Dulcotrol Dwca Assembly and Operating Instructions

Assembly and operating instructions
DULCOTROL® DWCa
EN
A1999
DULCOTROL® ___ ___ ___ ___ ___ ___ ___ ___ ___ ___ ___ ___ ___ ___ ___ ___
Please enter the identity code of your device here.
These operating instructions will allow you to install and calibrate the measuring plate with your individual components. All
other required measures are described in the operating instructions for the individual components. These operating instruc‐
tions are only valid if used in conjunction with the operating instructions for the individual components.
Please carefully read these operating instructions before use. · Do not discard.
The operator shall be liable for any damage caused by installation or operating errors.
The latest version of the operating instructions are available on our homepage.
Part no. 984397 BA DR 008 06/15 EN

Supplemental instructions
General non-discriminatory approach In order to make it easier to read, this document uses the male
form in grammatical structures but with an implied neutral sense. It
is aimed equally at both men and women. We kindly ask female
readers for their understanding in this simplification of the text.
Supplementary information Please read the supplementary information in its entirety.

Information
This provides important information relating to the cor‐

rect operation of the unit or is intended to make your
work easier.
Safety Information
The safety information includes detailed descriptions of the haz‐
ardous situation, see Ä Chapter 2.1 ‘Explanation of the safety
information’ on page 9
The following symbols are used to highlight instructions, links, lists,
results and other elements in this document:
More symbols
Symbol Description
Action, step by step
⇨ Outcome of an action
Links to elements or sections of these instructions or other applicable documents
n List without set order
[Button] Display element (e.g. indicators)
Operating element (e.g. button, switch)
‘Display /GUI’ Screen elements (e.g. buttons, assignment of function keys)
CODE Presentation of software elements and/or texts
2
Table of contents
Table of contents
1 Identity Code Ordering System for DULCOTROL® Meas‐
uring and Control Plates....................................................... 6
2 Safety and Responsibility...................................................... 9
2.1 Explanation of the safety information............................ 9
2.2 General Safety Information......................................... 10
2.3 Information in the Event of an Emergency.................. 14
2.4 Intended Use.............................................................. 14
2.5 Users' qualifications.................................................... 15
3 About This Product............................................................. 16
3.1 DULCOTROL® Measuring and Control Stations........ 16
4 Storage and Transport........................................................ 19
5 Overview of the Measuring Station..................................... 20
5.1 DULCOTROL® Measuring and Control Station with
Bypass Fitting DGMa.................................................. 20
Bypass Fitting DLG III................................................. 21
Pipework..................................................................... 23
5.4 Installation Diagram for DULCOTROL® Measuring
and Control Station..................................................... 24
6 Assembly of the Measuring Point ...................................... 25
6.1 Assembly (Mechanical)............................................... 25
6.1.1 Measuring Point....................................................... 27
6.1.2 Accessories............................................................. 28
7 Installing Sensors in the Bypass Fitting DGMa................... 29
7.1 Fitting the DGMa with Sensors................................... 29
7.2 Electrical Installation of the Sensors........................... 30
7.3 Adjusting the Flow Sensor Switching Point................ 32
8 Installing Sensors in the Bypass Fitting DLG III/IV............. 33
8.1 Fitting the DLG with Sensors...................................... 34
8.2 Hydraulic Installation................................................... 36
8.4 Starting Up the DLG................................................... 37
9 Installing Sensors in the Bypass Fitting with Pipework ...... 38
9.1 Fitting the Pipework with Sensors............................... 38
9.3 Hydraulic Installation, Bypass Fitting with Pipework... 41
9.4 Starting Up the Bypass Fitting with Pipework............. 41
10 Electrically and Hydraulically Assembling and Installing
the Measuring Points.......................................................... 42
10.1 Electrical Installation of the Measuring and Control
Station....................................................................... 43
10.1.1 Wiring Diagram for DACa and Measuring Plate.... 45
10.1.2 Wiring Diagram for DACa and Measuring Plate -
Fluoride.................................................................. 48
10.1.3 Wiring Diagram for DACa, DCC and Measuring
Plate - Waste Water............................................... 50
10.2 Hydraulic Test Run after Installation......................... 53
3
Table of contents
11 Starting-up Sensors............................................................ 55
11.1 Preparation of Sensors............................................. 55
11.2 Sampling from the Bypass Fitting............................. 56
11.3 Calibrating the Sensors............................................ 56
11.4 Calibrating the Fluoride Sensor................................ 57
11.5 Removing and Fitting the Bypass Fitting Cup for
Calibration................................................................. 58
12 Controllers' User Interface.................................................. 59
12.1 Operating Concept.................................................... 59
12.1.1 Functions of the keys ............................................ 62
12.1.2 Changes the set operating language..................... 63
12.1.3 Acknowledge fault or warning message ............... 63
12.1.4 Key Lock ............................................................... 64
12.2 Operating Diagram for Measured Variable: Conduc‐
tive Conductivity........................................................ 65
12.2.1 Overview of equipment/Operating elements.......... 65
12.2.2 Entering values...................................................... 66
12.2.3 Adjusting display contrast...................................... 66
12.2.4 Continuous display................................................ 67
12.2.5 Information display................................................. 67
12.2.6 Password............................................................... 68
12.3 Operating Diagram for Measured Variable: Inductive
Conductivity.............................................................. 69
12.3.1 Overview of equipment/Operating elements.......... 69
12.3.2 Entering values...................................................... 70
12.3.3 Adjusting display contrast...................................... 70
12.3.4 Continuous display................................................ 71
12.3.5 Information display................................................. 71
12.3.6 Password............................................................... 72
13 Commissioning the Controller diaLog DACa...................... 73
13.1 Commissioning......................................................... 73
13.1.1 Switch-on behaviour during commissioning.......... 73
13.1.2 Adjusting the backlight and contrast of the con‐
troller display.......................................................... 74
13.1.3 Resetting the operating language.......................... 74
13.1.4 Defining metering and control processes.............. 74
14 Commissioning the Compact Controller for Conductive
Conductivity........................................................................ 76
14.1 Measured variables.................................................. 76
15 Commissioning the Compact Controller for Inductive Con‐
ductivity............................................................................... 78
15.1 Measured variables.................................................. 78
16 Configuration of the Controllers.......................................... 80
16.1 Configuration of the Compact Controllers DCCa...... 80
16.2 Configuration of the diaLog Controller DACa........... 80
17 Calibrating the Controller diaLog DACa.............................. 82
17.1 Calibration................................................................. 82
17.1.1 Calibrating the pH sensor...................................... 83
17.1.2 Calibrating the ORP Sensor.................................. 95
17.1.3 Calibrating the Fluoride Sensor............................. 99
17.1.4 Calibrating Amperometric Sensors...................... 104
4
Table of contents
17.1.5 Calibrating Oxygen Sensors................................ 110

17.1.6 Measured value [mA general] calibration............ 118
17.1.7 Calibrating conductivity........................................ 118
17.1.8 Calibrating temperature....................................... 120
18 Calibrating the Compact Controller for Conductive Con‐
ductivity............................................................................. 121
18.1 Calibrating [CAL] the conductivity sensor .............. 121
18.1.1 Calibration of the cell constant............................. 122
18.1.2 Calibration of the temperature coefficient............ 124
19 Calibrating the Compact Controller for Inductive Conduc‐
tivity................................................................................... 127
19.1 Calibrating [CAL] the conductivity sensor .............. 127
19.1.1 Calibration of the cell constant............................. 128
19.1.2 Calibration of the temperature coefficient............ 130
19.1.3 Calibration of the zero point................................. 132
20 Maintenance..................................................................... 135
20.1 DGMa: Replacing the Modules............................... 136
20.2 Flushing the Bypass Fitting with Pipework............. 138
21 Troubleshooting................................................................ 140
22 Decommissioning and Disposal........................................ 142
22.1 Temporary Decommissioning (Less Than 4
Weeks).................................................................... 142
22.2 Temporary Decommissioning (Longer Than 4
Weeks).................................................................... 142
22.3 Final Decommissioning........................................... 143
23 Technical Data and Operating Parameters....................... 144
23.1 Flow and Operational Test of Flow Control............ 145
24 Spare Parts and Accessories............................................ 147
24.1 Spare Parts............................................................. 147
24.2 Accessories............................................................ 155
25 EC Declaration of Conformity .......................................... 156
26 Index................................................................................. 157
5
Identity Code Ordering System for DULCOTROL® Measuring and Control Plates
1 Identity Code Ordering System for DULCOTROL® Measuring

and Control Plates
Identity code ordering system for DULCOTROL® measuring and control plates
DWCa DULCOTROL measuring and control system
Application
P Potable water (1 or 2 for "water to be measured")
W Waste water (4, 5, 6 or 7 for "water to be measured")
Water to be measured
1 Potable water / product water, T< 45 °C
2 Rinsing water / industrial water / process water, T< 45 °C
Cooling water (planned for the future)
4 Clear waste water
5 Waste water with solid particle fraction, turbid
6 Waste water with solid particle fraction, containing sludge (sensors directly in the pipe, no
filter)
7 Waste water with fluoride and pH < 7
Channel 1, measured variable 1
C0 Free chlorine < pH 8
C1 Free chlorine > pH 8 and stable
G0 Total chlorine (free and combined chlorine)
P0 pH
R0 ORP
D0 Chlorine dioxide
I0 Chlorite
L0 Conductivity
Z0 Ozone
F0 Fluoride (pH min.= 5.5, pH max. = 8.5)
H0 Hydrogen peroxide
A0 Peracetic acid
X0 Dissolved oxygen
Channel 2, measured variable 2 (optional)
00 none
C0 Free chlorine < pH 8
C1 Free chlorine pH value > 8.0 and stable
G0 Total chlorine (free and combined chlorine)
P0 pH
R0 ORP
D0 Chlorine dioxide
I0 Chlorite
6
L0 Conductivity
Z0 Ozone
F0 Fluoride
H0 Hydrogen peroxide
A0 Peracetic acid
X0 Dissolved oxygen
Measurement - Control
0 All measured variables can be measured
9 All measured variables bidirectionally controllable
Communication interface
0 none
4 PROFIBUS-DP
6 LAN interface
Data logger
0 none
1 Data logger with measured value display on SD card
Hardware extension
0 none
1 Protective RC circuit for output relay
Sensor equipment
0 With sensors
1 Without sensors
Design
0 Plate-mounted with ProMinent Logo
(M) Modified design
Sample water preparation
0 none
1 with filter (not with waste water = 6)
Approvals
01 CE (Standard)
Documentation language*
EN German
EN English
FR French
IT Italian
NL Dutch
ES Spanish
7
PL Polish
SV Swedish
HU Hungarian
PT Portuguese
CS Czech
* All EU languages + other languages are available.
8
Safety and Responsibility
2 Safety and Responsibility

2.1 Explanation of the safety information
Introduction These operating instructions provide information on the technical
data and functions of the product. These operating instructions pro‐
vide detailed safety information and are provided as clear step-by-
step instructions.
The safety information and notes are categorised 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 threatening danger. If this is
disregarded, it will result in fatal or very serious
injuries.
WARNING!
Possible consequence: Fatal or very serious injuries.
Warning!
– Denotes a possibly hazardous situation. If this is
disregarded, it could result in fatal or very serious
injuries.
CAUTION!
Possible consequence: Slight or minor injuries, mate‐
rial damage.
Caution!
– Denotes a possibly hazardous situation. If this is
disregarded, it could result in slight or minor inju‐
ries. May also be used as a warning about material
damage.
9
NOTICE!
Damage to the product or its surroundings
Note!
– Denotes a possibly damaging situation. If this is
disregarded, the product or an object in its vicinity
could be damaged.
Type of information
Hints on use and additional information
Source of the information, additional measures
Information!
– Denotes hints on use and other useful information.
It does not indicate a hazardous or damaging sit‐
uation.
2.2 General Safety Information
WARNING!
Failure of the control and impact on the process
Cause: If the controller or other parts of the measuring
plate fail, then the process, in the bypass of which the
measuring plate is working, will no longer be measured
and regulated.
The process, in the bypass of which the measuring
plate is working, will become out of control and could
cause harmful reactions.
Measure: It is the responsibility of the operator and/or
manufacturer of the entire system in which the meas‐
uring plate is installed to take appropriate measures to
ensure that the failure of the measuring plate or of indi‐
vidual components of the measuring plate do not have
a damaging effect on the entire process and/or the
overall system.
These measures can include, for example:
– Redundant design of the measuring and control
station.
– Connection of an appropriate alarm device to the
measuring plate and/or the controller.
– The alarm relay on the controller could be set to
[fail save] and be evaluated as an overall alarm for
the process.
– Installation of additional safety systems from active
or passive system components, with the purpose
of making the technical systems safer for operators
and users.
10
WARNING!
Operation in areas with an explosive atmosphere
Possibility of an explosion
Do not operate the systems in areas where there is a
risk of explosion. The system is not intended for opera‐
tion in areas at risk from explosion. The system itself
does not present a risk of explosion.
WARNING!
Pumping flammable media
Pumping flammable media is not permitted. Observe
the material safety data sheet for the medium.
WARNING!
Live parts
Measures:
– Disconnect the system from the power supply
before opening the housing of a component.
– If the housing of the pump, controller, terminal box
or other components is broken, ruptured or obvi‐
ously damaged, immediately switch off the system
and arrange for its repair.
– Only carry out set-up / maintenance / repair and
service work when the system is shut down and
the electrical power disconnected. Calibration and
maintenance work on the sensors represents an
exception to this. This work can be carried out
while the system is live. Please also observe the
information in the operating instructions for the
sensors and controllers.
– Check that the seals are sitting correctly after
closing the housing of the pump, controller or ter‐
minal box
We fundamentally recommend the use of appropriate
residual current circuit breakers (RCCB) or other
residual current devices (RCD) providing they can be
installed sensibly and professionally within the elec‐
trical installation. Please adhere to all national stand‐
ards and regulations.
11
WARNING!
Danger from hazardous substances!
Please ensure when handling hazardous substances
that you have read the latest safety data sheets pro‐
vided by the manufacture of the hazardous substance.
The actions required are described in the safety data
sheet. Check the safety data sheet regularly and
replace, if necessary, 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 producing an associ‐
ated hazard assessment for the workstations affected.
WARNING!
Unexpected start-up
– Unexpected start-up of the DULCOTROL® meas‐
uring/control station after failure or malfunction of
the control/power supply or as a deliberate action
due to a control process.
– Danger due to unexpected actions of the systems.
– Disconnect the DULCOTROL® measuring/control
station from the power supply in the event of mal‐
function/failure of the control or power supply.
– When the system is switched on after an interrup‐
tion to the power supply and/or after a long period
of operation without feed chemical, make allow‐
ance for the run in periods of the sensor. Limit the
maximum capacity of the metering pump so that no
dangerous overdosing can occur during the run in
period.
WARNING!
Operating error / Unauthorised access
– Measure: Ensure that there can be no unauthor‐
ised access to the unit.
– Ensure that the unit is only operated by adequately
qualified and technically expert personnel.
– Please also observe the operating instructions for
controllers and fittings and any other units, such as
sensors, sample water pumps ...
– The operator is responsible for ensuring that per‐
sonnel are qualified.
12
WARNING!
Lightning strike on outdoor installations
Danger due to overvoltage resulting from a lighting
strike on outdoor installations, which are connected to
the DULCOTROL® measuring/control station.
Measures:
– Do not use the DULCOTROL® measuring/control
station directly or indirectly outdoors.
– Ensure there is sufficient earthing potential when
installing electrical components.
WARNING!
Effects of chemicals in the event of a leak
– Measure: Make sure that the system is installed
correctly and regularly check it for leak-tightness,
wear and the brittleness of hoses and connectors
and lines caused by the effects of chemicals.
– Ensure that the unit is only operated by adequately
qualified and technically expert personnel.
– The operator is responsible for ensuring that per‐
sonnel are qualified.
NOTICE!
Hydraulic leaks
Bear in mind the material resistance of all wetted
materials of all units (see for example the ProMinent
Resistance List in the product catalogue or at
www.prominent.com)
Take appropriate measures to ensure that there is no
danger to personnel, products or equipment in the
event of hydraulic leaks. An appropriate measure
might include a sufficiently large floor drain.
Indoors or protective covering

Protect the DULCOTROL® measuring/control station
from direct sunlight and other UV sources
The unit is only intended for use indoors. When using
outdoors, provide a protective housing to offer protec‐
tion against the weather, lighting and the sun's rays
(UV radiation) etc.
13
2.3 Information in the Event of an Emergency

n Electrical emergency: Switch off the DULCOTROL® measuring/
control station via the main switch or at the position specified
by the operator.
n Hydraulic emergency: Hydraulically isolate the DULCOTROL®
measuring/control station via the ball valve(s), if necessary,
observing the instructions in the material safety data sheet for
the feed chemical.
2.4 Intended Use

n The unit is only intended for measuring or controlling a meas‐
uring parameter in aqueous media, within the measuring range
of the sensors used and in accordance with the identity code
and specifications on the unit's nameplate.
n Compare the identity code on the nameplate with the identity
code in the overview and the applications stated there.
Ä further information on page 6
n The unit is not intended for measuring or regulating gaseous or
solid media.
n Only use the unit in accordance with the technical data and
specifications provided in these operating instructions and in
the operating instructions for the individual components!
n You are obliged to observe the information contained in the
operating instructions at the different phases of the device's
service life (such as assembly, installation, etc.).
n Do not use the unit outdoors.
n All other uses or a modification of the unit are only permitted
with the written authorisation of the manufacturer.
n Only allow adequately qualified personnel to operate the unit,
see Ä Chapter 2.5 ‘Users' qualifications’ on page 15. The oper‐
ator of the unit is responsible for ensuring that personnel are
qualified.
14
2.5 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 con‐
ducted 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‐ A qualified employee is deemed to be a person who is able to assess the
sonnel tasks assigned to him and recognize possible hazards based on his/her
training, knowledge and experience, as well as knowledge of pertinent regula‐
tions. The assessment of a person's technical training can also be based on
several years of work in the relevant field.
Electrician Electricians are deemed to be people, who are able to complete work on elec‐
trical systems and recognize and avoid possible 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 environment in
which the are employed and know the relevant standards and regulations.
Electricians must comply with the provisions of the applicable statutory direc‐
tives on accident prevention.
Customer Service depart‐ Customer Service department refers to service technicians, who have
ment received proven training and have been authorised by ProMinent to work on
the system.
Note for the system operator

The pertinent accident prevention regulations, as well
as all other generally acknowledged safety regulations,
must be adhered to!
15
About This Product
3 About This Product

