ProMinent DULCOMETER User manual

DULCOMETER® Compact Controller
pH/redox measured variable
Assembly and operating instructions
A0206
Part no. 986214 BA DM 190 10/11 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.

986214, 2, en_GB
© 2011
ProMinent Dosiertechnik GmbH
Im Schuhmachergewann 5 - 11
69123 Heidelberg
Telephone: [phone]
Fax: [phone]
email: [email protected]
Internet: www.prominent.com
2

Table of contents
1 Introduction............................................................................................................. 5
1.1 Explanation of the safety information............................................................. 5
1.2 Users' qualifications........................................................................................ 7
2 Safety and responsibility......................................................................................... 9
2.1 General Safety Information............................................................................ 9
2.2 Correct and proper use................................................................................ 10
3 Functional description........................................................................................... 12
3.1 Flow diagram................................................................................................ 13
3.2 Overview of the first level menu................................................................... 14
4 Mounting and installation...................................................................................... 17
4.1 Scope of delivery.......................................................................................... 19
4.2 Mounting (mechanical)................................................................................. 19
4.2.1 Wall mounting............................................................................................ 19
4.2.2 Pipe mounting........................................................................................... 21
4.2.3 Control panel mounting............................................................................. 22
4.3 Installation (electrical)................................................................................... 30
4.3.1 Cable Cross-Sections and Cable End Sleeves......................................... 31
4.3.2 Installation of coaxial cable to guard terminal XE1.................................... 31
4.3.3 Installation (electrical)................................................................................ 36
4.4 Switching of inductive loads......................................................................... 36
5 Commissioning..................................................................................................... 39
5.1 Initial commissioning.................................................................................... 39
5.2 Selection of the measured variable.............................................................. 39
5.3 Setting the controller during commissioning................................................. 39
6 Operating diagram................................................................................................ 41
6.1 Overview of device /Control elements.......................................................... 41
6.2 Adjusting display contrast............................................................................. 42
6.3 Continuous display....................................................................................... 43
6.4 Info display................................................................................................... 43
6.5 Password...................................................................................................... 45
7 Operating menus for the pH and redox measured variables................................ 46
7.1 pH sensor calibration (CAL)......................................................................... 46
7.2 Redox sensor calibration (CAL)................................................................... 54
Table of contents
3

7.3 Limit value setting (LIMITS).......................................................................... 56
7.4 Control setting (CONTROL)......................................................................... 58
7.5 Input setting (INPUT).................................................................................... 61
7.6 Output setting (OUTPUT)............................................................................. 64
7.7 DEVICE setting............................................................................................ 68
8 Control parameters and functions......................................................................... 69
8.1 DULCOMETER® Compact Controller function states ................................. 69
8.2 STOP/START key........................................................................................ 71
8.3 Priming (PRIME).......................................................................................... 72
8.4 Hysteresis limit............................................................................................. 73
8.5 Temperature correction variable for pH........................................................ 74
8.6 Checkout time measurement variable and correction variable.................... 75
8.7 Checkout time control................................................................................... 75
8.8 Power relay "P-REL" as limit value relay...................................................... 76
8.9 Setting and functional description of "Relay Used as a Solenoid Valve" .... 77
8.10 Alarm relay................................................................................................. 79
8.11 "Error logger" operating mode.................................................................... 79
9 Maintenance......................................................................................................... 80
9.1 Changing the fuse, DULCOMETER® Compact Controller........................... 80
9.2 Fault reporting and troubleshooting.............................................................. 81
10 Technical data DULCOMETER® Compact Controller........................................... 84
10.1 Permissible ambient conditions.................................................................. 84
10.2 Sound Pressure Level................................................................................ 84
10.3 Material data............................................................................................... 85
10.4 Chemical Resistance.................................................................................. 85
10.5 Dimensions and weights............................................................................ 86
11 Electrical data....................................................................................................... 87
12 Spare parts and accessories................................................................................ 90
13 Standards complied with....................................................................................... 91
14 Disposal of used parts.......................................................................................... 92
15 Declaration of Conformity..................................................................................... 93
16 Index..................................................................................................................... 94
Table of contents
4

