OPTOD NUMERICAL

SENSOR

User manual

AQUALABO CONTROLE 1 Version 1.1

35 Rue Michel Marion – 56850 CAUDAN, FRANCE Update: January 2016
Tel.: +33(0) 1 72 87 97 90
 CONTENTS

1. GENERAL ..............................................................................................................3

2. CHARACTERISTICS .............................................................................................4
2.1 Technical characteristics................................................................................................................ 4
2.2 CE compliance................................................................................................................................. 5

3. DESCRIPTION. ......................................................................................................6
3.1 Product overview............................................................................................................................. 6
3.2 Applications ..................................................................................................................................... 6
3.3 Construction and dimensions........................................................................................................ 6
3.4 Communication. .............................................................................................................................. 7
3.4.1 Modbus RTU registers. ............................................................................................................... 7
3.4.2 SDI12 frame................................................................................................................................ 7
3.5 Compensation.................................................................................................................................. 8
3.5.1 Influences on the measurement. ................................................................................................ 8
3.5.2 Temperature compensation. ....................................................................................................... 8
3.5.3 Atmospheric pressure. ................................................................................................................ 8
3.5.4 Salinity......................................................................................................................................... 8
3.6 Sampling rate ................................................................................................................................... 8

4. INSTALLATION. ....................................................................................................8
4.1 Sensor installation option .............................................................................................................. 8
4.1.1 Accessories for immersion installation........................................................................................ 8
4.1.2 Accessories for PVC pipe-mounting ......................................................................................... 11
4.1.3 Accessories for stainless steel pipe-mounting.......................................................................... 11
4.2 Installation of the sensor in the accessories of assembly........................................................ 12
4.2.1 Insertion in a pole...................................................................................................................... 12
4.2.2 Insertion into the PVC in-pipe mounting system....................................................................... 13
4.2.3 Insertion into the Stainless steel in-pipe mounting system....................................................... 13
4.3 Electrical connections. ................................................................................................................. 14

5. STARTUP AND MAINTENANCE........................................................................14

5.1 Initial startup .................................................................................................................................. 14
5.2 Calibration ...................................................................................................................................... 15
5.2.1. Calibration in 2 point. ............................................................................................................... 15
5.2.2. Calibration in 1 point. ............................................................................................................... 16
5.3 Maintenance ................................................................................................................................... 16
5.3.1. Cleaning. .................................................................................................................................. 16
5.3.2. Change of the DODISK............................................................................................................ 17
5.3.3. Storage. ................................................................................................................................... 17

AQUALABO CONTROLE 2 Version 1.1

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 1. General

In order to maintain and ensure the good working order of the OPTOD sensor, users must comply with
the safety precautions and warnings featured in this manual.

Assembly and activation:

- Assembly, electrical connection, activation, operation and maintenance of the measuring system
must only be carried out by specialist personnel authorized by the user of the facilities.
- Trained personnel must be familiar with and comply with the instructions in this manual.
- Make sure the power supply complies with the specifications before connecting the device.
- A clearly-labeled power switch must be installed near the device.
- Check all connections before turning the power on.
- Do not attempt to use damaged equipment: it may represent a hazard and should be labeled as
faulty.
- Repairs must only be carried out by the manufacturer or by AQUALABO CONTROL's after-sales
service department.

Marking on the body of the sensor:

The marking on the body of the sensor indicates the serial number of the sensor (for the traceability)
and the LOGO CE.

1 2 3

1 Datamatrix (contains the serial number)

2 Serial number OPTOD sensor : SN-PODOX-
YYYY
X : version
YYYY : number
3 CE mark

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 2. Characteristics
2.1 Technical characteristics.
The technical characteristics can be modified without advance notice.
Measures
Measure principle Optical measure by luminescence
0,00 to 20,00 mg/L
Measure ranges 0,00 to 20,00 ppm
0-200%
Resolution 0,01
+/- 0,1mg/L
Accuracy +/- 0,1 ppm
+/- 1 %
Response time 90% of the value in less than 60 seconds
Frequency of recommended measure >5 s
Water move No necessary move
Via NTC
Temperature compensation
(compensation active for temperature lower than 0°C)
Measurement range (Temperature) 0.00 to 50.00 °C
Resolution (Temperature) 0.01 °C
Accuracy (Temperature) 0.5°C
Storage temperature - 10°C to + 60°C