3.1 DULCOTROL® Measuring and Control Stations
DULCOTROL® measuring and control stations are online process
measuring/control stations mounted on a PE-plate installed in a
process water bypass. One or two measured variables can be
measured or regulated depending on the design ordered. The
sensor types and measuring fittings are coordinated to the sample
water specified.
With the DULCOTROL® DWCa product range, the term "sample
water" is defined as follows:
n Potable/product water treatment: water similar to potable
water, as is the case in the production of potable water but also
in the production of beverages or food.
n Rinsing/process/industrial water: this includes all rinsing
process in the food and beverage industry, which aim to clean
and disinfect pipework, vessels and machinery and/or highly
contaminated process or industrial process water.
With the DULCOTROL® DWCa product range, a distinction is
made between the following types of waste water:
n Waste water, clear
n Waste water with solid particle fraction, turbid
n Waste water with solid particle fraction, containing sludge
n Waste water with fluoride content, clear or turbid, pH < 7
The power supply to all electrically operated components is pro‐
vided via a terminal box with manually operated switches.
Scope of delivery Check the scope of delivery against the delivery note and identity
code.
Further applicable documents (oper‐ The operating instructions for the components below also apply
ating instructions) where these components form part of the scope of delivery of the
measuring plate supplied.
16
About This Product
diaLog DACa controller
Hardware design: Identity code for the diaLog DACa con‐

troller:
1-channel device without RC, without data logger DACa PA 6 1 0 0 0 0 0 0 0 01 0
1-channel device with RC, without data logger DACa PA 6 1 0 0 0 0 0 0 1 01 0
2-channel device without RC, without data logger DACa PA 6 1 4 0 0 0 0 0 0 01 0
2-channel device with RC, without data logger DACa PA 6 1 4 0 0 0 0 0 1 01 0
1-channel device without RC, with data logger DACa PA 6 1 0 0 0 0 0 1 0 01 0
1-channel device with RC, with data logger DACa PA 6 1 0 0 0 0 0 1 1 01 0
2-channel device without RC, with data logger DACa PA 6 1 4 0 0 0 0 1 0 01 0
2-channel device with RC, with data logger DACa PA 6 1 4 0 0 0 0 1 1 01 0
1-channel device, PROFIBUS® DP DACa PA 6 1 0 0 0 0 4 0 0 01 0
2-channel device, PROFIBUS® DP DACa PA 6 1 4 0 0 0 4 0 0 01 0
1-channel device with RC, PROFIBUS® DP DACa PA 6 1 0 0 0 0 4 0 1 01 0
2-channel device with RC, PROFIBUS® DP DACa PA 6 1 4 0 0 0 4 0 1 01 0
1-channel device, PROFIBUS® DP, with data logger DACa PA 6 1 0 0 0 0 4 1 0 01 0
1-channel device with RC, PROFIBUS® DP, with data logger DACa PA 6 1 0 0 0 0 4 1 1 01 0
2-channel device, PROFIBUS® DP, with data logger DACa PA 6 1 4 0 0 0 4 1 0 01 0
2-channel device with RC, PROFIBUS® DP, with data logger DACa PA 6 1 4 0 0 0 4 1 1 01 0
Compact controller
Hardware design: Identity code for the Compact controller:

Compact controller for conductive conductivity DCCaW006L30010
Compact controller for inductive conductivity DDCaW006L60010
17
About This Product
Sensors
Measured variable Water to be measured Sensor type Order number

Free chlorine with a pH 1 CLE 3-mA-0.5 ppm 792927
value < 8
Free chlorine with a pH 1 CBR 1-mA-0.5 ppm 1038016
value > 8
Free chlorine 2 CBR 1-mA-2 ppm 1038015
Total chlorine 1 CTE 1-mA-0.5 ppm 740686
Total chlorine 2 BCR 1-mA-2 ppm 1040115
pH 1 1 PHEP 112 SE 150041
pH 2 PHER 112 SE 1001586
ORP 1 RHEP-Pt-SE 150094
ORP 2 RHER-Pt-SE 1002534
ORP combined with ozone: 1/2 RHEP-Au-SE 1003875
R0 Z0
Chlorine dioxide 1 CDE 2-mA-0.5 ppm 792930
Chlorine dioxide 2 CDR 1-mA-2 ppm 1033393
(Temperature corrected)
Chlorite 1/2 CLT 1-mA-0.5 ppm 1021596
Conductivity, conductive 1 LFTK 1 DE 1002822
Conductivity, inductive 2 ICT 1 1023244
Ozone 1/2 OZE 3-mA-2 ppm 792957
Fluoride 1/2 FLEP 010-SE/FLEP 0100-SE 1028279
(Temperature corrected)
Reference electrode REFP- 1018458
SE
Pt 100 SE 305063
Transmitter 4 ... 20 mA FPV1 1028280
Hydrogen peroxide 1 PER 1-mA-200 ppm 1022509
Hydrogen peroxide 2 PER 1-mA-2000 ppm 1022510
Peracetic acid 1 PAA 1-mA-200 ppm 1022506
Peracetic acid 2 PAA 1-mA-2000 ppm 1022507
Dissolved oxygen 1/2 DO 1-mA-20 ppm 1020532
Temperature 1/2 Pt 100 SE 305063
18
Storage and Transport
4 Storage and Transport

CAUTION!
Danger of material damage
The device can be damaged by incorrect or improper
storage or transportation!
– The unit should only be stored or transported in a
well packaged state - preferably in its original
packaging.
– The packaged unit should also only be stored or
transported in accordance with the stipulated
storage conditions.
– The packaged unit should be protected from mois‐
ture and the ingress of chemicals.
Packaging material
Dispose of packaging material in an environmentally
responsible way. All packaging components carry the
corresponding recycling code .
Ambient conditions for storage and

transport CAUTION!
– Prior to storage or transport, ensure that the
system is free from feed chemical and water
– Flush out the wetted components including the
hoses using clean pure water
– Store and transport the system in its original pack‐
aging
– Also protect the packaged systems against damp,
exposure to chemicals and mechanical effects
fittings and other units, such as sensors, filters,
metering pumps ...
Storage temperature: + 5 ... 55 °C

Air humidity: < 90 % relative humidity, non-condensing
Humidity: None. Avoid rain and condensation.
Other: No dust, no direct sunlight.
NOTICE!
If the system is stored as an assembly with other com‐
ponents, then the storage and transport conditions
should be appropriate for the component with the least
resistance to external influences.
Storage period There is no limit to the storage period if no sensors are fitted.
Transport weight The transport weight depends on the configuration of the meas‐
uring plate and is between 8 ... 13 kg.
19
Overview of the Measuring Station
5 Overview of the Measuring Station

5.1 DULCOTROL® Measuring and Control Station with Bypass Fitting DGMa
1.
2.
3.
4.
9.
5.
8.
6.
7. A2020
Fig. 1: Bypass fitting DGMa

1. Controller 6. Sampling tap
2. Main switch 7. Potential equalisation pin
3. Flow control 8. Stopcock / flow adjustment
4. Bypass fitting DGMa 9. Filter
5. Stopcock
The DULCOTROL® measuring and control station with a modular
bypass fitting, type flow sensor DGMa, is optimised for clear water
and consists of 1 or 2 controllers, 1 ... 4 sensors and the bypass
fitting DGMa with integral flow control, for inserting the sensors. A
filter can optionally be fitted on the sample water input. Various
stopcocks enable the flow to be stopped or adjusted and the
system bled. The stopcocks are labelled on the plate.
The bypass fitting contains a potential equalisation pin (stainless

steel pin) for reference potential equalisation of the liquid, enabling
measurements with potential equalisation. Electrically wire the
potential equalisation pin to the controller, if necessary.
The bypass fitting has a sampling tap for extracting a sample of
water or for draining the bypass fitting.
20
5.2 DULCOTROL® Measuring and Control Station with Bypass Fitting DLG III
1.
2. 2a.
3.
4.
9.
5.
5a.
8.
7. 6.
A2014
Fig. 2: Bypass fitting DLG III

1. Controller 5a. Bypass fitting DLG with drain valve (depending
2. Terminal box with main switch (depending on on the design of the measuring plate)
the design of the measuring plate) 6. Stopcock/flow adjustment device
2a. Main switch (depending on the design of the 7. Stopcock
measuring plate) 8. Filter
3. Sampling tap 9. Potential equalisation pin
4. Sensor
5. Bypass fitting DLG with magnetic stirrer
(depending on the design of the measuring
plate)
The DULCOTROL® measuring and control station with a modular
bypass fitting, flow sensor DLG III or DLG IV, is optimised for turbid
waste water and industrial process water and consists of 1 or 2
controllers, 1 ... 4 sensors and the bypass fitting DLG III (1 ... 3
sensors) or DLG IV (4 sensors) with integrated flow control. A filter
can optionally be fitted on the sample water input. Various stop‐
cocks enable the flow to be stopped or adjusted and the system
bled. The stopcocks are labelled on the plate.
21
The bypass fitting contains a potential equalisation pin (stainless

steel pin) for reference potential equalisation of the liquid, enabling
The bypass fitting has a sampling tap for extracting a sample of
water or for draining the bypass fitting.
22
5.3 DULCOTROL® Measuring and Control Station with Pipework

1. 2.
3.
10.
4.
9. 5.
8.
7.
6.
A2019
Fig. 3: Pipework for ICT / O2 / pH / ORP

1. Controllers
2. Terminal box with master switch
3. Pipework
4. Flow control
5. Stopcock / flow adjustment
6. Flushing connector
7. Stopcock
8. Potential equalisation pin
9. Stopcock
10. Sampling tap
The DULCOTROL® measuring and control station with pipework is
optimised for waste water containing sludge and consists of 1 or 2
controllers, 1 ... 4 sensors and pipework with integrated flow con‐
trol, for fitting the sensors using an appropriate adapter. Various
stopcocks enable the flow to be stopped or adjusted and the
system bled. The stopcocks are labelled on the plate.
The pipework contains a potential equalisation pin (stainless steel
pin) for reference potential equalisation of the liquid, enabling
The pipework has a sampling tap for extracting a sample of water
or for draining the bypass fitting.
23
5.4 Installation Diagram for DULCOTROL® Measuring and Control Station

Schematic diagram of the components of a
DULCOTROL® measuring and control station, installed outside of
the measuring plate, in the order shown here, see original ProMi‐
nent accessories. The accessories illustrated are required
depending on the application.
NOTICE!
The installation sequence is binding and to be adhered
to.
1.
2.
3. 4. 5. 6.
7.
8.
10.
9.
A2106
Fig. 4: Installation diagram
Components:
1 Stopcock (supplied on site) 2 Process line
3 Heat exchanger (supplied on site) 4 Temperature control with shut-off valve. Not
included in the scope of delivery but necessary on
site at media temperatures of > 45 °C
5 Dirt filter (optional for pressure reducer) (to be pro‐ 6 Pressure reducer (only operate with dirt filter) (to
vided on site) be provided on site)
7 Dirt filter (optional via ID code) 8 Measuring plate
9 Free flow 10 Sample water pump "vonTaine" (to be provided
on site)
24
Assembly of the Measuring Point
6 Assembly of the Measuring Point

n User qualification, mechanical installation: trained qualified per‐
sonnel, see Ä Chapter 2.5 ‘Users' qualifications’ on page 15
WARNING!
and regulated.
overall system.
station.
the process.
and users.
CAUTION!
fittings and any other units, such as sensors,
sample water pumps ... !
6.1 Assembly (Mechanical)
WARNING!
– Live parts.
– Bear in mind any concealed installations when
drilling holes to secure the
DULCOTROL® measuring/control station.
25
CAUTION!
– Remove any water from the
DULCOTROL® measuring/control station and the
supplied components before assembly if feed
chemicals are being used, which should not come
into contact with water.
– Fix the DULCOTROL® measuring/control station
perpendicular and upright on a wall or a stable
mounting system. Pay attention to the load-bearing
capacity of the wall or the mounting system.
– Ensure that the
DULCOTROL® measuring/control station is easily
accessible.
CAUTION!
Possibility of over-metering the feed chemicals.
– Should the float of the flow module become stuck
due to dirt, the
DULCOTROL® measuring/control station can over-
meter.
– A filter may be required depending on the type and
quality of the sample water.
– Should the circulating pump not pump, the
DULCOTROL® measuring/control station can over-
meter.
– Lock the controller via the potential-free contact of
the circulating pump. In the event of the circulating
pump being "OFF", the
DULCOTROL® measuring/control station switches
to ‘PAUSE’ via the controller's pause input.
– Alternatively the metering pumps can be switched
in such a way that they only work together with the
circulating pumps.
26
6.1.1 Measuring Point

Select the mounting height so that:
n The controller's LCD display can be easily read
n The controller lid can still be parked in the "Park position"
n There is still space for maintenance work underneath the
bypass fitting
n There is sufficient room outside of the plate to fit accessories
Comply with the following drilling dimensions depending on the
size of the plate:
Fig. 5: Drilling template

The selection of the measuring plate depends on the bypass fitting
used and the number of controllers used.
The following applies in principle:
n With DGMa or DLGIII/IV: size 1
n With 2 controllers: size 2
n With pipework: size 3
Size 1 2 3
A 595 800 1000
B 745 800 800
C 555 760 960
D 705 760 760
Secure the DULCOTROL® measuring/control station, as close as

possible to the point of injection using hanger bolts. Leave an ade‐
quate gap from the wall for the cables on the back of the plate.
27
10 mm
1 2
4 3 3 4
A2107
Fig. 6: Hanger bolt

1. Rawlplug (design depending on the substrate and in line with
the stipulations of the rawlplug manufacturer)
2. Hanger bolt
3. Washer
4. Hexagonal nut
6.1.2 Accessories
Supplied with accessories: Fit any accessories supplied, such as heat exchanger, sample
water pump, pressure reducer or filter, in accordance with their
operating instructions upstream of the
DULCOTROL® measuring/control station (in the direction of flow).
The installation sequence is binding and to be adhered

to.
28
Installing Sensors in the Bypass Fitting DGMa
7 Installing Sensors in the Bypass Fitting DGMa

n User qualification, hydraulic installation: trained qualified per‐
n User qualification, electrical installation: Electrical technician,
see Ä Chapter 2.5 ‘Users' qualifications’ on page 15
WARNING!
findings.
CAUTION!
– Observe the maximum permissible operating
parameters for the entire installation (e.g. pres‐
sure, temperature, flow).
– In this respect, consider the lowest maximum per‐
missible operating parameters for the parts of the
integrated sensors; see their operating instruc‐
tions.
any other units, such as sensors, sample water
pumps ...
– Bear in mind the direction of flow of the sample
water.
– Do not exceed the maximum operating pressure.
– Fit an appropriate pressure reducer if unavoidable.
– Danger due to pressurised media. Before working
on the hydraulic part of the
DULCOTROL® measuring/control station, ensure
in a controlled manner that this part is at atmos‐
pheric pressure using the sampling tap.
– Wear safety goggles.
7.1 Fitting the DGMa with Sensors

Fitting sensor with PG 13.5 connector: 1. Remove the upper blanking plug from a module
2. With pH/ORP sensors: remove the sensor from its transport
protection container.
29
3. Screw in the sensor.

With the DULCOTEST® Perox sensor, screw the flow resister
of an in-line probe housing module into the module from
below
Amperometric sensors with

Ø = 25 mm Sensitive sensors are not ready mounted but supplied
loose with the measuring plate in their original pack‐
aging.
Push the sensor slowly into the in-line probe housing,
as the sensor diaphragm can otherwise extend
Requirement
The sensor is filled with electrolyte and the diaphragm
cap is screwed on tightly.
Accessories: Mounting kit, part number 815079.
Refer to the operating instructions for the respective
sensor.
1. Remove the upper blanking plug from a 25-mm module

1
2. Push the O-ring (4) first, then the assembly washer (5) onto
the sensor (3) from below
3. Push the holding bolt (1) from above onto the sensor (3)
4. Carefully push the sensor (3) into the module
5. Tighten the holding bolt (1)
2 6. Carefully push the flow resister (6) down into the module
3
4
5
6
A1247
Fig. 7: Fitting the sensors
7.2 Electrical Installation of the Sensors

The bypass fitting can be fitted with different sensors. All the dif‐
ferent types of sensors listed here can be fitted but do not have to
be.
30
Electrical installation of the flow

sensor Only wire protective low voltage (SELV in accordance
with EN 60335-1) to the flow sensor.
The cable needs to have a diameter of 4 mm, so that
the cable connector achieves degree of protection IP
65.
1. Hold the top part of the flow sensor and turn it a quarter-turn
counter-clockwise (bayonet fitting).
2. Loosen the clamping screw on the M12 threaded connector
and feed the cable through the alarm device
3. Remove 2 cm from the cable sheath
4. Isolate the ends of the wires
5. Fit the cable end sleeves
6. Connect the flow sensor to an alarm device as per the table:
Terminal Contact
1 NC
2 Root (C)
3 N/O
Technical data for the reed switch, potential-free:

n Switching power max. 3 W
n Switching voltage, max. 42 V protective low voltage
(SELV)
n Switching current max. 0.25 A
7. Bring approx. 5 cm of the cable into the flow sensor and
tighten the clamping screw on the M12 threaded connector
8. Push the top part of the sensor fully into the housing and
tighten it carefully in a clockwise direction until it can go no
further, ensuring that the nibs of the bayonet fixing do not
break off
Electrical installation of the ampero‐ 1. Turn the top part of the sensor a quarter turn counter-clock‐
metric sensors wise and remove it
and feed through the measuring line from the control device
3. Strip the cable ends, fit the cable ends with cable end
sleeves (⌀ max = 0.5 mm2) and connect the cable ends to the
2-wire connector: 1 = plus, 2 = minus
4. Insert approx. 5 cm of the measuring line into the sensor
5. Tighten the clamping screw on the threaded connector
6. Push the top part of the sensor right into the sensor shaft and
tighten it clockwise up to the stop
A0102
Fig. 8: 2-wire connection
31
Electrical installation of the ORP and Screw the measuring line coming from the controller onto the
pH sensor respective sensor.
7.3 Adjusting the Flow Sensor Switching Point
Task:
The flow sensor should switch when the flow falls; the
flow sensor is connected as an N/C (Term. 1 - Term. 2
= NC - C):
1. Use the ball valve to adjust the flow to 50 l/h

2. Hold the flow sensor in place and loosen the mounting clip a
little
3. Press the float down to 40 l/h using the flow sensor,
ð The connected alarm device should switch off
4. Hold the flow sensor in this position and tighten the mounting
clip
5. Lower the flow for test purposes
ð The alarm device should switch off
6. Check the threaded connector for leak-tightness
32
Installing Sensors in the Bypass Fitting DLG III/IV
8 Installing Sensors in the Bypass Fitting DLG III/IV

WARNING!
findings.
CAUTION!
tions.
pumps ...
water.
33
8.1 Fitting the DLG with Sensors

Fitting sensor with PG 13.5 connector:
Shaft diameter < 12 mm
You can fit sensors with a shaft diameter of up to 14
mm. It is essential that you fit an O-ring with a clamp
disc to seal sensors with a shaft diameter of < 12 mm.
Use an Allen key (width 10 mm) for dismantling to

ensure that the blanking threaded connector is not
damaged.
1. Use the Allen key to unscrew a blanking threaded connector

out of the top of the in-line probe housing
NOTICE!
Always read the assembly instructions provided by the
sensor manufacturer
Never use a tool to install sensors with a glass shaft.
With sensors with a glass shaft, this can cause tension
in the glass shaft, which could irreparably damage the
sensor.
2. Screw the sensor manually back into the in-line probe

housing until leak-tight
Amperometric sensors with

Ø = 25 mm Sensors with ⌀ = 25 mm
You can only fit sensors with ⌀ = 25 mm (e.g. chlorine
sensor type CLE 3) with the corresponding mounting
kit (Accessories, part number 815079).
34
1.
2.
3.
4.
5.
A0645
Fig. 9: Amperometric sensor

1. Threaded sleeve
2. Clamp disc
3. Sensor
4. O-ring
5. Washer
Requirement
The sensor is filled with electrolyte and the diaphragm
cap is screwed on tightly.
Accessories: Mounting kit, part number 815079.
Refer to the operating instructions for the respective
sensor.
1. Unscrew a large blanking threaded connector out of the top

of the in-line probe housing
Blanking threaded connector

Keep the blanking threaded connector. You can
use the blanking threaded connector to reseal
the in-line probe housing at a later stage. You
can then operate the in-line probe housing
without a sensor.
2. Push the O-ring (4) from below over the sensor (3) up to the
clamp disc (2)
3. Push the washer (5) from below over the sensor up to the O-
ring (4)
4. Insert the sensor into the in-line probe housing
5. Screw the sensor with the threaded sleeve (1) to the in-line
probe housing until liquid-tight
35
8.2 Hydraulic Installation
Free flow
Make sure that there is no overpressure > 1 bar and
also no negative pressure at the outlet of the DLG.
Overpressure damages the DLG. Negative pressure
damages the sensors fitted.
1. Use the hose connection set 8/5 mm (DLG III A) to seal the
sample water line or as an adhesive connection between
PVC-U pipe d16 and the adhesive connection d16
2. If fitted: Seal the backflushing line (inner diameter of the hose
4 - 6 mm)

be.

