Grundfos AQC-D12 Installation And Operating Instructions Manual

AQC-D12

Potentiostatic Measuring Cell,

Compact Measuring Systems

Installation and operating instructions

GRUNDFOS INSTRUCTIONS

2

Table of contents

3

AQC-D12

English (GB)

Installation and operating instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Deutsch (DE)

Montage- und Betriebsanleitung . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Español (ES)

Instrucciones de instalación y funcionamiento. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Français (FR)

Notice d'installation et de fonctionnement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

Magyar (HU)

Telepítési és üzemeltetési utasítás . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

Italiano (IT)

Istruzioni di installazione e funzionamento. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104

Nederlands (NL)

Installatie- en bedieningsinstructies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124

Polski (PL)

Instrukcja montażu i eksploatacji . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144

Português (PT)

Instruções de instalação e funcionamento. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164

Română (RO)

Instrucţiuni de instalare şi utilizare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184

Русский (RU)

Паспорт, Руководство по монтажу и эксплуатации . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204

Slovensko (SI)

Navodila za montažo in obratovanje . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224

Türkçe (TR)

Montaj ve kullanım kılavuzu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244

Declaration of conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 265

English (GB)

4

English (GB) Installation and operating instructions

Original installation and operating instructions

CONTENTS

Page

1. Symbols used in this document

4

2. Description of preassembled systems with

AQC-D12

5

3. Identification

5

3.1 Nameplate, AquaCell

5

3.2 Type key, AquaCell

6

3.3 Type key, preassembled systems

7

4. Description of AQC-D12

8

5. General information

8

6. Applications

8

7. Safety information

9

7.1 Obligations of the owner

9

7.2 Avoidance of danger

9

8. Technical data

9

8.1 General data

9

8.2 Versions

9

8.3 Measuring ranges

10

8.4 Dimensions / drilling diagram

10

9. Installation

11

9.1 Transport and storage

11

9.2 Unpacking

11

9.3 Installation requirements

11

9.4 Mounting

11

10. Startup

12

10.1 Installation of electrodes and sensors

12

10.2 Checking the position of the cleaning wing

12

10.3 Water connections

13

10.4 Preparing the electrode cable for connection to the

measuring amplifier

13

10.5 Electrical connections

14

10.6 Checks prior to start-up

15

10.7 Switching on

15

10.8 Calibrating the parameters Cl

2

, ClO

2

, O

3

16

11. Operation

18

11.1 Function

18

11.2 Operation

19

11.3 Switching off

19

11.4 Switching on again

19

11.5 Fault finding

20

12. Maintenance

21

12.1 Intervals for cleaning and maintenance

21

12.2 Cleaning and replacing the filter

21

12.3 Cleaning the measuring cell

21

13. Starting up the measuring cell

23

14. Spare parts and accessories

23

14.1 Electrodes, sensors and cables

23

14.2 Other parts

23

15. Disposal

23

Warning

Prior to installation, read these installation and

operating instructions. Installation and operation

must comply with local regulations and accepted

codes of good practice.

Note

These complete installation and operating

instructions are also available on www.grundfos.com.

Warning

If these safety instructions are not observed, it may

result in personal injury.

Caution

If these safety instructions are not observed, it may

result in malfunction or damage to the equipment.

Note

Notes or instructions that make the job easier and

ensure safe operation.

English (GB)

5

2. Description of preassembled systems with

AQC-D12

Fig. 1 AQC-D12 measuring cell with Conex DIA / DIS

measuring amplifier and controller

Fig. 2 AQC-D12 measuring cell with sensor interface

Fig. 3 AQC-D12 measuring cell with DIP measuring amplifier

and controller

3. Identification

3.1 Nameplate, AquaCell

Fig. 4 Nameplate, AquaCell

TM04 8617 3912

TM04 8618 3912

TM04 8619 3912

1

Conex DIA-1, Conex DIA-2, Conex DIA-2Q, Conex

DIS-D measuring amplifier and controller

2

Sensor interface for Conex DIA-1, Conex DIA-2,

Conex DIA-2Q, for panel-mounting

3 DIP measuring amplifier and controller

Man

Cal

OKEsc

1

2

DIP

Man Cal

OKEsc

Select

3

TM04 8668 3013

Pos. Description

1 Type designation

2 Model

3 Serial number

4 Maximum pressure [bar]

5 Product number

6 Year and week code

7 Country of origin

AQC-D11, P-AU-PCB-RCB, QS-T, H

314-306-10048

S/N: 07/44888

3,00 bar

95737669P11124563516

1

2

4

5

6

7

3

English (GB)

6

3.2 Type key, AquaCell

Example: AQC -D11, P AU-PCB-RCB, QS -T, H

Model

AQC AquaCell

AquaCell type

D11 Pressure-proof, with cleaning motor (Cl

2

, ClO

2

, O

3

)

D12 Pressure-proof, with hydromechanical cleaning (Cl

2

, ClO

2

, O

3

)

D13 Pressureless, with hydromechanical cleaning (Cl

2

, ClO

2

, O

3

)

Pressure-loading valve

P With pressure-loading valve

X Without pressure-loading valve

Electrodes for disinfection parameters

AU Gold

PT Platinum

Electrodes for pH

PCB pH, ceramic diaphragm, with buffer solution

PCX pH, ceramic diaphragm, without buffer solution

PTB pH, PTFE diaphragm, with buffer solution

PTX pH, PTFE diaphragm, without buffer solution

PKB pH, KCl filling, with buffer solution

PKX pH, KCl filling, without buffer solution

PGB pH, gel filling, with buffer solution

PGX pH, gel filling, without buffer solution

X Without electrode

Electrodes for redox potential (ORP)

