wtw CarboVis 700/5 IQ Set User manual

ba75405e01 12/2003
CarboVis 700/5 IQ Set
Operating manual
UV/VIS sensor set for the spectral determination
of carbon sum parameters
Set contents:
CarboVis 700/5 IQ
MIQ/VIS
MIQ/CHV
-
-
-
UV/VIS sensor
Connection module for UV/VIS sensors
Valve module

CarboVis 700/5 IQ Set
Accuracy when going to
press The use of advanced technology and the high quality standard of our
products are the result of continuous development. This may result in
differences between this operating manual and your instrument. Also,
we cannot guarantee that there are absolutely no errors in this manual.
Therefore, we are sure you will understand that we cannot accept any
legal claims resulting from the data, figures or descriptions.
Note
The latest version of the present operating manual can be found in the
Internet under www.WTW.com.
Copyright ©Weilheim 2003, WTW GmbH & Co. KG
Reprinting - even as excerpts - is only allowed with the explicit written
authorization of WTW GmbH & Co. KG, Weilheim.
Printed in Germany.

CarboVis 700/5 IQ Contents
0 - 1
1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.1 How to use this component operating manual . . . . . . . .1-1
1.2 Field of application . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2
1.3 Measuring principle of the UV/VIS sensor . . . . . . . . . . . 1-2
1.4 Structure of the UV/VIS sensor . . . . . . . . . . . . . . . . . . .1-3
1.5 Overview of the Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
1.6 Instrument identification . . . . . . . . . . . . . . . . . . . . . . . . .1-4
2 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2.1 Authorized use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
2.2 General safety instructions . . . . . . . . . . . . . . . . . . . . . . .2-2
3 Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3.1 System requirements of the IQ SENSOR NET . . . . . . . . . 3-1
3.2 Scope of delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3.3 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
3.3.1 Main steps for installation . . . . . . . . . . . . . . . . . 3-2
3.3.2 Mounting the sensor . . . . . . . . . . . . . . . . . . . . .3-3
3.3.3 Connecting the module stack (MIQ/VIS
+ MIQ/CHV) to the IQ SENSOR NET . . . . . . . . . . 3-4
3.3.4 Connecting the compressed-air hose . . . . . . . . 3-5
3.3.5 Connecting the sensor . . . . . . . . . . . . . . . . . . . 3-7
3.4 Initial commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
3.4.6 General information . . . . . . . . . . . . . . . . . . . . . .3-8
3.4.7 Carrying out the settings for the sensor on the
terminal of the IQ SENSOR NET system . . . . . . . 3-9
3.5 Reading out software versions . . . . . . . . . . . . . . . . . . .3-14
4 Measuring / operation . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4.1 Determination of measured values . . . . . . . . . . . . . . . .4-1
4.2 Measurement operation . . . . . . . . . . . . . . . . . . . . . . . . .4-2
4.3 Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-3
4.3.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-3
4.3.2 User calibration . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
4.3.3 Sensor check/Zero adjustment . . . . . . . . . . . . . 4-8
4.3.4 Sensor check with standard solutions . . . . . . .4-12
5 Maintenance and cleaning . . . . . . . . . . . . . . . . . . . . . 5-1
5.1 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1
5.2 Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1
5.2.1 Exterior cleaning . . . . . . . . . . . . . . . . . . . . . . . .5-1
5.2.2 Compressed-air driven cleaning of the
measurement windows . . . . . . . . . . . . . . . . . . .5-2
5.3 Exchange of components . . . . . . . . . . . . . . . . . . . . . . . .5-2
5.4 Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

