ProMinent DULCOTEST Assembly And Operating Instructions Manual

DULCOTEST

®

sensor ICT 5 and ICT 5-IMA

Sensor for electrical conductivity

Assembly and operating instructions

A2632

EN/DE

982358 BA DT 157 10/18 DE/EN

Please carefully read these operating instructions before use. · Do not discard.

The operator shall be liable for any damage caused by installation or operating errors.

The latest version of the operating instructions are available on our homepage.

Overall Table of Con‐

tents

EN

DULCOTEST

®

sensor ICT 5 and ICT

5-IMA Sensor for electrical conduc‐

tivity..................................................... 4

1 Introduction.................................... 8

1.1 Measuring principle.................... 8

1.2 Construction and function of

the sensor................................... 9

1.3 Nameplate................................ 12

1.4 Scope of delivery...................... 12

2 Safety and responsibility............. 13

2.1 Labelling of Warning Informa‐

tion............................................ 13

2.2 User qualification...................... 15

2.3 General safety information....... 16

2.4 Intended use............................. 17

2.5 Information in the event of an

emergency................................ 17

3 How to store and transport the

sensor.......................................... 18

3.1 Storage..................................... 18

3.2 Transport.................................. 18

4 Assembly and installation............ 19

4.1 Installation of sensor type ICT

5............................................... 20

4.2 Installation of sensor type ICT

5-IMA........................................ 23

4.3 Electrical installation................. 24

5 Maintenance................................ 26

6 Rectifying faults and malfunc‐

tions............................................. 27

7 Disposal of used parts................. 28

8 Accessories................................. 29

9 Technical data............................. 30

9.1 General data............................. 30

9.2 Certification/Test marks............ 31

9.3 Permitted process pressure..... 32

10 Dimensions................................ 33

DE

DULCOTEST

®

Sensor ICT 5 und

ICT 5-IMA Sensor für elektrolytische

Leitfähigkeit....................................... 36

1 Einleitung..................................... 40

1.1 Messprinzip.............................. 40

1.2 Aufbau und Funktion des Sen‐

sors........................................... 41

1.3 Typenschild.............................. 44

1.4 Lieferumfang............................ 44

2 Sicherheit und Verantwortung..... 45

2.1 Kennzeichnung der Warnhin‐

weise........................................ 45

2.2 Benutzer-Qualifikation.............. 47

2.3 Allgemeine Sicherheitshin‐

weise........................................ 48

2.4 Bestimmungsgemäße Verwen‐

dung......................................... 49

2.5 Angaben für den Notfall............ 49

3 So lagern und transportieren Sie

den Sensor.................................. 50

3.1 Lagerung.................................. 50

3.2 Transport.................................. 50

4 Montage und Installation............. 51

4.1 Montage des Sensortyps ICT

5............................................... 52

4.2 Montage des Sensortyps ICT

5-IMA........................................ 55

4.3 Elektrische Installation.............. 56

5 Wartung....................................... 58

6 Fehler und Störungen beheben... 59

7 Altteileentsorgung........................ 60

8 Zubehör....................................... 61

9 Technische Daten....................... 62

9.1 Allgemeine Daten..................... 62

9.2 Zulassungen/Prüfzeichen......... 63

9.3 Zulässiger Prozessdruck.......... 64

Overall Table of Contents

2

10 Abmessungen........................... 65

Overall Table of Contents

3

DULCOTEST

®

sensor ICT 5 and ICT 5-IMA

Sensor for electrical conductivity

Assembly and operating instructions

A2632

EN

982358 BA DT 157 10/18 DE/EN

Please carefully read these operating instructions before use. · Do not discard.

The operator shall be liable for any damage caused by installation or operating errors.

The latest version of the operating instructions are available on our homepage.

General non-discriminatory approach In order to make it easier to read, this docu‐

ment uses the male form in grammatical struc‐

tures but with an implied neutral sense. It is

aimed equally at both men and women. We

kindly ask female readers for their under‐

standing in this simplification of the text.

Supplementary information

Please read the supplementary information in its entirety.

Information

This provides important information relating to the correct operation of the unit or is intended

to make your work easier.