RCB ORP, ceramic diaphragm, with buffer solution

RCX ORP, ceramic diaphragm, without buffer solution

RTB ORP, PTFE diaphragm, with buffer solution

RTX ORP, PTFE diaphragm, without buffer solution

RRB ORP, without reference system, with buffer solution

RRX ORP, without reference system, without buffer solution

X Without electrode

Water sensor

QS With water sensor

X Without water sensor

Temperature sensor

T With Pt100 temperature sensor

X Without temperature sensor

Power supply

G 230/240 V, 50/60 Hz

H 115/120 V, 50/60 Hz

I 24 VDC

X Without power supply

English (GB)

7

3.3 Type key, preassembled systems

Example: DIA -1 -A D1 P -AU -PCB -QS -T W -H

Measuring amplifier and controller

DIA-1 Dosing Instrumentation Advanced with 1 input

DIA-2 Dosing Instrumentation Advanced with 2 inputs

DIA-2Q Dosing Instrumentation Advanced with 1 input + flow measurement

DIP Dosing Instrumentation Pool

DIS-PR Dosing Instrumentation Standard for pH/ORP measurement

DIS-D Dosing Instrumentation Standard for Cl

2

/ ClO

2

/ O

3

Assembly

APreassembled

Cell type

D11 Pressure-proof, with cleaning motor

D12 Pressure-proof, with hydromechanical cleaning

D13 Pressureless, with hydromechanical cleaning

D4 Pressureless, with cleaning motor, for total chlorine

D5 Pressureless, with cleaning motor, for free chlorine

P/R pH or ORP

PA/HP Peracetic acid or hydrogen peroxide

Pressure-loading valve

P With pressure-loading valve

X Without pressure-loading valve

Electrodes for disinfection parameters

AU Gold

PT Platinum

X Without electrode

Other electrodes

PCB pH, ceramic diaphragm, with buffer solution

PCX pH, ceramic diaphragm, without buffer solution

PTB pH, PTFE diaphragm, with buffer solution

PTX pH, PTFE diaphragm, without buffer solution

PKB pH, KCl filling, with buffer solution

PKX pH, KCl filling, without buffer solution

PGB pH, gel filling, with buffer solution

PGX pH, gel filling, without buffer solution

RCB ORP, ceramic diaphragm, with buffer solution

RCX ORP, ceramic diaphragm, without buffer solution

RTB ORP, PTFE diaphragm, with buffer solution

RTX ORP, PTFE diaphragm, without buffer solution

RRB ORP, without reference system, with buffer solution

RRX ORP, without reference system, without buffer solution

PA Peracetic acid

HP Hydrogen peroxide

X Without electrode

Water sensor

QS With water sensor

X Without water sensor

Temperature sensor

T With Pt100 temperature sensor

X Without temperature sensor

Mounting

W Wall-mounting

P Panel-mounting

Power supply

G 230/240 V, 50/60 Hz

H 115/120 V, 50/60 Hz

I 24 VDC

English (GB)

8

4. Description of AQC-D12

Fig. 5 AQC-D12 measuring cell

Fig. 6 AQC-D12, top view

5. General information

This manual contains all important information for users of the

AQC-D12 and the preassembled systems:

• technical data

• instructions for start-up, use and maintenance

• safety information.

Should you require further information, or should problems occur

which are not handled in sufficient depth in this manual, please

contact Grundfos.

6. Applications

The potentiostatic measuring cell AQC-D12 measures the

concentration of chlorine (Cl

2

) in the pH-range 4.5 to 8.2, chlorine

dioxide (ClO

2

) or ozone (O

3

). By means of the suitable

electrodes, it can also measure the pH value and redox potential

for treatment of swimming-pool water and drinking water.

The preassembled systems measure and control the following

parameters, depending on the measuring amplifier and controller

installed:

• Preassembled system with Conex DIA-1 measuring amplifier

and controller:

– Measurement: free chlorine (Cl

2

), as an option with pH

compensation, chlorine dioxide (ClO

2

), ozone (O

3

), pH,

temperature.

– Control: chlorine (Cl

2

), chlorine dioxide (ClO

2

), ozone (O

3

).

• Preassembled system with Conex DIA-2 measuring amplifier

and controller:

– Measurement: free chlorine (Cl

2

), as an option with pH

compensation, chlorine dioxide (ClO

2

), ozone (O

3

), pH,

temperature.

– Control: chlorine (Cl

2

), chlorine dioxide (ClO

2

), ozone (O

3

),

pH.

• Preassembled system with Conex DIA-2Q measuring amplifier

and controller:

– Measurement: free chlorine (Cl

2

), as an option with pH

compensation, chlorine dioxide (ClO

2

), ozone (O

3

), pH,

temperature.

– Control: chlorine (Cl

2

), chlorine dioxide (ClO

2

), ozone (O

3

),

pH, redox potential.

• Preassembled system with Conex DIS-D measuring amplifier

and controller:

– Measurement: chlorine (Cl

2

), chlorine dioxide (ClO

2

), ozone

(O

3

).

– Control: chlorine (Cl

2

), chlorine dioxide (ClO

2

), ozone (O

3

).

• Preassembled system with DIP measuring amplifier and

controller:

– Measurement: chlorine (Cl

2

), chlorine dioxide (ClO

2

), ozone

(O

3

), pH, redox potential, temperature.

– Control: chlorine (Cl

2

), chlorine dioxide (ClO

2

), ozone (O

3

),

pH.