65.
Terminal Contact
1 NC
2 Root (C)
3 N/O

(SELV)
break off
36
A0102
8.4 Starting Up the DLG
Flow control
The ball in the ball cage of the DLG III is only a visual
display and does not replace the electrical flow control
with measuring and control functions.
You can adjust the inlet side of the flow of the DLG III using the
regulating tap. The working range is reached when the white ball is
visible in the ball cage.
37
Installing Sensors in the Bypass Fitting with Pipework
9 Installing Sensors in the Bypass Fitting with Pipework

WARNING!
findings.
CAUTION!
tions.
pumps ...
water.
9.1 Fitting the Pipework with Sensors

Fitting sensor with PG 13.5 connector: 1. Remove the upper blanking plug from a module
2. With pH/ORP sensors: remove the sensor from its transport
protection container.
3. Screw in the sensor.
38
Assembling sensor DO 1
Sensor insert
The sensor insert is factory-inserted into the oxygen
sensor and no longer needs to be fitted on site.
4. 1.
3.
2.
A1284
Fig. 11: Construction of the sensor DO 1

1. Bracket for the sensor insert
2. Sensor diaphragm
3. Transmitter
4. Sensor insert
Do not remove the silicone paste on the rear of the

sensor insert.
The silicone paste protects the electrical contacts from
short-circuiting, even if any water enters their environ‐
ment.
The bracket for the sensor insert has a bayonet seal.
Loosen and tighten the bracket for the sensor insert.
1. If you have not yet done so: Dismantle the transmitter and
insert the sensor insert.
2. Insert the sensor insert into the transmitter, positioning the
sensor insert with the two pins into the corresponding holes
on the underside of the transmitter.
A1289
Fig. 12: Positioning the sensor insert on the DO 1

3. Screw the bracket for the sensor insert until the bayonet seal
snaps into place on the transmitter.
4. Fit the sensor in the pipe.
39

be.

65.
Terminal Contact
1 NC
2 Root (C)
3 N/O

(SELV)
break off
40
A0102
9.3 Hydraulic Installation, Bypass Fitting with Pipework
Free flow
Make sure that the system pressure specified on the
nameplate is not exceeded and that there is no nega‐
tive pressure.
Adhering the sample water lines

The manufacturer's specification for the different mate‐
rials, such as pipes, adhesive, straight unions etc., is
essential for the design of the adhesive.
Glue the sample water lines provided on site with the straight
unions of the bypass fitting. Refer to the drawing for sizing.
9.4 Starting Up the Bypass Fitting with Pipework
Flow control
Adjust the flow control.
You can adjust the flow of the bypass fitting with the pipework on
the ball valves. Adjust the flow so that the sensors have a sufficient
flow. Refer to the operating instructions for the sensors for the
"Flow" setpoint.
41
Electrically and Hydraulically Assembling and Installing the Measuring Points
10 Electrically and Hydraulically Assembling and Installing the

Measuring Points
WARNING!
and regulated.
overall system.
station.
the process.
and users.
CAUTION!
NOTICE!
Strain relief and decoupling of all connections
Provide all components with suitable strain relief,
decouplings and/or other protection devices to avoid
damage to connections, like pipework, cables etc.
between the measuring plate and the place of installa‐
tion.
42
10.1 Electrical Installation of the Measuring and Control Station
WARNING!
Live parts
Measures:
– Switch off the system until de-energised before
opening the housing of the controller and/or ter‐
minal box.
– If the housing of the controller and/or terminal box
is ruptured or obviously damaged, immediately
switch off the system and have it repaired.
exception to this. This can also be done when the
system is live. Please also observe the information
in the operating instructions for the sensors and
controller.
closing the housing of the controller and/or ter‐
minal box.
CAUTION!
Defective control by defective measured values
Cause: Electrical faults are coupled into the control cir‐
cuit via the sample medium.
Consequence: Defective control by defective meas‐
ured values. The measuring fault can lead to an
uncontrolled control circuit.
Measure: Do not fit any sources of EMC interference
into the water circulation system and close to the
system.
Perform regular comparative measurements with a
galvanically isolated measuring device.
Provide for potential separation of the power supply
from the measuring device to the power circuit of the
voltage to be measured or a potential separation in the
measuring signal path.
Connect the system to its own power supply, if
needed.
Fit a power repeater, if needed.
Note the electrical connection values on the nameplate of the

measuring and control station. The cable ends of the connecting
lines of the sensors are labelled according to the measured vari‐
able.
43

Measuring plate The cable ends of the connecting lines of the sensors are labelled
according to the measured variable. The cable ends are labelled
by a cable marker defined as follows for the respective measured
variables:
Measured variable Controller label Sensor type Cable label

pH pH PHES P
ORP Redox/ORP RHES R
Conductive conductivity Conductivity LFTK1 Pre-installed
Inductive conductivity Conductivity ICT Pre-installed
Chlorine CL CLE, CTE CL
Bromine Br BCR BR
Chlorine dioxide CLO2 CDE, CDP CD
Chlorite Chlorite CLT CT
Ozone O3 OZE OZ
Peracetic acid PES/PAA PAA PA
Hydrogen peroxide H2O2 PER PE
Dissolved oxygen O2 DO1 Pre-installed
Temperature Temperature PT PT
Fluoride Fluoride FLE F
1. Install a mains cable on the terminal box.

2. Wire up all inputs and outputs not yet connected as per the
wiring diagrams.
44
10.1.1 Wiring Diagram for DACa and Measuring Plate
Optional
Hauptschalter und Gehäuse

Messwasserfehler
A2094
Fig. 14: Wiring diagram for measuring plate, complete
45
Kunde Messplatte Regler
mV-Sensor Eingang
Drahtbrücke
Temperatursensor
optional
Hauptbaugruppe
Sensor-Eingang
optional
mV-Sensor Eingang
X0 Schirm erden!
Digitaler Kontakteingang 1
Pause
Messwasserfehler
Messwasserfehler
Impulsfrequenzausgang 1
Pumpe 1, heben
Pumpe 2, senken
Normsignal-Ausgang 1
Messwert Kanal *
Messwert Kanal *
mV-Sensor Eingang
Erweiterungsbaugruppe (Optional)
Drahtbrücke
Optional weitere
mA-Sensoren
mV-Sensor Eingang
Niveau in Behälter 1
Pause halten / Aus
Digitaler Kontakteingang 5 Pause halten / Aus
Pause halten / Aus
Pumpe 3, heben
Pumpe 4, senken
Leistungsrelais 1
Grenzwert * + Kanal *
Leistungsrelais 2
Alarmrelais
Netzanschluss
Klemmenkasten A2093
Fig. 15: Wiring diagram for DACa
46
Optional
Pumpe 1 heben / senken

Regler
Messwert Kanal 1
Pause
SCHIRM
Normsignal-Ausgang
Netzanschluss
Messplatte
Kunde
A2127
Fig. 16: Wiring diagram for DACa, conductivity, optional
47
10.1.2 Wiring Diagram for DACa and Measuring Plate - Fluoride
Hauptschalter + Gehäuse
Kunde (bauseits)
(lose Beistellung)
Magne t-Rührer
Messwasserfehler
OPTIONAL
A2097
Fig. 17: Wiring diagram for measuring plate, complete, fluoride
48
mV-Sensor Eingang
Drahtbrücke
Hauptbaugruppe
mV-Sensor Eingang
Pause
Messwasserfehler
Messwasserfehler Impulsfrequenzausgang 1
Pumpe 1, heben
Pumpe 2, senken
Messwert Kanal *
Messwert Kanal *
mV-Sensor Eingang
Drahtbrücke
mA-Sensor Eingang
Digitaler Kontakteingang 3 Niveau in Behälter 1 / Pause halten / Aus
Digitaler Kontakteingang 4 Niveau in Behälter 2 / Pause halten / Aus
Niveau in Behälter 3 / Pause halten / Aus

Pumpe 3, heben
Pumpe 4, senken
Leistungsrelais 1
Leistungsrelais 2 Grenzwert * + Kanal *
Netzanschluss
Klemmenkasten A2095
Fig. 18: Wiring diagram for DACa, fluoride
49
10.1.3 Wiring Diagram for DACa, DCC and Measuring Plate - Waste Water
Optional
Klemmenkasten
Hauptschalter
Netzteil
Netzfilter optional
Optional
Messwasserfehler
A2101
Fig. 19: Wiring diagram for measuring plate, complete, waste water
50
mV-Sensor Eingang
Hauptbaugruppe
Temperatursensor
optional
Sensor-Eingang Option
mA-Sensor Eingang
Option
Digitaler Kontakteingang 1 Pause

Messwasserfehler
Impulsfrequenzausgang 1 Pumpe 1, heben

Pumpe 2, senken
Messwert Kanal *
Normsignal-Ausgang 2,
Messwert Kanal *
mV-Sensor Eingang
Optional weitere
mA-Sensoren
mA-Sensor Eingang
Pause halten / Aus
Pause halten / Aus
Pause halten / Aus
Pumpe 3, heben
Pumpe 4, senken
Leistungsrelais 1
Leistungsrelais 2
Netzanschluss
Klemmenkasten A2098
Fig. 20: Wiring diagram for DACa, waste water
51
Optional
Pause
Normsignal-Ausgang
Messwert Kanal 1
Pumpe 1 heben / senken
Netzanschluss
Klemmenkasten
Netzfilter optional!
Messwasserfehler
88_02-401_00_38-4A
A2099
Fig. 21: Wiring diagram for DCC, power supply, flow meter, waste water
52
10.2 Hydraulic Test Run after Installation
CAUTION!
Warning of escaping feed chemical
Feed chemical can escape in the event that the hose
lines are incorrectly installed.
– Only use original hoses with the specified hose
dimensions.
– Avoid reducing the hose sizes.
Permissible operating conditions

The values for the permissible hydraulic operating con‐
ditions are given on the nameplate.
If not yet fitted: Fitting the hose lines 1. Cut off the ends of the hoses (6) so that they are straight.
2. Unscrew the union nut (5) and push over the hose together
with the clamp ring (4).
3. Push the hose end (6) up to the stop over the nozzle (3).
4. Tighten the union nut (5).
5. Pull on the hose (6) and tighten up the union nut (5).
1 Connector
1
2 Seal
3 Nozzle
2 4 Clamp ring
3 5 Union nut
6 Hose line
P_MAZ_0041_SW
Fig. 22: Installing the hose line
Hydraulic installation, bypass fitting

with pipework
NOTICE!
Decoupling the measuring plate from oscillations,
vibrations etc.
Put in place appropriate measures to decouple the
measuring plate and on-site pipework from oscillations,
vibrations, load, bending stress etc., which can be
transmitted by the glued pipes onto the measuring
plate. The operator is responsible for selecting the
appropriate measures.
53
Free flow
Make sure that the system pressure specified on the
nameplate is not exceeded and that there is no nega‐
tive pressure.
Adhering the sample water lines

The manufacturer's specification for the different mate‐
rials, such as pipes, adhesive, straight unions etc., is
essential for the design of the adhesive.
1.
A2124
Fig. 23: Bypass fitting straight union (1)

Glue the sample water lines provided on site with the straight
unions of the bypass fitting. Refer to the drawing for sizing.
Connect the additional hydraulic com‐ Pay attention to the operating instructions provided for the addi‐
ponents outside of the plate (optional) tional operational components outside of the plate when hydrauli‐
cally connecting them.
After successful installation, a hydraulic test run of the

DULCOTROL® measuring/control station is essential.
n Check the sampling tap. Make sure that the sampling tap is
closed, otherwise sample water will escape.
n Check all threaded connectors prior to initial commissioning.
n Open the stopcock/ball valve on the inlet and outlet side.
n Check the system for leak-tightness. Do not allow any liquids to
escape.
Should liquid escape: check the system and repair the leak.
54
Starting-up Sensors
11 Starting-up Sensors
n User qualification: trained user, see Ä Chapter 2.5 ‘Users'
qualifications’ on page 15
WARNING!
Sensor run-in periods
This can result in hazardous incorrect metering.
– Correct measuring and metering is only possible if
the sensor is working perfectly
– Observe the sensor operating instructions
– Calibrate the sensor after commissioning
WARNING!
findings.
CAUTION!
– The sampling tap must be closed, otherwise
sample water can escape.
– The sample water should be free from air bubbles
to ensure reliable measurement and control.
Should the sample water carry air with it as a result
of the process, then suitable means must be used
to separate out the air.
Maximum permissible operating pressure: 1 bar at maximum 45 °C

or see Ä ‘Permissible operating pressures’ on page 144
11.1 Preparation of Sensors

1. Tighten all threaded connectors and check that the threaded
connectors are leak-tight.
2. Check the positions of all shut-off valves. The position of the
shut-off valves has to guarantee that the
DULCOTROL® measuring/control station is tight and that
there is a flow of sample water.
3. Plug the mains plug into the sockets provided and switch on
the mains voltage.
55
Starting-up Sensors
4. Check the operating conditions, as described in the operating

instructions for the sensors, as follows:
n Flow
n Pressure
n Temperature
n pH
n Concentration of feed chemical
Adjust these values so that the values are within the sensor's
specification.
5. To condition the amperometric sensors, make sure that there
is electrical power to the sensors, that there is a flow of
chemical to be measured and that the appropriate run in
period given in the operating instructions for the sensor has
expired.
ð The sensor signal should be stable in terms of time after
conditioning.
Only then can the measuring point be calibrated. The
operating conditions have to remain as constant as pos‐
sible during this.
6. Calibrate the measuring points, as described in the operating
instructions supplied for the respective controller fitted.
7. The operating instructions supplied for the respective sensor
fitted provide detailed information on commissioning the sen‐
sors.
11.2 Sampling from the Bypass Fitting
Bleeding of the DLG

Remove sufficient sample water before taking a
sample to fully bleed the measuring point with meas‐
uring and control stations fitted with DLG bypass fit‐
ting. There should be no air in the bypass fitting during
sampling.
Sampling for calibration

When taking a sample to calibrate a sensor, make
sure that sufficient sample water is removed before
sampling in order to rule out particles of dirt, foreign
bodies etc. in the actual sample. Properly dispose of
the sample water that is removed.
The sampling points are labelled on the measuring and control

plate. The extraction of sample water is only permitted at these
sampling points. The extraction of sample water at other points on
the measuring and control station can lead to incorrect results, for
instance during calibration.
11.3 Calibrating the Sensors

All sensors are calibrated, as described in the operating instruc‐
tions for the controllers and sensors fitted. Any sample required is
taken at the sampling points labelled on the measuring plate, see
Ä Chapter 11.2 ‘Sampling from the Bypass Fitting’ on page 56.
56
Starting-up Sensors
11.4 Calibrating the Fluoride Sensor

There is a fundamental distinction between 1-point calibration and
2-point calibration. 1-point calibration is performed using a
standard solution with e.g. 1 ppm fluoride for calibration. 2-point
calibration is performed using two standard solutions, which have
to be more than 1 ppm apart (minimum value 0.5 ppm).
There are two options for calibrating a fluoride sensor:
n Calibration with a photometer DT2C (order number: 1039316)
n Calibration with a standard solution
The fluoride sensor is calibrated, as described in the operating
instructions for the controller and sensors fitted.
Calibration with a photometer DT2C Refer to the operating instructions for the photometer DT2C.
Calibration with a standard solution

Calibration instructions
Regularly check and calibrate the sensor.
Please note the applicable national guidelines.
The sensor needs to have run in prior to initial calibra‐
tion.
Observe the controller operating instructions.
Perform 2-point calibration during initial commis‐
sioning.
2-point calibration needs to be carried out less regu‐
larly than 1-point calibration.
The standard solution has to be evenly stirred with a magnetic

stirrer during calibration.
Use a standard solution with a conductivity of
> 1000 μS/cm(e.g. 1g/litre Na2SO4 solution) to accelerate potential
adjustment. The two standard solutions have to be more than 1
ppm apart (minimum value 0.5 ppm) to calibrate the slope (2-point
calibration).
1. Immerse the sensor, the reference electrode and the Pt 100
(if fitted) into the standard solution for calibration
2. Perform calibration in line with the controller's specification,
referring to the operating instructions for the controller.
57
Starting-up Sensors
11.5 Removing and Fitting the Bypass Fitting Cup for Calibration
1. 2.
3.
4.
5.
A2114
Fig. 24: Removing and fitting the bypass fitting cup for calibration
1. Ball valve, inlet side
2. Ball valve, outlet side
3. Cup with stirrer rod inserted
4. Magnetic stirrer
5. Wall bracket
1. Close the ball valves (1 and 2).
2. Remove the magnetic stirrer (4).
3. Remove the wall bracket (5).
4. Remove the container (3).
5. Empty the cup and fill with the standard solution.
Make sure that the stirrer rod is in the cup.
6. Fit the filled cup.
7. Fit the wall bracket and magnetic stirrer.
8. Switch on the magnetic stirrer.
9. Perform calibration, as described in the operating instructions
for the controller.
2-point calibration: Fill the cup with the second standard solu‐
tion if required. Perform calibration, as described in the oper‐
ating instructions for the controller.
10. Complete calibration, as described in the operating instruc‐
tions for the controller.
11. Open the ball valves (1 and 2).
ð The fluoride sensor is now calibrated.
58
Controllers' User Interface
12 Controllers' User Interface

