operating instructions of the fittings and any other existing assem-
blies such as sensors, sample water pump … !
5.1 Mounting (mechanical)
WARNING
• Live parts!
• Please make sure that there are no concealed wirings when drilling holes to mount the
DULCOTROL®measuring/control station.
CAUTION
• Remove any water from the DULCOTROL®measuring/control station and the supplied
components before assembly if metering media are used which may not come into
contact with water!
• Install the DULCOTROL®measuring/control station vertically and upright at a wall or a
stable support bracket! Make sure that the wall or support bracket can support the
station!
• The DULCOTROL®measuring/control station must be easily accessible!
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CAUTION
• Metering media may be metered in excess.
• If the float of the flow module gets stuck because of contaminations, the DULCOTROL®
measuring/control station may meter in excess!
• Install a filter, depending on the type and composition of the sample water.
• If the circulating pump does not deliver, the DULCOTROL®measuring/control station
may meter in excess!
• Interlock the control via the potential-free contact of the circulating pump. If the circu-
lating pump is “OFF”, the DULCOTROL®measuring/control station goes to “PAUSE” via
the pause input of the controller.
• Alternatively, the metering pumps can be switched such that they only work together
with the circulating pumps.
5.1.1 Measuring Station
The mounting height should be selected such that:
• the LCD panel of the control is well readable
• the cover of the controller can still be parked in “park position” (145 mm)
• there is still enough space below the in-line probe to carry out maintenance work (100 mm)
• there is enough space for the mounting of accessories beyond the panel
The following drilling dimensions are to be observed in accordance with the panel size:
Mounting/Installation
Number of measured variables 1 2 3
A 595 695 1000
B 745 695 800
C 555 655 960
D 705 655 760
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ProMinent®Page 19
Mounting/Installation
Install the DULCOTROL®measuring/control station as close as possible to the metering
station using hanger screws.
5.1.2 Accessories
With accessories: From the hydraulical point of view, install supplied accessories such as heat
exchanger, sample water pump, pressure reducer or filter upstream of the DULCOTROL®
measuring/control station, observing the respective operating instructions.
1 Plugs (type depending on the surface and according to the plug manufacturer’s specifications)
2 Hanger screw
3 U-washer
4 Hexagon nut
10 mm
12
34
1 Sample water pump (not in connection with pressure reducer)
2 Heat exchanger (water/water)
3 Filter
4 Pressure reducer (not in connection with sample water pump)
5 Temperature monitor with shut-off valve
Not included in delivery scope, to be installed by the customer at media temperatures > 55 °C
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5.2 Installation (hydraulic)
CAUTION
• Observe the maximum permissible operating parameters of the entire installation of the
DULCOTROL®measuring/control station (e.g. pressure, temperature, flow rate)!
• Observe the lowest maximum permissible operating parameters of the component parts
of the DULCOTROL®measuring/control station and the installed sensors (and their
operating instructions)!
• Please also read the operating instructions of the controllers and fittings and any other
existing assemblies such as sensors, sample water pump … !
• Ensure a correct flow direction of the sample water.
• The maximum operating pressure (1 bar) may not be exceeded.
• A pressure reducer must be installed.
• Hazards from media under pressure.
• Before starting work at the hydraulical part of the DULCOTROL®measuring/control
station, this part is to be depressurised in a controlled way using the sampling valve.
• Wear safety goggles.
Fittings
The bypass fitting (in-line probe) used depends in particular on the sample water, sometimes also
on the measured variable or the combination of the measured variables. For all clear waters, the
type DGMA with flow monitoring, and for contaminated waters, DLG III also with upstream flow
monitoring are always used.
Hydraulic Connection, Piping
The hydraulic connection of the sample water is made via a 8x5mm hose connection.
Shut-off ball valves are installed upstream and downstream of the bypass fitting. Upstream of the
bypass fitting, the optionally available sample water filter will be positioned. The bypass fittings
include a sampling valve. For an equipotential bonding circuit, a metal pin is integrated in the
bypass fittings (see operating instructions DULCOMETER®D1C, Part 1).
5.2.1 DULCOTROL®Measuring/Control Station
Connect the in-line probe or fitting to the sample water (see operating instructions of the
in-line probe or documentation of the fitting).
5.3 Installation of DULCOTROL®Measuring/Control Station (electrical)
WARNING
• Live parts!
• Disconnect from mains plug before opening the housing.
• De-energise damaged, defective or manipulated units by disconnecting the mains plug.
• The electrical installation of the electrical assemblies may only be performed by a
qualified electrician!
• The controller may only be opened by a qualified electrician!
• With only one controller: Install a mains switch to be able to quickly disconnect from the
mains supply in case of emergency! For stations with two or more controllers, the
switch is installed at the terminal box.
CAUTION
• Please also read the operating instructions of the controllers and fittings and any other
existing assemblies such as sensors, sample water pump … !
Mounting/Installation
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