ProMinent DULCOMETER User manual

DULCOMETER, Compact Controller
Measured variable: pH / ORP
Assembly and operating instructions
A0206
EN
Part no.: 986214 Version: BA DM 207 08/15 EN
Please carefully read these operating instructions before use. · Do not discard.
The operator shall be liable for any damage caused by installation or operating errors.
The latest version of the operating instructions are available on our homepage.

General non-discriminatory approach In order to make it easier to read, this
document uses the male form in grammat‐
ical structures but with an implied neutral
sense. It is aimed equally at both men and
women. We kindly ask female readers for
their understanding 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.
Safety Information
The safety information includes detailed descriptions of the hazardous situation, see
Ä Chapter 2.1 ‘Explanation of the safety information’ on page 8
The following symbols are used to highlight instructions, links, lists, results and other ele‐
ments 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
documents
nList without set order
[Button] Display element (e.g. indicators)
Operating element (e.g. button, switch)
‘Display /GUI’ Screen elements (e.g. buttons, assignment of function keys)
CODE Presentation of software elements and/or texts
Supplemental directives
2

Table of contents
1 Identity code........................................................................................................... 6
2 Introduction............................................................................................................. 8
2.1 Explanation of the safety information............................................................. 8
2.2 Users' qualifications...................................................................................... 10
3 Safety and responsibility....................................................................................... 12
3.1 General Safety Information.......................................................................... 12
3.2 Correct and proper use................................................................................ 13
4 Functional description........................................................................................... 15
4.1 Flow diagram................................................................................................ 16
4.2 Overview of the first level menu................................................................... 17
5 Assembly and installation..................................................................................... 20
5.1 Scope of delivery.......................................................................................... 22
5.2 Mounting (mechanical)................................................................................. 22
5.2.1 Wall mounting............................................................................................ 22
5.2.2 Pipe mounting........................................................................................... 24
5.2.3 Control panel mounting............................................................................. 25
5.3 Installation (electrical)................................................................................... 33
5.3.1 Cable Cross-Sections and Cable End Sleeves......................................... 34
5.3.2 Installation of coaxial cable to guard terminal XE1.................................... 34
5.3.3 Installation (electrical)................................................................................ 39
5.4 Switching of inductive loads......................................................................... 40
6 Commissioning..................................................................................................... 42
6.1 Initial commissioning.................................................................................... 42
6.2 Selection of the measured variable.............................................................. 42
6.3 Setting the controller during commissioning................................................. 42
7 Operating diagram................................................................................................ 44
7.1 Overview of equipment/Control elements.................................................... 44
7.2 Adjusting display contrast............................................................................. 45
7.3 Continuous display....................................................................................... 46
7.4 Info display................................................................................................... 46
7.5 Password...................................................................................................... 48
8 Operating menus for the measured variables pH and ORP................................. 49
8.1 pH sensor calibration (CAL)......................................................................... 49
Table of contents
3

8.2 Redox sensor calibration (CAL)................................................................... 57
8.3 Setting limit values
[LIMITS] ......................................................................... 59
8.4 Setting the control [CONTROL] .................................................................... 61
8.5 Input setting (INPUT).................................................................................... 64
8.6 Output setting (OUTPUT)............................................................................. 67
8.7 DEVICE setting............................................................................................ 71
9 Control parameters and functions......................................................................... 72
9.1 DULCOMETER® Compact Controller function states ................................. 72
9.2 STOP/START key........................................................................................ 74
9.3 Priming (PRIME).......................................................................................... 75
9.4 Hysteresis limit............................................................................................. 76
9.5 Temperature correction variable for pH........................................................ 77
9.6 Checkout time for measured variable and correction variable..................... 78
9.7 Checkout time control................................................................................... 78
9.8 Power relay "P-REL" as limit value relay...................................................... 79
9.9 Setting and functional description of "Relay Used as a Solenoid Valve" .... 80
9.10 Alarm relay................................................................................................. 82
9.11 "Error logger" operating mode.................................................................... 82
10 Maintenance......................................................................................................... 83
10.1 Changing the fuse, DULCOMETER® Compact Controller......................... 83
10.2 Fault reporting and troubleshooting............................................................ 84
11 Technical data DULCOMETER® Compact Controller........................................... 87
11.1 Permissible ambient conditions.................................................................. 87
11.2 Sound Pressure Level................................................................................ 87
11.3 Material data............................................................................................... 88
11.4 Chemical Resistance.................................................................................. 88
11.5 Dimensions and weights............................................................................ 89
12 Electrical data....................................................................................................... 90
13 Spare parts and accessories................................................................................ 93
14 Replacing spare part units ................................................................................... 94
14.1 Replacing the top part of the housing......................................................... 94
14.2 Replacing the lower part of the housing (wall/tube retaining bracket)........ 96
14.3 Replacing the lower part of the housing (control panel installation)........... 98
15 Standards complied with and Declaration of Conformity.................................... 102
Table of contents
4