One or two controllers with different user interfaces can be fitted,
depending on the selection using the identity code, on the
DULCOTROL® measuring and control station. These user inter‐
faces are described here and facilitate basic tasks on the control‐
lers. All other tasks, such as configuring the inputs and outputs
etc., are described in the detailed operating instructions for the
ProMinent® components.
DACa
12.1 Operating Concept
1.
A1035
Fig. 25: Operating cross (1) / Active keys are displayed in [black] in the display; inactive keys in [grey].
For example, the following path is presented:
Continuous display ➨ ➨ or [calibrate] ➨ ➨ or
[slope] ➨ ➨
Continuous display [Calibrate] [Slope]
A1036
Fig. 26: 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 12.1.1
‘Functions of the keys ’ on page 62.
➨ = 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 identical wording in the controller display.
59
Additional information can be obtained via the key.
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. 27: Example of the continuous display when used with a

measuring channel (e.g. pH)
-15 7.55
7.20
25 0.30
0.50
A1177
Fig. 28: Example of the continuous display when used with two
measuring channels (e.g. pH/chlorine)
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 controller 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 .
ð In front of the selected parameter there is an arrow tip,
which marks the selected parameter.
2. Press
ð You are now in the setting menu for the desired param‐
eter.
60
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 pos‐
sible setting range, the message
[range error] appears after pressing the
key. 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.
61
12.1.1 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 continuous display.
Start/Stop of the controller's control and metering function from any display.
To increase a displayed number value and to jump upwards in the operating 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.
To decrease a displayed number value and to jump down in the operating menu.
Moves the cursor to the left.
62
12.1.2 Changes the set operating language

1. Simultaneously press the keys and
ð The controller changes to the menu for setting the oper‐
ating language.
Language 2
Language
German
A1482
Fig. 29: 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
ð The controller changes back to the continuous display
and indicates the selected operating language.
12.1.3 Acknowledge fault or warning message

If the controller recognises an error [Error], the control is stopped,
the backlight switches to red lighting and the alarm relay is deacti‐
vated. You can access the next value to be set by pressing the
key. In this process, the controller indicates all errors and warn‐
ings. The pending alarm messages can be selected and, if
required, acknowledged/confirmed. 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 mes‐
sage 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 sensor
has not been calibrated yet, further processing using the controller
is possible with or without acknowledgement of the message.
In the event of an error message [Error], [e.g.] the controller signals
that no sensor is connected, then after acknowledgement of the
message, no further processing is possible using the controller.
You must now rectify the error - for this see the chapter on Diag‐
nostics and Troubleshooting.
63
Fig. 30: Alarm message, controller stops control
12.1.4 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 simultaneously pressing and . An activated key lock is indi‐
cated by the symbol.
64
12.2 Operating Diagram for Measured Variable: Conductive Conductivity

12.2.1 Overview of equipment/Operating elements
n User qualification: instructed user, see Ä Chapter 2.5 ‘Users'
A0291
Fig. 31: Overview of equipment/Operating elements
Function Description
1st respective measured vari‐ Affix the measured variable label here
able
2. LCD display
3. UP key To increase a displayed numerical value and move up in the operating
menu
4. INFO/RIGHT key Opens the information menu or moves the cursor one place to the right
5. OK key To apply, confirm or save a displayed value or status or To confirm an
alarm
6. DOWN key To decrease a displayed numerical value and move down in the operating
menu
7. MENU key To access the controller's operating menu
8. STOP/START key Starts and stops the control and metering function
9. ESC key Moves one level back in the operating menu, without storing or changing
entries or values
Switches the measured variables in the continuous display.
10. CAL key To access the calibration selection menu (cell constant and temperature
coefficient) and navigate within the calibration menu.
65
11. f-REL LED Shows the activated state of the f-relay
12. P-REL LED Shows the activated state of the P-relay
13. ERROR LED Indicates a controller error state. A text message is displayed simultane‐
ously in the LCD display of the continuous display
12.2.2 Entering values

Described by the example of entering setpoints in the Control
menu.
※CONTROL
SET= 01.000
A1634
Fig. 32: Entering values

1. Use to select each position of the value to be entered.
You can also select and change the unit of the

value to be entered.
2. Enter the values using the and keys

3. : The value entered is transferred to the memory.
4. : Cancelling the input of values without saving the entered
value. The original value is retained.
12.2.3 Adjusting display contrast

If the DULCOMETER® Compact Controller is set to ‘continuous
display’ , you can set the contrast of the LCD-display. By pressing
the key you can adjust the LCD display contrast so it is darker.
By pressing the key you can adjust the LCD display contrast so
it is lighter. Here each key press represents a contrast level. I.e.
the key must be pressed once for each contrast level.
66
12.2.4 Continuous display
7
ConC µS/cm 1
2
6
3
5 4
A1614
Fig. 33: Continuous display

1 Measured variable (switch using ESC), the fol‐ 4 Possible error text: for example "Limit↓" (direc‐
lowing are possible: [ConC], [RES], [TDS] and tion of limit value transgression e.g. value below
[SAL] the limit in this case)
2 Reference temperature or temperature compen‐ 5 Temperature (correction variable)
sation 6 Measured value (actual value)
3 Control variable 7 Operating status
The bottom line displays the current measuring temperature and a
temperature manually entered. The temperature display cannot be
switched off.
The temperature (measuring temperature or reference tempera‐
ture) is needed to calculate all measured variables, which is why
the second line of the continuous display therefore displays infor‐
mation about temperature compensation and the reference tem‐
perature.
The setpoint is displayed in the Information menu.
Switching between measured varia‐ Use the key to switch between the controller's measured varia‐
bles bles [ConC], [RES], [TDS] and [SAL] in the continuous display.
Depending on the measured variable set, the settings of variables
are changed or the variables are hidden completely in the
[INPUT Ø TCOMP] menu and in the [LIMIT] menu.
12.2.5 Information display

The most important parameters for each first-level menu item are
displayed in the Information display.
Use to access the Information display from the continuous dis‐
play. Pressing again calls up the next Information display.
Pressing calls up the continuous display again.
67
ⒾLIMITS ⒾCONTROL
LIMIT↑= 0.020 PUMP: dosing ↓
LIMIT↓= 0.010 SET= 1.000mS/cm
TYPE: P
ⒾVERSIONS Ⓘ INPUT
SW-VER 01.00.00.00 SENSOR: LF1
BL-VER 03.02.02.01 TEMP: auto
SN 2366733289 (07) CONTACT: pause
Ⓘ CAL
CELLC: 1.0000cm-1
TCOEFF= 1.90%/°C
ⒾLAST ERR. Ⓘ INPUT_2 Ⓘ OUTPUT

mA Range↑ 88 min TREF: lin 25.0 °C P-REL: alarm
mA Range ↓ 136 min CABLE LEN: 3.00m f-REL: dosing
AUTORNG: 33 mA OUT: meas val
A1615
Fig. 34: Information display

Use to move from the information display currently shown to the
selection menu for this information display.
Use to move directly back to the information display.
12.2.6 Password
Access to the setting menu can be limited by a password. The con‐
troller is delivered with the password ‘5000’ . The controller is set
up with the pre-set password ‘5000’ so that access is possible to
all menus.
≡MENU
INPUT
MENU
OUTPUT
DEVICE
※DEVICE ※DEVICE
PASSWORD: ****
RESTART DEVICE... NEW PASSW. 5000
FACTORY RESET 5000=FREE A1616
Fig. 35: Setting the password
Password Possible values

Factory setting Increment Lower value Upper value Remark
5000 1 0000 9999 5000 = [FREE]
68
12.3 Operating Diagram for Measured Variable: Inductive Conductivity

12.3.1 Overview of equipment/Operating elements
A0291
Fig. 36: Overview of equipment/Operating elements
1st respective measured vari‐ Affix the measured variable label here
able
2. LCD display
3. UP key To increase a displayed numerical value and move up in the operating
menu
4. INFO/RIGHT key Opens the information menu or moves the cursor one place to the right
5. OK key To apply, confirm or save a displayed value or status or To confirm an
alarm
6. DOWN key To decrease a displayed numerical value and move down in the operating
menu
7. MENU key To access the controller's operating menu
8. STOP/START key Starts and stops the control and metering function
9. ESC key Moves one level back in the operating menu, without storing or changing
entries or values
Switches the measured variables in the continuous display.
10. CAL key To access the calibration selection menu (cell constant and temperature
coefficient) and navigate within the calibration menu.
69
11. f-REL LED Shows the activated state of the f-relay
12. P-REL LED Shows the activated state of the P-relay
13. ERROR LED Indicates a controller error state. A text message is displayed simultane‐
ously in the LCD display of the continuous display
12.3.2 Entering values

Described by the example of entering setpoints in the Control
menu.
※CONTROL
SET= 01.000
A1634
Fig. 37: Entering values

1. Use to select each position of the value to be entered.
You can also select and change the unit of the

value to be entered.
2. Enter the values using the and keys

3. : The value entered is transferred to the memory.
4. : Cancelling the input of values without saving the entered
value. The original value is retained.
12.3.3 Adjusting display contrast

If the DULCOMETER® Compact Controller is set to ‘continuous
display’ , you can set the contrast of the LCD-display. By pressing
the key you can adjust the LCD display contrast so it is darker.
By pressing the key you can adjust the LCD display contrast so
it is lighter. Here each key press represents a contrast level. I.e.
the key must be pressed once for each contrast level.
70
12.3.4 Continuous display
7
ConI µS/cm 1
2
6
3
5 4
A1861
Fig. 38: Continuous display

1 Measured variable (switch using [ESC]): the fol‐ 4 Possible error text: for example [Limit↓] (direc‐
lowing are possible: [ConI], [RES], [TDS] and tion of limit value transgression e.g. value below
[SAL] the limit in this case)
2 Reference temperature or temperature compen‐ 5 Temperature (correction variable)
sation 6 Measured value (actual value)
3 Control variable 7 Operating status
The bottom line displays the current measuring temperature and/or
a temperature manually entered. The temperature display cannot
be switched off.
The temperature (measuring temperature or reference tempera‐
ture) is needed to calculate all measured variables, which is why
the second line of the continuous display therefore displays infor‐
mation about temperature compensation and the reference tem‐
perature.
The setpoint is displayed in the Information menu.
bles bles [ConI], [RES], [TDS] and [SAL] in the continuous display.
12.3.5 Information display

The most important parameters for each first-level menu item are
displayed in the information display.
Use to access the information display from the continuous dis‐
play. Pressing again calls up the next information display.
Pressing calls up the continuous display again.
71
ⒾLIMITS ⒾCONTROL
LIMIT↑= 0.020 PUMP: dosing ↓
LIMIT↓= 0.010 SET= 1.000mS/cm
TYPE: P
ⒾVERSIONS Ⓘ INPUT
SW-VER 01.00.00.00 SENSOR: LF1
BL-VER 03.02.02.01 TEMP: auto
SN 2366733289 (07) CONTACT: pause
Ⓘ CAL
CELLC: 1.0000cm-1
TCOEFF= 1.90%/°C
ⒾLAST ERR. Ⓘ INPUT_2 Ⓘ OUTPUT

mA Range↑ 88 min TREF: lin 25.0 °C P-REL: alarm
mA Range ↓ 136 min CABLE LEN: 3.00m f-REL: dosing
AUTORNG: 65 mA OUT: meas val
A1862
Fig. 39: Information display

Use to move from the information display currently shown to the
selection menu for this information display.
Use to move directly back to the information display.
12.3.6 Password
Access to the setting menu can be restricted by a password. The
controller is delivered with the password ‘5000’ . The controller is
set up with the pre-set password ‘5000’ so that access is possible
to all menus.
≡MENU
INPUT
MENU
OUTPUT
DEVICE
※DEVICE ※DEVICE
PASSWORD: ****
RESTART DEVICE... NEW PASSW. 5000
FACTORY RESET 5000=FREE A1863
Fig. 40: Setting the password
Password Possible values

Factory setting Increment Lower value Upper value Remark
5000 1 0000 9999 5000 = [FREE]
72
Commissioning the Controller diaLog DACa
13 Commissioning the Controller diaLog DACa

Sample water faults and alarm relays
If the sample water falls below the minimum flow vol‐
umes (sample water fault), the controller DACa
switches to fault mode and control of both measuring
channels stops.
The alarm relay is not factory-activated.
13.1 Commissioning
WARNING!
Sensor run-in period
This can result in hazardous incorrect metering
Take into consideration the sensor's run-in period
during commissioning:
– There has to be adequate feed chemical in the
sample water for your application (e.g. 0.5 ppm
chlorine)
the sensor is working perfectly.
– It is imperative that you adhere to the sensor's run-
in periods.
– Calculate the run in period when planning commis‐
sioning.
– It may take a whole working day to run in the
sensor.
– Refer to the sensor's operating instructions.
After mechanical and electrical installation, integrate the controller

into the measuring point.
13.1.1 Switch-on behaviour during commissioning

Switching On - First Steps
Installation and function control
– Check that all the connections have been made
correctly
– Ensure that the supply voltage matches the
voltage indicated on the nameplate
1. Switch the supply voltage on

2. The controller displays a menu in which you can set the lan‐
guage with which you wish to operate the controller
73
3. Wait for the controller's module scan
Module scan
Base module
Softw. version: 01.00.00.00
Expansion module
Softw. version: 01.00.00.00
continue with <OK>

Auto continue in 10 s A1081
Fig. 41: Module scan

ð The controller indicates the controller modules installed
and identified.
4. Press
ð The controller now changes to its continuous display.
From the continuous display, you can access all the con‐
troller's functions using .
13.1.2 Adjusting the backlight and contrast of the controller display

Continuous display ➨ ➨ [Setup] ➨ [Device setup]➨ or
[Device configuration] ➨ [Backlight]
Under this menu item you can set the brightness and contrast of
your controller display to match the ambient conditions at your
installation location.
13.1.3 Resetting the operating language
Resetting the operating language

In the event that a foreign and hence incomprehen‐
sible operating language has been set, the controller
can be reset to the basic setting. This is implemented
by the simultaneous pressing of the and keys.
If you no longer know whereabouts you are in the
operator menu, you must press the key as often as
necessary until the continuous display becomes visible
again.
13.1.4 Defining metering and control processes

Set the controller once you have integrated it into the control cir‐
cuit. Setting the controller adapts it to your process.
Define the following parameters to set up a controller:
n What type of a process is planned?
n Which measured variables are there?
74
n Is there an in-line, batch or circulation process planned?

n Should the controller operate as a one-way or two-way control?
n Which control variables are there?
n What control parameters are necessary?
n What should the controller do in [HOLD]?
n How should the actuators be controlled?
n How should the mA-outputs be set?
75
Commissioning the Compact Controller for Conductive Conductivity
14 Commissioning the Compact Controller for Conductive Con‐

ductivity
WARNING!
Sensor run in period
This can result in dangerous incorrect metering
Consider the run in period of the sensor during com‐
missioning:
– It is imperative that you adhere to the run in
periods of the sensor.
sioning.
– It may take a whole working day to run-in the
sensor.
– Observe the sensor operating instructions.
14.1 Measured variables

The controller can process the following measured variables:
n Conductive conductivity [ConC]
n Resistance [RES]
n TDS value [TDS]
n Salinity [SAL]
bles bles [ConC], [RES], [TDS] and [SAL] in the continuous display.
Measured variable: conductive con‐ Symbol displayed in the controller's display: [ConC]
ductivity [ConC]
Units of measurement: μS/cm, mS/cm , S/cm. The measuring
range is automatically detected and switched by the controller.
Physical variable: specific electrical conductivity (K). Only this
measured variable is emitted at the mA output, independently of
the measured variable set on the controller. The setting of the
measured variable on the controller only affects the layout of the
display and not the output at the mA output.
Measured variable: Resistance [RES] Symbol displayed in the controller's display: [RES]
Units of measurement: MΩcm, kΩcm, Ωcm, measuring range is
automatically detected and switched by the controller
Physical variable: specific electrical resistance.
Calculating the specific resistance: ρ (Tref) = 1/K (Tref)
76
Commissioning the Compact Controller for Conductive Conductivity
Measured variable: TDS value Symbol displayed in the controller's display: [TDS] (total dissolved
solids)
Unit of measurement: ppm (mg/l)
Physical variable: Total of all inorganic and organic substances dis‐
solved in a solvent
Display range: 0 …. 2000 ppm
Temperature range: 0 … 35 °C
[TLIMIT↑]: ≤ 40 °C
Setting the TDS value displayed: You can set a multiplicative factor
[TDS] in the [INPUT] menu, with which the TDS value displayed
can be changed.
Displayed TDS value [ppm] = К (25 °C) [uS/cm] * TDS factor
Setting range of TDS factor: 0.400 … 1.000 (Default: 0.640)
Temperature compensation is always linear with the TDS display
with a reference temperature of 25 °C .
Measured variable: Salinity (SAL) Symbol displayed in the controller's display: [SAL] units: ‰ (g/kg)
Physical variable: Mass of salts in a kg of water given in PSU
(practical salinity units).
The salinity is derived from the conductivity measured, with a
specified non-linear temperature compensation and a reference
conductivity (KCL).
Display range: 0 …. 70.0 ‰
[TLIMIT↑]: ≤ 35 °C
The salinity [SAL] is calculated based on the
[Practical Salinity Scale 1978 (PSS-78)]
77
Commissioning the Compact Controller for Inductive Conductivity
15 Commissioning the Compact Controller for Inductive Con‐

ductivity
WARNING!
Sensor run in period
This can result in dangerous incorrect metering
Consider the run in period of the sensor during com‐
missioning:
– It is imperative that you adhere to the run in
periods of the sensor.
sioning.
sensor.
– Observe the sensor operating instructions.
15.1 Measured variables

The controller can process the following measured variables:
n Inductive conductivity [ConI]
n Resistance [RES]
n TDS value [TDS]
n Salinity [SAL]
bles bles [ConI], [RES], [TDS] and [SAL] in the continuous display.
Measured variable: Inductive conduc‐ Symbol displayed in the controller's display: [ConI]
tivity [ConI]
Units of measurement: μS/cm, mS/cm , S/cm. The measuring
range is automatically detected and switched by the controller
Physical variable: specific electrical conductivity (K). Only this
measured variable and the correction variable ‘Temperature’ are
emitted at the mA output, independently of the measured variable
set on the controller. The setting of the measured variable on the
controller only affects the layout of the display and not the output at
the mA output.
Measured variable: Resistance [RES] Symbol displayed in the controller's display: [RES]
Units of measurement: MΩcm, kΩcm, Ωcm. The measuring range
is automatically detected and switched by the controller
Physical variable: specific electrical resistance.
Calculating the specific resistance: ρ (Tref) = 1/K (Tref)
78
Commissioning the Compact Controller for Inductive Conductivity
Measured variable: TDS value Symbol displayed in the controller's display: [TDS] (total dissolved
solids)
Unit of measurement: ppm (mg/l)
Physical variable: Total of all inorganic and organic substances dis‐
solved in a solvent
Display range: 0 …. 2000 ppm
[TLIMIT↑]: ≤ 40 °C
Setting the TDS value displayed: You can set a multiplicative factor
[TDS] in the [INPUT] menu, with which the TDS value displayed
can be changed.
Displayed TDS value [ppm] = К (25 °C) [uS/cm] * TDS factor
Setting range of TDS factor: 0.400 … 1.000 (Default: 0.640)
Temperature compensation is always linear on the TDS display
with a reference temperature of 25 °C.
Measured variable: Salinity (SAL) Symbol displayed in the controller's display: [SAL] units: ‰ (g/kg)
Physical variable: Mass of salts in one kg of water given in PSU
(practical salinity units).
The salinity is derived from the conductivity measured, with a
specified non-linear temperature compensation and a reference
conductivity (KCL).
Display range: 0 …. 70.0 ‰
[TLIMIT↑]: ≤ 35 °C
The salinity [SAL] is calculated based on the
[Practical Salinity Scale 1978 (PSS-78)]
79
Configuration of the Controllers
16 Configuration of the Controllers