Contents CarboVis 700/5 IQ
0 - 2
6 Spare parts, maintenance means, accessories . . . . 6-1
7 What to do if... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
7.1 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-1
7.2 Function check of the cleaning function . . . . . . . . . . . . .7-5
8 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
8.1 Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-1
8.1.1 General data . . . . . . . . . . . . . . . . . . . . . . . . . . .8-1
8.1.2 Electrical data . . . . . . . . . . . . . . . . . . . . . . . . . .8-2
8.1.3 Measurement conditions . . . . . . . . . . . . . . . . . .8-2
8.1.4 Measuring ranges and resolution . . . . . . . . . . .8-3
8.2 MIQ/VIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-4
8.3 MIQ/CHV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-5
9 Indexes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
9.1 Explanation of the messages . . . . . . . . . . . . . . . . . . . . .9-1
9.1.1 Error messages . . . . . . . . . . . . . . . . . . . . . . . . .9-1
9.1.2 Info messages . . . . . . . . . . . . . . . . . . . . . . . . . .9-3
9.2 Status info . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-4
10 Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1
10.1 Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-1

CarboVis 700/5 IQ Set Overview
1 - 1
1Overview
1.1 How to use this component operating manual
Structure of the
IQ SENSOR NET operating
manual
Fig. 1-1 Structure of the IQ SENSOR NET operating manual
The IQ SENSOR NET operating manual has a modular structure like the
IQ SENSOR NET itself. It consists of a system operating manual and the
operating manuals of all the components used.
Please file this component operating manual in the ring binder of the
system operating manual.

Overview CarboVis 700/5 IQ Set
1 - 2
1.2 Field of application
The CarboVis 700/5 IQ Set is an online measuring system for in-situ
determination of carbon sum parameters in waste water treatment
plants. The range of application comprises control, feedback control
and monitoring. The CarboVis 700/5 IQ Set can be used in the inlet or
outlet.
Compressed-air
cleaning The CarboVis 700/5 IQ Set is equipped with a compressed-air
operated cleaning system for the sensor. It works effectively and
without side-effects. The cleaning system is maintenance free and
wear free.
1.3 Measuring principle of the UV/VIS sensor
The UV/VIS sensor operates according to the measuring principle of
UV/VIS spectrometry.
Any substance contained in a measuring solution weakens a light
beam that penetrates the measuring solution. The weakening
(absorbance) of the light beam is measured for different wavelengths.
The wavelength dependent distribution produces the absorbance
spectrum.
The wavelength range where an absorbance occurs characterizes the
substance. The amount of the substance determines the extent of the
absorbance.
The influence of typical interference matrix variants occurring at
municipal waste water treatment plants can be eliminated by including
the entire absorbance spectrum.
With this measuring principle, measuring does not take place
continuously but at intervals.

CarboVis 700/5 IQ Set Overview
1 - 3
1.4 Structure of the UV/VIS sensor
A UV/VIS sensor contains a light source (1), a measuring gap (3) to
enable the contact of light with the measuring solution, and a detector
(5) to measure the alleviated light beam.
Thesenderoftheopticalsystem(2)directsa lightbeam,themeasuring
beam (6), through the measuring solution and a second light beam, the
reference beam (8), over a distance without measuring solution. The
test sample is between both measurement windows (3) in the
measuring gap.
The receiver of the optical system (4) directs the measuring beam and
reference beam to the detector. In the detector, the light is received by
fixed photo diodes.
Fig. 1-2 Structure of a UV/VIS sensor
1Light source
2Sender of the optical system
3Measuring gap between the measurement
windows
4Receiver of the optical system
5Detector
6Measuring beam
7Cleaning nozzles of the compressed-air cleaning
system
8Reference beam
8
34
67
21 5

Overview CarboVis 700/5 IQ Set
1 - 4
1.5 Overview of the Set
The following overview shows the integration of the
CarboVis 700/5 IQ Set in the IQ SENSOR NET.
Fig. 1-3 The CarboVis 700/5 IQ Set in the IQ SENSOR NET
1.6 Instrument identification
A name plate with the exact designation and series number of the UV/
VIS sensor is fixed on the sensor cable. The name plates of the
IQ SENSOR NET modules are on the lateral outside of the enclosures.