TM04 8620 3912TM04 8621 3912

Pos. Description

A pH electrode / location for pH electrode

B Redox electrode / location for redox electrode

C

Pt100 temperature sensor / location for temperature

sensor (C1) with screw plug (C2)

D Water sensor

E Connection for sample water inlet

F Connection for sample water outlet

X Sample water shut-off valve

G Regulation of sample water quantity

H Sample water filter

I Sampling cock

J Measuring electrode for Cl

2

, ClO

2

, O

3

K

Reference electrode for Cl

2

, ClO

2

, O

3

/ location for

reference electrode

L Cover with threaded ring

M Acrylic glass cylinder

A / B

L

K

M

X, G

E

J

H

I

G

X

D

C2

F

A / B

KDC

English (GB)

9

7. Safety information

7.1 Obligations of the owner

The owner of the plant is responsible for

• compliance with country-specific safety regulations

• training of operating personnel

• provision of prescribed protective gear

• implementation of regular maintenance.

7.2 Avoidance of danger

8. Technical data

8.1 General data

The AQC-D12 is a pressure-proof measuring cell with

hydromechanical cleaning for recirculation of sample water.

• Measuring parameters:

– free chlorine, chlorine dioxide, ozone

– optional: pH value, redox potential, temperature (for

compensation of pH, Cl

2

, ClO

2

, O

3

).

• Sample water:

– free of solids

– min. conductivity: 50 µS/cm

– temperature: 0-40 °C

– pH value (only measuring parameter Cl

2

): pH 4.5 - 8.2

– inlet pressure: max. 3 bar, min. 0.2 bar

– counterpressure: max. 3 bar

– pressure difference: approx. 0.2 bar.

• Permissible ambient temperature: 0 to 45 °C.

• Permissible storage temperature:

– -20 to +65 °C

– Electrodes: -10 to +30 °C.

• Permissible humidity: max. 90 % relative humidity (without

condensation).

• Sample water flow rate: min. 20; max. 45 l/h.

• Materials of parts that come into contact with the media:

PMMA, PVC, EPDM.

• Electrode materials: gold, platinum, glass, nickel, PVC.

• Connections:

– inlet: for PVC hose 6/12 or PVC pipe 12 x 1.2

– outlet: for PVC hose 6/12 or PVC pipe 12 x 1.2.

Measuring parameters: chlorine, chlorine dioxide and ozone

• Measuring ranges: Dependent on the measuring amplifier.

See section 8.3.1 Measuring ranges for Cl

2

, ClO

2

, O

3

, pH,

ORP.

• Sensitivity: < 20 ppb.

• Accuracy: < - 5 %/+ 5 % of full-scale value.

• Repeatability: < - 5 %/+ 5 %.

• Response time: t

90

< 60 s.

8.2 Versions

• Power supply:

– 230/240 V, 50/60 Hz (standard)

– 115/120 V, 50/60 Hz

– 24 VDC (not with DIP).

• Equipment/options:

– gold electrode for free chlorine, chlorine dioxide, ozone

(standard)

– platinum electrode

– redox single-rod measuring chain (electrode)

– redox electrode (with DIP)

– pH single-rod measuring chain (electrode).

8.2.1 AquaCell AQC-D12

• Cables:

– connecting cables for the electrodes, 3 m, with free cable

end

– cable for measuring electrode, 2 m, with free cable end

– water sensor with cable, 3 m, with free cable end.

• Options:

– Pt100 temperature sensor with cable, 3 m.

8.2.2 Preassembled systems

• Cables:

– connecting cables for the electrodes, 1 m, preconnected

– cable for measuring electrode, 1.2 m, preconnected

– water sensor with cable, 1 m, preconnected.

• Options:

– Pt100 temperature sensor with cable, 1 m.

Product numbers of the spare parts and optional accessories, see

section 14. Spare parts and accessories.

Warning

Cleaning, maintenance and repairs must only be

carried out by authorised personnel!

Warning

Other applications than those described in section

6. Applications are considered as non-approved and

are not permissible.

Derivates of chloro isocyanuric acid cannot be

measured or controlled.

Grundfos cannot be held liable for any damage

resulting from incorrect use.

Caution

Observe the installation and operating instructions of

the electrodes!

English (GB)

10

8.3 Measuring ranges

8.3.1 Measuring ranges for Cl

2

, ClO

2

, O

3

, pH, ORP

Preassembled system with Conex DIA

Preassembled system with Conex DIS-D

* Effective measuring range: 0.00 - 5.00

Preassembled system with DIP

8.3.2 Measuring ranges for temperature

(not with Conex DIS-D)

8.4 Dimensions / drilling diagram

Fig. 7 AQC-D12 measuring cell

Fig. 8 Preassembled systems

(example: system with Conex DIA for wall-mounting)

Cl

2

[mg/l]

ClO

2

[mg/l]

O

3

[mg/l]

pH

ORP

[mV]

0.00 - 0.50 0.00 - 0.50 0.00 - 0.50 0.00 - 14.00

-1500 -

+1500

0.00 - 1.00 0.00 - 1.00 0.00 - 1.00 2.00 - 12.00 0-1000

0.00 - 2.00 0.00 - 2.00 0.00 - 2.00 5.00 - 9.00

0.00 - 5.00 0.00 - 5.00 0.00 - 5.00

0.0 - 10.0 0.0 - 10.0

0.0 - 20.0

freely selectable between

0.0 - 50.0 0.0 - 50.0 0.00 - 5.00 0.00 - 14.00

-1500 -

+1500

Cl

2

[mg/l]

ClO

2

[mg/l]

O

3

[mg/l]

0.00 - 2.00 0.00 - 2.00 0.00 - 2.00

0.00 - 20.00 0.00 - 20.00 0.00 - 20.00*

Cl

2

[mg/l]

ClO

2

[mg/l]

O

3

[mg/l]

pH

ORP

[mV]

0.00 - 0.50 0.00 - 0.50 0.00 - 0.50 0.00 - 14.00

-1500 -

+1500

0.00 - 1.00 0.00 - 1.00 0.00 - 1.00 2.00 - 12.00 0-1000

0.00 - 2.00 0.00 - 2.00 0.00 - 2.00 5.00 - 9.00

0.00 - 5.00 0.00 - 5.00 0.00 - 5.00

0.0 - 10.0 0.0 - 50.0

0.0 - 30.0

freely selectable between

0.0 - 30.0 0.0 - 50.0 0.00 - 5.00 0.00 - 14.00

-1500 -

+1500

°C °F

0 to +50 32 to 122

0 to +100 32 to 212

-5 to +120 23 to 248

TM04 8622 3912TM04 8623 3912

365

105

120

125

137

475

495

475

133

117

Man

Cal

OKEsc

495

English (GB)

11

9. Installation

9.1 Transport and storage

9.2 Unpacking

• Check scope of delivery.