The measured variables, sensor types and the measuring ranges
of the sensors fitted are pre-set in the controllers when the meas‐
uring and control station is delivered. The correct presettings are
the prerequisites for correct calibration of the measuring and con‐
trol station. The operating instructions for the individual compo‐
nents provide information on customer-specific adjustments
16.1 Configuration of the Compact Controllers DCCa
Archiving the settings

The settings on the DCCa have to be manually docu‐
mented and archived, as electronic archiving is not
possible with this unit.
Compact controller DCCa used as a transmitter

The Compact controller DCCa only works as a trans‐
mitter and delivers an mA signal to the diaLog con‐
troller DACa. The measuring range can only be
adjusted and the conductivity sensor calibrated on the
Compact controller DCCa. The output of the Compact
controller DCCa is factory-configured to the applica‐
tion-based measuring range.
You have to adjust the outputs of the Compact controller

DCCa in line with the requirements of your application, refer‐
ring to the operating instructions for the controller.
Presetting: inductive conductivity: 0 … 1000 mS/cm, conduc‐
tive conductivity: 0 … 20 mS/cm.
16.2 Configuration of the diaLog Controller DACa
Only when measuring conductivity

When measuring conductivity the compact controller
DCCa acts as a transmitter for the diaLog controller
DACa. The output of the compact controller DCCa is
connected to the input of the diaLog controller DACa.
You therefore have to set the same measuring range
limits on both units.
Configuration and archiving on an SD card

The factory-set configuration of the diaLog controller
DACa is stored on an SD card. This SD card is located
in the SD slot behind the interface cover carrying the
SD logo. If necessary the configuration can be read
from the SD card and the controller DACa can be
returned to its original factory configuration. You can
also save and secure your specific configuration.
80
Configuration of the Controllers
Additional SD card
Saving the user specific configuration on an additional
SD card. Do not overwrite the original SD card with the
factory configuration.
You have to adjust the outputs of the diaLog controller DACa in

line with the requirements of your application, referring to the oper‐
ating instructions for the controller.
81
Calibrating the Controller diaLog DACa
17 Calibrating the Controller diaLog DACa

17.1 Calibration
Settings for [Channel 2]

In its 2-channel version, the controller has two meas‐
urement channels. This description for [Channel 1]
applies correspondingly for the settings in [Channel 2].
The procedure for making the settings for the channel
in question is identical, however the parameters to be
set may be different. Differences are pointed out and
are also described.
Display tolerances
Display tolerances between the sensor and/or meas‐
uring device and controller have to be calibrated with
sensors and/or with output signals of measuring
devices that do not require calibration or where calibra‐
tion is performed in the sensor/measuring device. The
relevant information for this is contained in the respec‐
tive operating instructions for the sensor or measuring
device.
Continuous display ➨ Menu ➨ or [Calibration] ➨

or
Continuous display ➨
Calibration
Please select channel
Channel 1 Chlorine
Channel 2 pH [mV]
A1606
Fig. 42: Please select channel
82
CAL Cl
Last calibration 31.03. 2013 13:11:11
Slope 100 %
Zero point 4.00 mA
Slope calibration
Calibration of zero point
A1039
Fig. 43: Display [Calibration] with the example of [Chlorine]
Calibrating measuring channel 1 and measuring

channel 2
The calibration processes are identical for measuring
channel 1 and measuring channel 2. However, it is
necessary to calibrate each measuring channel sepa‐
rately
17.1.1 Calibrating the pH sensor

To ensure a high level of measuring accuracy, adjust the pH
sensor at set time intervals. This calibration interval seriously
depends on the application of the pH sensor and on the required
measurement accuracy and reproducibility. The calibration interval
can vary between daily and every few months.
Valid calibration values
Assessment Zero point Slope

Very good -30 mV … +30 mV 56 mV/pH … 60 mV/pH
Good -45 mV … +45 mV 56 mV/pH … 61 mV/pH
Acceptable -60 mV … +60 mV 55 mV/pH … 62 mV/pH
If you measure the pH with potential equalisation, set

this [Potential equalisation] procedure as a parameter
when selecting the measured variable as a parameter.
Calibrate the pH-sensor for the function: pH compen‐

sation for chlorine measurement
It is mandatory that the pH measurement is always
calibrated first, followed by the chlorine measurement.
Calibration of the chlorine measurement should always
follow every further calibration of the pH measurement,
otherwise the chlorine measurement will be inaccurate.
83
Selecting the calibration process Select the calibration process prior to initial calibration. This selec‐
tion is saved until you select a new process.
n 2-point calibration: This is the recommended calibration
process because it evaluates the sensor characteristic data:
asymmetric potential, slope and response speed. 2 buffer solu‐
tions are needed for 2-point calibration, e.g. pH 7 and pH 4 if
subsequent measurement is to be performed in an acidic
medium or pH 7 and pH 10, if subsequent measurement is to
be performed in an alkaline medium. The buffer gap should be
at least 2 pH units.
n Samples (1-point) calibration: There are two options here.
Samples (1-point) calibration is only recommended with reser‐
vations. From time to time check the sensor with 2-point cali‐
bration.
– The pH sensor remains in the sample medium and you
should calibrate a sample of the medium to be measured
against an external comparison measurement. Perform the
comparison measurement using an electrochemical
method. Deviations of up to ± 0.5 pH units can occur using
the phenol red method (photometer).
–Calibration solely using a pH 7 buffer. This only calibrates
the zero point. The sensor is not checked for an acceptable
slope.
n Data input: With this calibration method, using a comparison
measuring device, determine in advance the characteristic data
of the pH sensor (asymmetry and slope) at standard tempera‐
ture and enter this data into the controller. The comparative
calibration should not be more than one week old because the
pH sensor's characteristic data changes if the data is saved for
longer.
84
Buffer temperature dependencies

Buffer temperature
At temperatures that differ by 25 °C in the process,
adjust the pH of the buffer solution by entering the ref‐
erence values printed on the buffer solution bottle into
the controller prior to calibration.
Buffer temperature dependencies

An incorrectly entered buffer temperature can lead to
incorrect calibration.
Each buffer has different temperature dependencies.
You have various choices in terms of compensating for
these temperature dependencies, so that the controller
can correctly process the buffer temperature.
– Buffer temperature [Manual]: Ensure that the buffer
temperature is identical for both buffers. Enter the
buffer temperature in the [CAL Setup] menu item in
the controller.
– Buffer temperature [Automatic]: Then immerse the
temperature sensor connected to the controller
together with the pH sensor into the buffer. Wait for
a sufficiently long period of time until the pH and
temperature sensor have recorded the buffer tem‐
perature.
– Buffer temperature [Off]: this setting is not recom‐
mended. Please use another setting.
The sensor stability information displayed during calibration,

[acceptable], [good] and [very good], indicates to what extent the
sensor signal fluctuates during calibration. At the start of calibra‐
tion, the waiting time for stabilising of the measured value is 30
seconds; during this waiting time, [Please wait!] flashes in the dis‐
play. You cannot continue with calibration during this waiting time.
If the pH sensor is cold, e.g. < 10 °C, then the pH sensor responds
slowly and you have to wait a few minutes until the sensor signal
has stabilised.
The controller has no waiting time limit. You will see the actual
[sensor voltage] in mV and can identify high fluctuations and
assign influences to them, such as the movement of the sensor
cable.
Calibration is impossible if the sensor signal is very unsteady and
the sensor signal is disrupted by external influences, or if the
sensor cable has a cable break or the coaxial cable is damp. Rec‐
tify any fault or cable break.
You can only continue with calibration once the signal bar has
reached the [acceptable] range and remains there or moves
towards [good] or [very good]. Changes to the signal within the
ranges [acceptable], [good] and [very good] are permitted.
The signal fluctuation width within the ranges is specified as fol‐
lows:
n first 30 seconds wait time, then evaluation of the sensor signal
– Acceptable: 0.5 mV/30s
– Good: 0.3 mV/30s
– Very good: 0.1mV/30s
85
CAL pH
Buffer 1:
Buffer 2:
Calibr.param. for 25 °C
Slope
% Slope
Asymmetry
Zero point
Accept with <CAL> A1019
Fig. 44: Display of the calibration result
CAL pH
Sensor quality
Asymmetry in mV
-60 -30 0 30 60
good
acceptable
good
55 56 57 58 59 60 61 62
Slope in mV/pH A1481
Fig. 45: Displayed after the key has been pressed
17.1.1.1 Selecting the Calibration Process for pH

To calibrate the controller there are three available calibration pro‐
cesses:
n 2-point
n Sample (1-point)
n Data input
Selecting the calibration process 1. Continuous display ➨
ð The Calibration menu is displayed, you may need to
select [Channel 1] or [Channel 2], depending on the
measuring channel on which the pH measurement is per‐
formed.
86
2. Press
CAL pH
Calibration process 2 point
Buffer detection requirement
Buffer manufacturer ProMinent
Buffer value 1 pH 7
Buffer value 2 pH 4
Buffer temperature Off

A1025
Fig. 46: Selecting the calibration process

ð The menu for selecting the calibration process appears.
3. Use the arrow keys to select the required menu item and
press
ð The input window appears and you can make the neces‐
sary settings for your process
4. Use the arrow keys to select the calibration process and
press
5. Continue with
ð You can now start your chosen calibration process.
17.1.1.2 2-point pH sensor calibration (CAL)
Correct sensor operation

– Refer to the sensor's operating instructions
– 2-point calibration is strongly recommended and is
preferable to other methods
– Remove the sensor from the in-line probe housing
and re-fit it for calibration. To do this, refer to the
operating instructions for your in-line probe
housing
87
Determining buffer detection

There are 2 methods of buffer detection with 2-point
calibration.
[Requirement]: you have to select 2 buffers from the 4
possible buffer sets for this. Adhere to the selected
order, e.g. buffer value 1: pH 7 and buffer value 2: pH
4 for calibration.
– ProMinent® (pH 4; 7; 9; 10)
– NBS/DIN 19266 (pH 1; 4; 7, ; 9)
– DIN 19267 (pH 1;4; 7; 9; 13)
– Merck + Riedel® (pH 2; 4; 7; 9; 12)
The buffer sets vary with regard to their pH values and
temperature dependencies configured in the controller.
The pH values for the different temperatures are also
printed on the buffer containers.
[Manual]: enter the buffer value with the associated
temperature into the controller.
– The pH values of the buffer solution at tempera‐
tures that deviate from 25 °C are displayed in a
table on the label of the buffer bottle.
Select the buffer you require.
CAL pH
Buffer detection Manual
Buffer manufacturer ProMinent
Buffer value 1 pH 7
Buffer value 2 pH 4
Buffer temperature Manual

Buffer temperature 25.0 °C A1512
Fig. 47: Example: Display in[CAL Setup]
Buffer used
Dispose of the used buffer solution. For more informa‐
tion: refer to the buffer solution safety data sheet.

Valid calibration:
– Zero point -60mV…+60 mV
– Slope 55 mV/pH…62 mV/pH
You need two test containers with buffer solution for calibration.
The pH values of the buffer solutions should be at least 2 pH
values apart. Thoroughly rinse the sensor with water when
changing the buffer solution.
88
CAL pH
Last calibration 06/04/2013 14:26:07
Slope 56.64mV/pH
Zero point 7,00 pH
CAL setup
continue with <CAL> A1016
Fig. 48: pH sensor calibration (CAL)

1. Then press
2. Rinse the sensor thoroughly with water before drying with a
cloth (pad dry, don't rub)
3. Immerse the sensor in test container 1 containing buffer solu‐
tion (e.g. pH 7). When doing so, move the sensor gently
4. Continue with
ð Calibration is running . [Please wait!] flashes.
CAL pH
Sensor calibration in buffer 1
Sensor voltage 0.1 mV
Buffer temperature 25.0 °C
The stability is:
acceptable good very good
Fig. 49: Display of the sensor stability achieved

5. The [acceptable / good / very good] range is displayed
ð The black part of the horizontal bar indicates the range
detected.
6. Continue with
7. [Buffer detection] e.g. [Manual]: Press and set the buffer
value for buffer 1 to the value of the buffer you are using with
the four arrow keys. Confirm the input of the value with
8. Remove the sensor from the buffer solution, rinse thoroughly
in water and then dry with a cloth (pad dry, don't rub!)
9. Continue with
10. Immerse the sensor in test container 2 containing buffer solu‐
tion (e.g. pH 4). When doing so, move the sensor gently
11. Continue with
89
CAL pH
Sensor calibration in buffer 2
Sensor voltage 173 mV
Buffer temperature 25.0 °C
The stability is:

detected.
13. Continue with
14. [Buffer detection] [Manual]: Press and set the buffer value
for buffer 2 to the value of the buffer you are using with the
four arrow keys. Confirm input of the value by pressing
15. Continue with
CAL pH
Buffer 1:
Buffer 2:
Calibr.param. for 25 °C
Slope
% Slope
Asymmetry
Zero point
Fig. 51: Display of the calibration result

16.
Incorrect calibration
An error message appears should the result of
the calibration lie outside the specified tolerance
limits. In this case the current calibration will not
be applied.
Check the prerequisites for calibration and clear
the error. Then repeat calibration.
Transfer the result of the calibration into the controller

memory by pressing
ð The controller displays the continuous display again and
operates with the results of the calibration.
90
17.1.1.3 pH sensor calibration (CAL) with an external sample (1-point)
Measuring and control behaviour of the controller

during calibration
During calibration the actuating outputs are deacti‐
vated. Exception: a basic load or a manual control vari‐
able has been set. This remains active. The measured
value output [standard signal output mA] is frozen, cor‐
responding to its settings in the mA output menu.
When calibration/testing has been completed success‐
fully, all of the error checks relating to the measured
value are restarted. The controller saves all the deter‐
mined data for zero point and slope upon a successful
calibration.
NOTICE!
Poor sensor operation and fluctuating pH values
during the process
The calibration method with an external sample has a
number of disadvantages compared with the buffer
solution calibration method. If the pH value fluctuates
significantly during the process, then the pH value may
change by a variable amount in the period between
sampling, sample measurement and entry of the pH
value into the controller. This could mean that the pH
value entered into the controller does not correspond
to the actual pH value in the process. Consequently
the result is a linear displacement of the pH value
across the entire measuring range.
If the pH sensor no longer reacts to changes in the pH
value and only gives out a constant uniform mV signal,
this cannot be detected using the calibration method
with an external sample. With the calibration method
with two buffers (e.g. pH 7 and pH 4), this becomes
apparent if the pH sensor does not detect any changes
in the pH value.
The calibration method with an external sample should
only be used with installations where there is poor
access to the pH sensor and the identical or very uni‐
form pH values are used in the process. In addition the
pH sensor should be regularly serviced or replaced.

– Correct measuring, control and metering is only
possible if the sensor is working perfectly
Evaluation Zero point Slope

Good -45 mV … +45 mV 56 mV/pH … 61 mV/pH
91
CAL pH
Zero point
Slope
CAL setup
Calibration process Sample (1-point)
Buffer temperature Manual
continue with <CAL>
A1023

1. Continue with
2. Take a water sample at the in-line probe housing and, using
a suitable method (measuring strips, hand measuring instru‐
ment), measure the pH value of the sample
CAL pH
1) Take sample
2) Determine pH value
pH value
Change with <OK> continue with <CAL>

A1022
Fig. 53: Instructions for determining the pH value using the

[Sample] method
3. Press
4. Use the arrow keys to enter the pH value you have deter‐
mined in the controller
5. Press
6. Accept the pH value by pressing
ð All the values of the calibration result are shown in the
display.
92
An error message appears if the result of the calibra‐
tion lies outside the specified tolerance limits. In this
case, the current calibration is not applied.
Check the prerequisites for calibration and clear the
error. Then repeat calibration.
7. Transfer the result of the calibration into the controller

memory by pressing
17.1.1.4 Calibration of the pH Sensor (CAL) by [Data Input]
Data input
Using the
[Calibration of the pH sensor (CAL) by data input] cali‐
bration method, the sensor's known data is entered
into the controller. Calibration by data input is only as
accurate and reliable as the method with which the
data was determined.
The sensor data must have been determined in real-
time. The more up-to-date the sensor data is, the more
reliable is this calibration method.


during calibration
calibration.
Evaluation Zero point Slope

Good -45 mV … +45 mV 56 mV/pH … 60,5 mV/pH
93
CAL pH
Zero point 7,00 pH
Slope 59.16 mV/pH
CAL setup
Calibration process Data input

1. Continue with
CAL pH
Slope -58.07 mV/pH
at 25.0 °C
Asymmetry -6.4 mV
at 25.0 °C
or
Zero point 6.88 pH
at 25.0 °C
Fig. 55: Selection of the settable parameters

2. Use the arrow keys to select the required menu item and
press
ð The entry window appears.
3. Enter the values for your sensor using the arrow keys and
press
4. Continue with
An error message appears if the result of the calibra‐
tion lies outside the specified tolerance limits. In this
case, the current calibration is not applied.
error. Then repeat calibration.

memory by pressing
94
17.1.2 Calibrating the ORP Sensor

17.1.2.1 Selecting the calibration process for ORP
Selecting the calibration process There are two calibration processes available for calibrating the
controller:
n 1-point (with buffer solution)
n Data input
1. Continuous display ➨
CAL ORP
Offset 0.0 mV
CAL setup

Pot. equalisation No
continue with <CAL>

A1027
Fig. 56: [ORP] calibration menu

ð The calibration menu is displayed.
2. Use to select the Setup menu or start calibration by
pressing
Selecting the calibration process 3. [CAL Setup]: Press
ð The menu for selecting the calibration process appears.
4. Using the arrow keys select the required menu item
[Calibration process] and press
ð The input window appears.
5. Use the arrow keys to select the calibration process and
press
6. Continue with
17.1.2.2 1-point calibration of ORP sensor (CAL)

housing
95
ORP sensor calibration

The ORP sensor cannot be calibrated. Only an
[OFFSET] deviation of magnitude ± 40 mV can be set
and thus compensated. If the ORP sensor deviates by
more than ± 40 mV from the reference value, then it
must be checked in accordance with the requirements
of the sensor operating instructions.

during calibration
calibration.
Buffer used
Dispose of the used buffer solution. For more informa‐
tion: refer to the buffer solution safety data sheet.
You need one test container with a buffer solution for calibration.
CAL ORP
Offset 0.0 mV
CAL setup

Pot. equalisation No
continue with <CAL>

A1027
Fig. 57: 1-point calibration of ORP sensor (CAL)

1. Continue with
96
CAL ORP
Immerse sensor in buffer
continue with <CAL>

A1028
Fig. 58: 1-point calibration of ORP sensor (CAL)

2. Carry out the instructions and then press
CAL ORP
Sensor calibration in buffer
The stability is:

detected.
4. Continue with
CAL ORP
Buffer value 165 mV
Offset 0.0 mV
Fig. 60: Adjusting the buffer value

