ProMinent DULCOMETER User manual

DULCOMETER®
Multi-parameter Controller diaLog DACa
Assembly and operating instructions
A1111
Part no. 985217 BA DM 194 02/13 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!
Technical changes reserved.

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
Read the following supplementary infor‐
mation in its entirety!
The following are highlighted separately in
the document:
nEnumerated lists
Instructions
ðResults of the instructions
Information
This provides important information
relating to the correct operation of the
system or is intended to make your
work easier.
Safety information
Safety information are provided with
detailed descriptions of the endangering
situation, see
Ä Chapter 4.1 ‘Explanation
of the safety information’ on page 18
Supplemental instructions
2

Table of contents
1 Operating concept.................................................................................................. 7
1.1 Functions of the keys .................................................................................. 10
1.2 Changes the set operating language........................................................... 11
1.3 Acknowledge fault or warning message ...................................................... 12
1.4 The key lock ................................................................................................ 13
2 Entries in the display [menu]................................................................................. 14
3ID Code................................................................................................................. 15
3.1 A complete measuring station may comprise the following:......................... 17
4 Safety and Responsibility..................................................................................... 18
4.1 Explanation of the safety information........................................................... 18
4.2 General safety notes.................................................................................... 19
4.3 Intended Use................................................................................................ 20
4.4 Users' qualifications...................................................................................... 21
5 Functional description........................................................................................... 23
6Mounting and installation...................................................................................... 24
6.1 Scope of supply............................................................................................ 26
6.2 Mounting mechanical................................................................................... 26
6.2.1 Wall mounting............................................................................................ 26
6.2.2 Control panel installation........................................................................... 28
6.3 Electrical installation..................................................................................... 31
6.3.1 Specification of the threaded connectors.................................................. 32
6.3.2 Terminal diagram...................................................................................... 33
6.3.3 Cable Cross-Sections and Cable End Sleeves......................................... 39
6.3.4 Wall mounting and control panel installation............................................. 40
6.3.5 Switching of inductive loads...................................................................... 41
6.3.6 Connect the sensors electrically to the controller...................................... 43
7 Commissioning..................................................................................................... 48
7.1 Switch-on behaviour during commissioning................................................. 48
7.2 Adjusting the backlight and contrast of the controller display....................... 49
7.3 Resetting the operating language................................................................ 49
7.4 Defining the metering and control process................................................... 49
8 Configuration of measured variables.................................................................... 50
8.1 Information about the measured variables................................................... 51
Table of contents
3

9 Calibrating the controller....................................................................................... 58
9.1 Calibrating the pH measured value.............................................................. 59
9.1.1 Selection of the pH calibration process..................................................... 63
9.1.2 2-point pH sensor calibration (CAL).......................................................... 64
9.1.3 pH sensor calibration (CAL) with an external sample............................... 67
9.1.4 Calibration of the pH sensor (CAL) by data input...................................... 70
9.2 Calibrating the ORP measured value........................................................... 73
9.2.1 Selection of the calibration process for ORP............................................. 73
9.2.2 Single point calibration ORP sensor (CAL)............................................... 73
9.2.3 ORP sensor data calibration (CAL)........................................................... 75
9.3 Calibrating fluoride (F-) measured value [mA].............................................. 77
9.3.1 Selection of the calibration process for fluoride......................................... 77
9.3.2 2-point fluoride sensor calibration (CAL)................................................... 78
9.3.3 1-point fluoride sensor calibration (CAL)................................................... 80
9.4 Calibrating the measured value for amperometric measured variables....... 82
9.4.1 Selection of the calibration process for amperometric measured varia‐
bles............................................................................................................ 82
9.4.2 Slope calibration........................................................................................ 83
9.4.3 Calibration of zero point............................................................................ 86
9.5 Calibrating the measured value for the measured variable DO................... 88
9.5.1 Selection of the calibration process for the measured variable O2............ 89
9.5.2 Selection of the calibration process for the measured variable DO.......... 90
9.5.3 Zero point calibration for the measured variable DO................................. 92
9.5.4 DO value calibration for the measured variable DO.................................. 94
9.6 Measured value [mA general] calibration..................................................... 96
10 Setting the [Control].............................................................................................. 97
10.1 Control parameter [Type]......................................................................... 104
10.2 Control parameter [System response]...................................................... 105
10.3 Control parameter [Setpoint].................................................................... 105
10.4 Control parameter [xp].............................................................................. 106
10.5 Control parameter [Ti].............................................................................. 107
10.6 Control parameter [Td]............................................................................. 107
10.7 Control parameter [Add. Basic load]........................................................ 107
10.8 Control parameter [Checkout time].......................................................... 107
10.9 Control parameter [max. ctrl var.]............................................................. 107
10.10 Disturbance variable............................................................................... 107
Table of contents
4

