Testomat 2000-englisch

Operating instructionsContents

Introduction (1)

Short description (1)

Reagents available for the Testomat® 2000 (1)

Notes for the user (2)

Note about the operational reliability (2)

Safety notes (2)

Installation and commissioning (3)

Installation (3)

Electrical connection (3)

Mains water supply (3)

Operation with small aerator (4)

Water to drain (4)

Commissioning (4)

Installation diagram (Example) (4)

General Description (5)

Internal construction (5)

Terminal block identification (6)

Functions (6)

Description of displays and operating features (7)

Display functions (7)

Status of limit value displays (7)

Measured value display (7)

Limit value display (7)

Alarm and maintenance message (7)

Status display (8)

Description of the relay outputs (8)

(Flush) External flush valve (8)

LV1 and LV2 Limit value outputs (8)

1 or 2 Measuring points switch-over (8)

AUX Programmable function output (9)

Alarm Fault message output (9)

Maintenance message (9)

Description of the signal inputs and output (10)

Start external analysis start (10)

Stop external analysis stop (10)

IN1 and IN2 universal inputs (10)

OUT Interface output (10)

Function characteristics (11)

Mode of operation (11)

Analysis cycle (11)

Displayed unit (11)

Type of reagent (11)

Setting the Timer (12)

Monitoring of limit value (12)

Hysteresis (13)

Lock out (13)

Logic functions (13)

Function IN1 (14)

Water meter (14)

Plant conrtol (14)

BOB-Operation (14)

Alarm / Message (15)

Function AUX (15)

Service II (15)

Calibration (15)

Reset operating time (15)

Maintenance interval (15)

Water quantity RESET (15)

Plant control RESET (15)

Interfaces (optional) (16)

Structure of the menu (16)

Selection and input (16)

Start menu (16)

Selection (16)

Input (16)

End menu (16)

Information menu "i" (17)

Structure of the "i" menu (17)

Customer service (17)

Operating values (17)

Program values (17)

Error registration (17)

Maintenance (17)

Program menu "M" (18)

Service I (18)

Input reagent (18)

Manual operation (18)

Confirm maintenance (19)

Diagnosis (19)

Date/time of day (19)

Basic program (19)

Program values (19)

Structure of the basic program (20)

Error messages / trouble shooting (21)

Further information (22)

Maintenance (22)

Description of maintenance work (22)

Cleaning the measuring chamber & sight-glass windows22 Cleaning the filter housing (22)

Note on care for the unit (22)

Spare Parts List Testomat® 2000 (23)

Technical appendix (24)

Block diagram "Testomat® 2000" (24)

Technical data (24)

TÜV-certificate (25)

1

Introduction

This operating instruction describes installation, operation and programming of the analysis unit Testomat ® 2000.

We recommend that, whilst familiarising yourself with the operation of the unit aided by this manual, you have immediate access to the unit in order to perform the functions and combinations as described. As certain functions are interrelated,it is advisable to follow the instructions in the given order.

Should problems or questions arise which are not described in this manual and/or cannot be solved, our customer service is always at your disposal.

Try to identify the problem as accurately as possible and record the conditions under which it has occurred. This will enable us to offer you swift effective assistance.

Symbols and abbreviations used in these instructions:

L

Note for the user

"STANDBY" = STANDBY lamp is “ON”Important to observe / warning note

"M" = Press menu key M

T Tip: Helpful hint

º SERVICE º MANUAL OPERATION º FLUSH = Sequence in a menu selection

Short description

The Testomat ® 2000 is used for the automatic measuring and monitoring of the residual / total hardness (water hardness), the carbonate hardness, the minus m-value and the p-value.

The parameter to be measured and the respective measuring range are determined by the choice of the reagent and by the corresponding user program.

Reagents available for the Testomat ® 2000

The various measuring parameters and ranges are determined by the choice of the reagents. The table gives a summary of the different possibilities.

Parameter/Type of reagent

Water hardness TH 2005Water hardness TH 2025Water hardness TH 2100Water hardness TH 2250Water hardness TH 2500Carbonate hardness

TC 2050

minus m-value TM 2005p-value

TP 2100U n i t

°dH

(Resolution)

0.05 - 0.50(0.01)0.25 - 2.50(0.05) 1.0 - 10.0

(0.2)

2.5 - 25.0(0.2)

5.0 - 50.0(0.5)

0.5 - 5.0(0.5)

--°f

(Resolution)

0.09 - 0.(0.02)0.45 - 4.48(0.1) 1.79 - 17.9(0.4) 4.48 - 44.8(0.4)8.95 - .5(1.0)0.90 - 8.96(0.9)--ppm CaCO 3(Resolution)

0. - 8.93(0.2) 4.47 - 44.7(0.9)17.9 - 179(3.8)44.8 - 448

(3.8)

.5 - 5(9.5)---mmol/l

(Resolution)

0.01 - 0.09(0.01)0.04 - 0.45(0.01)0.18 - 1.79(0.04)0.45 - 4.48(0.04)0.9 - 8.95(0.1)

0.18 - 1.79(0.18)

0.05 - 0.50(0.01)

1 - 15(1)

L

A consistently reliable result can be guaranteed by the TESTOMAT ® 2000 only with the use of original

HEYL Testomat ® 2000 reagents ! Failure or problems which are caused by the use of different indicators are not covered by the warranty or refund services.