5. Press and use the four arrow keys to adjust the mV value
of the buffer you are using
97
6. Press
memory by pressing
ð The controller operates with the calibration results.
17.1.2.3 Calibration data for ORP sensor (CAL)

housing
ORP sensor calibration

The ORP sensor cannot be calibrated. Only an
‘OFFSET’ deviation of magnitude ± 40 mV can be set
and thus compensated. If the ORP sensor deviates by
more than ± 40 mV from the reference value, then it
must be checked in accordance with the requirements
of the sensor operating instructions.

during calibration
calibration.
98
CAL ORP
Offset 0.0 mV
Last calibration 21.05.2013 14:59:56
CAL setup
Calibration process Data input offset
continue with <CAL>

A1032
Fig. 61: Data input, ORP sensor calibration (CAL)

1. Continue with
CAL ORP
Offset 0.1 mV
Fig. 62: Adjusting the [Offset]

2. Press and use the four arrow keys to adjust the mV value
of the buffer you are using
3. Press
memory by pressing
ð The controller operates with the calibration results.
17.1.3 Calibrating the Fluoride Sensor

17.1.3.1 Selection of the calibration process for fluoride
To calibrate the controller there are two available calibration pro‐
cesses:
n 1 point
n 2 point
99
Calibration process selection 1. Continuous display ➨
CAL F-
1 ppm = 185.0 mV 16:51:18
11/11/2011
Slope -59.16 mV/dec 11:11:11
100 % 11/11/2011
Single point calibration
Two point calibration
A1037
Fig. 63: Calibration menu [Fluoride]

2. Using the arrow keys select the desired menu item. Press the
key
ð You can now start the selected calibration process.
17.1.3.2 2-point fluoride sensor calibration (CAL)

– The carrying out of a 2-point calibration is strongly
recommended and is to be preferred to other
methods
– For calibration the sensor must be removed and
refitted in the in-line probe housing. To do this,
observe the operating instructions of your in-line
probe housing
Material required for calibration of fluoride sensors:

n Two test containers with calibrating solution

during calibration
calibration.
100
Used calibration solution

Dispose of the used calibration solution. For more
information: see calibration solution safety data sheet.
Two test containers with a calibration solution are required for cali‐
bration. The fluoride content of the calibrating solutions should be
at least 0.5 ppm F- apart from each other. The sensor should be
rinsed thoroughly with fluoride-free water when changing the cali‐
brating solution.
1. Press the key in the continuous display.
2. Using the arrow keys select [Two point calibration]
3. Then press
CAL F-
Immerse sensor in buffer 1
Sensor value 2.50 ppm

Start with <CAL>

A1038
Fig. 64: Fluoride sensor calibration (CAL)

4. Immerse the sensor in test container 1 with calibration solu‐
tion. When doing so gently move the sensor
5. Then press
ð [Calib. in progress] .
CAL F-
A1040

6. Then press to change the ppm value or press to con‐
tinue with the calibration
7. Then press
101
CAL F-
Immerse sensor in buffer 2
Start with <CAL> A1041

9. Then press
10. Then press to adjust the ppm value or press to con‐
11. Then press
12. Import the result of the calibration into the controller memory
by pressing the key
Should the result of the calibration lie outside
the specified tolerance limits, an error mes‐
sage appears. In this case the current cali‐
bration will not be applied.
Check the prerequisites for the calibration
and clear the error. Then repeat the calibra‐
tion
17.1.3.3 1-point fluoride sensor calibration (CAL)

– The carrying out of a 2-point calibration is strongly
recommended and is to be preferred to other
methods
– For calibration the sensor must be removed and
refitted in the in-line probe housing. To do this,
observe the operating instructions of your in-line
probe housing
102
Material required for calibration of fluoride sensors:

n One test container with calibration solution

during calibration
calibration.
Used calibration solution

Dispose of the used calibration solution. For more
information: see calibration solution safety data sheet.
One test container with calibration solution are required for calibra‐
tion.
2. Using the arrow keys select [Single point calibration]
3. Then press
CAL F-
Immerse sensor in buffer

Start with <CAL>

A1042

5. Then press
103
CAL F-
A1043

6. Then press to change the ppm value or press to con‐
7. Then press
by pressing the key
tion
17.1.4 Calibrating Amperometric Sensors
Calibrating Amperometric Sensors

The process for calibrating amperometric sensors is
identical with all amperometric measured variables.
The process for calibrating amperometric measured
variables is described throughout based on the meas‐
ured variable chlorine [Cl]. All other measured varia‐
bles require the same process as the measured vari‐
able chlorine [Cl].
The following measured variables can be calibrated
using the process described here:
– Chlorine
– Chlorine dioxide
– Bromine
– Chlorite
– Ozone
– Peracetic acid (PES)
– H2O2
104
Calibration combining pH and chlorine

It is imperative that you always calibrate the pH meas‐
urement first before the chlorine measurement. The
chlorine measurement always needs to be calibrated
any further time the pH measurement is calibrated.
Otherwise the chlorine measurement will be inaccu‐
rate.
17.1.4.1 Selecting the calibration process for amperometric measured variables

There are two calibration processes available for calibrating the
controller:
n Calibrating the slope
n Calibrating the zero point
Selecting the calibration process 1. Continuous display ➨
CAL Cl
Last calibration 31.03. 2013 13:11:11
Slope 100 %
Zero point 4.00 mA
Slope calibration
Calibration of zero point
A1039
Fig. 69: [Chlorine] calibration menu

2. Use the arrow keys to select the chosen menu item. Press
105
17.1.4.2 Calibrating the slope
CAUTION!
Correct sensor operation / Run-in period
– Please read the operating manual for the sensor
– Please also read the operating manuals for the fit‐
tings and other components used
– It is imperative that the run in periods of the sen‐
sors are adhered to
– The run in periods should be allowed for when
planning commissioning
– It may take an entire working day to run in the
sensor

during calibration
calibration.
The measured value frozen at the start of calibration is suggested

as a reference value. The reference value can be set using the
arrow keys. Calibration is only possible if the reference value is ≥ 2
% of the measuring range of the sensor.
NOTICE!
Prerequisites for correct calibration of the sensor slope
– The reference method needed is used, depending
on the feed chemical used (e.g. DPD 1 for free
chlorine).
– The run-in period for the sensor has been com‐
plied with; refer to the operating instructions for the
sensor.
– There is permitted and constant flow at the in-line
probe housing
– There is temperature balance between the sensor
and the sample water
– There is a constant pH value in the permitted
range
Material required for calibration of amperometric sensors:

n A reference method suitable for the measured variable in ques‐
tion
106
Remove sample water directly at the measuring point and deter‐

mine the content of the feed chemical in the sample water in [ppm]
using an appropriate reference method (e.g. DPD, titration etc.).
Enter this value into the controller as follows:
1. Press in the continuous display.
2. Use the arrow keys to select [Slope calibration]
3. Continue with
CAL Cl
Latest sensor measured values
Concentration
Sensor current
1) Wait until meas values stable

2) Take sample and continue with <CAL>
A1044
Fig. 70: Reference value calibration shows the actual sensor

values
4. Continue with
CAL Cl
Determine reference value
Measured value upon sampling

A1045
Fig. 71: Reference value calibration, the sensor value is frozen

here; now take the sample and measure using DPD, for example
5. Then press to adjust the ppm value or press to con‐
107
CAL Cl
Calibration successful
Slope
Zero point
continue with <CAL>

A1047
Fig. 72: Calibrating the reference value

memory by pressing
An error message appears if the result of the
calibration lies outside the specified tolerance
limits. In this case, the current calibration is
not applied.
Check the prerequisites for calibration and
clear the error. Then repeat calibration
Permitted calibration range

The permitted calibration range is 20 ... 300% of the
sensor's rated value.
Example of a shallow slope: Blocking of the sensor
membrane leads to a low slope (low slope = low
sensor sensitivity)
Example of a steep slope: Surfactants make the
sensor membrane more permeable, leading to a
steeper slope (steep slope = high sensor sensitivity)
17.1.4.3 Calibration of zero point
Necessity for calibrating the zero point

Calibration of the zero point is not generally necessary.
A calibration of the zero point is only necessary if the
sensor is operated at the lower limit of the measuring
range or if the 0.5 ppm sensor version is used.
108
CAUTION!
sors are adhered to
sensor

during calibration
calibration.
NOTICE!
Prerequisites for a correct calibration of the sensor
zero point
– The run in period for the sensor has been adhered
to
– There is permitted and constant flow at the in-line
probe housing
– There is temperature balance between the sensor
and the sample water
– There is a constant pH value in the permitted
range

2. Using the arrow keys select the [Zero point]
3. Then press
109
CAL Cl
Zero point
Range
Accept with <CAL>

A1046
Fig. 73: Calibration of zero point

4. Then press
CAL Cl
Slope
Zero point
continue with <CAL>

A1048
Fig. 74: Calibration of zero point

by pressing the key
tion
17.1.5 Calibrating Oxygen Sensors

Specifying the calibration interval The calibration interval depends heavily on:
n the application
n the installation location of the sensor
110
If you wish to calibrate a sensor for a special application and/or a

special installation location, then you can determine the calibration
intervals using the following method. Check the sensor, e.g. one
month after commissioning:
1. Remove the sensor from the medium
2. Clean the outside of the sensor with a damp cloth
3. Then gently dry the sensor membrane for example using a
paper towel
4. After 20 minutes measure the oxygen saturation index in the
air
5. Protect the sensor from external influences, such as sunlight
and wind
ð Now decide depending on the expected result:
Amperometric sensor: Calibrate the sensor if the meas‐
ured value is not 102 ± 2 %SAT.
If the value is within the setpoint range, then you can
extend the calibration interval. Repeat this process
monthly and determine the optimum calibration interval
for your application from the results.
Calibration specifications of the sensor man‐

ufacturer
When determining the calibration interval,
also take into consideration the operating
instructions for the sensor, which may offer
additional and/or different calibration inter‐
vals.
17.1.5.1 Selection of the calibration process for the measured variable O2

To calibrate the controller there are three available calibration pro‐
cesses:
n automatic
n DO value
n Zero point
Calibration process selection 1. Continuous display ➨
CAL DO
Zero point
Slope
automatic
DO value
Zero point
A1049
Fig. 75: Calibration menu [DO]

111
2. Using the arrow keys select the desired menu item. Press the
key
ð You can now start the selected calibration process.
17.1.5.2 Selection of the calibration process for the measured variable DO
CAUTION!
sors are adhered to
sensor

during calibration
calibration.

2. Using the arrow keys select [automatic]
3. Then press
112
CAL DO
Water temp.
Adjusting the concentration
Air temperature
Air pressure
higher than
Sea level
Relat. humidity
Salinity of the
Water
Fig. 76: Selection of the calibration process for the measured vari‐
able DO
4. Then press to adjust the values or press to continue
with the calibration
CAL DO
Sensor head up
Minimum waiting time 5 min
Time: XX.XX min
continue with <CAL>

A1075
Fig. 77: Selection of the calibration process for the measured vari‐
able DO
5. Hold the DO sensor head up in the ambient air.
ð The calibration takes place. The elapsed time is dis‐
played. The minimum waiting time for a correct calibra‐
tion is 5 minutes
6. Press the key to import the result of the calibration into the
memory of the controller
and operates with the results of the calibration.
tion
113
17.1.5.3 Zero point calibration for the measured variable DO
CAUTION!
sors are adhered to
sensor

during calibration
calibration.

2. Using the arrow keys select [Zero point]
3. Then press
CAL DO
Water temp.
Air temperature
Air pressure
higher than
Sea level
Relat. humidity
Salinity of the
Water
Fig. 78: Zero point calibration for the measured variable DO

114
CAL DO
Zero point
Range
Accept with <CAL>

A1079

5. Then press
CAL DO
Slope
Zero point
continue with <CAL>

A1080

6. Press the key to import the result of the calibration into the
memory of the controller
and operates with the results of the calibration.
The controller displays the continuous display again and
tion
115
17.1.5.4 DO value calibration for the measured variable DO
CAUTION!
sors are adhered to
sensor

during calibration
calibration.

2. Using the arrow keys select [DO value]
3. Then press
CAL DO
Water temp.
Air temperature
Air pressure
higher than
Sea level
Relat. humidity
Salinity of the
Water
Fig. 81: DO value calibration for the measured variable DO

116
CAL DO
DPD value

Sensor current 8.03 mA
Start with <CAL>

A1076

5. Then press
CAL DO
1) Take sample
2) Determine DPD value
7.04 ppm

A1077

6. Take a water sample and determine the DPD value with a
suitable measuring instrument.
117
CAL DO
Slope
Zero point
continue with <CAL>

A1078

by pressing the key
tion
17.1.6 Measured value [mA general] calibration
Measured value [mA general] calibration

The measured value [mA general] cannot be cali‐
brated, this menu item is shown ‘greyed out’ and has
no purpose.
17.1.7 Calibrating conductivity

during calibration
calibration.
118
You may need a manual measuring instrument for the conductivity

measured variable. This manual instrument should measure and
display sufficiently accurately to guarantee successful calibration.
2. Use the arrow keys to select [Calibrate slope]
3. Then press
4. Follow the instructions in the controller display and perform
calibration
5. Then press
6. Then press to adjust the µS/cm value or press to con‐
tinue with calibration
CAL Cl
Slope
Zero point
continue with <CAL>

A1047
Fig. 85: Calibrating the reference value

by pressing
ð The controller shows the continuous display again and
limits. In this case the current calibration is
not carried over.
eliminate the error. Then repeat calibration.
119
17.1.8 Calibrating temperature

during calibration
calibration.
You may need a manual measuring instrument for the temperature

measured variable. This manual instrument should measure and
display sufficiently accurately to guarantee successful calibration.
2. Then press
3. Follow the instructions in the controller display and perform
calibration
4. Then press
5. Then press to adjust the value or press to continue with
calibration
by pressing
ð The controller shows the continuous display again and
limits. In this case the current calibration is
not carried over.
eliminate the error. Then repeat calibration.
120
Calibrating the Compact Controller for Conductive Conductivity
18 Calibrating the Compact Controller for Conductive Conduc‐

tivity
18.1 Calibrating [CAL] the conductivity sensor
The following calibration functions are available depending on the
type of sensor:
n Calibration of the cell constant
n Calibration of the temperature coefficient

– Observe the operating instructions for the sensor
An error message ‘ERR’ appears if the result of the
calibration lies outside the specified tolerance limits. In
this case the current calibration is not applied.
error. Then repeat calibration
In the event of repeated calibration failure, observe the
notes given in the sensor operating instructions.
During calibration, the controller sets the control outputs to ‘0’ .

Exception: If a basic load or a manual control variable has been
set. This remains active. The mA standard signal output is frozen.
When calibration has been completed successfully, all of the error
checks relating to the measured value are restarted. The controller
saves the data determined for the cell constant and temperature
coefficient when the calibration is successful.
The conductivity sensors can be calibrated using 3 different
methods. The cell constant is adjusted directly or indirectly in all
methods:
n Calibration compared to a reference solution
n Calibration compared to a reference measurement (e.g.
manual measuring device)
n Calibration by entering a precisely known or determined cell
constant
121
18.1.1 Calibration of the cell constant
CAL
CELLCONST
TCOEFF
CAL CELLCONST
TCoeffCAL 1.90%/°C
CAL CELLCONST
COND= 43,2µS/cm @25°C
CAL_T= 155.0 °C
CAL=CONTINUE
CAL CELLCONST@25°C
COND= 043,975 µS/cm
CAL CELLCONST
CELLC 1.0000cm-1 OK
CAL=ACCEPT
A1625
Fig. 86: Calibration of the cell constant

Calibration compared to a calibration 1. Press and move the cursor using the or key to
solution [CELLCONST] and confirm with .
2. Enter the temperature coefficient of the calibration solution.
The temperature coefficient of the calibration sol‐

ution is specified on the storage tank for the cali‐
bration solution. ProMinent's calibration solution
has a temperature coefficient of 2% /K.
Confirm with .
3. Now dip the sensor into the calibration solution and gently
move the sensor.
4. Wait until the conductivity and temperature measured value
has stabilised.
Press .
ð The conductivity value measured is displayed.
5. Now enter the conductivity value measured using the , or
keys, in accordance with the conductivity value specified
on the calibration solution.
ð If calibration has been completed successfully, the con‐
troller stores the determined values for the cell constant
and the error checks relating to the measured value are
restarted. The numerical setting range of the cell con‐
stant is not limited.
6. Press twice to return to the continuous display.
122
Calibration compared with a reference

measurement (e.g. manual measuring Temperature coefficient of the measuring solution
device) The temperature coefficient of the measuring solution
has to be known.
1. Press , leaving the sensor in the application in which the

sensor is fitted.
2. Move the cursor using the or key to [CELLCONST] and
confirm with .
3. Enter the temperature coefficient of the measuring solution.
Confirm with .
4. Press .
5. Now enter the conductivity value displayed using the ,
or keys, in accordance with the reference value measured.
Calibration by entering a precisely

known cell constant
1. Press and move the cursor using the or key to
[INPUT]
Confirm with .
2. Move the cursor using the or key to [CELLC].
Confirm with .
3. Now adjust the precisely known or previously determined cell
constant using the , or keys.
Confirm with .
Sensor status
Display Meaning Status

[OK] In order Cell constant = 0.005 / 15.0
[WRN] Warning none
[ERR] Error Cell constant < 0.005 or cell constant > 15
123
18.1.2 Calibration of the temperature coefficient
Conductivity sensors with temperature element

You can only calibrate the temperature coefficient with
conductivity sensors with a temperature elements,
because it is impossible to calculate the temperature
coefficient without measuring the temperature.
Temperature change
It is recommended that the temperature is changed by
no more than 0.5 °C per minute, or with a temperature
change of e.g.10°C you will need to wait for a min‐
imum of 20 minutes before calibration.
124
CAL
CELLCONST
TCOEFF
CAL TEMPCOEFF
CAL_T1= 22.0 °C
CAL=CONTINUE
CAL TEMPCOEFF
CHANGE TEMP
T2 > 32.0 °C or
T2 < 12.0 °C
I.
CAL TEMPCOEFF
WAIT
T2 > 32.0 °C or
T2 < 12.0 °C
II.
CAL TEMPCOEFF
STABLE ?
CAL_T2= 43.0 °C
CAL=CONTINUE
III.
CAL TEMPCOEFF
ACCEPT ?
CAL_T2= 43.0 °C
CAL=CONTINUE
CAL TEMPCOEFF
TCOEFF=0.00%/°C
CAL=OLD
A1626
Fig. 87: Calibration of the temperature coefficient

I. If the temperature change is greater than 2°C,
the note changes to [WAIT]
II. If the temperature is within the specified range,
the note changes to [STABLE]
III. When a stable final temperature has been
reached, the note changes to [ACCEPT?] Cali‐
bration can now be terminated manually.
1. Calibrate at the first calibration temperature calibration tem‐
perature; this calibration temperature should be close to the
selected reference temperature.
2. Press [CAL] to accept the first calibration point. At the same
time the temperature ranges for the second temperature
value are given.
3. Note: [CHANGE TEMP], now immerse the sensor in the
same liquid with the second calibration temperature (min‐
imum temperature difference ± 10°C)
4. If the measured temperature has changed by more than
2°C , [WAIT] displayed.
125
5. If the temperature has changed by more than 10°C,

[STABLE?] is displayed, and you can now terminate calibra‐
tion if the displayed temperature value no longer changes. To
do so, press [CAL].
6. When the Maximum/Minimum temperature has been
reached, [ACCEPT?] is displayed
ð You can now terminate calibration. To do so, press
[CAL].
This process may take 10 ... 20 minutes

depending on the type of sensor.
7. Use [CAL] to accept the temperature coefficient or [ESC] to

discard it
Sensor status

[OK] In order ΔTkal > 20 °C
[WRN] Warning ΔTkal = 10 °C…20 °C
[ERR] Error ΔTkal < 10 °C
ΔTkal = Temperature difference of the calibration liquids
126
Calibrating the Compact Controller for Inductive Conductivity
19 Calibrating the Compact Controller for Inductive Conductivity

19.1 Calibrating [CAL] the conductivity sensor
The following calibration functions are available depending on the
type of sensor:
n Calibration of the cell constant
n Calibration of the temperature coefficient
n Calibration of the zero point

– Refer to the operating instructions for the sensor
An error message ‘ERR’ appears if the result of the
calibration lies outside the specified tolerance limits. In
this case the current calibration is not applied.
error. Then repeat calibration
In the event of repeated calibration failure, refer to the
information given in the sensor operating instructions.
During calibration, the controller sets the control outputs to ‘0’ .