10.11 Remote setpoint via a 0/4 ... 20 mA analog signal................................. 110
10.12 [Parameter switch] via the digital input or [Timer].................................. 112
11 Setting the [Limit values]..................................................................................... 116
11.1 Function of the limit values....................................................................... 116
11.2 Setting Limit value channel 1................................................................... 118
11.2.1 Setting [Limit 1]...................................................................................... 119
11.2.2 Setting [Limit 2]...................................................................................... 119
11.2.3 Setting [System response].................................................................... 119
12 Setting the [Pumps]............................................................................................ 120
12.1 Setting up [Pump 1].................................................................................. 120
13 Setting the [Relays]............................................................................................. 123
13.1 Setting Relay 1......................................................................................... 123
13.1.1 Function description [Off]...................................................................... 125
13.1.2 Function description [Limit 1] or [Limit 2]............................................... 125
13.1.3 Function description [Control variable].................................................. 125
13.1.4 Function description [Timer].................................................................. 125
13.1.5 Function description [Control variable].................................................. 126
14 Setting [Digital inputs]......................................................................................... 127
14.1 Setting [Digital input 1]............................................................................. 127
15 Setting the [mA outputs]..................................................................................... 130
15.1 Setting [mA outputs]................................................................................. 131
16 The [Service]....................................................................................................... 133
16.1 Setting the [Wash timer]........................................................................... 133
17 Setting [Device setup]......................................................................................... 134
17.1 Setting the [Language]............................................................................. 135
17.2 Setting the [Device configuration]............................................................. 136
17.3 Setting the [Extended configuration]........................................................ 136
17.4 Update...................................................................................................... 137
17.5 Setting the [Access code]......................................................................... 138
18 Diagnostics......................................................................................................... 139
18.1 Display the [Logbook]............................................................................... 139
18.1.1 Display the [Calibration log book].......................................................... 139
18.1.2 Read [Error log book]............................................................................ 139
18.1.3 Read [Data log book]............................................................................. 140
Table of contents
5

18.1.4 Read-off stored [Messages].................................................................. 140
18.2 Display [Simulation].................................................................................. 140
18.3 Display [Device information]..................................................................... 140
18.4 Error messages........................................................................................ 141
18.5 Help texts................................................................................................. 143
19 Communication and connection......................................................................... 145
19.1 Profibus DP module ................................................................................ 145
19.2 Module for Modbus RTU.......................................................................... 145
19.3 LAN module.............................................................................................. 145
19.4 WLAN module.......................................................................................... 145
20 Controller technical data..................................................................................... 146
21 Spare parts and accessories.............................................................................. 149
21.1 Spare parts............................................................................................... 149
21.2 Accessories.............................................................................................. 150
22 Necessary formalities......................................................................................... 151
22.1 Disposal of used parts.............................................................................. 151
22.2 Standards complied with and conformity declaration............................... 151
23 Glossary.............................................................................................................. 152
24 Index................................................................................................................... 160
Table of contents
6

1 Operating concept
A1035
1.
Fig. 1: Operating cross (1) / Active keys are displayed in [black] in the display; inactive
keys in [grey].
For example, the following path is represented:
Continuous display ➨ ➨ or
[calibrate] ➨ ➨ or [slope] ➨ ➨
Continuous display [Calibrate] [Slope]
A1036
Fig. 2: A display change is made within a sequence of actions.
I. Continuous display 1
II. Display 2
III. Display 3
IV. Display 4
The function of the keys is described in table
Ä Chapter 1.1 ‘Functions of the keys ’
on page 10 .
➨ = describes as a symbol an action by the operator, that leads to a new possibility for
an action.
[Naming in the display] = square brackets contain the name that appears with the iden‐
tical wording in the controller display.
You can query further information via the key, e.g. which current terminal the input
was assigned to.
Operating concept
7

Illumination of the display
In the case of an error with the status [ERROR], the backlight of the display changes
from ‘white’ to ‘red’ . This makes it easier for the operator to react to an error.
Fig. 3: This is the appearance of the continuous display when used with one measuring
channel (e.g. pH)
A1177
7.55
7.20
0.50
0.30
25
-15
Fig. 4: This is the appearance of the continuous display when used with two measuring
channels (e.g. pH/chlorine)
Operating concept
8