Warning information

Warning information includes detailed descriptions of the hazardous situation, see

Ä Chapter 2.1

‘Labelling of Warning Information’ on page 13

.

The following symbols are used to highlight instructions, links, lists, results and other elements in

this document:

Tab. 1: More symbols

Symbol Description

Action, step by step.

⇨ Outcome of an action.

Links to elements or sections of these instructions or other applicable docu‐

ments.

n

List without set order.

[Button]

Display element (e.g. indicators).

Operating element (e.g. button, switch).

Supplemental directives

5

Symbol Description

‘Display /GUI’

Screen elements (e.g. buttons, assignment of function keys).

CODE

Presentation of software elements and/or texts.

Supplemental directives

6

Table of contents

1 Introduction............................................................................................................................. 8

1.1 Measuring principle........................................................................................................ 8

1.2 Construction and function of the sensor......................................................................... 9

1.3 Nameplate.................................................................................................................... 12

1.4 Scope of delivery.......................................................................................................... 12

2 Safety and responsibility....................................................................................................... 13

2.1 Labelling of Warning Information.................................................................................. 13

2.2 User qualification.......................................................................................................... 15

2.3 General safety information........................................................................................... 16

2.4 Intended use................................................................................................................. 17

2.5 Information in the event of an emergency.................................................................... 17

3 How to store and transport the sensor.................................................................................. 18

3.1 Storage......................................................................................................................... 18

3.2 Transport...................................................................................................................... 18

4 Assembly and installation...................................................................................................... 19

4.1 Installation of sensor type ICT 5................................................................................... 20

4.2 Installation of sensor type ICT 5-IMA........................................................................... 23

4.3 Electrical installation..................................................................................................... 24

5 Maintenance.......................................................................................................................... 26

6 Rectifying faults and malfunctions......................................................................................... 27

7 Disposal of used parts........................................................................................................... 28

8 Accessories........................................................................................................................... 29

9 Technical data....................................................................................................................... 30

9.1 General data................................................................................................................. 30

9.2 Certification/Test marks................................................................................................ 31

9.3 Permitted process pressure......................................................................................... 32

10 Dimensions........................................................................................................................... 33

Table of contents

7

1 Introduction

These operating instructions provide informa‐

tion on the technical data and functions of the

DULCOTEST

®

sensor for inductive conduc‐

tivity, ICT 5 and ICT-IMA.

Sensor type ICT 5 is designed for continuous

flow operation.

Sensor type ICT 5-IMA is integrated in an

immersion tube for immersion in a storage tank

and in an open channel.

The sensor records the electrolytic conductivity

of an aqueous process liquid online. Both types

of sensor work on the basis of an inductive

measuring principle. The sensor is almost

maintenance-free due to the inductive meas‐

uring process. Solid deposits and fatty or oily

films on the surface of the sensor have no

impact on its measuring precision. The sensor

is particularly suitable for measuring high con‐

ductivities of up to 2000 mS/cm. A stand-alone

temperature sensor (Pt1000) with a short

response time records the process tempera‐

ture. The temperature sensor is enclosed within

a protective stainless steel sleeve. Tempera‐

ture correction of the conductivity measurement

in the connected controller is provided for by

the temperature sensor (Pt1000).

Typical applications

The sensor is predominantly designed for appli‐

cations in water treatment and for water moni‐

toring, e.g.:

n Contaminated waste water and process

water

n Air conditioning plants and chillers

n Blowdown control in cooling towers,

n Flushing baths,

n Vehicle washing systems,

n Salt water desalination (feed),

n Swimming pool water control.

You can also use both types of sensor in conta‐

minated water or in aggressive media, which is

chemically inert to PVC/EPDM and/or PP/

EPDM (depending on the design of the sensor).

1.1 Measuring principle

The electrolytic conductivity is measured with

an inductive sensor. The sensor contains a

transmission and receiver coil. Sine alternating

voltage feeds the transmission coil. A sample

flow is induced into the receiver coil depending

on the conductivity of the liquid to be meas‐

ured. The sample flow is proportional to the

conductivity of the medium.