Exception: If a basic load or a manual control variable has been
set. This remains active. The mA standard signal output is frozen.
When calibration has been completed successfully, all the error
checks relating to the measured value are restarted. The controller
saves the data determined for the cell constant and temperature
coefficient when calibration is successful.
The conductivity sensors can be calibrated using 3 different
methods. The cell constant is adjusted directly or indirectly with all
methods:
n Calibration compared to a reference solution
n Calibration compared to a reference measurement (e.g.
manual measuring device)
n Calibration by entering a precisely known or determined cell
constant
127
19.1.1 Calibration of the cell constant
CAL
CELLCONST
TCOEFF
ZERO
CAL CELLCONST
TCoeffCAL 1.90%/°C
CAL CELLCONST
COND= 43,2µS/cm @25°C
CAL_T= 155.0 °C
CAL=CONTINUE
CAL CELLCONST@25°C
COND= 043,975 µS/cm
CAL CELLCONST
CELLC 1.0000cm-1 OK
CAL=ACCEPT
A1865
Fig. 88: Calibration of the cell constant

Calibration compared to a calibration 1. Press and use the or key to move the cursor to
solution [CELLCONST] and confirm with .
2. Enter the temperature coefficient of the calibration solution.
The temperature coefficient of the calibration sol‐

ution is specified on the storage tank for the cali‐
bration solution.
Confirm with .
3. Now dip the sensor into the calibration solution and gently
move the sensor.
4. Wait until the conductivity and temperature measured value
has stabilised.
Press .
5. Now use the , or keys to set the conductivity value
measured, in accordance with the conductivity value speci‐
fied on the calibration solution.
128
Calibration compared with a reference

measurement (e.g. manual measuring Temperature coefficient of the measuring solution
device) The temperature coefficient of the measuring solution
has to be known.
1. Press , leaving the sensor in the application in which the

sensor is fitted.
2. Use or key to move the cursor to [CELLCONST] and
confirm with .
3. Enter the temperature coefficient of the measuring solution.
Confirm with .
4. Press .
5. Now use the , or keys to enter the conductivity value
displayed, in accordance with the reference value measured.
Calibration by entering a precisely

known cell constant
1. Press and use the or key to move the cursor to
[INPUT]
Confirm with .
2. Use the or key to move the cursor to [CELLC].
Confirm with .
3. Now use the , or keys to adjust the precisely known
or previously determined cell constant.
Confirm with .
Sensor status

[OK] In order Cell constant = 0.005 / 99.9
[WRN] Warning none
[ERR] Error Cell constant < 0.005 or cell constant > 100
129
19.1.2 Calibration of the temperature coefficient
Conductivity sensors with temperature element

You can only calibrate the temperature coefficient with
conductivity sensors with a temperature element,
because it is impossible to calculate the temperature
coefficient without measuring the temperature.
Temperature change
It is recommended that the temperature is changed by
no more than 0.5 °C per minute, or with a temperature
change of e.g. 10 °C you will need to wait for a min‐
imum of 20 minutes before calibration.
130
CAL
CELLCONST
TCOEFF
CAL TEMPCOEFF
CAL_T1= 22.0 °C
CAL=CONTINUE
CAL TEMPCOEFF
CHANGE TEMP
T2 > 32.0 °C or
T2 < 12.0 °C
I.
CAL TEMPCOEFF
WAIT
T2 > 32.0 °C or
T2 < 12.0 °C
II.
CAL TEMPCOEFF
STABLE ?
CAL_T2= 43.0 °C
CAL=CONTINUE
III.
CAL TEMPCOEFF
ACCEPT ?
CAL_T2= 43.0 °C
CAL=CONTINUE
CAL TEMPCOEFF
TCOEFF=0.00%/°C
CAL=OLD
A1866
Fig. 89: Calibration of the temperature coefficient

I. If the temperature change is greater than 2°C,
the message changes to [WAIT]
II. If the temperature is within the specified range,
the message changes to [STABLE ?]
III. When a stable final temperature has been
reached, the message changes to [ACCEPT?].
Calibration can now be terminated manually.
1. Calibrate at the first calibration temperature calibration tem‐
perature; this calibration temperature should be close to the
selected reference temperature.
2. Press [CAL] to accept the first calibration point. At the same
time the temperature ranges for the second temperature
value are given.
3. Important note: [CHANGE TEMP], now immerse the sensor
in the same liquid with the second calibration temperature
(minimum temperature difference ± 10 °C)
4. If the measured temperature has changed by more than
2 °C, [WAIT] is displayed.
131
5. If the temperature has changed by more than 10 °C,

[STABLE?] is displayed, and you can now terminate calibra‐
tion if the displayed temperature value no longer changes
(fluctuation < 0.3% of the value displayed). To do so, press
[CAL].
6. When the Maximum/Minimum temperature has been
reached, [ACCEPT?] is displayed
ð You can now terminate calibration. To do so, press
[CAL].
This process may take 10 ... 20 minutes

depending on the type of sensor.
7. Use [CAL] to accept the temperature coefficient or [ESC] to

discard it
Sensor status

[OK] In order [ΔTcal] > 20 °C
[WRN] Warning [ΔTcal] = 10 °C…20 °C
[ERR] Error [ΔTcal] < 10 °C
[ΔTcal] = Temperature difference of the calibration liquids
19.1.3 Calibration of the zero point
Dry the sensor and keep it free from electromagnetic

fields
If the zero point of the sensor is to be calibrated, it is
necessary to remove, rinse and dry the sensor before
calibration. No electromagnetic fields can influence the
sensor as these electromagnetic fields could distort
calibration. Keep devices that transmit radiation far
from the sensor, such as mobile phones, WLAN
routers, sources of high voltage, transformers etc.
132
CAL
CELLCONST
TCOEFF
ZERO
CAL ZERO
Put LF-Sensor
in air
CAL=ACCEPT
CAL ZERO
SENSOR= 762.µS
STABLE (10 sec)?
CAL=ACCEPT
CAL ZERO
ZERO = 710.793 µS
CAL=ACCEPT OK=RESET
A1942
Fig. 90: Calibrating the zero point / The [CAL] [ZERO] default value corresponds to the default value of the
sensor selected.
Zero point calibration limits
Sensor Value
ICT1 65 uS
ICT2 4 uS
CLS52 4 uS
Manual 50 uS
Calibrating the zero point 1. Press , removing the sensor from the application in which it
is fitted.
2. Rinse the sensor with clean water and dry it.
3. Use the or key to move the cursor to [ZERO] and con‐
firm with .
4. Hold the sensor in the air.
Press .
5. Wait for the process [WAIT ...]
ð [STABLE (10 sec)?] = The value displayed needs to be
displayed stably for longer than 10 seconds. (Fluctuation
< 0.5% of the displayed value).
6. Press .
7. Press , or
Press if you wish to use the [ZERO] default value and then
press .
ð The new value for the zero point is carried over into the
memory and the controller shows the continuous display
again.
133
CAL ZERO
ZERO = 373.793 µS ERR
CAL=OLD OK=RESET A1945
Fig. 91: Display of incorrect calibration

8. In the event of incorrect calibration, press to retain the old
calibration value and press to use the factory settings.
134
Maintenance
20 Maintenance
WARNING!
findings.
WARNING!
Live parts
Measures:
– Disconnect the system from the power supply
before opening the housing of a component.
– If the housing of the pump, controller, terminal box
or other component is broken, ruptured or obvi‐
ously damaged, immediately switch off the system
and arrange for its repair.
exception to this. This work can be carried out
while the system is live. Please also observe the
information in the operating instructions for the
sensors and controllers.
closing the housing of the pump, controller or ter‐
minal box
CAUTION!
–
135
Maintenance
These parts of the DULCOTROL® measuring/control station

require the following maintenance:
Part Maintenance Frequency

With continuous flow through the installation
Parts through which sample water Check for leaks According to the internal specifica‐
flows tion of the system operator
Flow control Test the flow control
n Record the flow value
n Lower the flow - the controller
should switch to "Pause"
n Readjust the recorded flow
value.
With a flushed and depressurised installation
Sample water pump See operating instructions in the See operating instructions in the
appendix appendix
Filter Clean, if not possible replace car‐ As necessary, depending on the
tridge degree of dirt in the sample water.
V82 pressure reducer See manufacturer's instructions in See manufacturer's instructions in
the appendix the appendix
Honeywell pressure reducer See manufacturer's instructions in See manufacturer's instructions in
the appendix the appendix
Sensor Maintenance: See the sensor See the sensor operating instruc‐
operating instructions tions
Bypass fitting DLG Unscrew the cup and clean the According to the internal specifica‐
sensors tion of the system operator
20.1 DGMa: Replacing the Modules
WARNING!
findings.
1. Close the ball valve in the feed of the in-line probe housing
2. Close the shut-off valve in the outlet of the in-line probe
housing
136
Maintenance
3. Unscrew the sensors and store the sensors as described in

the operating instructions for the sensors
4. Remove all hoses from the in-line probe housing
5. Unscrew all modules and loosen the modules from the
holding clips
6. Drain the modules
7. Loosen the module to be replaced from the module block
8. Check whether all O-rings are correctly fitted
27
0°
I. II. III. A1249
Fig. 92: Replacing/adding modules

I. Position (front view)
II. Turn clockwise (side view)
III. Finished (front view)
9.
Make sure that all the arrows on the modules
point in the same direction.
Reposition the modules if they do not screw
easily into each other.
The connection will otherwise become loose and
will no longer be able to be loosened without
damage.
Position the new module on the module block

10. Turn the module clockwise until it hangs vertically down‐
wards
11. Fit the complete new module block
12. Close the drain nozzle and the sampling tap
13. Screw in the sensors and calibrate if necessary, referring to
the operating instructions for the sensors
14. Fit all hoses on the in-line probe housing
15. Open the ball valve a little and check the leak-tightness of the
corresponding module before fully opening the ball valve
16. Adjust the flow
137
Maintenance
20.2 Flushing the Bypass Fitting with Pipework

When do you have to flush the fitting? You have to flush the fitting
when:
n There is insufficient flow
n The sensors deliver incorrect measured values caused by con‐
tamination
n For decontamination purposes before maintenance
n Preventative maintenance.
3.
2.
1.
A2113
Fig. 93: Flushing the bypass fitting with pipework

1. Rinsing water inlet
2. Rinsing and sample water outlet
3. Sample water input
138
Maintenance
Nameplate / System pressure

Set the system pressure stated on the nameplate
during flushing but do not exceed it. Use a pressure
reducer if necessary.
Do not allow sample water to enter the flushing pipe
feed. Take appropriate self-sealing technical measures
to prevent backwashing.
1. Make sure that the waste water line is sufficiently large in the
direction of the flushing and sample water outlet (2) to enable
the rinsing water to drain away properly.
2. Make sure that the rinsing and sample water outlet is fully
open.
3. Close the sample water inlet (3).
4. Open the rinsing water inlet (1).
ð The bypass fitting with pipework is flushed.
5. Close the rinsing water inlet (1).
6. Open the sample water inlet (3).
ð The bypass fitting with pipework is flushed and once
again operational.
7. Check the flow and use the ball valves (1 and 3) to adjust the
flow if necessary.
139
Troubleshooting
21 Troubleshooting
CAUTION!
sensors, sample water pumps ... !
– Adhere to the material safety data sheets for the
media used in your process!
NOTICE!
– With terminal boxes: A wiring diagram is enclosed
in the documentation for the DULCOTROL® meas‐
uring/control station.
Fault Cause Remedy

No or insufficient sample water Filter blocked Clean or replace the filter. See
flow manufacturer's documentation
(Flow meter shows no or too low a Sample water pumps not working Check and, as necessary, repair
flow) or working incorrectly the electrical power supply. See
wiring diagram.
Mechanical causes: See manufac‐
turer's documentation
Blockage of the pipework system Check the pipework system and
clean as necessary
Defective metering and control Controller with no or without suffi‐ Check and, as necessary, repair
performance cient functionality the electrical power supply. See
wiring diagram and controller
operating instructions
Defective or incorrectly calibrated Refer to the operating instructions
sensors for the sensor and controller
Check and, as necessary, repair
the electrical power supply. See
wiring diagram
Power failure, sensors in run in Stop the control and observe the
phase, therefore faulty measure‐ run in period for the sensors
ment
Incorrect composition and/or con‐ Adhere to the material safety data
centration of the feed chemical sheets for the media used in your
process! Check the quality and/or
quantity of the feed chemical and
correct as necessary
Incorrect allocation of the feed Check the feed chemical alloca‐
chemical tion and correct as necessary
Measuring errors Air in the system Bleed the system
Temperature outside of the speci‐ Install heat exchanger upstream
fication of the measuring point
Changed process parameters, Check the suitability of the sen‐
e.g. water quality sors
Pressure too high Fit a pressure reducer
140
Troubleshooting
Fault Cause Remedy

No sampling possible Negative pressure in the system Fully open inlet shut-off valve,
adjust flow at the outlet shut-off
valve.
Leakage Pressure too high Fit a pressure reducer
Leakage Repair leak
141
Decommissioning and Disposal
22 Decommissioning and Disposal

WARNING!
findings.
CAUTION!
– Only allow an electrical technician to disconnect
the measuring plate from the mains/power supply.
– Thoroughly rinse the sample water line with a suit‐
able medium (see material safety data sheet).
– Also necessary after brief decommissioning (up to
12 h): Observe the sensor operating instructions.
22.1 Temporary Decommissioning (Less Than 4 Weeks)
CAUTION!
With temporary decommissioning. Close the ball valves so

that the sensors remain surrounded by the sample water.
22.2 Temporary Decommissioning (Longer Than 4 Weeks)
CAUTION!
Unscrew the sensors and store the sensors properly, as

described in the operating instructions for the sensors.
142
Decommissioning and Disposal
22.3 Final Decommissioning

CAUTION!
– The electrolyte of the sensors can be corrosive.
– Capture any escaping electrolyte. Wear suitable
safety gloves and glasses, referring to the material
safety data sheet for the electrolyte.
– Dispose of waste water in an environmentally-
friendly manner.
NOTICE!
Regulations governing the disposal of used parts
– Note the current national regulations and legal
standards which apply in your country
The manufacturer will take back decontaminated used units pro‐

viding they are covered by adequate postage.
Decontaminate the unit before returning it for repair. To do so,
remove all traces of hazardous substances. Refer to the Material
Safety Data Sheet for your feed chemical.
A current Declaration of Decontamination is available to download
on the ProMinent website. Please also observe the information on
the current Declaration of Decontamination.
143
Technical Data and Operating Parameters
23 Technical Data and Operating Parameters

Permissible operating pressures
Application Type Sample water Operating pressure

Potable water (P) C0, C1, D0, I0, Z0, F0, H0, X0 1 1 bar at 45 °C
Potable water (P) G0, A0 1 3 bar at 45 °C
Potable water (P) P0, R0, L0 1 6 bar at 45 °C
Waste water (W) C0, C1, D0, I0, Z0, F0, H0, X0 2, 4, 5, 7 1 bar at 45 °C
Waste water (W) G0, A0 2, 4, 5, 7 3 bar at 45 °C
Waste water (W) X0 6 1 bar at 45 °C
Waste water (W) P0, R0, L0 6 6 bar at 45 °C
Definition of "sample water"
Water to be measured Description Definition

1 Potable water Drinking water in accordance with the
German Drinking Water Ordinance.
2 Rinsing water Process water with a low purity level (with
small particles of dirt, turbid appearance)
Process water
Industrial process water
4 Clear waste water Waste water with a low purity level (with
small particles of dirt and chemical pollu‐
tion)
5 Waste water with solid particle frac‐ Waste water with a low purity level (with
tion, turbid particles of dirt < 1 mm, floating bodies,
turbid and chemical pollution)
6 Waste water with solid particle frac‐ Municipal waste water with coarse impuri‐
tion, containing sludge ties; industrial waste water (from the
paper or metal industry), max. permitted
particles of dirt 3 mm and chemical pollu‐
tion
7 Waste water with fluoride and pH < 7 Waste water with a low purity level (with
small particles of dirt, turbid appearance)
Accuracy Refer to the specifications for the series components
Material specifications/Manufacturing Refer to the specifications for the series components. The pipe‐
processes/Chemical resistance work in the bypass is made of PVC fittings.
Electrical data The electrical components have a wide-voltage power supply and
can be operated at 100 ... 230 VAC, 50/60 Hz.
Electrical connection:
n 100 … 230 V 50/60 Hz
n 0.7 … 0.3 A
n 35 W
144
Temperature data Ambient temperature: +5 … +50°C

Medium temperature: max. sample water temperature 45 °C
Medium temperature: max. sample water temperature 35 °C (with
fluoride)
Climate Air humidity: max. 90 % relative air humidity, non-condensing.
Protection against contact and Degree of protection: IP 65

humidity (IP)
Transport weight The transport weight depends on the configuration of the meas‐
uring plate and is between 8 ... 13 kg.
Free flow / No overpressure or negative pressure

Make sure that there is no overpressure > 1 bar and
also no negative pressure at the outlet of the meas‐
uring plate. Overpressure damages the bypass fitting.
Negative pressure damages the sensors fitted. Use
the stopcocks to adjust the pressure at the sample
water inlet and outlet. Route the pipework so that the
sample water can drain unimpeded.
23.1 Flow and Operational Test of Flow Control

Set the ranges of the reed switch on the flow control DGMa and/or
DLG to Minimum and Maximum, switching the DACa from Opera‐
tion to Pause when doing so
Check:
n The wiring to the controller is correct
n The switching function of the flow sensor
n The correct configuration of the controller
n The alarm relay (e.g. horn)
Switching point of the flow control
Water to be Description Bypass fitting Nominal cross Permissible flow Control switches
measured section off
l/h
mm at l/h
1 Potable water DGMa 4 20 … 60 < 20
2 Rinsing water DLG III 6 40 … 65 < 20
Process water
Industrial
process water
4 Waste water, DLG III 6 40 … 65 < 20
clear
145
Water to be Description Bypass fitting Nominal cross Permissible flow Control switches
measured section off
l/h
mm at l/h
5 Waste water DLG III 6 40 … 65 < 20
with solid par‐
ticle fraction,
turbid
7 Waste water DLG III 6 40 … 65 < 20
with fluoride
and pH < 7
146
Spare Parts and Accessories
24 Spare Parts and Accessories