When monitoring residual/total hardness, larger quantities of heavy-metal ions in the softened water can affect the colour reaction, especially iron above 0.5 mg/l, copper above 0.1 mg/l and aluminium above 0.1 mg/l (brownish-red colour indication).The measuring is possible in a range of pH 4-10.5.

At a concentration of more than 100 mg/l of CO 2 (carbon dioxide) in the water, the excess carbon dioxide must be removed by installing a Type R aerator in the feed water line to the TESTOMAT ® 2000 unit. When using the TESTOMAT ® 2000 (carbonate hardness, water hardness) for monitoring a de-carbonisation installation (weakly acidic cation exchanger) without its own irrigator, a small scale irrigator must always be installed upstream of the device. For water which contains acetate with low pH-values we offer a special version of the TESTOMAT ®2000.

Concentration values of these ingredients can be determined safely and simply with our TESTOVAL colorimetric test

comparators.

•Repeated switching 'on' and 'off':

Wait at least for 5 seconds before you switch the unit repeatedly 'on' or 'off' at the main switch.

• Observation of the environmental conditions:

In order to guarantee a reliable operation, the unit must only be used under the environmental conditions described in the technical data. Protect the controller against excessive humidity, condensation and water-splash.

• Safety seal:

The original seals attached during manufacture (e.g. EPROM labels) must not be broken, otherwise all warranty rights are lost.

• Malfunction / repair of defective units:

The repair of a defective unit is only possible when the unit is dismantled and returned to us with a description of the fault.This in no way affects the guarantee rights. In addition, please inform your supplier of the reagent type used and of the quality of treated water measured.

Before you return the unit for repair, remove the reagent bottle and ensure that the measuring chamber is flushed out and empty.

• Electrical load capacity

The maximum electrical load capacity of the relay outputs and the total power rating must not be exceeded.

• Operate the Testomat® 2000 strictly in accordance with the manufacturer's instructions.

• Environmental protection regulations

Please observe the environmental protection regulations and collect any unused reagent for safe disposal in accordance with local statutory requirements.

Operational Checks

Careful handling of the unit increases both the operational reliability and the service life!

Therefore the following visual inspection should be carried out at regular intervals.

•Are the hose connections with the dosing pump free of leaks?

•Is there any air inside the dosing hoses?

•Are all the water connections free of leaks?

•Are the doors of the unit properly closed? (Check door seals !)

•Is the unit unduly contaminated with dirt?

Maintenance and servicing notes

(see page 22)

Safety notes

• The unit must be installed and operated in compliance with the relevant standards (e. g. DIN, VDE, UVV) or in accordance with the regulations laid down by the individual country.

• Some functions (e. g. the manual analysis) allow the direct manipulation of the installation without locking or monitoring. These functions may only be used by trained staff and for this reason they are only accessible after a pass word has been entered.

• If you observe the unit malfunctioning, switch it off immediately. Then shut off the water supply and contact your supplier.

• Do not attempt to repair the unit yourself (loss of warranty rights); instead always get in touch with the authorised service staff. This is the only way a reliable and safe operation of the unit can be ensured.

• After a protective circuit (fuse) has tripped, first of all, attempt to correct the cause of the malfunctioning (e. g. replace the solenoid valve) before reactivating the protective circuit. Frequent tripping is always due to a fault which, in certain circumstances, may also cause damage to the unit.

• Observe the safety notes about working with reagents, chemicals and cleaning agents.

Ignoring these notes can result in damage to the unit as well as the installation and may result in a loss of

warranty rights.

2

3

Installation and commissioning

Installation and commissioning must be undertaken only by authorised technicians!

Installation

The unit should be fixed vertically!Avoid tension of the housing.

The unit doors swing to the left when they are opened. Please ensure that there is sufficient space for opening them. In this way, you facilitate the electrical installation and later maintenance and service work.

Electrical connection

Check supply voltage on the rating plate!