Sensor
Dimensions Diameter : 25 mm ; length : 146 mm
Stainless steel version 450g (sensor + cable 3 m)
Weight
Titanium version 300 g (sensor + cable 3 m)
Standard Version in passivated Stainless steel 316L body,
strainer and screw,

For Seawater application Version in Titanium body, strainer

and screw,
Wetted material
Cable : polyurethane jacket
Steam gland : Polyamide

Patch with active material (black) – DO DISK : Optical

isolation silicon
No cross-sensitivity with :
pH 1 – 14 ; CO2, H2S, SO2
DO disk
Cross-sensitivity to Organic solvents, such as acetone,
toluene, chloroform or methylene chloride
Chlorine gas
Maximum pressure 5 bars
IP classification IP68
9 armoured connectors, polyurethane jacket, bare-wires or
Connection
waterproof Fisher connector
Standard : 3, 7 and 15 m (other length on request).
Sensor cable
100 m Max. Up to 100 m with junction box.
Communication – Power supply
Signal interface Modbus RTU RS-485 and SDI-12
5 to 12 volts for cable 0-15 m
Power requirements 7 to 12 volts for cable >15 m
Max. 13.2 V
Standby 25 µA
Average RS485 (1 measure/ seconde) : 4,4 mA
Average SDI12 (1 measure/ seconde) : 7,3 mA
Consumption
Current pulse : 100 mA
Heating time : 100 mS
Protection against the inversions of polarity

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 2.2 CE compliance.

Pursuant to the article 11 of the directive 89 / 336 / EEC relative to the electromagnetic compatibility.

We declare that the digital sensor of the range DIGISENS sensor OPTOD was tested and declared in
compliance with the European standards :

Standard tests : EN 61326-1 edition 2013

Emission - EMC EN 55022 Class B
Immunity - EN 61000-4-3 A
EN 61000-4-2 B
EN 61000-4-6 A
EN 61000-4-4 B
Shone disturbances : EN 55011B

Identification of the measurement process : composed of :

1- one probe
2- Ponsel’s cable.
EN 61000-4-5 Not concerned for sensors with a cable lower or equal to 30 M

Commercial name : DIGISENS range

Manufacturer AQUALABO CONTROLE –Ponsel Mesure

35 Rue Michel MARION
56850 CAUDAN

Responsible UE : AQUALABO CONTROLE – Ponsel Mesure

35 Rue Michel MARION
56850 CAUDAN

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 3. Description.
3.1 Product overview

The OPTOD dissolved oxygen sensor applies the luminescence-based optical measurement
technology and measures reliably and accurately without requiring calibration.
With no consumables or maintenance required, the OPTOD sensor gives an immediate return on the
investment. The only intervention required is to replace the DO disk every two years.
Since it does not consume oxygen, the OPTOD sensor can be used in all media; even when there is a
very weak flow of water.

The OPTOD sensor offers the following advantages:

• Low operating costs due to reduced maintenance work (no electrolyte changes)
• Greater calibration intervals due to low drift behaviour
• No polarization voltage required • High measuring accuracy, even for low concentrations • Rapid
response times
• No minimum inflow (no oxygen consumption)
The sensor features excellent interference immunity thanks to the integrated preamplifier and digital
signal processing. The measured value for dissolved oxygen is automatically compensated with the
temperature, air pressure, and salinity (salt content), and transferred without interference to the
connected display unit and controller via a digital interface. The membrane cap is easy to replace,
meaning the sensor is very easy to maintain. The current calibration data is saved directly in the
sensor electronics. As a result, the Plug and Play function of the system is enabled without the need
for recalibration. The sensor also includes a log book containing the last ten successful calibrations in
the form of a ring buffer.