16 Disposal of Used Parts....................................................................................... 103
17 Index................................................................................................................... 104
Table of contents
5

1 Identity code
DCCa DULCOMETER® Compact,
Mounting type
E Spare part units
W Wall/pipe mounting IP 67
S With fitting kit for control panel mounting IP 54
Design
00 With ProMinent® logo
E1 Spare part unit, controller housing lower part (processor/PCB), fully
assembled
E2 Spare part unit, controller housing top part (processor/PCB), fully
assembled
Operating voltage
6 90 … 253 V, 48/63 Hz
Measured variable
C0 Free chlorine
NG pH/ORP (switchable)
L3 Conductive conductivity (designation: COND_C)
L6 Inductive conductivity (designation: COND_I)
Hardware extension
0 None
Approvals
01 CE (Standard)
Certificates
0 None
Operating instructions language
EN German KR Korean
Identity code
6

DCCa DULCOMETER® Compact,
EN English LT Lithuanian
ES Spanish LV Latvian
IT Italian NL Dutch
FR French PL Polish
FI Finish PT Portuguese
BG Bulgarian RO Romanian
ZH Chinese SV Swedish
CZ Czech SK Slovakian
EL Greek SL Slovenian
HU Hungarian RU Russian
YES Japanese TH Thai
Identity code
7

2 Introduction
Data and functions
These operating instructions describe the
technical data and functions of the
DULCOMETER® Compact Controller,
measured variable pH / ORP.
2.1 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
situation. 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
situation. If this is disregarded,
it could result in slight or minor
injuries. May also be used as a
warning about material
damage.
Introduction
8

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

2.2 Users' qualifications
WARNING!
Danger of injury with inadequately qualified personnel!
The operator of the plant / device 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 per‐
sonnel.
–Unqualified personnel should be kept away from the hazard zone
Training Definition
Instructed personnel An instructed person is deemed to be a person who has been
instructed and, if required, trained in the tasks assigned to
him/her and possible dangers that could result from improper
behaviour, as well as having been instructed in the required
protective equipment and protective 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 ProMinent or another
authorised distribution partner.
Trained qualified per‐
sonnel
A qualified employee is deemed to be a person who is able to
assess the tasks assigned to him and recognize possible haz‐
ards based on his/her training, knowledge and experience, as
well as knowledge of pertinent regulations. The assessment of
a person's technical training can also be based on several
years of work in the relevant field.
Introduction
10

Training Definition
Electrician Electricians are deemed to be people, who are able to com‐
plete work on electrical systems and recognize and avoid pos‐
sible 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 envi‐
ronment in which the are employed and know the relevant
standards and regulations.
Electricians must comply with the provisions of the applicable
statutory directives on accident prevention.
Customer Service
department
Customer Service department refers to service technicians,
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
acknowledged safety regulations, must be adhered to!
Introduction
11

3 Safety and responsibility
3.1 General Safety Information
WARNING!
Live parts!
Possible consequence: Fatal or
very serious injuries
– Measure: Disconnect the
mains power supply prior to
opening the housing
–De-energise damaged, defec‐
tive or manipulated units by
disconnecting the mains plug
WARNING!
Unauthorised access!
Possible consequence: Fatal or
very serious injuries
– Measure: Ensure that there
can be no unauthorised
access to the unit
WARNING!
Operating errors!
Possible consequence: Fatal or
very serious injuries
– The unit should only be oper‐
ated by adequately qualified
and technically expert per‐
sonnel
–Please also observe the oper‐
ating instructions for control‐
lers and fittings and any other
component groups, such as
sensors, measuring water
pumps ...
– The operator is responsible for
ensuring that personnel are
qualified
CAUTION!
Electronic malfunctions
Possible consequence: Material
damage to destruction of the unit
– The mains connection cable
and data cable should not be
laid together with cables that
are prone to interference
–Measure: Take appropriate
interference suppression
measures
Safety and responsibility
12