CarboVis 700/5 IQ Set Safety
2 - 1
2 Safety
This component operating manual contains special instructions that
must be followed in the operation of the CarboVis 700/5 IQ Set. Thus,
it is essential to read this component operating manual before carrying
out any work using this sensor or the set. In addition to this manual, the
SAFETY chapter of the IQ SENSOR NET system operating manual must
be followed.
Always keep this component operating manual together with the
system operating manual andanyother componentoperating manuals
in the vicinity of the IQ SENSOR NET system.
Special user
qualifications The CarboVis 700/5 IQ Set was developed for applications in online
measurement - essentially in the field of wastewater treatment. Thus,
we assume that the operators are familiar with the necessary
precautions to take when dealing with chemicals as a result of their
professional training and experience.
General safety
instructions Safety instructions of this operating manual can be recognized by the
warning symbol (triangle) in the left-hand column. The signal word
(e.g. "Caution") indicates the danger level:
Warning
indicates instructions that must be followed precisely in order to
prevent serious dangers to persons.
Caution
indicates instructions that must be followed precisely in order to
avoid slight injuries or damage to the instrument or the
environment.
Other labels
Note
indicates notes that draw your attention to special features.
Note
indicates cross-references to other documents, e.g. operating
manuals.

Safety CarboVis 700/5 IQ Set
2 - 2
2.1 Authorized use
The authorized use of the CarboVis 700/5 IQ Set consists of its use as
a sensor in the IQ SENSOR NET.
The technical specifications according to chapter 8 TECHNICAL DATA
mustbeobserved.Only operationaccordingto the instructions givenin
this operating manual is considered to be authorized.
Any other use is considered to be unauthorized. Unauthorized use
invalidates any claims with regard to the guarantee.
Caution
Only operate the sensor together with the MIQ/VIS connection
module.
2.2 General safety instructions
The sensor left the factory in a safe and secure technical condition.
Function and
operational safety The failure-free function and operational safety of the sensor is only
guaranteed if the generally applicable safety measures and the special
safety instructions in this operating manual are followed during its use.
The failure-free function and operational safety of the sensor is only
guaranteed under the environmental conditions that are specified in
chapter 8 TECHNICAL DATA.
The specified temperature (see chapter 8 TECHNICAL DATA) must be
maintained during the operation and transport of the sensor. Protect
the sensor, particularly against frost or overheating.
Caution
The sensor may only be opened by specialists authorized by
WTW.

CarboVis 700/5 IQ Set Safety
2 - 3
Safe operation If safe operation is no longer possible, the sensor must be taken out of
operation and secured against inadvertent operation.
Safe operation is no longer possible if the sensor:
lhas been damaged in transport
lhas been stored under adverse conditions for a lengthy period of
time
lis visibly damaged
lno longer operates as described in this manual.
If you are in any doubt, contact the supplier of your sensor.
Obligations of the
operator The operator of the sensor must ensure that the following rules and
regulations are followed when dealing with hazardous substances:
lEEC directives for protective labor legislation
lNational protective labor legislation
lSafety regulations
lSafety data sheets of the chemical manufacturer.

Safety CarboVis 700/5 IQ Set
2 - 4

CarboVis 700/5 IQ Set Commissioning
3 - 1
3 Commissioning
3.1 System requirements of the IQ SENSOR NET
Software versions of the
controller and terminal
components
The operation of the CarboVis 700/5 IQ requires thefollowing software
versions in the IQ SENSOR NET:
3.2 Scope of delivery
The following parts are contained within the scope of delivery of the
CarboVis 700/5 IQ Set:
lUV/VIS sensor CarboVis 700/5 IQ with cable (15 m)
lMIQ/VIS connection module and MIQ/CHV valve module. Both
modules are preassembled with a ready-wired valve control line.
All openings and open electrical contacts are closed with suitable
covers or blank covers.
lMIQ module assembly material:
– 6 x cable glands with seal
– 6 x ISO blind nuts M4
– 6 x cheese-head screws M4x16 with plastic washers
– 1 x contact base with suitable screws
l15.5 m compressed-airhose with screwed jointandhoseclip, ready
to be connected to the sensor and valve module
lSensor sleeve
lProtective ring
lOperating manual
lMIC/C184 Controller software: Version 2.66 or higher
Terminal software: Version 2.66 or higher
lMIQ/MC Controller software: Version 2.66 or higher
lMIQ/T2020 Terminal software: Version 2.66 or higher
lIQ Software Pack Software version: 4.10 or higher