• Assemble as soon as possible after unpacking.

9.3 Installation requirements

• The location must be vibration-free, dry, dust-free and free of

corrosive, pungent fumes or aggressive solvents.

• Maximum permissible cable length:

– Individual AQC-D12 measuring cell: distance between

measuring cell and measuring amplifier or sensor interface

3 m.

– Preassembled systems with Conex DIS, DIA or DIP for

wall-mounting: completely prewired.

– Preassembled systems with Conex DIA for panel-mounting:

the distance between measuring amplifier and sensor

interface must be less than 100 m.

• Ensure a continuous supply of sample water.

• Install the measuring cell so that the sample water feed line is

as short as possible, in order to reduce the delay time of the

measuring cell.

• Observe the permissible inlet pressure and counterpressure of

the sample water.

– Fit a pressure booster pump or pressure reducer, if

necessary.

• If the counterpressure may fall below 0.3 bar or if there is an

open outflow, a pressure-loading valve must be fitted to the

outlet of the measuring cell (F). The pressure-loading valve

(V) is available with an adaptor for the measuring cell

(Grundfos product number 99253231).

• Provide possibilities to shut-off the sample water (U). You can

use the Grundfos installation set 95727420 on the discharge

side.

Fig. 9 AQC-D12 with pressure-loading valve / installation set

9.4 Mounting

The measuring cell is fastened to the mounting plate at the

factory.

Individual AQC-D12 measuring cell

1. Drill two dowel holes with a diameter of 8 mm and min. 50 mm

deep. See section 8.4 Dimensions / drilling diagram.

2. Mount the measuring cell and the mounting plate on the wall

using the mounting material provided.

Fig. 10 Mounting of AQC-D12 measuring cell

Preassembled systems

1. Drill four dowel holes with a diameter of 10 mm and min. 60

mm deep. See section 8.4 Dimensions / drilling diagram.

2. Mount the preassembled system and the mounting plate on

the wall using the mounting material provided. Distance

between the mounting plate and the wall:

min. 20 mm.

Fig. 11 Mounting sequence for preassembled systems

Caution

Transport device carefully, do not throw.

Store in dry conditions between -20 and +65 °C.

Store electrodes between -10 and +30 °C. Keep

protective caps moist with 3-molar potassium

chloride solution.

Caution

Do not allow any foreign bodies to enter!

Warning

For safety reasons, the customer must install an

earth leakage circuit breaker for the measuring

amplifier.

Caution

Non-observance of the installation requirements may

result in damage or errors in measurement!

Note

For safety during service and maintenance, switch

off the measuring amplifier and the measuring cell at

all poles.

For easy switch-off, install an all-pole mains switch in

front of the measuring amplifier.

Note

The installation of the sample-water feed pipe must

not contain any copper. Copper interferes with the

measurement and can damage the electrodes.

TM04 8624 3912

Caution

The measuring cell or preassembled system must be

mounted vertically!

TM03 5856 1106

Caution

Do not pinch the cable!

Observe the mounting sequence below.

TM03 5857 1106

F

V

U

F

20 mm

English (GB)

12

10. Startup

10.1 Installation of electrodes and sensors

10.1.1 Fitting of electrodes

1. Unscrew the plugs of the holders (A, B) to be used.

2. Remove the protective caps from the electrodes. Keep them

for electrode removal.

3. Screw the electrodes into the holders by hand.

– Screw reference electrode in location K.

– Screw pH electrode in location A.

– Screw redox electrode in location B.

Fig. 12 Holders for electrodes

10.1.2 Water sensor

10.1.3 Temperature sensor

1. Remove lock screw (C2), store for later use.

2. Screw in Pt100 temperature sensor (C1) (optional).

Fig. 13 Temperature sensor

10.2 Checking the position of the cleaning wing

1. Visual inspection:

– The cleaning wing (S) must be seated on the measuring

electrode as shown.

Fig. 14 Position of the cleaning wing

2. If the cleaning wing is not seated correctly:

– Screw out the measuring electrode.

– Insert cleaning wing into the bore of the measuring electrode

using the entry pilot. It must be possible to freely move the

cleaning wing.

– Carefully screw in the measuring electrode again.

Caution

Observe the installation and operating instructions of

the electrodes!

TM04 8625 3912

Note

The water sensor is next to the cleaning wing.

pH (A) / Redox (B)

K

pH (A) / Redox (B)

J

F

E

TM04 8626 3912

Caution

The cleaning wing falls out when the measuring

electrode (J) is removed.

TM04 8627 3912

C

C2

S

J

English (GB)

13

10.3 Water connections

If the counterpressure may fall below 0.3 bar or if there is an open

outflow, a pressure-loading valve must be fitted to the outlet of

the measuring cell.

1. Connect the sample water inlet and outlet to the connections

for the sample water inlet (E) and outlet (F).

Fig. 15 Water connections

10.3.1 Mounting the pressure-loading valve

1. Unscrew the connection of the sample water outlet (F).

2. Screw the pressure-loading valve and adaptor (V) onto the

measuring cell outlet.