Setting of the various parameters in the adjustable menus
No time-controlled menu items
The controller does not exit any menu items in a time-controlled manner, the con‐
troller remains in a menu item until this menu item is exited by the user.
1. Select the desired parameter in the display using the keys or .
ðIn front of the selected parameter there is an arrow tip, which marks the
selected parameter.
2. Press
ðYou are now in the setting menu for the desired parameter.
3. You can adjust the desired value in the setting menu using the four arrow keys and
then save it using the key
ð
Range error
If you enter a value that is outside the possible setting range, the message
[range error] appears. By pressing or you return to the value to be
set.
Once the key is pressed, the controller returns to the menu
Interrupting the setting process
Pressing the key returns to the menu without saving a value.
Operating concept
9

1.1 Functions of the keys
Functions of the keys
Key Function
Confirmation in the setting menu: Confirms and saves the input values.
Confirmation in the continuous display: Displays all information about
saved errors and warnings.
Back to the continuous display or to the start of the respective setting
menu, in which you are currently located.
Enables direct access to all of the controller's setting menus.
Enables direct access to the controller's calibration menu from the contin‐
uous display.
Start/Stop of the controller's control and metering function from any dis‐
play.
To increase a displayed number value and to jump upwards in the oper‐
ating menu.
Confirmation in the setting menu: Moves the cursor to the right.
Confirmation in the continuous display: Displays further information about
the controller input and output values.
Operating concept
10

Key Function
To decrease a displayed number value and to jump down in the operating
menu.
Moves the cursor to the left.
1.2 Changes the set operating language
1. Simultaneously press the keys and
ðThe controller changes to the menu for setting the operating language.
A1482
Language 2
Language
German
Fig. 5: Menu for setting the operating language
2. Now using keys and you can set the desired operating language
3. Confirm your selection by pressing the key
ðThe controller changes back to the continuous display and indicates the
selected operating language.
Operating concept
11

1.3 Acknowledge fault or warning message
If the controller recognises an error, control is stopped, the backlight switches to red
lighting and the alarm relay is deactivated. You can access the next value to be set by
pressing the key. In doing so, the controller shows you all errors and warnings; you
can select and, where necessary, acknowledge the current alarm messages. If you
acknowledge an error, the alarm relay activates and the backlight switches back to white
light. In the bottom part of the display, the error or warning message that has occurred
remains displayed, such as
[Error 01] , until the cause has been cleared.
In the event of a warning, e.g. the controller signals that a calibration is required, further
processing using the controller is possible with or without acknowledgement of the mes‐
sage.
In the event of an error message [Error] , e.g. the controller signals that a sensor is
missing, then after acknowledgement of the message, no further processing is possible
using the controller. You must now clear the error - see
Ä Chapter 18 ‘Diagnostics’
on page 139 .
7.55
0.30
7.20
0.50
Fig. 6: Alarm message, controller stops control
Operating concept
12

1.4 The key lock
The controller has a key lock. If the key
lock is activated, the keys cannot be
pressed. The key lock can be activated or
deactivated by simultaneous pressing of
the and keys. Activation of the key
lock is indicated by the symbol in the
display.
Operating concept
13

2 Entries in the display [menu]
Name of the menu item Jump to chapter
[Measurement] Ä Chapter 8 ‘Configuration of measured variables’
on page 50
[Limits] Ä Chapter 11 ‘Setting the [Limit values]’ on page 116
[Control] Ä Chapter 10 ‘Setting the [Control]’ on page 97
[Calibration] Ä Chapter 9 ‘Calibrating the controller’ on page 58
[Pumps] Ä Chapter 12 ‘Setting the [Pumps]’ on page 120
[Relay] Ä Chapter 13 ‘Setting the [Relays]’ on page 123
[Digital inputs] Ä Chapter 14 ‘Setting [Digital inputs]’ on page 127
[mA outputs] Ä Chapter 15 ‘Setting the [mA outputs]’ on page 130
[Diagnostics] Ä Chapter 18 ‘Diagnostics’ on page 139
[Service] Ä Chapter 16 ‘The [Service]’ on page 133
[Setup] Ä Chapter 17 ‘Setting [Device setup]’ on page 134
Entries in the display [menu]
14

