ProMinent DULCO turb C Series, TUC 1, TUC 2, TUC 4, TUC 3 Assembly And Operating Instructions Manual
Assembly and operating instructions
DULCO® turb C
Turbidity sensor
Please carefully read these operating instructions before use! · Do not discard!
The operator shall be liable for any damage caused by installation or operating errors!
Technical changes reserved.
Part no. 986062 BA DT 034 01/11 EN
ProMinent Dosiertechnik Heidelberg GmbH
Im Schuhmachergewann 5 - 11
69123 Heidelberg
Telephone: +49 6221 842-0
Fax: +49 6221 842-419
email: info@prominent.de
Internet: www.prominent.com
986062, 1, en_GB
© 2011
2
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
Read the following supplementary
information in its entirety!
The following are highlighted sepa‐
rately in the document:
n Enumerated lists
Instructions
Results of the instructions
ð
Information
Safety information are provided with
detailed descriptions of the endan‐
gering situation, see
Ä Chapter 1.1
„Explanation of the safety informa‐
tion“ on page 6
This provides important informa‐
tion relating to the correct opera‐
tion of the system or is intended to
make your work easier.
Safety information
3
Table of contents
Table of contents
Introduction................................................................................................ 6
1
1.1 Explanation of the safety information................................................. 6
1.2 Users' qualifications........................................................................... 8
2 Safety and responsibility.......................................................................... 10
2.1 General safety information .............................................................. 10
2.2 Correct and proper use.................................................................... 11
3 Functional description / product identification.......................................... 12
3.1 Scope of delivery............................................................................. 16
4 Mounting and Installation......................................................................... 17
4.1 Wall mounting.................................................................................. 18
4.2 Installation (hydraulic)...................................................................... 21
4.3 Installation (electrical)...................................................................... 23
5 Operating diagram................................................................................... 26
5.1 Overview of device /Control elements............................................. 26
5.2 Overview of operating structure....................................................... 27
6 Commissioning........................................................................................ 30
6.1 Load drying agent............................................................................ 30
6.2 Routine measurement..................................................................... 33
6.3 Access code.................................................................................... 34
6.4 Device configuration........................................................................ 35
6.4.1 Selecting the output...................................................................... 35
6.4.2 Configuration of fault current (ERLV)............................................ 37
6.4.3 Configure alarm ........................................................................... 38
6.4.4 OFFSET configuration.................................................................. 41
6.4.5 Extended settings......................................................................... 43
7 Operation................................................................................................. 55
7.1 Calibrate sensor............................................................................... 55
7.1.1 Standard solutions for calibration................................................. 55
4
Table of contents
7.1.2 Perform calibration........................................................................ 59
8 Maintenance, troubleshooting and repair................................................ 66
8.1 Information about fault maintenance............................................... 66
8.1.1 System error messages................................................................ 67
8.1.2 Faults in the process..................................................................... 67
9 Spare parts and accessories................................................................... 69
Standards complied with.......................................................................... 70
10
11 Disposal of used parts............................................................................. 71
12 Declaration of Conformity........................................................................ 72
13 Index........................................................................................................ 73
5
Introduction
1 Introduction
Data and functions
This operating manual provides infor‐
mation on the technical data and
functions of the DULCO®
bidity sensor.
turb C tur‐
DANGER!
Nature and source of the danger
Consequence: Fatal or very
serious injuries.
1.1 Explanation of the safety information
Introduction
These operating instructions provide
information on the technical data and
functions of the product. These oper‐
ating instructions provide 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 sym‐
bols are used to denote different sit‐
uations. The symbols shown here
serve only as examples.
Measure to be taken to avoid this
danger
Danger!
Denotes an immediate threat‐
–
ening danger. If this is disre‐
garded, it will result in fatal or
very serious injuries.
WARNING!
Nature and source of the danger
Possible consequence: Fatal or
very serious injuries.
Measure to be taken to avoid this
danger
Warning!
Denotes a possibly hazardous
–
situation. If this is disregarded,
it could result in fatal or very
serious injuries.
6
Introduction
CAUTION!
Nature and source of the danger
Possible consequence: Slight or
minor injuries, material damage.
Measure to be taken to avoid this
danger
Caution!
Denotes a possibly hazardous
–
situation. If this is disregarded,
it could result in slight or minor
injuries. May also be used as
a warning about material
damage.
NOTICE!