Introduction

8

1.2 Construction and function of the sensor

The inductive transducer of the two types of sensor ICT 5 and ICT 5-IMA consists of a hermetically

sealed polypropylene (PP) body. A transmission coil and a receiver coil are incorporated in the

transducer. A flow opening in the sensor (sensor eye) permits the measuring medium to flow

through. There is galvanic isolation between the sample medium and the signal output. A stand-

alone temperature sensor (Pt1000) with a short response time records the process temperature. The

temperature sensor is enclosed within a protective stainless steel sleeve.

A2617

4

3

2

1

5

Fig. 1: Components

1 PP sensor body

2 Transmission coil

3 Sensor eye through which the sample

medium flows

4 Receiver coil

5 Temperature sensor, stand-alone, enclosed

within a stainless steel sleeve

Introduction

9

Sensor type ICT 5

The sensor type ICT5 is connected to a standard DN40 T-piece (on site) using a threaded socket

and a union nut for operation in the flow.

A2641

Fig. 2: Sensor type ICT 5

1. Threaded socket, G 1 1/2” (PVC or PP)

2. Union nut (PVC or PP)

Introduction

10

Sensor type ICT5-IMA

The sensor type ICT5-IMA is immersed by the fully assembled immersion tube (1 m) in the storage

tank and channel.

A2642

Fig. 3: Sensor type ICT 5-IMA

1. Fixed cable, 10 m

2. Threaded connector M16, degree of protec‐

tion, IP68 (up to 0.2 m)

3. PP

4. PP

Introduction

11

1.3 Nameplate

The cell constant K is needed for calibration on the transmitter/controller.

A2637

Fig. 4: ICT5 nameplate

A2638

Fig. 5: ICT5-IMA nameplate

1.4 Scope of delivery

Scope of delivery of sensor type ICT 5:

n Sensor type ICT 5, order number 1095248

n Straight solvent union PVC for adaptation

of the sensor to a standard T-piece DN40,

PVC (T-piece not included in the scope of

delivery)

n Assembly and operating instructions

Scope of delivery of sensor type ICT 5-IMA:

n Sensor type ICT 5-IMA, order number

1095249

n Assembly and operating instructions

Introduction

12

2 Safety and responsibility

2.1 Labelling of Warning Infor‐

mation

Introduction

These operating instructions provide informa‐

tion on the technical data and functions of the

product. These operating instructions provide

detailed warning information and are provided

as clear step-by-step instructions.

The warning information and notes are categor‐

ised 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.

Description of hazard

– Denotes an immediate threatening

danger. If the situation 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.

– Denotes a possibly hazardous sit‐

uation. If the situation is disre‐

garded, it could result in fatal or

very serious injuries.

CAUTION!

Nature and source of the danger

Possible consequence: Slight or minor

injuries. Material damage.

Measure to be taken to avoid this

danger.

– Denotes a possibly hazardous sit‐

uation. If the situation is disre‐

garded, it could result in slight or

minor injuries. May also be used

as a warning about material

damage.

Safety and responsibility

13

NOTICE!

Nature and source of the danger

Damage to the product or its surround‐

ings.

Measure to be taken to avoid this

danger.

– Denotes a possibly damaging sit‐

uation. If the situation is disre‐

garded, 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.

–

Denotes hints on use and other

useful information. It does not indi‐

cate a hazardous or damaging sit‐

uation.

Safety and responsibility

14

2.2 User qualification

WARNING!

Danger of injury with inadequately qualified personnel

The operator of the system / equipment is responsible for ensuring that the qualifications are

fulfilled.

If inadequately qualified personnel work on the unit or loiter in the hazard zone of the unit,

this could result in dangers that could cause serious injuries and material damage.

– All work on the unit should therefore only be conducted by qualified personnel.

– Unqualified personnel should be kept away from the hazard zone.

The pertinent accident prevention regulations, as well as all other generally acknowledged

safety regulations, must be adhered to.

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 and pos‐

sible dangers that could result from improper behaviour, as well as

having been instructed in the required protective equipment and protec‐

tive 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 the manufacturer or another authorised distribution

partner.

Trained, qualified per‐

sonnel

A trained, 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 training, knowledge and experience, as well as knowledge

of pertinent regulations. A trained, qualified employee must be able to

perform the tasks assigned to him independently with the assistance of

drawing documentation and parts lists. The assessment of a person's

technical training can also be based on several years of work in the rel‐

evant field.