Basic requirement

The external cables (e. g. water meter, interface) should be kept as short as possible and clear of power cables.Connection

Loosen both fastening screws and open the upper door. Pierce the required rubber cable glands with a screwdriver and insert the cable (1). Then pull back the cable until the bush (2) has been turned over. Ensure that the leads are held securely in the terminals then close the upper door after the installation is completed using the two fastening screws.

Mains water supply

The temperature of the sample water must be between 10 °C and 40 °C. Higher water temperatures can lead to damage to all parts coming into contact with water (e. g. filter housing, measuring chamber)!Lower water temperatures can cause misting on the sight-glass windows.

L

In the event of higher temperatures, the Type KCN cooler must be installed in the branch line of the TESTOMAT ®.Hot water can lead to scalding!

L

Heavy pressure oscillation should be avoided!

The branch line should be positioned as close as possible to the outlet from the water softening plant. The branch line to the Testomat ® with a hand-operated shut-off valve must be kept as short as possible and not longer than a maximum

of 5 meters. It is important that the branch line connection is taken vertically from the top of the main soft water line in

order to prevent dirt particles from entering into the measuring chamber.

When operating the Testomat ® 2000 with the pressure range of 0.1 to 1 bar remove the valve body out of the regulator/filter housing.

Plug connector

The unit is equipped as a standard with a plug connector for opaque plastic hoses 6/4 x 1 (external diameter 6 mm/internal diameter 4 mm).

Quick-acting coupling (accessory: Optional adapter for water inlet, Order no. 40123)

When fabric reinforced pressure hoses (e.g. for existing installations) are used, please replace the plug connector at the controller and filter housing with a plug for the quick-acting coupling (not included with the delivery).

Dimensioned sketch

4

General description\nInternal construction\n\n5\n\n\r\n

Terminal block identification\nFunctions IN = Input, OUT = Output Nr. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 Terminal PE N (U) L (V) l n Flush LV1 LV2 Measuring point 1/2 AUX Alarm Type IN IN OUT OUT OUT OUT OUT OUT OUT Function Mains - Protective earth (5 x) Mains, N = Neutral (U = 24 V) Mains, L = Live (V = 24 V) Live, switched (8 x) Neutral, switched (8 x) External flush valve Limit value output 1 - Normally closed Limit value output 1 - Normally open Limit value output 1 - Common Limit value output 2 - Normally closed Limit value output 2 - Normally open Limit value output 2 - Common Measuring point 1 - Normally closed Measuring point 2 - Normally open Measuring point switch-over - Common Universal output Fault message - Normally closed Fault message - Normally open Fault message - Common Maintenance message - Normally closed Maintenance message - Normally open Maintenance message - Common External analysis start Common earth for inputs External analysis stop Common earth for inputs Universal input 1 Common earth for inputs Universal input 2 (Water meter) Common earth for inputs 0/4 - 20 mA or serial interface Note Only at mains 115 / 230 V ! Mains - input 24 V / 115 V / 230 - 240 V AC Mains voltage, max. 4 A Volt-free relay output max. load 240 V AC, 4 A Volt-free relay output max. load 240 V AC, 4 A Volt-free relay output max. load 240 V AC, 4 A Volt-free relay output max. load 240 V AC, 4 A Volt-free relay output max. load 240 V AC, 4 A Volt-free relay output max. load 240 V AC, 4 A Volt-free relay output max. load 240 V AC, 4 A Only for volt-free normally open contact! Only for volt-free normally open/ normally closed contact ! Only for volt-free normally open/ normally closed contact! Only for volt-free normally open contact! Potential output ! 28 = 0/4 - 20 mA, 29 = 2\n\nMaintenance Start\n2\n\nOUT IN IN IN IN OUT\n\nStop\n2\n\nIN1\n2\n\nIN2\n2\n\nOUT\n\n6\n\n\r\n

Description of displays and operating features\n(1) Power switch The 'ON'/'OFF' switch is located on the righthand side panel. (2) Unit fuse (inside the unit) Protects outputs against overload and short circuit. 3 Status of limit value displays Displays the status of the limit values LV1 (1) and LV2 (2). 4 Text display Displays the actual analysis, all important status results and programming data in a 4-line LCDisplay. 5 Alarm Displays a function fault. 6 Maintenance message Displays a maintenance request. 7 Status display 6 LEDs signal the current status (analysis and unit status) of the Testomat® 2000. 8 Programming keys (Cursorblock with ENTER) These keys are used to enter all values and programming data. Function keys: 9 "Manual" = manual start of an analysis 10 STANDBY = manual analysis stop/standby 11 "Alarm" = quits alarm message 12 i-key Call-up all unit information (see i-Menu). 13 M-key Call-up the programming menu for user and specific unit settings (see M-Menü).\n\nSTANDBY\n\nDisplay functions\nStatus of limit value displays 1 and 2\n\nThe display signals the status of the limit values. 1: The red display lamp lights up if the limit value 1 is reached or exceeded. Lights up green if the measured value falls below the set limit value. 2: The red display lamp lights up if the limit value 2 is reached or exceeded. Lights up green if the measured value falls below the set limit value. Measured value display In line 2 and 3 the actual measured value for measuring point 1 (M1:) and 2 (M2:) are shown. When the measured value falls below the measuring range "<" is displayed: e. g. M1: < 0. ppm CaCO3 When the measured value exceeds the measuring range ">" is displayed: e. g. M1: > 179 ppm CaCO3 Limit value displays The adjustable limit values are shown in the bottom display line. Alarm and maintenance message Display of present error messages (red) and of present maintenance request (yellow).\n\nL\n\nError messages are displayed alternately with the normal display text and can only be deleted by cancellation and correction of the fault.\n\n7\n\n\r\n