Nature and source of the danger
Damage to the product or its sur‐
roundings
Measure to be taken to avoid this
danger
Type of information
Hints on use and additional infor‐
mation
Source of the information, addi‐
tional measures
Information!
–
Denotes hints on use and
other useful information. It
does not indicate a hazardous
or damaging situation.
Note!
Denotes a possibly damaging
–
situation. If this is disregarded,
the product or an object in its
vicinity could be damaged.
7
Introduction
1.2 Users' qualifications
WARNING!
Danger of injury with inadequately qualified personnel!
The operator of the plant / device is responsible for ensuring that the qualifi‐
cations are fulfilled.
If inadequately qualified personnel work on the unit or loiter in the hazard
zone of the unit, this could result in dangers that could cause serious injuries
and material damage.
– All work on the unit should therefore only be conducted by qualified per‐
sonnel.
Unqualified personnel should be kept away from the hazard zone
–
Training Definition
Instructed per‐
sonnel
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 pro‐
tective 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
personnel
A qualified employee is deemed to be a person who is
able to assess the tasks assigned to him and recognize
possible hazards based on his/her training, knowledge
and experience, as well as knowledge of pertinent regu‐
lations. The assessment of a person's technical training
can also be based on several years of work in the rele‐
vant field.
8
Introduction
Training Definition
Electrician Electricians are deemed to be people, who are able to
complete work on electrical 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 appli‐
cable statutory directives on accident prevention.
Customer Service
department
Customer Service department refers to service techni‐
cians, who have received proven training and have been
authorised by ProMinent to work on the system.
Note for the system operator
The pertinent accident prevention regulations, as well as all other generally
acknowledged safety regulations, must be adhered to!
9
Safety and responsibility
2 Safety and responsibility
2.1 General safety information
WARNING!
WARNING!
Live parts!
Possible consequence: Fatal or
very serious injuries
– Measure: Disconnect the
mains power supply prior to
opening the housing
Disconnect damaged, defec‐
–
tive or manipulated devices
from the power supply
WARNING!
Unauthorised access!
Possible consequence: Fatal or
very serious injuries.
– Measure: Ensure that there
can be no unauthorised
access to the unit
Operating errors!
Possible consequence: Fatal or
very serious injuries.
– The unit should only be oper‐
ated by adequately qualified
and technically expert per‐
sonnel
Please also observe the oper‐
–
ating instructions for control‐
lers and fittings and any other
component groups, such as
sensors, sample water
pumps ...
– The operator is responsible
for ensuring that personnel
are qualified
CAUTION!
Electronic malfunctions
Possible consequence: Material
damage right through to destruc‐
tion of the unit
10
– The mains connection cable
and data cable should not be
laid together with cables that
are prone to interference
Measure: Take appropriate
–
interference suppression
measures
NOTICE!
Safety and responsibility
2.2 Correct and proper use
Correct and proper use
Damage to the product or its sur‐
roundings
– The unit is not intended to
measure or regulate gaseous
or solid media
The unit may only be used in
–
accordance with the technical
details and specifications pro‐
vided in these operating
instructions and in the oper‐
ating instructions for the indi‐
vidual components
NOTICE!
Correct sensor operation
Damage to the product or its sur‐
roundings
– Correct measuring and control
is only possible if the sensor is
working perfectly
Check and calibrate the
–
sensor regularly
NOTICE!
Correct and proper use
The device is designed to
measure the turbidity of water.
The unit may only be used in
accordance with the technical
details and specifications provided
in this operating manual and in
the operating manuals for the indi‐
vidual components (such as, for
example, controllers, sensors, fit‐
tings, calibration devices,
metering pumps, etc.).
Any other uses or modifications
are prohibited.
11
Functional description / product identification
3 Functional description / product identification
Brief functional description
The DULCO® turb C is designed for the online measuring of turbidity in
untreated water, process water and treated process water in drinking water pro‐
cessing plants.
The DULCO® turb C product range is comprised of four device types:
Types TUC 1 and TUC 3 work with infrared light and fulfil the requirements of
the international standards ISO 7027 and DIN EN 27027.
Types TUC 2 and TUC 4 work with white light and fulfil USA standard US EPA
180.1.
Both device types can be equipped with ultrasonic cleaning (TUC 3 / TUC 4) or
without ultrasonic cleaning (TUC 1 / TUC 2). The sample cell ultrasonic cleaning
system extends the calibration and maintenance intervals in media where
coating formation is common.
