ProMinent Dulcodes M User manual

ProMinent
®
Please read the operating instructions through completely before commissioning this equipment! Do not discard!
Any part which has been subject to misuse is excluded from the warranty!
Part No. 987340 ProMinent Dosiertechnik GmbH •69123 Heidelberg •Germany BA DS 007 07/05 GB
Operating Instructions
Dulcodes M
UV-System
Please affix device label here!

ProMinent®
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Notes for the User / Publishing details
Notes for the User
These operating instructions contain
a description of the product in
continuous text,
•lists
instructions
and safety advice with pictograms as follows:
DANGER
Ignoring safety information can endanger life or result in serious injury!
CAUTION
Ignoring safety information can result in injury to persons or damage to machinery or
other materials.
IMPORTANT
Ignoring safety information can result in damage to machinery or other materials.
NOTE
Special guidelines.
Publishing details:
Operating Instructions
Dulcodes M UV-System
© ProMinent Dosiertechnik GmbH, 2001
Address:
ProMinent Dosiertechnik GmbH
Im Schuhmachergewann 5-11
69123 Heidelberg · Germany
[email protected]
www.prominent.com
Subject to technical alterations.

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Table of Contents
Table of Contents
Notes for the User .................................................................................................................................................................... 2
1Application..................................................................................................................................................................................... 5
2Safety Guidelines..................................................................................................................................................................... 5
3Function ........................................................................................................................................................................................... 6
4Controller ........................................................................................................................................................................................ 7
4.1 Display .................................................................................................................................................................................. 7
4.2 Function Keys.................................................................................................................................................................. 8
4.3 Operating Status Display and Parameter Setting ............................................................................... 9
4.3.1 Trend Display .................................................................................................................................................. 11
4.3.2 Starting a Wiper Cycle ............................................................................................................................. 12
4.3.3 Changing the Access code .................................................................................................................. 12
4.3.4 Setting the Language ............................................................................................................................... 13
4.3.5 Changing the Lamp Performance .................................................................................................. 13
4.3.6 Sensor Signal System .............................................................................................................................. 14
4.3.7 Sensor Calibration ...................................................................................................................................... 14
4.3.8 Setting the safety threshold in operating mode “control off” ................................... 14
4.3.9 Setting the warning threshold in operating mode “control on” .............................. 15
4.3.10 Setting the Wiper Interval...................................................................................................................... 16
4.3.11 Setting the Display range of the Trend Display .................................................................... 16
4.3.12 Sensor Signal Analogue Output: Setting the Output Signal ...................................... 16
4.3.13 Setting the Maximum Operating Temperature ..................................................................... 16
4.3.14 Maximum Rinse Duration Following a Temperature Rise ............................................ 17
4.3.15 Setting the Start Rinse Duration ...................................................................................................... 17
4.3.16 Setting the Maximum Free Rinse Duration ............................................................................. 17
4.3.17 Activating Lamp Post-Burn ................................................................................................................. 18
4.3.18 Setting the Minimum Line Voltage ................................................................................................. 18
4.3.19 Pause Function ............................................................................................................................................. 18
4.3.20 Displaying/Resetting the Counters ................................................................................................ 18
4.3.21 Switching the control on/off
(only for systems with electronic control gear) ................................................................... 19
4.3.22 Alarm Relay ...................................................................................................................................................... 19
4.3.23 Booster Pump Relay ................................................................................................................................. 19
4.3.24 Fault Switch Input ....................................................................................................................................... 19
5Assembly and Installation ............................................................................................................................................... 20
5.1 Radiation Chamber ..................................................................................................................................................... 20
5.1.1 Preparation for Assembly...................................................................................................................... 20
5.1.2 Assembly ............................................................................................................................................................ 23
5.1.3 Attaching the Warning Sign ................................................................................................................. 23
5.1.4 Hydraulic Connections ............................................................................................................................ 23
5.2 Control Cabinet .............................................................................................................................................................. 23
5.2.1. Installation ......................................................................................................................................................... 23
5.2.2 Electrical Connections ............................................................................................................................. 24
5.2.3 Attaching the Temperature Sensor ................................................................................................ 24
5.2.4 Positioning and Connecting the Limit Switches ................................................................. 24
5.2.5 Connecting the UV Sensor .................................................................................................................. 25
5.2.6 Attaching the Wiper Motor ................................................................................................................... 25
5.2.7 Installing the Terminal Box ................................................................................................................... 25