24.1 Spare Parts
Please also observe the lists in the operating instructions for con‐
trollers and fittings and any other units, such as sensors, sample
water pumps ... ! In addition, spare parts can be purchased from
our Service department.
The replacement diaLog DACa controller is supplied with a default
configuration. When commissioning the diaLog DACa controller,
the previous configuration of the old controller can be transferred
using the SD card.
Position number Quantity Description Part number

100 1 DACAPA61000000001000 1048190
100 1 DACAPA61000000101000 1048191
100 1 DACAPA61400000001000 1048192
100 1 DACAPA61400000101000 1048193
101 1 DCCAP006L3001000 1044468
101 1 DCCAP006L6001000 1044550
200 1 DGMA bypass fitting 1050374
201 1 Bypass fitting DLG III with backflushing 1050142
202 1 Bypass fitting DLG IV Dulcotrol 1050143
203 1 Filter 1050293
204 1 Fitting, flow meter 1050292
300 1 Fluoride sensor, FLEP-010/0100-SE 1028279
300 1 ORP sensor, REFP-SE 1018458
300 1 pH sensor, PHEF -012-SE 1010511
300 1 ORP sensor RHEP-Au-SE 1003875
300 1 Conductivity sensor, LFTK 1 DE 1002822
300 1 ORP sensor RHER-Pt-SE 1002534
300 1 pH sensor, PHEP -112 SE 1001586
300 1 ORP sensor RHEX-Pt-SE 305097
300 1 pH sensor PHEX -112 SE 305096
300 1 Temperature sensor, Pt-100-SE 305063
300 1 ORP sensor, RHEP-Pt-SE 150094
300 1 pH sensor, PHEP-112-SE 150041
301 1 Bromine sensor, BCR 1-mA- 1040115
301 1 Chlorine sensor, CBR 1-mA- 1038016
301 1 Chlorine sensor, CBR 1-mA- 1038015
301 1 Chlorine dioxide sensor CDR 1-mA-2 ppm 1033393
301 1 Hydrogen peroxide sensor, PER 1-mA-50 ppm 1030511
301 1 Hydrogen peroxide sensor, PER 1-mA-2000 p 1022510
147
Position number Quantity Description Part number

301 1 Hydrogen peroxide sensor, PER 1-mA-200 pp 1022509
301 1 PES sensor, PAA 1-mA-2000 p 1022507
301 1 PES sensor, PAA 1-mA-200 pp 1022506
301 1 Chlorite sensor, CLT 1-mA-0.5 ppm 1021596
301 1 Ozone sensor, OZE 3-mA- 2 ppm 792957
301 1 ClO2 sensor, CDE 2-mA-0.5ppm 792930
301 1 Chlorine sensor, CLE 3-mA-0.5ppm 792927
301 1 Chlorine sensor, CTE 1-mA-0.5ppm 740686
302 1 Transmitter, 4 ... 20 mA, FPV1 1028280
302 1 Transmitter, 4 ... 20 mA, FP100 1031331
303 1 Conductivity sensor ICT1 1023244
304 1 Thermal switch 7760491
305 1 Oxygen sensor, fully assembled 1031715
500 1 Magnetic stirrer 790915
501 * 1 Magnetic stirring rod, 15x6, PRFE 790917
502 * 1 SD card, industrial 732483
503 * 1 Coaxial cable, 0.8 m, SN 6, open end 1006410
504 * 1 Control cable, LiYY, 2 x 0.25 mm2 725122
505 * 1 Cable, complete, LFTK, 3 m, screened 1046012
506 * 1 Cable, control cable, 5 m, SN 6, open end 1003208
507 * 1 Filter element, FL-5-10 1031210
508 * 1 Filter element, FL-5-100 1031211
148
Measuring plate DWCa with DGMA

and filter
40124337
A2128
Fig. 94: Measuring plate DWCa with DGMA and filter
149
Measuring plate DWCa with DLG III

and filter
40124338
A2129
Fig. 95: Measuring plate DWCa with DLG III and filter
150
Measuring plate DWCa with DLG III,

filter and stirrer
40124341
A2130
Fig. 96: Measuring plate DWCa with DLG III, filter and stirrer
151
Measuring plate DWCa with ICT/pH/

RH/Temperature
40124390
A2131
Fig. 97: Measuring plate DWCa with ICT/pH/RH/Temperature
152
Measuring plate DWCa with oxygen

measurement for potable water
40130341
A2133
Fig. 98: Measuring plate DWCa with oxygen measurement for potable water
153
Measuring plate DWCa with filter,

DLG and ICT
40124458
A2134
Fig. 99: Measuring plate DWCa with filter, DLG and ICT
154
Measuring plate DWCa with O2/ICT/

pH/ORP
40124467
A2135
Fig. 100: Measuring plate DWCa with O2/ICT/pH/ORP
24.2 Accessories
Photometer
Component Order number

Photometer DT1B 1039315
Photometer DT2C 1039316
The scope of delivery of the photometer includes a transport case, accessories, cuvettes and reagents.
155
EC Declaration of Conformity
25 EC Declaration of Conformity
We,
n ProMinent GmbH
n Im Schuhmachergewann 5 - 11
n D - 69123 Heidelberg,
hereby declare that the product specified in the following, complies
with the relevant basic health and safety requirements of the EC
Directive, on the basis of its functional concept and design and in
the version distributed by us. Any modification to the product not
approved by us will invalidate this declaration.
Extract from the EC Declaration of Conformity
Designation of the product: DULCOTROL® DWCa

Product type: DWCa _ _ _ _ _ _ _ _ _ _ _ 0 _ _ _ _ _
Serial number: see nameplate on the unit
Relevant EC directives: Low Voltage Directive 2006/95/EC
EC EMC Directive (2004/108/EC)
Harmonised standards applied, EN 61010-1: 2010
in particular:
EN 61326 - 1: 2013, Class A, industrial sector
Date: 15.05.2015
The EC Declaration of Conformity is available to download on our

homepage.
156
Index
26 Index
A Fitting sensors with screw thread PG 13.5 . . 34, 38
Fitting sensors with shaft diameter 25 mm (only
Accuracy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
DLG III A or B) . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Action, step by step . . . . . . . . . . . . . . . . . . . . . . . . 2
Flammable media . . . . . . . . . . . . . . . . . . . . . . . . 11
Actuating outputs . . . . . . . . . . . . 109, 112, 114, 116
Flushing the bypass fitting with pipework . . . . . 138
Air humidity . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
Function of the keys . . . . . . . . . . . . . . . . . . . . . . 59
Alarm equipment . . . . . . . . . . . . . . . . . . . 11, 25, 42
Further applicable documents . . . . . . . . . . . . . . . 16
Alarm relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Ambient temperature . . . . . . . . . . . . . . . . . . . . . 145
Applied harmonised standards . . . . . . . . . . . . . 156 G
Archiving the settings . . . . . . . . . . . . . . . . . . . . . 80 Galvanically isolated measuring device . . . . . . . . 43
Area at risk from explosion . . . . . . . . . . . . . . . . . 11 General non-discriminatory approach . . . . . . . . . . 2
Assembly height . . . . . . . . . . . . . . . . . . . . . . . . . 27 Guard plate (IP) . . . . . . . . . . . . . . . . . . . . . . . . . 145
B H
Backlight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 Hanger bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Ball valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Hydraulic leaks . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Brightness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 Hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . 53
Bypass fitting . . . . . . . . . . . . . . . . . . . . . . . . . 20, 22
I
C In-line probe housing . . . . . . . . . . . . . . . . . . . . . . 23
Cable marker . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 Incorrect metering . . . . . . . . . . . . . . . . . . . . . . . . 55
Calibrating Amperometric measured Variables . 104 Indoors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Calibrating Chlorine . . . . . . . . . . . . . . . . . . . . . . 104 Installation diagram . . . . . . . . . . . . . . . . . . . . . . . 24
Calibrating the "Conductivity" measured variable Installation diagram for accessories . . . . . . . . . . 28
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
Calibrating the "Temperature" measured vari‐ K
able . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120 Key Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Calibrating the zero point . . . . . . . . . . . . . . . . . 106
Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82 L
Calibration solution . . . . . . . . . . . . . . . . . . . . . . . 57 Language settings . . . . . . . . . . . . . . . . . . . . . . . . 63
Chemical resistance . . . . . . . . . . . . . . . . . . . . . 144 Life phases . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Circulating pump . . . . . . . . . . . . . . . . . . . . . . . . . 26 Lightning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Climate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145 Links to elements or sections of these instruc‐
Concealed installations . . . . . . . . . . . . . . . . . . . . 26 tions or other applicable documents . . . . . . . . . . . 2
Contamination . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Live parts . . . . . . . . . . . . . . . . . . . . . . . . . . . 11, 43
Contrast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Contrast setting . . . . . . . . . . . . . . . . . . . . . . . 66, 70
Control outputs . . . . . . . . . . . . . . . . . . . . . . . . . 106
M
Control stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 Mains switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Manufacturing processes . . . . . . . . . . . . . . . . . 144
D Material specifications . . . . . . . . . . . . . . . . . . . . 144
Maximum operating pressure . . . . . . . . . . . . . . 144
Data input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93 Measuring plate . . . . . . . . . . . . . . . . . . . . . . . . . 44
Decoupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 Medium temperature . . . . . . . . . . . . . . . . . . . . . 145
Defective control by defective measured values . 43 Metering pumps . . . . . . . . . . . . . . . . . . . . . . . . . 26
Definition of "sample water" . . . . . . . . . . . . . . . . 144 Moisture protection (IP) . . . . . . . . . . . . . . . . . . . 145
Degree of protection: IP 65 . . . . . . . . . . . . . . . . 145 More symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Designation of the product . . . . . . . . . . . . . . . . 156 Mounting system . . . . . . . . . . . . . . . . . . . . . . . . . 26
Direction of flow . . . . . . . . . . . . . . . . . . . . 29, 33, 38
Drilling template . . . . . . . . . . . . . . . . . . . . . . . . . 27
N
E Non-discriminatory approach . . . . . . . . . . . . . . . . 2
Electrical data . . . . . . . . . . . . . . . . . . . . . . . . . . 144
Electrical installation of the amperometric sen‐
O
sors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31, 37, 40 Operating Concept . . . . . . . . . . . . . . . . . . . . . . . 59
Electrical installation of the flow sensor . . 31, 36, 40 Operating elements . . . . . . . . . . . . . . . . . . . . 65, 69
Electrical installation of the ORP and pH sensor Operating errors . . . . . . . . . . . . . . . . . . . . . . . . . 13
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32, 37, 41 Operating language . . . . . . . . . . . . . . . . . . . . 63, 74
Emergency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Operating pressure . . . . . . . . . . . . . . . . . . . . . . 144
Outdoor applications . . . . . . . . . . . . . . . . . . . . . . 14
F Overview of equipment . . . . . . . . . . . . . . . . . 65, 69
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11, 25, 42
157
Index
P Question: Which calibration process can you

use to calibrate the pH value? . . . . . . . . . . . . . . . 86
Parked position . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Question: Which values render pH calibration
PE plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
valid? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Permissible operating pressures . . . . . . . . . . . . 144
pH calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Pipework . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 R
Poor sensor operation and fluctuating pH values Recycling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
during the process . . . . . . . . . . . . . . . . . . . . . . . . 91 Redundant design . . . . . . . . . . . . . . . . . . 11, 25, 42
Potential adjustment . . . . . . . . . . . . . . . . . . . . . . 57 Regulating tap . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Potential equalisation pin . . . . . . . . . . . . . 20, 21, 23 Relevant EC directives . . . . . . . . . . . . . . . . . . . 156
Potential separation of the power supply . . . . . . . 43 Remove and refit the fluoride sensor in the in-
Power repeater . . . . . . . . . . . . . . . . . . . . . . . . . . 43 line probe housing . . . . . . . . . . . . . . . . . . . 100, 102
Protective housing . . . . . . . . . . . . . . . . . . . . . . . . 13 Remove and refit the pH sensor in the in-line
probe housing . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Q Residual current circuit breaker (RCCB) . . . . . . . 11
Residual current devices (RCD) . . . . . . . . . . . . . 11
Qualification . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Resistance list . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Question: Are there disadvantages with pH cali‐
Risks of explosion . . . . . . . . . . . . . . . . . . . . . . . . 11
bration with an external sample? . . . . . . . . . . . . . 91
Run in periods . . . . . . . . . . 106, 109, 112, 114, 116
Question: How are the device and sensor cali‐
brated? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
Question: How are the unit and sensor cali‐ S
brated? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127 Safety data sheet . . . . . . . . . . . . . . . . . . . . . . . . 55
Question: How can I reset the operating lan‐ Safety goggles . . . . . . . . . . . . . . . . . . . . 29, 33, 38
guage? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 Safety information . . . . . . . . . . . . . . . . . . . . . . . . . 9
Question: How can I set or change the operating Sample water fault . . . . . . . . . . . . . . . . . . . . . . . 73
language? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 Sample water temperature . . . . . . . . . . . . . . . . 145
Question: How can I store and transport the Sampling tap . . . . . . . . . . . . . . . . . . . . . . . . . 22, 23
product? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Scope of delivery . . . . . . . . . . . . . . . . . . . . . . . . . 16
Question: How do I adjust the display bright‐ Sensor function . . . . . . . . . 106, 109, 112, 114, 116
ness? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 Serial number . . . . . . . . . . . . . . . . . . . . . . . . . . 156
Question: How do I adjust the display contrast? . 74 Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
Question: How do I calibrate the sensor's zero Sources of EMC interference . . . . . . . . . . . . . . . 43
point? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132 Standard signal outputs . . . 106, 109, 112, 114, 116
Question: How does the controller operate? . . . . 59 Starting up the DLG . . . . . . . . . . . . . . . . . . . . . . 37
Question: How does the key lock work? . . . . . . . 64 Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Question: What ambient conditions need to be Strain relief . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
taken into consideration? . . . . . . . . . . . . . . . . . . 19 Sunlight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Question: What can be calibrated? . . . . . . 121, 127
Question: What happens in the event of incor‐ T
rect calibration? . . . . . . . . . . . . . . . . . . . . . 121, 127 Temperature data . . . . . . . . . . . . . . . . . . . . . . . 145
Question: What information is made available in Test container 1 with buffer solution . . . . . . . . . . 88
the continuous display? . . . . . . . . . . . . . . . . . 67, 71 Test container 1 with fluoride calibration solution
Question: What information is made available in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100, 102
the info display? . . . . . . . . . . . . . . . . . . . . . . 68, 72 Test container 2 with buffer solution . . . . . . . . . . 88
Question: What type of buffer solutions do I Test container 2 with fluoride calibration solution
need for a fluoride calibration? . . . . . . . . . 101, 103 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Question: What type of buffer solutions do I Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
need for pH calibration? . . . . . . . . . . . . . . . . . . . 88
Question: Which calibration process can you U
use to calibrate amperometric measured varia‐ Users' qualifications . . . . . . . . . . . . . . . . . . . . . . 15
bles? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105 UV sources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Question: Which calibration process can you
use to calibrate the DO measured variable? . . . 111
Question: Which calibration process can you
Z
use to calibrate the fluoride value? . . . . . . . . . . 100 ZERO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
Question: Which calibration process can you Zero point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
use to calibrate the ORP value? . . . . . . . . . . . . . 95 Zero point calibration . . . . . . . . . 109, 112, 114, 116
158
159
ProMinent GmbH
Im Schuhmachergewann 5 - 11
69123 Heidelberg, Germany
Telephone: +49 (6221) 842-0
Fax: +49 (6221) 842-419
Email: info@prominent.com
Internet: www.prominent.com
984397, 1, en_GB
© 2015

Dulcotrol Dwca Assembly and Operating Instructions

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Dulcotrol Dwca Assembly and Operating Instructions

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Assembly and operating instructions

Part no. 984397 BA DR 008 06/15 EN

Supplementary information Please read the supplementary information in its entirety.

This provides important information relating to the cor‐

17.1.5 Calibrating Oxygen Sensors................................ 110

1 Identity Code Ordering System for DULCOTROL® Measuring

2 Safety and Responsibility

2.2 General Safety Information

Indoors or protective covering

2.3 Information in the Event of an Emergency

2.4 Intended Use

2.5 Users' qualifications

Note for the system operator

3 About This Product

diaLog DACa controller

Hardware design: Identity code for the diaLog DACa con‐

2-channel device, PROFIBUS® DP DACa PA 6 1 4 0 0 0 4 0 0 01 0

1-channel device with RC, PROFIBUS® DP DACa PA 6 1 0 0 0 0 4 0 1 01 0

2-channel device with RC, PROFIBUS® DP DACa PA 6 1 4 0 0 0 4 0 1 01 0

1-channel device, PROFIBUS® DP, with data logger DACa PA 6 1 0 0 0 0 4 1 0 01 0

2-channel device, PROFIBUS® DP, with data logger DACa PA 6 1 4 0 0 0 4 1 0 01 0

Hardware design: Identity code for the Compact controller:

Measured variable Water to be measured Sensor type Order number

4 Storage and Transport

Ambient conditions for storage and

Storage temperature: + 5 ... 55 °C

5 Overview of the Measuring Station

Fig. 1: Bypass fitting DGMa

The bypass fitting contains a potential equalisation pin (stainless

Fig. 2: Bypass fitting DLG III

The bypass fitting contains a potential equalisation pin (stainless

5.3 DULCOTROL® Measuring and Control Station with Pipework

Fig. 3: Pipework for ICT / O2 / pH / ORP

5.4 Installation Diagram for DULCOTROL® Measuring and Control Station

Fig. 4: Installation diagram

6 Assembly of the Measuring Point

6.1 Assembly (Mechanical)

6.1.1 Measuring Point

Fig. 5: Drilling template

Secure the DULCOTROL® measuring/control station, as close as

Fig. 6: Hanger bolt

The installation sequence is binding and to be adhered

7 Installing Sensors in the Bypass Fitting DGMa

7.1 Fitting the DGMa with Sensors

3. Screw in the sensor.

Amperometric sensors with

1. Remove the upper blanking plug from a 25-mm module

Fig. 7: Fitting the sensors

7.2 Electrical Installation of the Sensors

Electrical installation of the flow

Technical data for the reed switch, potential-free:

Fig. 8: 2-wire connection

7.3 Adjusting the Flow Sensor Switching Point

1. Use the ball valve to adjust the flow to 50 l/h

8 Installing Sensors in the Bypass Fitting DLG III/IV

8.1 Fitting the DLG with Sensors

Use an Allen key (width 10 mm) for dismantling to

1. Use the Allen key to unscrew a blanking threaded connector

2. Screw the sensor manually back into the in-line probe

Amperometric sensors with

Fig. 9: Amperometric sensor

1. Unscrew a large blanking threaded connector out of the top

Blanking threaded connector