3.2 Applications

The compact and robust stainless steel or titanium sensor is particularly well suited to the following
typical areas of application:
• Industrial and municipal sewage treatment plants
• Wastewater management (nitrification and de-nitrification)*
• Surface water monitoring
• Fish farming, aquaculture
• Drinking water monitoring

3.3 Construction and dimensions.

1 2 3 4 5

(1) Stainless steel membrane cap (or titanium) with DODISK

(2) Membrane cap seal
(3) Sensor body with measurement electronics
(4) Cable bushing
(5) Securely connected connection cable

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 3.4 Communication.
3.4.1 Modbus RTU registers.
The link protocol must correspond to MODBUS RTU.
See document:
- Modbus_over_serial_line_V1_02.pdf
- Modbus_Application_Protocol_V1_1a.pdf
- Modbus memory for PONSEL digital Sensors :
SENSOR_TramesCom_xxx_UK.xls (refer to http://www.ponsel-
web.com/)

The Modbus memory plane is identical for each parameter of the Sensors.
The Modbus protocol for the Sensors allows you to measure the parameter (+ temperature) of the
Sensor and to calibrate the parameter (+ temperature). Furthermore, there are certain numbers of
functions such as:
- Select the averaging value
- Read the Sensor description
- Return to default coefficients
- Modify the Sensor address
- Information on measures conducted (Out Of Specification
measures, measures in progress, etc.).
- Date and name of the operator who performed the calibration
- etc.

To have more information on the open PONSEL’s Modbus protocol please consult the last version of
the following documents :
- the pdf file : Modbus_SpecificationsVxxx-EN
- the excel file : Digital sensor Frame_XXX_UK

3.4.2 SDI12 frame.

A list of SDI12 registers is available for network communication. Refer to http://www.ponsel-web.com/

for more information.

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 3.5 Compensation

3.5.1 Influences on the measurement.

The oxygen measurement is dependent on parameters:
• The temperature of the measurement medium
• The air pressure (atmospheric pressure)
• The salinity of the measurement medium
The degree of solubility of oxygen in water is dependent on the temperature, the salinity, and
the air pressure. This dependency is stored in the sensor's measurement electronics in the
form of functions. The sensor can therefore determine the oxygen concentration of the measurement
medium, in order to digitally transmit the influencing factors above, in compensated form, to the
transmitter/controller.

3.5.2 Temperature compensation.

The temperature compensation is automatic and managed directly by the sensor via the integrated
sensor of temperature (NTC).

3.5.3 Atmospheric pressure.

With the most frequently used calibration method – end value calibration of the sensor in water
vapor-saturated air – the air pressure must be taken into account.
For this purpose, the air pressure can, for example, be transmitted to the sensor by the way of your
terminal, where it is saved.
By default the value of the atmospheric used for the compensation is 1013 hPa.

3.5.4 Salinity.
The value for the salinity of the measurement medium could be transmitted to the sensor by the way of
your terminal.
By default the value of the salinity used for the compensation is 0 g/Kg.

3.6 Sampling rate

Optical oxygen sensors do not carry out any continuous measurements.To extend the operating life of
the optical membrane, the measurement interval can be set to a value superior to 10 seconds.

4. Installation.
4.1 Sensor installation option

For the installation of the sensors in condition of immersion or in-pipe insertion, we advise to use
accessories adapted and proposed by AQUALABO CONTROLE.

4.1.1 Accessories for immersion installation.

In immersion condition, it is necessary to maintain the sensor by the body and not to leave the sensor
suspended by the cable at the risk of damaging the sensor
AQUALABO CONTROLE proposes a range or pole (short and long version) in order to install the
sensor in open basins. It can be positioned a considerable distance from the basin edge with the
bracket suspended on a chain, for example.
Please note the following when planning your set-up:
• The fitting must be easily accessible to allow the sensor or the fitting itself to be maintained
and cleaned regularly
• Do not allow the fitting (and thus also the sensor) to swing against and hit the basin edge
• When working with systems involving pressure and/or temperature, ensure that the fitting
and sensor meet all relevant requirements
• The system designer must check that the materials in the fitting and sensor are suitable for
the measurement (chemical compatibility, for instance)

Material PVC
Admissible temperature 0 to 60 °C
Pressure max. 5 bars

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 Short pole
The short pole is available in 2 versions :
- version with elbowed shutter. The nozzle of support is included in
the offer.
Elbowed shutter
STRAIGHT SHORT POLE
PF-ACC-C-00266 FOR OPTOD SENSOR (1495
Ring shutter mm, ELBOWED SHUTTER)
STRAIGHT SHORT POLE
PF-ACC-C-00267 FOR PHEHT SENSOR (1495
mm, ELBOWED SHUTTER)
STRAIGHT SHORT POLE
FOR C4E/NTU SENSOR
PF-ACC-C-00268
(1495 mm, ELBOWED
SHUTTER)
- version with shutter for mounting with chain The nozzle of
support is included in the offer.