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Inhaltsverzeichnis
5.3 Installing the Lamp Protection Tube .............................................................................................................. 25
5.4 Installing and Connecting the Lamp ............................................................................................................. 26
5.4.1 Mounting the Safety Shield on the Wiper Motor ................................................................ 26
6Commissioning ......................................................................................................................................................................... 27
6.1 Checking the Seals and Bleeding the Radiation Chamber ......................................................... 27
6.2 Switching on the UV Disinfection System ................................................................................................ 27
6.3 Calibrating the UVC Sensor ................................................................................................................................. 28
6.3.1 Calibrating the Sensor ............................................................................................................................. 28
6.3.2 Setting the radiation output in operating mode “control off” ................................... 29
6.3.3 Setting the radiation output in operating mode “control on” ................................... 29
7Maintenance ................................................................................................................................................................................ 31
7.1 Replacing the Lamp ................................................................................................................................................... 32
7.2 Cleaning the Lamp Protection Tube .............................................................................................................. 33
7.3 Cleaning the UVC Sensor ...................................................................................................................................... 35
7.3.1 Calibrating the Sensor ............................................................................................................................. 35
7.4 Wiper Maintenance ..................................................................................................................................................... 35
7.5 Replacing the Fan Filter Mats and Air Exit Filter ................................................................................. 36
8Troubleshooting ........................................................................................................................................................................ 36
Appendix
Operation Log ................................................................................................................................................................................. 40
EC Declaration of Conformity ............................................................................................................................................ 41
Data sheet ......................................................................................................................................................................................... 42
Spare parts list ............................................................................................................................................................................... 43

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Application / Safety Guidelines
1Application
Dulcodes M UV systems are used to disinfect and treat
•drinking water,
•process water and
•swimming pool water.
Dulcodes M UV disinfection involves exposing the water to be treated to short-wave ultraviolet
light. This so-called UV-C radiation eradicates bacteria quickly and reliably.
UV radiation breaks down the harmful substances in swimming pool water effectively and
reliably kills bacteria that even chlorine struggles to eradicate.
Dulcodes M UV systems are supplied ready for connection. There are various models to choose
from and each one has a specific identity code.
Performance data is provided in the data sheet that accompanies the Dulcodes M UV system.
Supplied as standard •Radiation chamber
•UV lamp with protection tube
•Control cabinet containing the ballast and system controller
•Motor-driven wiper
•UV-C sensor
•Operating instructions manual and data sheet
2Safety Guidelines
DANGER
•Do not change or block access!
UVC radiation is hazardous to the eyes and skin.
UV radiator only to be commissioned when fully assembled!
Both the UV lamp and UV disinfection system must be installed as instructed before
the lamp can be commissioned.
•AUVC sensor that has not been calibrated correctly cannot function properly. This
may result in the consumer obtaining water that has not been disinfected adequately.
•Before commissioning the system, any pipework that transports the treated water
should also be disinfected, e.g. with high chlorination, for applications in which high
levels of disinfection are required (e.g. the disinfection of drinking water). This is
particularly important in pipework where bacterial proliferation already exists.
•Ensure that
•the maximum flow is not exceeded and
•UV transmission does not fall below the minimum level
otherwise adequate disinfection cannot be guaranteed.
•The system must not be switched on until the radiation chamber is full of water.
•Apart from when the lamp is warming up, ensure that there is sufficient flow through
the radiation chamber to prevent the chamber from overheating.
If the flow is interrupted, switch off the system.
•In addition to UV treatment, swimming pool water must also be subjected to a form of
disinfection with a repository effect, e.g. chlorination.
•The UV disinfection system must be installed in a dry place that is protected from frost,
chemicals, dyes and vapours.
•The ambient temperature and the heat radiation from hot surfaces in the near
environment must not exceed 40 °C.
•Asuitable filter should be installed in front of the UV disinfection system if there are
any suspended solids or dissolved solids in the water to be treated.
•Ensure that the maximum operating pressure specified in the accompanying data sheet
is not exceeded.
•Switch off at the mains before installing and connecting the UV lamp.
NOTE
Please refer to the technical data sheet that accompanies each Dulcodes M UV system.
Please follow the separate operating instructions enclosed for special applications that
require the sensor signal to be displayed in W/m2.