3. Screw the connection of the sample water outlet onto the

pressure-loading valve.

Fig. 16 Pressure-loading valve

10.4 Preparing the electrode cable for connection to

the measuring amplifier

Cables for electrodes (A, B, K)

1. Cut the electrode cables to the desired length plus

approximately 80 mm for the connections.

2. Remove 80 mm of the outer insulation.

3. Disentangle the braided screen until you reach the next part of

the insulation, and twist it to form a wire.

4. Strip the braided screen (for instance using a shrink hose),

and fit a wire end ferrule.

5. Remove the black (conductive) sheath of the insulated

electrode wire until you reach the insulation.

6. Dismantle the end of the electrode wire.

7. Fit a wire end ferrule to the electrode wire.

Fig. 17 Cable for electrodes (A, B, K)

Cable for measuring electrode (D), temperature sensor (C),

water sensor (D)

1. Cut cables to the desired length plus approximately 65 mm for

the connections.

2. Remove 65 mm of the outer insulation.

3. Dismantle the end of the wires.

4. Fit wire end ferrules to the wires.

Warning

Danger of injuries!

At a pressure of more than 3 bar and if the

measuring cell is not deaerated, the cell might burst.

Do not exceed the max. system pressure of 3 bar.

Fit pressure reducer, if necessary.

Caution

Observe the local pressure! The permissible primary

water pressure is 0.3 to 3.0 bar.

Fit a pressure booster pump, if necessary.

Check the tightness of the measuring cell.

Caution

Only tighten the union nut by hand. Do not use any

tools!

TM04 8628 3912TM04 8788 1313

Caution

Observe the correct installation of the

pressure-loading valve. The arrow on the

pressure-loading valve must point in flow direction!

F

E

F

V

Note

The preassembled systems are prewired.

Warning

The electrical connection should be carried out by

qualified personnel!

Observe the local safety regulations!

Protect the cable connections and plugs against

corrosion and humidity.

TM03 5868 1106

TM03 5869 1106

70 10

Insulated

braided

screen

English (GB)

14

10.5 Electrical connections

Preassembled systems

The preassembled systems are prewired.

1. Connect an earth leakage circuit breaker in front of the

measuring amplifier.

2. Connect the electricity supply to the measuring amplifier.

AQC-D12 measuring cell

1. Connect electrodes to the corresponding terminals of the

measuring amplifier.

2. Connect measuring electrodes to the corresponding terminals

of the measuring amplifier. Fit the screen according to the

installation and operating instructions of the measuring

amplifier and controller.

3. Connect the water sensor to the corresponding terminals of

the measuring amplifier.

4. Connect an earth leakage circuit breaker in front of the

measuring amplifier.

5. Connect the electricity supply to the measuring amplifier.

Fig. 18 Conex DIA-1 / DIA-2 / DIA-2Q for panel-mounting

Fig. 19 Conex DIA-1 / DIA-2 / DIA-2Q for wall-mounting

Warning

The electrical connection should be carried out by

qualified personnel!

Before connecting the supply cables, check that the

supply voltage specified on the nameplate

corresponds to the local conditions!

Before connecting the supply cables, switch off the

electricity supply!

Observe the local safety regulations!

Protect the cable connections and plugs against

corrosion and humidity.

Connect an earth leakage circuit breaker in front of

the measuring amplifier.

Caution

Observe the installation and operating instructions of

the measuring amplifier and controller!

Note

The cables are not preconnected. See section

10.4 Preparing the electrode cable for connection to

the measuring amplifier.

Caution

Observe the installation and operating instructions of

the measuring amplifier and controller!

Caution

Before connecting the supply cables, check that the

supply voltage specified on the nameplate

corresponds to the local conditions!

Observe the installation and operating instructions of

the measuring amplifier and controller!

TM04 8629 3912TM04 8630 3912

1/11

1/13

4/1

1/12 1/14

4/3

4/2

4/4

3/1 3/3

3/2 3/4

B

A

1

4

Conex

2/3

2/4

+

-

12

MB/RG/C

7

1

6

Pt 100

2

8

9

1

4

11

8

11

12

9

10

Sensorinterface

7

1

37

38

39 40 41 42

6

12

4

1

15 17

19

21 23 25 27 29 31 33 35

363432302826242220

18

16

9

8

2

1

4

11

8

11

12

9

10

English (GB)

15

Fig. 20 Conex DIS-D

Fig. 21 DIP

10.6 Checks prior to start-up

• Check the tightness of the whole system.

• Check the electrical connections.

10.7 Switching on

Fig. 22 Setting the quantity of sample water

1. Close the sample water shut-off valve (X).

2. Close the regulation of sample water quantity (G).

3. Close the sampling cock (I).

4. Open the inlet and outlet side of the customer's sample water

connection.

5. For deaeration, loosen the pH or redox electrode until the air

has escaped, then fasten it.

6. Open sample water shut-off valve (X) approx. two turns up to

the limit stop.

7. Open regulation of sample water quantity (G) slowly.

– Avoid turbulent flow!

8. Check that the cleaning wing (S) rotates.

– Try, if necessary, to briefly increase the quantity of sample

water with the regulation of sample water quantity (G) in

order to move the cleaning wing.

– If the cleaning wing still does not rotate, check and correct

its position, if necessary. See section 10.2 Checking the

position of the cleaning wing.

9. Switch on the measuring amplifier.

10. Only switch on the device controlled after the first calibration,

if applicable.