Status display\nThe flow diagram displays the actual operational status.\n\nDescription of relay outputs\n(Flush) External flush valve In the event that when installing the unit, the use of a long sampling tube is unavoidable, we recommend the fitting of a programmed flush valve upstream of the unit. Also, in cases where the unit is used for monitoring two measuring points, an external flush valve should be installed in order to prevent faulty measurements caused by mixing of the samples. Immediately before each analysis the external flush valve is opened for a programmed period, thereby allowing the tube up to the Testomat® 2000 to fill with water to be measured. Please ensure that the programmed flush time is sufficiently long to avoid any air-lock. You set the flush time with menu item "M" º BASIC PROGRAM º PROGRAM VALUES º FLUSH TIMES/INTERVAL º EXTERNAL FLUSH TIME . LV1 and LV2 Limit value outputs For reporting that a limit value has been exceeded, two volt-free relay contacts are available. For both contacts the limit values, the hysteresis and the function can be independently programmed: Function Type of contact Action programmable: S Continuous contact S Impulse (1 - 99 seconds/minutes) S Interval (1 - 99 seconds/minutes) S Two -step regulator (one measuring point only) S Hysteresis (1, 2 or 3 limit value in excess) programmable: S Continuous contact S Impulse (1 - 99 seconds/minutes) S Interval (1 - 99 seconds/minutes) S Hysteresis (1, 2 or 3 limit value in excess)\n\nLV1\nS active at limit value in excess of limit value 1 or measuring point 1 volt-free change-over contact\n\nLV2\nS active at limit value in excess of limit value 2 or measuring point 2 Menu values: "M" º BASIC "M" º BASIC "M" º BASIC "M" º BASIC "M" º BASIC volt-free change-over contact\n\nPROGRAM PROGRAM PROGRAM PROGRAM PROGRAM\n\nº º º º º\n\nPROGRAM PROGRAM PROGRAM PROGRAM PROGRAM\n\nVALUES VALUES VALUES VALUES VALUES\n\nº º º º º\n\nLIMIT VALUES FUNCTION LV1 FUNCTION LV2 HYSTERISIS LV1 HYSTERISIS LV2\n\n(Measuring points 1 or 2) Measuring points switch-over If you use the unit for monitoring two measuring points, the solenoid valves (individual valves or one 3/2-way distributing valve) must be connected to the corresponding sampling tubes. It is important that the terminals are strictly allocated to the appropriate measuring points. Terminal 9 = Measuring point 1 Terminal 10 = Measuring point 2 "M" º BASIC PROGRAM º PROGRAM VALUES º MEASURING POINTS\n\n8\n\n\r\n