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Function
3Function
The water to be disinfected flows through the stainless steel radiation chamber alongside the UV
lamp.
The Powerline UV lamp is a highly efficient generator of UVC radiation, which is particularly
effective at disinfecting water. It is housed in a protection tube made of high-grade quartz
through which a high level of UV radiation is able to pass.
The compact design of the radiation chamber and the ideal flow within it enable the water to be
radiated evenly.
The control system and UVC sensor monitor the UV disinfection system.
Commissioning The UV lamp ignites after the UV disinfection system has been switched on. After ignition, the
lamp requires approximately 1 minute to reach its operating temperature and full UVC capacity.
The UVC sensor monitors the output of the UVC lamp. About 10 seconds after the safety
threshold has been exceeded, the rinsing valve opens and the start rinsing period commences.
If the safety threshold is not exceeded within the maximum warm-up period, two wiper cycles
are triggered and the rinsing valve is opened. If the safety threshold is not exceeded within the
maximum free rinsing period either, the control system switches off the UV disinfection system
and reports a fault.
After the start rinsing period, the stop valve opens and the UV disinfection system commences
normal operation.
Normal operation During normal operation the UVC sensor continues to monitor UVC output:
If UVC output falls below the warning threshold, a warning signal is given. If UVC output falls
below the safety threshold, the stop valve closes, two wiper cycles are triggered and the rinsing
valve opens. If the safety threshold is not exceeded again within the maximum free rinsing
period, the control system switches off the UV disinfection system and reports a fault.
The lamp is monitored to ensure that it is burning correctly. If the lamp fails, the stop valve
closes and the control system switches off the UV disinfection system and reports a fault.
Controlled operation Using controlled operation, automatic regulation of the radiation output maintains the UV probe
signal at a predetermined value. The reference value is either entered directly into control drive
(operating mode: manual control) or is preset by a variable output signal 0/4-20 mA (operating
mode: external mode)
Wiper An automatic motor-driven wiper removes any impurities that settle on the lamp’s protective
tube during operation. While the system is running, the wiper moves along the tube at intervals
set by the operator.
If output falls below the safety threshold, two wiper cycles are triggered.
If the UV sensor signal does not exceed the safety threshold during the warm-up period, two
wiper cycles are triggered at the end of the warm-up period.
Temperature monitoring The temperature of the water in the radiation chamber is monitored continuously while the lamp
is in operation.
As soon as the temperature of the water exceeds the maximum operating temperature, the
rinsing valve opens. If the temperature has not dropped within a preset time, i.e. it still exceeds
the maximum operating temperature the system will report a fault.
Switching off If the UV system is switched off, the stop valve closes and the lamp is switched off. If post
burning is required, the lamp will not be switched off until the post burning period is complete.
Cooling off After the system has been switched off, the Powerline UV lamp cannot be re-ignited until it has
cooled sufficiently. Therefore, the system moves into cooling mode.
If the START/STOP key is pressed during the cooling period, the system will restart
automatically when the remainder of the cooling period has elapsed. Even if the pause status is
cancelled during the cooling period, the system will not start until the cooling period is
complete. (Only for maintenance: An attempt to ignite the lamp can be made during the cooling
period by pressing the enter key).
NOTE
The radiation chamber cannot be emptied in order to carry out maintenance until the
cooling period has elapsed.