TM04 8631 3912TM04 8632 3912

Pos. Description

1Brown

2White

3Black

4Blue

6 Outer conductor (screen)

7 Inner conductor

8 Reference electrode

9 Measuring electrode with counter-electrode

10 Counter-electrode

11 Pt100 temperature sensor (not with Conex DIS-C)

12 Water sensor

7

1

6

9

8

2

20 2122

19

12

4

1

14 16

8

12

9

10

7

1

6

12

4

9

8

2

1

4

1

53

55 57

54 56 58

63 65

64

66

11

8

11

12

9

10

Caution

Observe the installation and operating instructions of

the measuring amplifier and the device controlled!

Warning

At a pressure of more than 3 bar and if the

measuring cell is not deaerated, the cell might burst.

Ensure draining and deaeration.

Do not exceed the max. system pressure of 3 bar.

Do not put a damaged measuring cell under

pressure!

Caution

At first start-up or after long-term stop: Let the

system run for at least two hours to avoid faulty

measurements and calibration!

TM04 8633 3912

I

GX

English (GB)

16

10.7.1 Setting the quantity of sample water

A correct measurement can only be taken, if the quantity of

sample water is within a defined range. This range is from 200 to

800 rotations/minute of the cleaning wing.

• Set the quantity of sample water with the regulation (G) so that

the measuring amplifier shows a sample water flow rate of 200

to 800 rotations/minute. The bar in the display of the

measuring amplifier shows the range. The exact speed can be

taken from the service menu.

10.8 Calibrating the parameters Cl

2

, ClO

2

, O

3

Due to the electro-chemical behaviour of the measuring cell, no

zero-point adjustment is necessary. Only the rate of rise

(sensitivity) must be adjusted during calibration.

• Check the calibration after 24 hours. Repeat, if necessary.

10.8.1 Photometrical determination of a reference value

1. Open the sampling cock (I), and let the water run for a few

seconds.

2. Take a water sample, and close the sampling cock.

3. Determine the concentration of the measuring parameter

photometrically, for instance using the Grundfos DIT hand

photometer.

4. Keep this value as a reference value.

10.8.2 Calibration example based on chlorine measurement

with pH compensation (not with Conex DIS-D)

• Define the basic settings for the measuring amplifier.

Calibrating the pH value

• DIP: Push the button underneath the right-hand display.

• Conex DIA and DIP: Use the [CAL] button to select the

calibration function CAL. The LED illuminates.

1. If necessary, enter the code number for CAL (or full)

authorisation.

2. Change to the menu "calibration" with the [OK] button.

3. Select the measured variable "pH", and confirm with [OK].

– Selection possibilities: "cal. meas. value" (= measured

value), "cal. result" and "cal. cycle" (= count-down function

which triggers the alarm "calibrate sensor" after a selectable

time interval of 1-100 days).

4. Select the line "cal. meas. value" with [UP]/[DOWN].

5. Select one of the defined buffer solutions ("GRUNDFOS",

"DIN/NIST", "others"), and press [OK].

– The menu "temperature" is selected automatically.

6. Enter the temperature of the buffer solutions.

7. Press [OK] to jump to the menu "buffer value 1".

8. "GRUNDFOS" or "DIN/NIST" buffer solutions: Select one of

the available buffer values.

Caution

At first start-up or after long-term stop: Let the

system run for at least two hours to avoid faulty

measurements and calibration!

Caution

During calibration: Keep pH value, sample water flow

rate and water temperature constant.

Caution

Observe the installation and operating instructions of

the photometer!

Caution

Observe the installation and operating instructions of

the measuring amplifier and controller!

Note

When carrying out a chlorine measurement with pH

compensation, the pH value must be calibrated first,

since the pH value is used when calibrating the

chlorine value!

pH

cal. meas. value

cal. result

cal. cycle

buffer

GRUNDFOS

DIN/NIST

others

buffer value 1

4.01 pH

7.00 pH

9.18 pH

English (GB)

17

Buffer 1

1. Fill buffer solution 1 from the supply bottle into a clean vessel.

2. Remove the electrode from the measuring cell, and immerse

in the buffer solution.

3. Press [OK] to read in the temperature of the sample water and

the measured signal.

4. Discard buffer solution 1.

– Do not return the used buffer solution to the supply bottle!

5. Flush electrode with water.

6. Press [OK] to jump to the menu "buffer value 2".

Buffer 2

1. Select buffer value 2.

2. Fill buffer solution 2 into a clean vessel.

3. Immerse the electrode.

4. The measured signal is read in and compared with the buffer

values.

– The calibration result (sensor slope and asymmetry

potential) is displayed.

5. Discard buffer solution 2.

6. Flush the electrode with water, and return to the measuring

cell.

7. Go back to the menu "calibration" with [ESC].

Then calibrate the chlorine value.

Calibrating the chlorine value

• DIP: Push the button underneath the left-hand display.

• Conex DIA and DIP: Select the calibration function with the

[CAL] button. The LED illuminates.

1. Press [OK] to select the menu "calibration".

2. Select "chlorine", and confirm with [OK].

3. Select "cal. meas. value".

4. Enter the reference value.

– The measured signal is read in automatically and compared

with the reference value.

– The calibration result (sensor slope) is displayed.

Reading calibration data in the diagnostics menu "service"

• Select "service" in the "main menu" with [UP]/[DOWN], and

press [OK] (DIP: on both displays).

– The data of the last 10 calibrations can be read.

10.8.3 Calibrating the parameters chlorine, chlorine dioxide

or ozone with Conex DIS-D

1. Press the [CAL] button to select the calibration menu.

– The CAL LED next to the [CAL] button illuminates.

– The display shows the current measured value.

– To prevent overdosing, the controllers must be switched off,

and the device controlled must be closed.

2. Use [UP]/[DOWN] to select the reference value.

3. Start the calibration with [OK].

– The sensor data are then read in.

– The slope (sensitivity) of the sensor is calculated.