1 Introduction
Data and functions
These operating instructions describe the
technical data and functions of the
DULCOMETER® Compact Controller pH /
redox measured variable.
Order number DULCOMETER® Compact
Controller pH / redox measured variable:
1035638
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.
1.1 Explanation of the safety
information
Introduction
These operating instructions provide infor‐
mation on the technical data and functions
of the product. These operating instruc‐
tions provide detailed safety information
and are provided as clear step-by-step
instructions.
The safety information and notes are cate‐
gorised according to the following
scheme. A number of different symbols
are used to denote different situations.
The symbols shown here serve only as
examples.
DANGER!
Nature and source of the danger
Consequence: Fatal or very serious
injuries.
Measure to be taken to avoid this
danger
Danger!
–Denotes an immediate threat‐
ening danger. If this is disre‐
garded, it will result in fatal or
very serious injuries.
WARNING!
Nature and source of the danger
Possible consequence: Fatal or very
serious injuries.
Measure to be taken to avoid this
danger
Warning!
–Denotes a possibly hazardous sit‐
uation. If this is disregarded, it
could result in fatal or very
serious injuries.
Introduction
5

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.
NOTICE!
Nature and source of the danger
Damage to the product or its sur‐
roundings
Measure to be taken to avoid this
danger
Note!
–Denotes a possibly damaging sit‐
uation. If this is disregarded, the
product or an object in its vicinity
could be damaged.
Type of information
Hints on use and additional informa‐
tion
Source of the information, additional
measures
Information!
– Denotes hints on use and other
useful information. It does not
indicate a hazardous or dam‐
aging situation.
Introduction
6

1.2 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 personnel.
–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
7

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 acknowl‐
edged safety regulations, must be adhered to!
Introduction
8

2 Safety and responsibility
2.1 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, defective
or manipulated units by discon‐
necting 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 operated
by adequately qualified and tech‐
nically expert personnel
–Please also observe the oper‐
ating instructions for controllers
and fittings and any other compo‐
nent groups, such as sensors,
measuring water pumps ...
– The operator is responsible for
ensuring that personnel are quali‐
fied
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 inter‐
ference suppression measures
Safety and responsibility
9

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 instruc‐
tions and in the operating instruc‐
tions for the individual
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 initial
operation
– It may take a whole working day
to run-in the sensor
– Please read the operating instruc‐
tions 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)
2.2 Correct and proper use
NOTICE!
Compensation for control deviations
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
10

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 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, for example, sensors,
fittings, calibration devices, metering
pumps etc.).
Any other uses or modifications are
prohibited.
Safety and responsibility
11

3 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
12

3.1 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
13

3.2 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 6 ‘Oper‐
ating diagram’
on page 41
Changes to the calibration menu.
Functional description
14

Display view Selection
with:
Reference Function
CAL pH
SLOPE 59.16 mV/pH OK
CAL=START
ZERO 0.00 mV OK
A0332
Ä Chapter 7.1 ‘pH
sensor calibration
(CAL)’ on page 46
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 8.2
‘STOP/START key’
on page 71
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 6.3
‘Continuous dis‐
play’ on page 43
Changes from the continuous dis‐
play to the setting menu.
≡MENU
LIMITS
CONTROL
INPUT A0326
Ä Chapter 7.3
‘Limit value setting
(LIMITS)’
on page 56
Enables the setting of the limit
value for limit value monitoring.
≡MENU
LIMITS
CONTROL
INPUT A0327
Ä Chapter 7.4
‘Control setting
(CONTROL)’
on page 58
Enables parameter setting for the
control.
≡MENU
LIMITS
CONTROL
INPUT A0328
Ä Chapter 7.5
‘Input setting
(INPUT)’
on page 61
Enables setting of the measured
value input parameter.
Functional description
15