AUX Programmable function output The function of this volt-free relay output is programmable: 1. Message of an actual analysis "M" º BASIC PROGRAM º PROGRAM VALUES º FUNCTION AUX º CONTACT DURING ANALYSIS and/or 2. Contact before an analysis, e. g. control of a cooler "M" º BASIC PROGRAM º PROGRAM VALUES º FUNCTION AUX º CONTACT BEFORE ANALYSIS or 3. Contact after an analysis "M" º BASIC PROGRAM º PROGRAM VALUES º FUNCTION AUX º CONTACT AFTER ANALYSIS Alarm Fault message The "Alarm" output is a volt-free change-over relay contact. During trouble-free operation the contact between the terminals 15 – 16 is closed and the one between terminals 14– 16 is open. When the voltage fails, the contact between terminals 14 – 16 is closed and the one between 15 – 16 is open. The unit is equipped with a range of monitoring functions. You can define certain situations as a fault and program a corresponding message either as continuous contact (A) or as a message impulse (M). - With a continuous contact, the "Alarm" output remains activated (with terminals 15 – 16 closed) as long as the fault persists. - For a message impulse, the output is alternately switched 'on' for 2 seconds and then switched 'off' for 5 seconds. - If several faults with different programmed messages are reported simultaneously, the output is switched to continuous contact. - The red LED "Alarm (5)" and the text on the display indicate a fault. - The error signal at the "Alarm" output is deleted by cancelling the fault with the "Horn" key. - An error message can only be deleted after the fault has been corrected. - Exception: The maintenance date has been exceeded. This message is confirmed in the M-menu, see below (maintenance). - Each new fault is entered into the fault history (also see i-menu, page 17). The following faults activate the "Alarm" output and are displayed: The following conditions always trigger an error message: Power failure Low-water pressure Function fault optics Measuring fault analysis Function fault dosing pump Function fault outlet to drain Function fault failure 24V Error messages are described on page 21. Maintenance message The "Maintenance" output is a volt-free change-over relay contact. During trouble-free operation without a programmed maintenance interval the contact between terminals 17 – 19 is closed and the one between 18 – 19 is open. The unit is equipped with a range of monitoring functions and a programmable maintenance interval. The maintenance message is always a continuous contact. A maintenance request is displayed by the yellow "Maintenance" LED. The maintenance display can only be deleted after the condition has been corrected or after the maintenance request has been confirmed. "M" º SERVICE º CONFIRM MAINTENANCE The following conditions activate the "Maintenance" output: Reagent low level Measuring chamber dirty (Measuring fault dirtiness) Maintenance date reached Dosing inaccuracy (Function fault dosing ferror) For a more detailed description of the programming refer to pages 18-20. For general maintenance refer to page 22. Conditions which can be programmed as faults: Reagent low level Function fault dosing error Measuring fault dirtiness Measuring fault turbid Plant control Transfer error Measuring range exceeded Maintenance interval exceeded\n\n9\n\n\r\n

Description of the signal inputs and output\n\nL\n\nConnect the signal inputs "Start

Diagram of dynamics

Setting the timer

Internal flush

In order to ensure the analysed sample represents the actual value, the sampling tube must be sufficiently well flushed taking its length into consideration. After the

installation has been out of operation for a longer period or in the case of long analysis intervals, it is sensible to select a flushing time in excess of 60 seconds. Flush is initiated by simultaneously opening the Testomat ® 2000’s inlet and the outlet valves.

L

The analysis interval directly depends on the programmed flush time. If a flush time of, for example, 90 seconds is set, the analysis interval itself cannot be shorter than 90 seconds.

External flush

In cases where a very short analysis interval is required, a very long (several meters) sampling tube must be used or a tube with a large diameter is used, an external flush valve should be installed upstream of the Testomat ® 2000. This is connected to the "Flush" outlet. The external flush time for the valve depends, like the flush time for flush by the unit, on length and diameter of the connection to the Testomat ® 2000.Example:

For connections longer than 3 m and an internal tube diameter of 4 mm, a minimal internal flushing time of 10 seconds is required to ensure a valid sample is taken from the sampling tube. The quantity of flush water for an internal flush of 1 minute is 0.5 litre.

Interval pause

In the case of timed triggering of the analysis, the interval between two analyses (plus flush time) is determined by the interval pause. The shortest interval can be 0 minute. In this case, the analyses are carried out continuously. The longest interval is 99 minutes.

Monitoring of limit value

You can program the limit value on a continuous scale. The range for the limit value depends on the reagent type used and on the programmed unit.Example :

Number of measuring points

1

2

Function LV1 1., 2. or 3. Exceeds upper limit value 1., 2. or 3. Exceeds Measuring point 1Function LV2

1.,

2. or

3. Exceeds

lower limit value

1.,

2. or

3. Exceeds

Measuring point 2

Two outputs for the limit value are available for monitoring. The functions of these outputs can be programmed

independently from each other:Two limit values:

1 LV1 = Limit value 1

2 LV2 = Limit value 2

Two measuring 1 LV1 = Measuring point 1points:

2 LV2 = Measuring point 2

When the limit value LV1 is exceeded, limit value control display lights up LV1 RED and the relay output LV1 reacts as programmed in the switch function. As long as this limit value is not exceeded, the display lights up GREEN .The unit operates in the same way for the limit value LV2.

When the unit is used for monitoring two limit values, the outputs for the limit values are strictly allocated to those limit values!

When the unit is used for monitoring two measuring points the outputs for the limit values are strictly allocated to those measuring points!

Two-point only with 2 limit values and 1 measuring point

Hysteresis

Each limit value output reacts only after the 1st , 2nd or 3rd bad analysis result has been

detected (suppression of the first or the second measured value).