NOTICE!
Correct and proper use
Damage to the product or its sur‐
roundings
– The unit is not intended to
measure or regulate gaseous
or solid media
–The unit may only be used in
accordance with the technical
details and specifications pro‐
vided in these operating
instructions and in the oper‐
ating instructions for the indi‐
vidual components
NOTICE!
Correct sensor operation / Run-in
time
Damage to the product or its sur‐
roundings
– Correct measuring and dosing
is only possible if the sensor is
working perfectly
–It is imperative that the run-in
times of the sensors are
adhered to
– The run-in times should be
allowed for when planning ini‐
tial operation
– It may take a whole working
day to run-in the sensor
– Please read the operating
instructions for the sensor
NOTICE!
Correct sensor operation
Damage to the product or its sur‐
roundings
– Correct measuring and dosing
is only possible if the sensor is
working perfectly
–Check and calibrate the
sensor regularly
NOTICE!
Compensation of control deviations
Damage to the product or its sur‐
roundings
– This controller cannot be used
in control circuits which require
rapid compensation (< 30 s)
3.2 Correct and proper use
NOTICE!
Compensation for control devia‐
tions
Damage to the product or its sur‐
roundings
– The controller can be used in
processes, which require com‐
pensation of > 30 seconds
Safety and responsibility
13

NOTICE!
Correct and proper use
The unit is intended to measure
and regulate liquid media. The
marking of the measured variables
is located on the controller and is
absolutely binding.
The unit may only be used in
accordance with the technical
details and specifications provided
in this operating manual and in the
operating manuals for the indi‐
vidual components (such as, for
example, sensors, fittings, calibra‐
tion devices, metering pumps etc.).
Any other uses or modifications
are prohibited.
Safety and responsibility
14

4 Functional description
Brief functional description
The DULCOMETER® Compact Controller
for pH and redox measured variables pro‐
vides basic functions for water treatment
applications. It has a fixed configuration
with the following features:
nMeasured variables pH and redox
(can be switched over on the
DULCOMETER® Compact Controller)
nLanguage independent operation (use
of abbreviations, such as
[INPUT] ,
[OUTPUT] , [CONTROL] , [ERROR] )
nIlluminated display
n3 LEDs indicate the operating states
(
[f-REL] active, [P-REL] active, error)
nSensor monitoring of pH
nP or PID control characteristics
nSelectable control direction (raise or
lower measured value)
nImpulse frequency relay
[f-REL] for
metering pump control
nPower relay
[P-REL] , configurable as
alarm, limit value or pulse width
modulated (PWM) control output for
metering pumps
nAnalogue output 0/4…20 mA, can be
configured as a measured value or
correction variable
nSuction function for all actuators
nDigital input to switch off the
DULCOMETER® Compact Controller
or to process a sample water limit
contact by remote control
nTemperature sensor input (Pt 1000)
for temperature compensation of the
pH value
nProtection class IP67 (wall/pipe
mounting), protection class IP54 (con‐
trol panel mounting)
Applications:
nWaste water treatment
nTreatment of drinking water
nSwimming pool water treatment
Functional description
15

4.1 Flow diagram
mA Output
Frequency relay
(f-REL)
(Pump:Metering)
Power relay
(P-REL)
Corrected
measured value
Input
temperature as
correction variable
Contact input for
PAUSE / HOLD
Input
measured value
from the sensor
Control
(P or PID)
Correction
Alarm
Limit
Actuating variable (PWM)
Actuating variable Measured value Correction value
Actuating variable (metering stroke)
Function depends on
the configuration
Limit value
monitoring
A0325
STOP
START
Manual 0 ... 25 mA
Function depends
on the configuration
Priming 16 mA
Priming 80 % of "PUMPMAX"
Priming 100 %
Fig. 1: Flow diagram
Functional description
16

4.2 Overview of the first level menu
A0276
OPERATION pH
6.20
80.0 °C
7.20
0%
LIMIT ↓
≡MENU
MENU
LIMITS
CONTROL
INPUT
LIMITS SETUP
≡MENU
LIMITS
CONTROL
INPUT
≡MENU
LIMITS
CONTROL
INPUT
≡MENU
OUTPUT
CONTROL
INPUT
≡MENU
DEVICE
OUTPUT
INPUT
ESC
ESC
ESC
ESC
ESC
CONTROL SETUP
INPUT SETUP
OUTPUT SETUP
DEVICE SETUP
STOP pH
6.20
80.0 °C
7.20
0%
LIMIT ↓
START
STOP
CAL pH CAL
ESC
Fig. 2: Overview of the first level menu; shown for pH
Display view Selection
with:
Reference Function
OPERATION pH
6.20
80.0 °C
7.20
0%
LIMIT ↓
A0329
Ä Chapter 7 ‘Oper‐
ating diagram’
on page 44
Changes to the calibration menu.
Functional description
17