– The calibration result is displayed immediately after

calibration.

– The sensor slope is displayed in µA/ppm.

Calibration result

• The result of the current (last) calibration can be displayed in

the code menu at any time:

– Code 51: display of calibrated slope in µA/ppm.

Error message when reading in the current signal of the

sensor system

• The alarm LED flashes.

• The display shows code *13* (slope error).

The alarm is triggered, if the plausibility check results in an

upward or a downward violation of the following slope ranges,

depending on the selected measuring cell:

• Press [OK] to acknowledge the error message and to return to

the display level.

– The calibration data are imported.

CALDATA pH

slope

- 60.17 mV/pH

asym.pot

19 mV

chlorine

cal. meas. value

cal. result

cal. cycle

CALDATA chlorine

slope

34.67 µA/ppm

Measuring cell Lower limit Upper limit

AQC-D12 2.5 µA/ppm 70.0 µA/ppm

Note

The controller is operating in emergency mode!

Eliminate the fault, see section 11.5 Fault finding,

and calibrate again!

English (GB)

18

11. Operation

11.1 Function

Various oxidation agents are used for the disinfection of

swimming-pool water and drinking water, for instance chlorine

(Cl

2

), chlorine dioxide (ClO

2

) and ozone (O

3

).

It is necessary to measure the concentration of the oxidation

agent and to regulate its dosing.

• Concentration of oxidation agent is too low:

– Disinfection effect is too weak.

• Concentration of oxidation agent is too high:

– Danger to health

– Unpleasant odour and taste

– Corrosion damage

– Increased operating costs.

The AQC-D12 measuring cell is used for measuring the

concentration of chlorine (Cl

2

), chlorine dioxide (ClO

2

) or ozone

(O

3

). It is equipped with a water sensor, an optional Pt100

temperature sensor and additional holders for pH electrodes and

redox electrodes.

Preassembled systems with Conex DIA, Conex DIS and DIP are

used when the values of decontamination agents, pH and

redox-potential have to be determined and controlled. The basic

element of the preassembled systems is the AQC-D12 measuring

cell.

11.1.1 Functional principle of measurement

• Sample water is taken at a representative position and passed

to the measuring cell via an integral filter.

– The water flow rate can be adjusted on the measuring cell.

– A water sensor serves to trigger an alarm or to switch off the

control function, if there is a sample water deficiency. It is

also used for checking the cleaning wing.

– The agent to be determined (Cl

2

, ClO

2

or O

3

) is measured at

the gold or platinum electrode.

• The agent to be determined generates an electric current in

the µA range, proportional to its concentration.

– The measuring cell is controlled by a potentiostat in the

measuring amplifier.

– A constant voltage is applied to the measuring electrode. An

exactly defined potential of the measuring electrode is

retained by means of the reference electrode. This results in

a linear response for the measuring cell as well as a stable

zero point for the measurement.

• The Conex or DIP measuring amplifiers and controllers

– amplify the current

– calculate it using the calibration parameters

– display the concentration as a digital value

– control a gas dosing unit or a dosing pump (device

controlled).

11.1.2 Electrode cleaning

The measuring electrode and the counter-electrode are

continuously cleaned of deposits by a cleaning wing.

• This ensures uniform sensitivity for the measuring cell over a

long period.

• The cleaning wing is driven hydraulically.

11.1.3 Influence of temperature

The current generated on the electrodes depends on the

temperature of the sample water.

• The measured value increases by approx. 4 % per 1 °C

increase.

• Temperature variations can be compensated by the measuring

amplifier, if the temperature compensation function is

activated.

– The temperature can be measured with a Pt100 temperature

sensor optionally integrated into the measuring electrode.

– The temperature measuring signals are transferred to the

measuring amplifier and calculated using the electrode

signals.

11.1.4 Influence of the pH value on the chlorine measurement

Free, active chlorine is considered as the total of molecular

chlorine gas (Cl

2

), hypochlorous acid (HOCl) and hypochlorite

anions (OCl

-

). Dissolved chlorine gas in molecular form

practically does not exist at the application-dependent pH values

(pH 4.5 to 8.2), but is subject to hydrolysis in the presence of

water according to the equation

Cl

2

+ H

2

O HOCl + HCl

The resulting hypochlorous acid is the actually effective

compound for disinfection of the water. The dissociation of acid to

anions is primarily according to an equilibrium dependent on the

pH value according to the equation

HOCl + H

2

O H

3

O

+

+ OCl

-

Fig. 23 HOCl-OCl diagram

The measuring cell for chlorine primarily only determines the

portion of hypochlorous acid that is relevant for disinfection.

Since the dependence on the pH value is particularly large in the

actually relevant range between pH 7 and pH 8.2, this

dependence must be compensated for in the measuring amplifier

if the pH value varies considerably. The pH value must therefore

also be measured, and the pH compensation function must be

activated on the measuring amplifier.

TM03 5879 1106

4

100

% HOCl

80

60

40

20

0

20

40

60

80

100

% OCl

-

pH

0 °C

10 °C

30 °C

OCl

-

HOCl

5

6

7

89

10 11

English (GB)

19

11.2 Operation

11.2.1 Switching on

See section

10.7 Switching on.

11.2.2 Operating state

11.2.3 Adjusting / setting the quantity of sample water

A correct measurement can only be taken, if the quantity of

sample water is within a defined range. This range is from 200 to

800 rotations/minute of the cleaning wing.

• Set the quantity of sample water with the regulation (G) so that

the measuring amplifier shows a sample water flow rate of 200

to 800 rotations/minute. The bar in the display of the

measuring amplifier shows the range. The exact speed can be

taken from the service menu.