This increases the reliability during the evaluation of the analysis e. g. after the measuring point has been switched over or if the sampling line has possibly not been

flushed sufficiently. The hystereses of the two outputs LV1 and LV2 can be set independently from each other.

Operation: With a hysteresis of 2 a further analysis is carried out immediately the limit value has been exceeded. Only if the limit value of this analysis is exceeded again, is the corresponding output energised. If you have set a hysteresis of 3, the corresponding output reacts only after the limit value has been exceeded for the 3rd time in succession.

Lock out

Monitoring of the analysis with 'lock out' after the 1st , 2nd or 3rd limit values have been exceeded (= hysterisis) aids error diagnosis. If a limit value (programmable LV1 or LV2) is exceeded as often as it is programmed (limit value output is activated). The unit remains static in the analysis position and switches to standby mode ("STANDBY"

lamp lights up). In the lock out mode (displayed text "STANDBY"), the sample remains in the measuring chamber. In this way, the analysis result can be visually checked for disruptions from extraneous factors (e.g. during the water hardness measurement an excessive iron or copper content results in a brown discoloration of the water).The lock out is disengaged by pressing the "STANDBY" key.

Further analysis requests are suppressed by means of a signal at the Start input.

Logic functions of the limit value outputs LV1 and LV2

L

Logic functions 0 and 2: If Lock out is programmed, output relay LV1 pulls up

according to the programe until a manual release is effected (press "STANDBY"key).

Logic function 0, Duration

Output relay LV1 or LV2 pulls up when the measured value rises above limit value LV1 or LV2. If the measured value falls below the limit value LV1 or LV2 without lock out, the relevant relay drops out again.

Logic function 1, Impulse

If the measured value rises above limit value LV1 or LV2, the relevant output pulls up for a set time t.

Independent of the time taken for the limit value to rise above the set limit, the relevant output always remains in the "ON" position for the set time.

Logic function 2, Interval

If the measured value rises above one limit value, the relevant output pulls up at intervals with the time set.(Impulse/Pause)

Logic function 3, Two-point

If the upper limit value LV1 is exceeded, the output relay LV1 pulls up. If the lower limit value LV2 falls below the set limit, output relay LV1 drops out.

The output relay LV2 pulls up according to the programmed logic function.

L If lock out is programmed, this logic function cannot be selected !

L

This function is possible if different values are selected for LV1 and LV2 with one measuring point only. For example for LV1 =3.57 ppm CaCO 3 and for LV2 =1.79 ppm CaCO 3.

Function IN1

With dynamic analysis control or programmed plant monitoring, the regeneration message received from the water treatment plant controller must be connected to IN1 (a volt free contact is required). The energised status of IN1 must be correspondingly programmed to the output function of the controller.

Water meter

For quantity dependent analysis triggering with dynamic analysis control and operational monitoring of the water treatment plant (see Plant Control) it is necessary to connect a water meter to the IN2 input.

Program the corresponding water meter rating under menu item "WATER METER ".

Plant control

For monitoring the installation, a certain water quantity can be defined, for which none

of the limit values (LV1 or LV2) may be exceeded.

Example: A "RESERVE" quantity of 50 m³ has been entered. If the water quantity actually produced between two

occurances of exceeded limit values is less than the programmed water quantity, either an alarm or a message (depending on the program) is triggered.

"M" º BASIC PROGRAM º PROGRAM VALUES º ALARM/MESSAGE

The flashing error message "Plant control" appears.

The water quantity for plant monitoring is reset after limit value LV1 or LV2 have been exceeded, or via a signal at the IN1 input (regeneration message from the process controller) or manually in the SERVICE II menu.

When a "0" has been entered for the water quantity (minimum reserve quantity), no monitoring is carried out.

BOB-Operation (BOB = Operation without constant supervision)

The Testomat 2000 conforms to the german TRD 604 safety standard for monitoring of water hardness associated with steam boiler installations, when operation without constant supervision is a relevant safety feature (= B etrieb O hne ständige B eaufsichtigung = BOB-operation).

When the BOB function is programmed, the unit constantly monitors the reagent quantity available. For calculating the

reagent consumption per analysis, a measured value of 1.48 ppm CaCO 3 (0.015 mmol/l alkaline earth ions) is used. If the residual reagent quantity insufficient for the set BOB period (programmable between 24 and 120 h), an alarm is activated.BOB on:

Continuous monitoring of the residual reagent quantity. ALARM message (if programmed) when the available quantity falls below the minimum quantity for the BOB period: the BOB indication lamp flashes, the maintenance reagent lamp lights up, the maintenance output is energised.