Display view Selection
with:
Reference Function
≡MENU
OUTPUT
CONTROL
INPUT
A0330
Ä Chapter 7.6
‘ Output setting
(OUTPUT)’
on page 64
Enables setting of the mA output
parameter.
≡MENU
DEVICE
OUTPUT
INPUT
A0331
Ä Chapter 7.7
‘DEVICE setting’
on page 68
Enables adjustment of the pass‐
word and the controller
[RESTART] function.
Functional description
16

4 Mounting and installation
nUser qualification, mechanical instal‐
lation: trained qualified personnel, see
Ä Chapter 1.2 ‘Users' qualifications’
on page 7
nUser qualification, electrical installa‐
tion: Electrical technician, see
Ä Chapter 1.2 ‘Users' qualifications’
on page 7
CAUTION!
Possible consequence: Material
damage.
The hinge between the front and rear
part of the housing cannot absorb
high mechanical loading. When
working on the DULCOMETER®
Compact Controller, 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 during con‐
troller mounting in the control panel
mounting, the check strap (part
number 1035918) is fitted for strain
relief and mechanical securing.
Without the check strap, the ribbon
cable or its socket may be damaged if
they fall our of the controller upper
housing.
NOTICE!
Mounting position and conditions
– The controller fulfils the IP 67
degree of protection requirements
(wall/pipe mounting) or IP 54
(control panel mounting). This
degree of protection is only ach‐
ieved if all seals and threaded
connectors are correctly fitted.
–The installation (electrical) can
only take place after mounting
(mechanical)
– Ensure that there is unimpeded
access for operation
– Secure, low-vibration fixing
– Avoid direct sunlight
– Permissible ambient temperature
of the controller at the installation
location: -10 ... +60 °C at max.
95% relative air humidity (non-
condensing)
– The permissible ambient tem‐
perature of the connected sen‐
sors and other such components
must be considered
– The controller is only suitable for
operation in closed rooms. If
operated outside, the controller
must be protected against the
environment by a suitable protec‐
tive enclosure
Measured value and operating
position
– Install the device in a favourable
position for reading and operating
(preferably at eye level)
Mounting and installation
17

Mounting position
– Leave sufficient free space for the
cables
Packaging material
Dispose of packaging material envi‐
ronmentally. All packaging compo‐
nents are provided with their corre‐
sponding recycling .
Mounting and installation
18

4.1 Scope of delivery
The following parts belong to the standard scope of delivery of a DULCOMETER® Com‐
pact Controller.
Description Quantity
Assembled device 1
Cable connection set DMTa/DXMa (metr.) 1
Operating instructions 1
4.2 Mounting (mechanical)
The DULCOMETER® Compact Controller is suitable for mounting on a wall, a pipe or a
control panel.
Mounting materials (contained in the scope of delivery):
Description Quantity
Wall/pipe bracket 1
Round head screws 5x45 mm 2
Washer 5.3 2
Rawlplug Ø 8 mm, plastic 2
4.2.1 Wall mounting
Mounting (mechanical)
Mounting and installation
19

2
1
A0273
Fig. 3: Removing the wall/pipe bracket
1. Remove the wall/pipe bracket. Pull
the two snap-hooks (1) outwards
and push upwards
2. Fold out the wall/pipe bracket (2)
and pull out in a downwards direc‐
tion
3. Mark two drill holes diagonal to
each other by using the wall/pipe
bracket as a drilling template
4. Drill holes: Ø 8 mm, d = 50 mm
A0274
Fig. 4: Screwing on the wall/pipe bracket
using washers
5. Screw on the wall/pipe bracket
using the washers
6. Suspend the DULCOMETER®
Compact Controller at the top in the
wall/pipe bracket and push using
light pressure at the bottom against
the wall/pipe bracket. Then press
upwards until the DULCOMETER®
Compact Controller audibly snaps
into position.
Mounting and installation
20