Commissioning CarboVis 700/5 IQ Set
3 - 2
3.3 Installation
3.3.1 Main steps for installation
Caution
The sensor may only be electrically connected to the MIQ/VIS
module while the module is not supplied with voltage (dead).
The following steps are required to install the CarboVis 700/5 IQ Set:
lMake sure that there is enough system power available in the
IQ SENSOR NET (see IQ SENSOR NET system operating manual).
Note
The CarboVis 700/5 IQ Set requires altogether 9 W power:
lMake sure thatthe allowed maximum cable length tothe next power
supply module is not exceeded (see system operating manual).
lConnect the compressed-air hose to the CarboVis 700/5 IQ (see
section 3.3.4).
lMount the sensor (see section 3.3.2)
lConnect the compressed-air hose to the MIQ/CHV (see section
3.3.4).
lConnect the MIQ/CHV to the compressed-air supply.
lConnect the module stack (MIQ/VIS + MIQ/CHV) to the
IQ SENSOR NET (see section 3.3.3).
lConnect the sensor to the MIQ/VIS (see section 3.3.5).
lCarry out afunction check of the cleaning function (see section 7.2).
CarboVis 700/5 IQ 6.5 W
MIQ/VIS 0.5 W
MIQ/CHV 2 W

CarboVis 700/5 IQ Set Commissioning
3 - 3
3.3.2 Mounting the sensor
Caution
The sensor is an optical precision instrument that is to be
protected against shocks. Make sure the distances to the wall,
bottom and other installation surroundings are sufficient. If
necessary, protect the sensor from hitting using the protective
ring provided.
Caution
Always make sure that the surface of the enclosure is not
damaged by sharp-edged objects. The enclosure of the sensor
may not touch any metallic objects in order to prevent contact
corrosion.
Caution
Do not suspend the sensor on the sensor connection cable.
A wide rangeof mounting accessories is available for the installation of
the CarboVis 700/5 IQ (see chapter 6 SPARE PARTS, MAINTENANCE
MEANS, ACCESSORIES). Thus, all prevalent ways of mounting are
possible.
Generally, observe the following general rules when mounting the
sensor at the measuring location:
Horizontal installation When mounting the sensor horizontally, the measuring gap opening
should be on the side. Thus, the compressed air can escape upward
after cleaning and no sediment can collect in the measuring gap. The
sensor should be aligned in parallel with the flow direction.
Fig. 3-1 Horizontal installation

Commissioning CarboVis 700/5 IQ Set
3 - 4
Vertical installation When mounting the sensor vertically, make sure that interfering
elements in the measuring gap (e.g. air bubbles from the compressed-
air cleaning) can escape with the flow. In the case of vertical
installation, the minimum flow rate is 0.2 m/s in order to keep the
measuring gap optimally clean.
Fig. 3-2 Vertical installation
Protective ring When installing the sensor, always make sure it cannot knock against
a wall or another obstacle.
Make sure the safety margins are sufficient (e.g. with suspended
mounting). If this is not possible due to the conditions at the installation
location, protect the sensor with the protective ring supplied.
Fig. 3-3 Mounting the protective ring
3.3.3 Connecting the module stack (MIQ/VIS + MIQ/CHV)
to the IQ SENSOR NET
The IQ SENSOR NET offers a variety of options to connect the module
stack to the system (stack mounting, distributed mounting, etc.). The
individual types of installation are described in detail in the
INSTALLATION chapter of the system operating manual.