Display view Selection
with:
Reference Function
CAL pH
SLOPE 59.16 mV/pH OK
CAL=START
ZERO 0.00 mV OK
A0332
Ä Chapter 8.1 ‘pH
sensor calibration
(CAL)’ on page 49
The calibration menu enables cali‐
bration of controller and sensor.
OPERATION pH
6.20
80.0 °C
7.20
0%
LIMIT ↓
A0329
Stop/Start the control and
metering function.
STOP pH
6.20
80.0 °C
7.20
0%
LIMIT ↓
A0333
Ä Chapter 9.2
‘STOP/START key’
on page 74
By pressing the STOP key, the
control is stopped. The STOP key
can be pressed independently of
the currently displayed menu.
However the STOP state is only
shown in the continuous display.
OPERATION pH
6.20
80.0 °C
7.20
0%
LIMIT ↓
A0329
Ä Chapter 7.3
‘Continuous dis‐
play’ on page 46
Changes from the continuous dis‐
play to the setting menu.
≡MENU
LIMITS
CONTROL
INPUT A0326
Ä Chapter 8.3 ‘Set‐
ting limit values
[LIMITS]’
on page 59
Enables the setting of the limit
value for limit value monitoring.
≡MENU
LIMITS
CONTROL
INPUT A0327
Ä Chapter 8.4 ‘Set‐
ting the control
[CONTROL]’
on page 61
Enables parameter setting for the
control.
Functional description
18

Display view Selection
with:
Reference Function
≡MENU
LIMITS
CONTROL
INPUT A0328
Ä Chapter 8.5
‘Input setting
(INPUT)’
on page 64
Enables setting of the measured
value input parameter.
≡MENU
OUTPUT
CONTROL
INPUT
A0330
Ä Chapter 8.6 ‘
Output setting
(OUTPUT)’
on page 67
Enables setting of the mA output
parameter.
≡MENU
DEVICE
OUTPUT
INPUT
A0331
Ä Chapter 8.7
‘DEVICE setting’
on page 71
Enables adjustment of the pass‐
word and the controller
[RESTART] function.
Functional description
19

5 Assembly and installation
nUser qualification, mechanical instal‐
lation: trained qualified personnel, see
Ä Chapter 2.2 ‘Users' qualifications’
on page 10
nUser qualification, electrical installa‐
tion: Electrical technician, see
Ä Chapter 2.2 ‘Users' qualifications’
on page 10
CAUTION!
Possible consequence: Material
damage.
The hinge between the front and
rear part of the housing cannot
absorb high levels of mechanical
loading. When working on the
DULCOMETER® Compact Con‐
troller, firmly hold the top section of
the controller housing.
CAUTION!
Check band for strain relief
Possible consequence: Material
damage.
The ribbon cable and its socket
cannot be mechanically loaded.
Hence it is essential that when
mounting the controller in the con‐
trol panel mounting, the check
strap (part number 1035918) is
fitted for strain relief and mechan‐
ical securing. Without the check
strap, the ribbon cable or its socket
could be damaged if they were to
fall out of the controller upper
housing.
NOTICE!
Mounting position and conditions
– The controller conforms to IP
67 degree of protection (wall/
pipe mounting) or IP 54 (con‐
trol panel mounting) require‐
ments. This degree of protec‐
tion is only achieved if all seals
and cable glands are correctly
fitted.
–The (electrical) installation
should only take place after
(mechanical) installation
– Ensure that there is unim‐
peded access for operation
– Ensure safe and low-vibration
fastening
– Avoid direct sunlight
– Permissible ambient tempera‐
ture of the controller at the
installation location: -10 ... +60
°C at max. 95% relative air
humidity (non-condensing)
– Take into consideration the
permissible ambient tempera‐
ture of the sensors and other
components connected
– The controller is only suitable
for operation in closed rooms.
If operated outside, the con‐
troller must be protected
against the environment by a
suitable protective enclosure
Assembly and installation
20