11.3 Switching off

11.3.1 Short-term stop (up to one week)

1. Close and/or switch off the device controlled.

2. Wait until the display of the measuring amplifier is at zero.

3. Switch off the electricity supply to the measuring amplifier.

4. Close the connection to the sample water inlet (E) and outlet

(F).

11.3.2 Long-term stop

1. Close and/or switch off the device controlled.

2. Wait until the display of the measuring amplifier is at zero.

3. Switch off the electricity supply to the measuring amplifier.

4. Close the connection to the sample water inlet (E) and outlet

(F).

5. Open the sampling cock (I), and drain water.

6. Remove the measuring electrode (J), clean and store dry.

7. Remove the reference electrode (K), and remove the pH

electrode (A) and redox electrode (B), if applicable. Fit thread

protection caps, and clean the electrodes.

8. Fit protective caps on the electrodes. The protective caps

must be filled with 3-molar potassium chloride solution.

9. Store electrodes with protective caps in a dry place. If they are

stored for an extended period of time, it may be necessary to

add 3-molar potassium chloride solution after a while.

10. Before starting up again, and if it is very dirty, clean the whole

measuring cell. See section

12. Maintenance.

11.4 Switching on again

11.4.1 After short-term stop

1. Open the connection to the sample water inlet (E).

2. Open the connection to the sample water outlet (F).

3. Check the quantity of sample water.

4. Switch on the measuring amplifier.

5. Take a reference measurement.

6. Recalibrate, if necessary. See section

10.8 Calibrating the

parameters Cl

2

, ClO

2

, O

3

.

7. Switch on the device controlled, if applicable.

11.4.2 After long-term stop / inspection

If the measuring cell has been switched off for a long period of

time or has been emptied, for instance for inspection, it is

necessary to start up the measuring cell. See section

10.6 Checks prior to start-up and 10.7 Switching on.

Caution

Observe the installation and operating instructions of

the measuring amplifier and the device controlled!

Note

For information on operation of the measuring cell in

the operating state, please see the installation and

operating instructions of the relevant measuring

amplifier.

Caution

The measuring cell may be damaged if the reference

electrode (K) is not connected, and the electricity

supply is switched on!

Caution

Observe the installation and operating instructions of

the measuring amplifier and controller!

Note

The delay time of the measuring cell can be reduced

by increasing the sample water flow rate.

Caution

To avoid a dosing error, the device controlled must

be switched off each time the measuring system is

switched off.

Observe the installation and operating instructions of

the measuring amplifier and the device controlled!

Caution

To protect the electrodes, do not drain the water!

Make sure that the water level in the measuring cell

is sufficiently high for the reference electrode (K) to

be immersed at least 2 cm during device stop.

Caution

Observe the installation and operating instructions of

the electrodes!

Caution

Observe the installation and operating instructions of

the measuring amplifier and the device controlled!

Caution

Let the system run for at least two hours to avoid

faulty measurements and calibrations!

English (GB)

20

11.5 Fault finding

Caution

Observe the installation and operating instructions of

the measuring amplifier and controller!

Fault Cause Remedy

1. No display. No electricity

supply to the measuring

cell.

a) A disinfection or oxidation agent is missing in the

sample water.

Check the concentration by making a reference

measurement. Check the dosing units, and

activate dosing. Check the settings of the

measuring amplifier.

b) The electrode cable connection is interrupted. Remake the connection. Replace damaged

cables.

c) No or too low sample water flow rate. Clean the filter, check the flow rate, and check

the sample water inlet pressure.

d) The measuring electrode is faulty. Replace the measuring electrode.

e) The measuring electrode is contaminated or made

passive by deposits.

Dismantle, clean or replace the measuring

electrode.

2. The measured value is

lower than the reference

measurement.

a) The measuring electrode is faulty. Replace the measuring electrode.

b) The measuring electrode is contaminated or made

passive by deposits.

Remove, clean or replace the measuring

electrode.

c) The temperature has fallen since the calibration. Activate the automatic temperature

compensation, if applicable. Recalibrate.

d) The system has run too short time prior to

calibration.

Let the system run for at least two hours.

Recalibrate.

e) Unsuitable chlorination agent. Only use chlorine solutions such as chloric gas,

sodium hypochlorite and chlorinated lime. Do

not use organic products such as

trichloroisocyanuric acid.

f) Incorrect reference measurement during

calibration.

Check the reference measurement, and take

another measurement. Recalibrate.

g) The pH value for the chlorine measurement has

risen since the calibration.

Keep the pH value constant. Activate the pH

value compensation, if applicable. Recalibrate.

h) The quantity of sample water is set too low. Check and set the quantity of sample water.

Check the filter, and clean it, if necessary.

i) The cleaning wing is blocked. Fit the cleaning wing correctly.

3. The measured value is

higher than the reference

measurement.

a) The temperature has risen since the calibration. Activate the automatic temperature

compensation, if applicable. Recalibrate.

b) The pH value for the chlorine measurement has

fallen since the calibration.

Keep the pH value constant. Activate the pH

value compensation, if applicable. Recalibrate.

c) Interference by other oxidation agents in the

sample water.

Analyse the sample water. Check the chemicals

used.

4. The measured value is

unstable.

a) Interferences on the signal lines. Check the screen and the connections to the

amplifier.

b) The reference electrode diaphragm is blocked. Clean the diaphragm (on the side at the bottom

of the reference electrode) using diluted

hydrochloric acid (10 %). Replace the reference

electrode, if necessary.

c) The measuring electrode is contaminated or faulty. Clean the measuring electrode using a diluted

abrasive cleaning agent. Replace measuring

electrode, if necessary.

d) The filter is contaminated, and the quantity of

sample water is therefore too low.

Check the filter, and clean it, if necessary.

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Grundfos AQC-D12 Installation And Operating Instructions Manual

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