3 ID Code
Device identification / identity code
DULCOMETER®, Multi-parameter Controller diaLog DACa
D
A
C
a
Version
00 With ProMinent® Logo
S0 With fitting kit for control cabinet
Operating voltage
6 90 ... 253 V, 48/63 Hz
Channel 1*
1 Measurement + control, 2 pumps, 2 control inputs, 2 mA outputs
Channel 2**
0 No second channel
2 Package 2: Disturbance variable (mA) or external remote setpoint
via mA or pH compensation for chlorine (all acting on channel 1)
3 Package 3: 2nd measurement + control, additionally 2 pumps, addi‐
tionally 3 control inputs
4 Package 4: 2nd measurement + control, additionally 2 pumps, addi‐
tionally 3 control inputs, disturbance variable (mA or frequency), pH
compensation for chlorine
Software default settings
0 no default settings
1 Batch neutralisation 2 x pH measurement with 1-2-way con‐
troller and final inspection
2 Flow neutralisation 2 x pH measurement with 1-2-way con‐
troller, disturbance variable and final inspection
3 pH-/ORP measurement/control (pH 2 page, ORP 1-way)
4 pH-/Cl2 measurement/control (pH 2-way, chlorine 1-way)
ID Code
15

DULCOMETER®, Multi-parameter Controller diaLog DACa
5 pH-/ClO2 measurement/control (pH 2-way, chlorine dioxide 1-
way)
6 pH-/Cl2 measurement/control with disturbance variable (pH 2-
way, chlorine 1-way)
7 ClO2/ORP measurement/control (chlorine dioxide 1-way, ORP
for monitoring)
Channel connections
0 Channel 1/2 via terminals (mA and mV)
1 Channel 1 via SN 6 coaxial connector (only for pH and ORP
via mV)
2 Channel 2 via SN 6 coaxial connector (only for pH and ORP
via mV)
3 Channel 1 and 2 via SN 6 coaxial connector (only for pH
and ORP via mV)
Connection of digital sensors / actuators
0 none
Communication
0 none
Data logger
0 no data logger
1 Data logger with measured value presentation
with SD card
Hardware expansion
0 none
1 Protective RC circuit for output relay
Certifications
0 None (CE standard)
Certificates
ID Code
16

DULCOMETER®, Multi-parameter Controller diaLog DACa
0 None
Documentation language***
DE German
EN English
FR French
ES Spanish
Footnotes concerning the identity code
* Selection of the measured variable upon initial commissioning
** Selection of the measured variable takes place upon initial commissioning or via
software default setting. Higher order packages include the options of the preceding
packages.
*** Other languages can be supplied upon request
3.1 A complete measuring sta‐
tion may comprise the fol‐
lowing:
nMeasuring transducer / Controller
DACa (see identity code)
nFitting: DGMa..., DLG III ...
npH sensor (dependent upon the appli‐
cation)
nORP sensor (dependent upon the
application)
ne.g. chlorine, chlorine dioxide,
chlorite, bromine, dissolved oxygen
sensor
nTransducer for pH or ORP
(dependent on the set evaluation, pH
[mA], ORP [mA])
nSensor cable
ID Code
17

4 Safety and Responsibility
4.1 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.
Safety and Responsibility
18

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.
4.2 General safety notes
WARNING!
Live parts!
Possible consequence: Fatal or very
serious injuries
– Measure: Before opening the
housing or before carrying out
installation work, ensure the
devices are voltage-free.
–Disconnect damaged, defective
or tampered-with devices from
the power supply.
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 pro‐
vided by the manufacture of the haz‐
ardous substance. The actions
required are described in the safety
data sheet. Check the safety data
sheet regularly and replace, if neces‐
sary, as the hazard potential of a sub‐
stance 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 pro‐
ducing an associated hazard assess‐
ment for the workstations affected.
Safety and Responsibility
19

WARNING!
Unauthorised access!
Possible consequence: Fatal or very
serious injuries.
– Measure: Ensure that there can
be no unauthorised access to the
device
WARNING!
Operating faults!
Possible consequence: Fatal or very
serious injuries.
– The unit should only be operated
by adequately qualified and tech‐
nically expert personnel
–Please also observe the oper‐
ating instructions for sensors and
fittings and any other units which
may be fitted, such as sample
water pumps ...
– The operator is responsible for
ensuring that personnel are quali‐
fied
NOTICE!
Correct sensor operation
Damage to the product or its sur‐
roundings
– Correct measuring and metering
is only possible if the sensor is
working perfectly
–Check and calibrate the sensor
regularly
4.3 Intended Use
Intended Use
The device is intended to measure
and regulate liquid media. The label‐
ling of the measured variables is indi‐
cated in the controller display and is
absolutely binding.
The unit may only be used in accord‐
ance with the technical details and
specifications provided in this oper‐
ating manual and in the operating
manuals for the individual compo‐
nents (such as sensors, fittings, cali‐
bration devices, metering pumps,
etc.).
Any other uses or modifications are
prohibited.
Compensation for control devia‐
tions
Damage to the product or its sur‐
roundings
– The controller can be used in pro‐
cesses, which require compensa‐
tion of > 30 seconds
Safety and Responsibility
20