STRAIGHT SHORT POLE

PF-ACC-C-00269 FOR OPTOD SENSOR (1550
mm, RING SHUTTER)
STRAIGHT SHORT POLE
PF-ACC-C-00270 FOR PHEHT SENSOR (1550
Nozzle mm, RING SHUTTER)
STRAIGHT SHORT POLE
PF-ACC-C-00271 FOR C4E/NTU SENSOR
(1550 mm, RING SHUTTER)

Long pole
The long poles are available in elbow version, for installations in aeration basin, and straight, for
applications in open channel. Every pole is equipped with an elbowed shutter and with waterproofness
joints. The lower part includes a nozzle which is adapted to the sensor what assures its mechanical
support.

Elbowed - Elbowed pole with elbowed shutter

shutter
90° ELBOW LONG POLE FOR
PF-ACC-C-00230 OPTOD SENSOR (2955 mm,
ELBOWED SHUTTER)
90° ELBOW LONG POLE FOR
PF-ACC-C-00261 PHEHT SENSOR (2955 mm,
ELBOWED SHUTTER)
90° ELBOW LONG PERCH
PF-ACC-C-00262 FOR C4E/NTU SENSOR (2955
mm, ELBOWED SHUTTER)

- Straight long pole with elbowed shutter

STRAIGHT LONG POLE FOR

PF-ACC-C-00263 OPTOD SENSOR (2745 mm,
ELBOWED SHUTTER)
STRAIGHT LONG POLE FOR
PF-ACC-C-00264 PHEHT SENSOR (2745 mm,
ELBOWED SHUTTER)
STRAIGHT LONG POLE FOR
PF-ACC-C-00265 C4E/NTU SENSOR (2745 mm,
ELBOWED SHUTTER)

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 Mounting accessories for pole.
The elements of fixation for the poles are flexible and specially studied to adapt themselves to the
different configurations of assembly.

- Pole kit fixation

Connection Connection
vertical pole/ horizontal axis/ POLE FIXATION KIT FOR
horizontal axis Pole NC-ACC-C-00009 NUMERICAL SENSOR
(ON LOW WALL)
POLE FIXATION KIT FOR
Horizontal NC-ACC-C-00010 NUMERICAL SENSOR
Vertical axis (ON LIFE LINE)
axis POLE FIXATION KIT FOR
NC-ACC-C-00011 NUMERICAL SENSOR
(ON VERTICAL AXIS)
VERTICAL AXIS FOR
PF-ACC-C-00272 NUMERICAL SENSOR POLE
(TO BE FIXED ON SOIL)

Example of mounting on vertical axis

Connection life line/

Horizontal axis
Horizontal axis

Life line

Chain

Exemple de montage sur garde-corps

Example of mounting on life line Example of mounting on low wall

- Accessories kit for assembly of poles with chain.

NC-ACC-C-00012 SHORT POLE FIXATION KIT FOR NUMERICAL SENSOR (ON LOW WALL)

NC-ACC-C-00013 SHORT POLE FIXATION KIT FOR NUMERICAL SENSOR (ON LIFE LINE)

NC-ACC-C-00014 SHORT POLE FIXATION KIT FOR NUMERICAL SENSOR (ON VERTICAL AXIS)
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 4.1.2 Accessories for PVC pipe-mounting

Every system of assembly is delivered with an adapter (and the appropriate joints) and one T of
assembly (45 ° for OPTOD sensor) to stick on a 50 mm diameter pipe. Its special design type ensures
the correct inflow to the sensor, thus preventing incorrect measurements.