BOB off:Without BOB function: the residual reagent quantity is only monitored for the minimum quantity (10 % level).Example:

BOB-Duration = 72 Hours Number of analyses per hour = 10

Necessary quantity of reagent for 72 h = 72 h x 10 Analysis/h x (3 x 30) µl/Analysis = .8 ml .(That corresponds to approx. 13% of a full level bottle)

A = Alarm / M = Message / - = no action

Ff. = Function fault Mf. = Measuring fault

A/M A/M A/M/-A/M A/M A/M A/M

A/M/-A/M/-A/M/-

A/M/-A/M/-A/M/-

A/M/-Alarm / Message

The unit is equipped with an alarm relay output for reporting errors. The events which could mean a fault at the unit or are intended to trigger a message, can either trigger an alarm (continuous contact) or a message (2 second impulse).For certain faults of the unit it is already pre-determined whether they trigger an alarm or a message!

The faults are entered into the fault history and stored if the event is programmed as an alarm or message. Should e. g. reagent low not be programmed as ALARM or MESSAGE, it is not registered in the fault history. Up to 20 error messages are stored. This list can be called up via the information menu. The information stored per event are the time (day, month, year and hour) and the type of the fault.

L

After a power failure, the error messages are lost.

Function AUX

The AUX relay output can be programmed for the following control functions:S It can be programmed as a functional output for providing a contact of a programmable duration before, or/and during or after an analysis.

You can e. g. control the cooling water flow in an upstream cooler by means of a solenoid valve. Then cooling water

flows only when necessary, i. e. while an analysis is being carried out.

Service II

The service II menu contains a number of functions for monitoring the operation of the unit.

L

The functions in the service II menu have a direct influence with the operation

and the monitoring functions of the unit!

Calibration

A calibration can be carried out to adapt the Testomat ® 2000 to e. g. the predominant turbidity of the raw water. For this purpose, a reference measurement is carried out.

Reset Operating time

After replacing the metering pump or the holder for the measuring chamber, you can reset the actual operating time to 0 hours:

"M" º BASIC PROGRAM º SERVICE II º RESET OPERATING TIME You can call up the actual operating time in the information menu:"i" º INFORMATION º OPERATING VALUES

Maintenance interval

The observance of the maintenance interval is monitored and displayed by the Testomat ® 2000. Here you program the desired maintenance interval in days.

Water quantity RESET

This effects in a reset of processed water quantity currently stored. This is of direct influence on the plant monitoring and the dynamic analysis control.

Plant control RESET

The plant monitoring is only reactivated after the subsequent limit value has been exceeded.

Displayed function

"i"

(Key)

"M"

Information Menu

Program Menu

Information Menu "i" Array Structure of the "i" menu

You can use the information menu to call

up the active settings and status of the

unit, the error registration, the date for the

next maintenance and the customer

service address.

Call (1)

You call up the information menu "i" by

pressing the "i" key.

Customer Service (2)

Display of the customer service address

or e.g. of a service telephone number.

These three lines can be independently

programmed in the basic program

(protected by pass word):

"M" º BASIC PROGRAM º

CUSTOMER SERVICE

Operating values (3)

Display of the current values.

Program values (4)

By pressing the arrow keys you can call up the menu item "Program values". By pressing "ENTER" you open the list with the set values. The active setting of a parameter can be queried by pressing "ENTER":

For example (4a): "i"º INFORMATION º PROGRAM VALUES º TYPE OF REAGENT

The selected function is marked by a star (in this context there are no active lines).

Error registration (5)

Open the error registration by pressing the "i" key and then "ENTER". The error registration is a list of the errors or status, that you have programmed as faults. This list is lost during a power failure and the recording is started afresh. Provided no faults have accumulated since the start-up, the display will show the last time the unit was switched on, e.g.: POWER FAILURE

from16.06.99 06:56

to16.06.99 07:09

Maintenance (6)

Display of the date of the next maintenance and of the programmed maintenance interval.

You can set the maintenance interval in the basic program (protected by pass word):

"M"º BASIC PROGRAM º SERVICE II

For further maintenance information refer to page 22 - onward.Program Menu "M" Array Call (1)

By pressing the "M" key the program menu

"M" is selected.

Except for the basic programming, you can

call up all functions without pass word

protection.

Service I (2)

Input Reagent (3)

After every refill or replacement of the reagent

bottle or of the reagent type, you have to enter

the new level. As soon as the menu item for

the filling level "INPUT REAGENT (0 - 100%)"

has been selected by pressing "ENTER

value is preset to 100%. If only a partially filled

bottle is connected, enter the corresponding %

value. When you have connected a full bottle,

confirm this value by pressing "ENTER".

Manual operation (4)

After you have confirmed the information

message (4) by pressing ENTER, you can

select the desired function using the arrow

keys and then activate them by pressing

"ENTER".