DULCO® turb C
Part
number
IOS
7027
US EPA
180.1
Ultrasonic cleaning
DIN EN
27027
TUC 1 1037696 Infrared No
TUC 2 1037695 White
No
light
TUC 3 1037698 Infrared Yes
TUC 4 1037697 White
Yes
light
12
Functional description / product identification
An inlet side pressure regulating valve is standard. The DULCO turb C pressure
regulating valve reduces the pressure from up to 13.8 bar (200 PSI) to 1.0 bar
(15 PSI).
Specifications
Measuring
0 – 1000.0 NTU
range
Accuracy limit ± 2 % of the displayed value or ± 0.02 NTU under 40 NTU,
depending on which value is the greater.
± 5 % of the displayed value above 40 NTU
Resolution 0.0001 NTU below 10 NTU
Response time configurable
Display Multiple row LCD display with backlighting
Alarm Two programmable alarms, 120 - 240 VAC, 2 A Form C
relay
Analogue
4 ... 20 mA, 600 Ω
output
Communication
Bi-directional RS-485, Modbus
interface
Maximum
water pressure
Integrated pressure regulating valve regulates 1380 kPa
(200 PSI). in relation to the flow rate
Flow rate 6 l/h ... 60 l/h
Operating tem‐
1 °C ... 50 °C
perature
13
Functional description / product identification
Materials that
come into con‐
Polyimide (PA), silicone, polypropylene (PP), stainless steel,
borosilicate glass
tact with the
media
Voltage supply 100 – 240 VAC, 47 – 63 Hz, 80VA
Galvanic Isola‐
tion
Ambient condi‐
tions
dual insulation, degree of interference overvoltage category
II
Not suitable for operation outdoors.
Operation altitude maximum 2000 m (above sea level).
maximum 95 % relative air humidity (non-condensing).
Enclosure
IP 66
rating
Standards
compliant with
Shipping
USEPA 180.1 for type
27027 for type
„White light“
approx. 2.5 kg
„Infrared“
weight
Option: ultrasonic cleaning (TUC 3 /
TUC 4)
The
„Ultrasonic cleaning“
option is
used in order to continuously clean
the sample chamber. It serves neither
to clean previously soiled sample
chambers, nor can it replace manual
operate the system. The system emits
an ultrasonic frequency via a spring to
a piezoelectric transducer, which is
connected to the base of the flowthrough cuvette. The cuvette's detec‐
tion system only works in
[AUTO mode]
cleaning. However, the cleaning inter‐
vals for manual cleaning can be sig‐
nificantly extended by the use of this
system. The use of a sample
chamber with an
transducer“
„ultrasound
is necessary in order to
; ISO 7027 and DIN EN
.
14
Functional description / product identification
The system can detect the following
fault states:
n Incorrect cuvette installed
n Error occurred in transducer
n Transducer has no contact to the
spring
If an error occurs, the message
[CLN]
appears in the lower part of the LCD
display. An alarm is triggered and 2
mA is applied to the current output.
The alarm relay is triggered if the
alarm funktion in
to
[ERROR]
[ALM1/ALM2]
is set
The 4 ... 20 mA output is set to 0, 2, 4
mA if the funktion
[error level] [ERLV]
was set to the corresponding mAlevel.
Interface RS-485
The DULCO® turb C
offers basic com‐
munications functions in combination
with straightforward applications, such
as
[Hilgraeve HyperTerminal]
(included with most
[Microsoft Windows software]
pack‐
ages). In addition, you can also use
[Visual Basic]
as well as other pro‐
grams.
15
Functional description / product identification
3.1 Scope of delivery
Packaging material
Dispose of packaging material environmentally. All packaging components
are provided with their corresponding recycling
code.
The following components are included as standard with a DULCO® turb C:
Description Quan‐
tity
DULCO® turb C with terminal boxes and integrated und flow fittings
1
Operating Manual 1
Packet drying agent 1
Cuvette 1
Hose kit
1
n Shut-off clamp (1 piece)
n Back-pressure valve (1 piece)
n Connection hoses with connection pieces for pressure regu‐
lating valves (2 pieces)
n Bleed screw (used in pressurised systems) (1 piece)
Remove the DULCO® turb C from the packaging. Carefully check the compo‐
nents. Ensure that no visible damage has been caused during shipping. If the
components supplied fail to comply with the order, please contact your local dis‐
tributor or the ProMinent customer services department immediately.