Safety and responsibility

15

Training Definition

Electrical technician An electrical technician is able to complete work on electrical systems

and recognise and avoid possible dangers independently based on his

technical training and experience as well as knowledge of pertinent

standards and regulations. An electrical technician must be able to per‐

form the tasks assigned to him independently with the assistance of

drawing documentation, parts lists, terminal and circuit diagrams. The

electrical technician must be specifically trained for the working environ‐

ment in which the electrical technician is employed and be conversant

with the relevant standards and regulations.

Service The Service department refers to service technicians, who have

received proven training and have been authorised by the manufacturer

to work on the system.

2.3 General safety information

WARNING!

Unauthorised access!

Possible consequence: Fatal or very

serious injuries

– Measure: Ensure that there can be

no unauthorised access to the

device

– Only trained personnel may fit,

install, service and operate this

sensor

CAUTION!

Functional limitations

Possible consequence: Slight or minor

injuries. Material damage

– Check the sensor regularly for dirt

and contamination

– Observe all applicable national

regulations relating to mainte‐

nance, service and calibration

intervals

Safety and responsibility

16

2.4 Intended use

n Only use the sensor to measure and regu‐

late electrolytic conductivity in aqueous

media, which are used in the applications

described in these operating instructions.

n All other uses or modifications are pro‐

hibited.

n The sensor is not a safety component in

the sense of DIN EN ISO

13849-1:2008-12. If there is a critical

process in your measurement and control

circuit, then it is your responsibility to make

sure this process is safe.

2.5 Information in the event of

an emergency

n In the event of an emergency, switch off

the controller

n If liquid escapes from the continuous flow

gauge, close the stopcocks on the inlet

and outlet installed by the customer

n Observe the plant operator's safety infor‐

mation before opening the continuous flow

gauge

Safety and responsibility

17

3 How to store and transport the sensor

Original packaging

User qualification: instructed user, see

Ä Chapter 2.2 ‘User qualification’ on page 15

Damage to the product.

n Only transport, ship and store the sensor

in its original packaging.

n Retain the packaging in its entirety

including the polystyrene inserts.

3.1 Storage

Storage and transport temperature:

n complete sensor -20 °C ... 75 °C.

Humidity: maximum 90 % relative air humidity,

non-condensing.

Other: No dust, no direct sunlight.

3.2 Transport

The sensor should be transported in its original

packaging and in compliance with the permis‐

sible environmental conditions. No further spe‐

cial conditions have to be observed in relation

to transport.

How to store and transport the sensor

18

4 Assembly and installation

n User qualification, mechanical installation:

trained and qualified personnel

Ä Chapter

2.2 ‘User qualification’ on page 15

n User qualification, electrical installation:

electrical technician

Ä Chapter 2.2 ‘User

qualification’ on page 15

WARNING!

Danger from hazardous substances!

Possible consequence: Fatal or very

serious injuries.

Please ensure when handling haz‐

ardous substances that you have read

the latest safety data sheets provided

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 substance 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

associated hazard assessment for the

workstations affected.

Installation site

Ensure that there is unimpeded access for sub‐

sequent calibration.

The mounting must be secure and low-vibra‐

tion.

Avoid direct sunlight.

Make sure that the medium flows correctly

through and around the sensor.

Maintain a minimum distance of 20 mm from

the sensor to the tube wall when installing in

pipework.

Minimum compensation will be achieved with

the “Installation factor” parameter if you cannot

adhere to these minimum spacings.

Provide a representative installation site for typ‐

ical conductivity and/or concentration when

immersing in a tank.

Assembly and installation

19

4.1 Installation of sensor type ICT 5

Fitting position

You can operate the sensor at any angle (0 ... 360°). The sensor is installed in a DN40 standard T-

piece, as shown in Fig. 6 with regard to its flow and the minimum distances from the walls.

1

3

2

A2618

Fig. 6: Fitting position of sensor type ICT5 in the T-piece (DN40)

1 ≧ 20 mm

2 Flow direction

3 Sensor

Assembly and installation

20

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