CarboVis 700/5 IQ Set Commissioning
3 - 5
3.3.4 Connecting the compressed-air hose
General instructions Observethefollowinginstructionswhenconnectingthecompressedair
hoses:
lFollow the specification of the compressed air according to chapter
8 TECHNICAL DATA.
lOnlyusethemountingmaterialprovidedtoconnectthe compressed
air.
Mounting the
compressed-air hose on
the sensor
Fig. 3-4 Mounting the compressed-air hose on the sensor
1Pull the adhesive tape off the screwed joint. When doing so
make sure not to lose the two white sealing rings (1).
2 As shown in Fig. 3-4, position the screwed joint at the sensor
with the aid of the screw (2) and the two sealing rings (1) and
carefully screw it tight. Orient the screwed joint so that the
compressed-air hose can be led to the MIQ/CHV along the
sensor suspension.
Caution: Tighten the screw only moderately to avoid damaging
the thread in the sensor.
3Run the compressed-air hose to the MIQ/CHV and cut it off at
a suitable length if necessary. To prevent foreign matter from
getting caught, use cable ties at sufficiently short distances to
attach the hose to the sensor and sensor suspension.
1
1
2
3
MIQ/CHV

Commissioning CarboVis 700/5 IQ Set
3 - 6
Connecting the
compressed-air hose to
the MIQ/CHV
Fig. 3-5 Connecting the compressed-air hose to the MIQ/CHV
Note on opening the
compressed-air line Pay attention to the following safety instruction if you want to open the
compressed air line (e.g. during a modification):
Warning
Danger of injury from lines that are under pressure. Before
opening the compressed air line, ensure that the relevant section
of the line is free of pressure. The compressed air glands in the
enclosure of the MIQ/CHV may only be opened by a service
technician authorized by WTW.
4Connect the other end of the compressed-air hose (4) to the
compressed-air outlet of the MIQ/CHV. Secure the connection
with a hose clip (5).
MIQ/CHV
UV/VIS-Sensor
4
5

CarboVis 700/5 IQ Set Commissioning
3 - 7
3.3.5 Connecting the sensor
Caution
The sensor may only be electrically connected to the MIQ/VIS
module while the module is not supplied with voltage (dead).
Caution
A UV/VIS sensor CarboVis 700/5 IQ may only be connected to the
IQ SENSOR NET via an MIQ/VIS module. Otherwise, the sensor will
be damaged.
Connecting the sensor
cable
Fig. 3-6 Connecting the UV/VIS sensor in the MIQ/VIS
1Open the MIQ/VIS module.
2 Connect the sensor to the terminal strip of the MIQ/VIS.
The cable colors must agree with the colors of the terminal
labeling. The terminal labeling is on the bottom of the module.
3Close the MIQ/VIS module.

Commissioning CarboVis 700/5 IQ Set
3 - 8
3.4 Initial commissioning
3.4.6 General information
Warning
Never look into the measurement window or put objects into the
measurement window during operation! The emitted UV radiation
can damage the eyes!
In the case of authorized use, inadvertent eye contact with the
light beam is not possible.
Thesensorispreparedfor operationintheaeration tankandcalibrated
in the factory. The sensor is immediately ready to measure. For use in
the inlet you only have to change the Measuring location setting.
Thecompressed-aircleaningfunctionisswitchedoninthefactory.The
first measuring cycle (cleaning and measuring) starts after initializing
the sensor in the IQ SENSOR NET.
Note
How to adjust the settings is described in the following section
(section 3.4.7).
Calibration after initial
commissioning On the basis of a reference measurement ("laboratory value"), check
whether the default settings deliver sufficiently accurate measured
values or whether you want to carry out a user calibration. If demands
on the measuring accuracy are high, you should always carry out a
Sensor check/Zero adjustment and a user calibration after the initial
commissioning (see section 4.3 CALIBRATION).
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