Please note the following when planning your piping set-up:

• The fitting must be easily accessible to allow the sensor or the fitting itself to be maintained
and cleaned regularly
• We recommend bypass measurements. It must be possible to remove the sensor through
the use of shut-off valves
• When working with systems involving pressure and/or temperature, ensure that the fitting
and sensor meet all relevant requirements
• The system designer must check that the materials in the fitting and sensor are suitable for
the measurement (chemical compatibility, for instance)

1
2

Mounting system for OPTOD sensor (PF-ACC-C-00224)

4.1.3 Accessories for stainless steel pipe-mounting
The accessories of assembly for stainless pipe are proposed with an adapter and its joints with or
without the systems of clamp / Nipple. The acceptable maximum pressure for the sensors is 5 bars.
The system of assembly can be delivered with or without stainless steel clamp.
The adapter is compatible with a 51 mm diameter external clamp

Mounting system for OPTOD sensor (PF-ACC-C-00227)

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 4.2 Installation of the sensor in the accessories of assembly

4.2.1 Insertion in a pole.

The sensor is mounted on the relevant fitting as described below, using a sensor holder, which
can be used both for the short and long pole:

1 Guide the sensor cable (3) through the nozzle (4) with union nut (5).
2 Insert the sensor cable into the fitting pipe (6) and completely feed through.
3 Remove the protective cap (1) on the sensor (2) and insert the sensor into the nozzle.

1 Insert the sensor (2) into the nozzle (4) as far as the stop.
2 Screw the sensor holder with the union nut (5) onto the fitting pipe (6) and tighten until handtight.

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 4.2.2 Insertion into the PVC in-pipe mounting system.

1 Unscrew the union nut (3) from the PVC flow fitting (1).
2 Guide the sensor cable (4) through the union nut on the fitting.
3 Insert the sensor (2) into the fitting as far as the position shown in the middle image above.
4 Screw the union nut onto the fitting as far as the stop.

4.2.3 Insertion into the Stainless steel in-pipe mounting system.

Adapter

Clamp

Nipple

Stainless steel pipe

OPTOD sensor

1 After welding the clamp on the stainless steel pipe, remove the clamp from the system and remove
the PVC adapter.
2 Unscrew the union nut from the adapter.
3 Guide the sensor cable through the union nut on the adapter.
4 Reposition the adapter in the nipple, and re-screw the union nut.

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 4.3 Electrical connections.

The sensor could deliver within version bare wire on 3, 7, 15 m or on other length (up to 100 m).

Power supply
5 to 12 volts for cable 0-15 m
Power requirements 7 to 12 volts for cable >15 m
Max. 13.2 V
Standby 25 µA
Average RS485 (1 measure/ seconde) : 4,4 mA
Average SDI12 (1 measure/ seconde) : 7,3 mA
Consumption
Current pulse : 100 mA
Heating time : 100 mS
Protection against the inversions of polarity

Wiring diagram

Cable lenght 15 to 100 meters

Red
Purple
Yellow Power supply
Orange V+
pink
2 - Blue SDI-12
3 - Black Power supply
V-
4 - Green B " RS-485 "
5 - White A " RS-485 "
6– Cable shield
Green/yellow with Power
supply V-

Cable length up to 15m

1- Red Power supply V+
2 - Blue SDI-12
3 - Black Power supply V-
4 - Green B " RS-485 "
5 - White A " RS-485 "
6– Cable shield with
Green/yellow Power supply V-

5. Startup and maintenance.

5.1 Initial startup

Once the sensor is connected to your terminal, the sensor is settled in its accessory of assembly and
the parameterization has been carried out on the display unit, the sensor is ready for initial
startup.

Note :
For measurement, you must eliminate bubbles trapped under the membrane.
Presence of chlorine will distort the measure (overestimation of dissolved oxygen level).
During the introduction of the sensor in measurement environment, wait for sensor’s temperature
stabilization before measure processing.
To optimize a sustainable functioning of your probe, we recommend you to respect a frequency of
measure superior to 10 seconds.

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 The membrane is vulnerable to : chemicals (organic solvents, acids, peroxide), mechanical
treatments (impact, abrasion, tearing).

Started :
Remove the black cap of protection (by holding the sensor head downward and by unscrewing the
hood towards the right).
The sensor is delivered dry and the DODISK must be rehydrated so that the measures are optimized.
After dry storage, rehydrate the membrane for a 12 hours period (one night) in clear water.