16
4 Mounting and Installation
Mounting and Installation
NOTICE!
Drying agent
Possible device malfunctions due
to moisture in the device.
Install the drying agent bag before
initial commissioning, see
Ä Chapter 6.1 „Load drying
agent“ on page 30
NOTICE!
Mounting position and conditions
– The installation (electrical)
may only take place after
mounting (mechanical)
Ensure that there is unim‐
–
peded access for operation
– Ensure for secure and vibra‐
tion-free fastening.
– Avoid direct sunlight
– Permissible ambient tempera‐
ture for the sensor at fitting
position: 1 ... 50℃ at max.
95% relative air humidity (non-
condensing)
– Consider the permissible
ambient temperature and the
connected components
Reading and operating posi‐
tion
–
Install the device in a favour‐
able position for reading and
operating (preferably at eye
level)
Mounting position
–
Leave sufficient free space for
the cables and necessary
work
Packaging material
Dispose of packaging material
environmentally. All packaging
components are provided with
their corresponding recycling
code.
17
Mounting and Installation
4.1 Wall mounting
Installation (mechanical)
NOTICE!
Distance to the sampling site
Install the sensor no further than maximum 3 meters from the sampling site.
This is the only way to ensure a quick response time from the system.
Free space above the sensor
Allow for at least 200mm free space above the sensor for all required work
on the sensor.
Fasten the sensor with four M6 screws and the terminal box with two M4
screws.
18
Mounting and Installation
Fig. 1: The diagram is not to scale. It is for information only. All values given in
millimetres.
A Terminal box
B
DULCO® turb C housing
19
Mounting and Installation
Fig. 2: The diagram is not to scale. It is for information only. All values given in
millimetres.
A Terminal box
B
DULCO® turb C housing
1. Fasten the terminal box (A) to the wall with two M4 screws
2.
Fasten the DULCO® turb C housing (B) above the terminal box to the wall
with four M6 screws
20
4.2 Installation (hydraulic)
Mounting and Installation
Leakage on the bleed screw
CAUTION!
Free outlet at sensor outlet
Feed the sample water which has
flowed through the sensor to a
free drain. The sampled water
may not be fed back into the
process.
CAUTION!
Algae growth under the influence
of light
Possible algae growth if unsuit‐
able hoses are used.
Do not use transparent hoses if
the installation is subjected to
powerful sources of light. This
prevents the formation of algae in
the installation.
Slight leakage may occur at the
bore hole for the bleed screw
during the installation process.
This will cease as soon as normal
flow is established.
In the event that the installation
continues to leak permanently at
this point due to the high pressure
in this area, we recommend
sealing off the bore hole with the
sealing plug supplied. In order to
ensure free drainage, a bleed
option must be installed at
another area of the outlet in order
to avoid overpressure or under‐
pressure in the system.
Permissible operating param‐
eters
–
Maximum liquid temperature
50 °C
–
Maximum pressure 13.8 bar
–
Flow rate 6 ... 60 l/h
21
Mounting and Installation
Fig. 3: Recommended pipes for the sensor
I. Flow unit
4. Hose connector. 4.75 mm interior
II. Sensor unit with operating unit
III. Terminal box
1. Backpressure valve. To regulate
the flow and in order to remove
small air bubbles
22
5. Detail: Hose
6. Detail: Union nut hose connection
diameter, 8 mm external diam‐
eter. Hose connection to the sam‐
pling site
Mounting and Installation
2. Vent screw. For use on pressur‐
ised systems. Not used for pres‐
sureless systems
3. Hose connector. 4.75 mm interior
diameter, 8 mm external diam‐
eter. Hose connection for free
sample water outlet
4.3 Installation (electrical)
WARNING!
Live parts!
Possible consequence: Fatal or
very serious injuries
– Measure: Disconnect the
power supply before opening
the housing
Disconnect damaged, defec‐
–
tive or manipulated devices
from the power supply
– The provision of a suitable
isolating device (emergencyoff switch, etc.) is the respon‐
sibility of the plant operator
7. Detail: Replacement hose con‐
nection
8. Shut-off clamp. To shut-off the
inlet in an emergency or for nec‐
essary work
The signal leads of the
DULCO® turb C may not be
routed alongside faulty cabling.
Faults could lead to malfunctions
in the DULCO® turb C.
NOTICE!
Do not route any RS-485 cables
in the same cable duct as the
power supply cable. This may
result in major anomalies.
23
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