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Controller
4Controller
Version As electronics and software are continuously being improved, the version number has been
introduced as a means of identifying the system. This should be given in the event of a query or
complaint.
Default setting The controller system of the Dulcodes M UV system is preset at the factory. Unless calibrating
the sensor, it is not usually necessary to change the settings.
NOTE
The settings can only be changed if the UV system has been switched off.
Exceptions: sensor calibration, setting the lamp output and triggering a wiper cycle.
4.1 Display
The system has a graphical display.
In operating mode It indicates the operating status.
Flashing arrows and displays are used to issue a warning.
A flashing error message indicates a fault.
In programming mode The numerical values and settings that can be changed are indicated as flashing text.
NOTE
If none of the keys are pressed for 5 minutes, the display returns to the normal operating
status display automatically.

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Controller
4.2 Function Keys
Graphical display
Function keys
Fig. 1: Display and control unit
STOP
START
START/STOP Switches the UV system on and off
CHANGE In operating mode: changes the display window
In programming mode: changes the parameter to be set
BACK Returns to the previous level in the menu
DOWN In programming mode: reduces the numerical value displayed
and changes a setting
UP In programming mode: increases the numerical value displayed
and changes a setting
ENTER In operating mode: changes to programming mode, triggers
an attempt to ignite the lamp during the
cooling period and acknowledges a fault
In programming mode: sets a value or status
NOTE
•Keep the START/STOP key depressed for at least 2 seconds each time.
•If none of the keys are pressed for 5 minutes, the display returns to the normal
operating status display automatically.
DULCODES
®
STOP
START
System
Off

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Controller
4.3 Operating Status Display and Parameter Setting
B
A
B
A
B
A
Control manual
Setpoint = xxx %
Safety threshold
-xx [%]
below setpoint
Warning threshold
-xx [%]
below setpoint
100 %
Perfor. xx,x KW
Temp xx °C
Start wiper cycle?
Trend display
A
Language
xxxxx
Change access
code
A
A
C
B
Version xxx
only systems with anelectrical ballast
Control off Control on
xxx %
Cal.-Faktor =
x,xxx
Time x:xx m
xx %
Safety threshold
xx %
Warning threshold
Sensor signal
displayed
in: x
A
A
A
A
A
B
B
B
B
B
100 %
Runtime xxx h
Turn-ons xxx mal
100 %
Setpoint:
xx %
Lamp perfor. xx.x kW
(min. x.x kW)
(max. x.x kW)
Jumps to “Change Access code” mode
Returns to trend display automatically Jumps to programming mode
Standard-Displays
C
A
xxx %
Cal.-Faktor =
x,xxx
Time x:xx m
A
B
A
B
Sensor signal
displayed
in: x
100 %
Current x,x A
Temp xx °C
Operating mode
Control on
Display appears only in
manual control mode
B
only systems with a
conventional ballast
This display can only be changed if
system is switched on
Returns to standard display
automatically
Display appears only when
system is running
This display can only be changed if
system is switched on
Display appears only when
system is running This display can only be changed
if system is switched on Display appears only when
system is running This display can only be changed
if system is switched on

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A
B
B
A
B
A
B
A
B
A
B
A
B
A
B
A
B
A
B
A
B
A
B
A
Oper. temp.
(min. xx °C)
(max. xx °C)
A
B
A
Control
xxx
B
A
B
A
Control
off
Control
on
B
A
B
A
Control
manual
A
A
External
control
XmA = yy%
20 mA = zzz%
only for equipment with
a conventional ballast
Controller
B
A
Control
xxx
Wiper interval
x.xx h:min
Start rinse duration
x min
Analogue output
x % = y mA
xxx % = yy mA
Display range
Trenddisplay
xxx Day(s)
Max. rinsing time
xx min
Max. free rinse
duration
x:xx h:min
Lamp hours
xx h
Lamp turn-ons
xx
Minimum
Line voltage
xxx V
Pause on
pause contact
xxx
Operating hours
xx h
Turn-ons xx
Lamp post-burning
Zeit x min