5.2 Calibration

The sensor is calibrated to specification at the factory. The manufacturer does not recommend
calibration unless periodically required by regulatory agencies. If calibration is required, let the sensor
come to equilibrium with the process before calibration. Do not calibrate the sensor at setup.
After the membrane cap is replaced, calibration should be carried out.
It is also advisable to regularly clean the sensor (see the chapter maintenance : 5.3);

5.2.1. Calibration in 2 point.

With two-point calibration, the zero point (0% - offset) and slope (100 %)of the sensor are calibrated.
This calibration method offers the greatest possible level of accuracy and is particularly recommended
for measurements of small oxygen concentrations.

It is carried out as follows:

Offset calibration :
• The sensor beforehand cleaned (to see chapter maintenance 5.3) is immersed in a water-sulphite
solution (sulphite concentration < 2 %) in order to determine the zero point (0 % saturation). Mix the
solution with the sensor so that the saturation in oxygen decreases more quickly (The oxygen fixed to
the DODISK) must be consumed),

Damage to the sensor membrane due to chemicals.

A damaged membrane can lead to incorrect measurement results.
The sensor membrane must not be in contact with the sulphite solution for
CAUTION! longer than one hour.

• Washing (with clear water) and drying the sensor,

Slope calibration :
• Sensor slope is determined by positioning in oxygen-saturated environment (100 % saturation.

The slope of the sensor is calibrated beyond the defined state of 100 % oxygen saturation. This state
can in principle be achieved in two ways:
• By positioning the sensor in water vapor-saturated air (for example, directly over a water
surface).
• By positioning the sensor in air-saturated water (air is directed through water until the water
is saturated with it). The illustration below is a representation of the conditions in air- saturated water.

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 • The sensor must be kept dry during the calibration process. Drops of water adhering to the
sensor membrane could distort the measurement result.
• The air pressure and temperature must remain constant during the calibration.

5.2.2. Calibration in 1 point.

The calibration in 1 point consists in propping up a 100% point : please consult the above chapter
(slope calibration).

5.3 Maintenance

The maintenance schedule shows minimum intervals for regular maintenance tasks. Perform
maintenance tasks more frequently for applications that cause electrode fouling.
Note: Do not disassemble the probe for maintenance or cleaning.

• The sensor must always be kept clean, particularly in the area around the optical membrane.
The presence of a biofilm on the membrane cap can lead to measuring errors.
• A dirty membrane should be cleaned with warm, soapy water. A soft sponge should be used
for cleaning (not an abrasive scouring sponge).
• If the sensor is put out of operation, it should be rinsed prior to being stored, and the protective
cap should be fitted with the protective case and a moist absorbent surface (like cotton).

5.3.1. Cleaning.
Rinse meticulously the sensor and the membrane with clear water.
If deposits like biofilm or mud persist, wipe the membrane gently with a sweet cloth or an absorbent
paper.

Attention : For the Titanium version clean the body of the sensor by means of acetone (do not
use methylated spirit, ethanol or methanol).

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 5.3.2. Change of the DODISK.
The average life time of the DODISK is of 2 years.
In case of deterioration of the DODISK or of difficulty on the processes of calibration, the DODISK will
be to change.

1 2 3

1 Unscrew the stainless steel DODISK (1) from the sensor body with measurement electronics (3).
When doing so, ensure that the optical window (2) of the sensor is not touched.
2 Remove the DODISK (Ref PF-CSO-C-00041 stainless steel version, PF-ACC-C-00045 Titanium
version) from the opaque protective film and screw slowly onto the sensor body. When screwing on,
ensure that the optical window of the sensor is not touched.
3 Rehydrate the membrane for a 12 hours period and recalibrate the sensor in 2 points (chapter
5.2.1)

Attention: do not unscrew the strainer containing the DODISK only in case of change.

5.3.3. Storage.
With the aim of keeping the active pastille operational quickly, keep the membrane hydrated with the
protective case and a moist absorbent surface (like cotton wool).
After dry storage, rehydrate the membrane for a 12 hours period.

AQUALABO CONTROLE After-Sales Service

AQUALABO CONTROLE
35 Rue Michel MARION
56850 CAUDAN
FRANCE

Tel.: +33 (0)1 72 87 97 93

Email: [email protected]

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