These functions are only used for monitoring

the operation and for commissioning.

L All manual functions can only be selected during an interval between two analyses. During manual operation, no analysis is carried out.

All signal inputs and outputs are locked.

Flush (5)

Start the flushing of the sampling tube through the internal valve by pressing "ENTER". When "ENTER" is pressed again, this function is terminated.

Flush chamber (6)

By pressing "ENTER

Drain chamber (7)

By pressing "ENTER" you open the outlet valve to drain the water from the measuring chamber.

By pressing the "ENTER" key again, this function is terminated.

Fill chamber (8)

When "ENTER" is pressed, the measuring chamber is filled.

Self-test (9)

By pressing "ENTER

Terminate this function by pressing "ENTER" again and you return to the "MANUAL OPERATION" menu.

Should any faults have been detected, a corresponding message is displayed!Confirm maintenance (10)

After you have carried out the maintenance, confirm this by pressing "ENTER" and leave this item by pressing "M". The maintenance interval is started afresh.

L A maintenance request at the end of the maintenance interval, must be confirmed in the M-menu. The message on the display is deleted and the maintenance output is reset.

Refer to page 22 for general maintenance.

Diagnosis (11)

You can call up the actual status of the signal inputs and outputs from a list.

An active status is marked with a * (see menu structure).

To change the status of an output press the "ENTER" key.

Date/Time of day (12)

You enter time of day and date by selecting the desired function using the arrow keys and activating them by pressing "ENTER". Then press the "M" key again to store the setting and to return to the display mode.

Basic program

This menu item is only reached after entering the pass word!

Example for a pass word entry:

>BASIC PROGRAM07:25

21.04.0007:25

Password:____ _ _ _ _

(5270)

After you have entered the pass word and confirmed it by pressing "ENTER

PROGRAM VALUES

To call up the factory-set basic default setting, briefly hold down the "M" and "i" key while switching the unit "ON". Values and settings are described in the structure of the basic program on page 20.

The following program values can be entered and stored in the basic program:

Abbreviations:s = seconds

m = minutes

h = hours

d= days

l = litresStructure of the basic program

To call up the factory-set basic default setting, briefly hold down the "M" and "i" key while switching the unit "ON". CAUTION, the last set of programming will be erased!Error Messages / Trouble Shooting

Displayed Message

(flashes at selected display)

Unit result functions Possible causes Remedies

POWER FAILURE 24 V CANCEL WITH HORN-KEY S After programming:

Continuous alarm or message

impulses

S Standby

• Internal power failure

of the 24 V supply

Replace fuse F4 or F8

(The control-lamp "Power" of the

dosing pump must light up ?)

Ff. DOSING PUMP CANCEL WITH HORN-KEY S After programming:

Continuous alarm or message

impulses

S Standby

• Dosing pump defective

• No dosing message from the

dosing pump

Replace dosing pump

Check cable to the dosing pump for

correct connection

Mf. TURBID

CANCEL WITH HORN-KEY S After programming:

Continuous alarm or message

impulses or no message

S Continue measurements

• The water is turbid / dirty Filter-out turbidity or dirt from the

water supply

MEASURING RANGE EXCEEDED CANCEL WITH HORN-KEY S After programming:

Continuous alarm or message

impulses or no message

S Continue measurements

• The measuring range is

exceeded

Choose another type of reagent

(Basic program)

LOW WATER-PRESSURE CANCEL WITH HORN-KEY S After programming:

Continuous alarm or message

impulses

S Standby

• No water input although LED

"IN" lights up

• Inlet pressure too low

• Overflow reagent is not active

Check water inlet

Connector of the inlet valve oxidised

Clean filter strainer

Replace valve block

Extract pressure regulator valve

Replace fuse F6

Ff. OUTLET TO DRAIN CANCEL WITH HORN-KEY S After programming:

Continuous alarm or message

impulses

S Standby

• Water remains in the

measuring chamber although

LED "OUT" lights up

Check water outlet

Connector of the outlet valve

oxidised

Replace valve block

REAGENT LOW

CANCEL WITH HORN-KEY S After programming:

Continuous alarm or message

impulses or no message

S LED and output "maintenance"

on

S Continue measurements

• Reagent quantity is below

minimum setting

without BOB: 50 ml (10 %),

with BOB: after calculation

Check reagent level, fill up if

necessary

(enter level: "M" º SERVICE)

Mf. DIRTINESS CANCEL WITH HORN-KEY S After programming:

Continuous alarm or message

impulses or no message

S LED and output "maintenance"

on

S Continue measurements

• Sight-glass windows dirty Clean sight-glass windows

Ff. OPTICS

CANCEL WITH HORN-KEY S After programming:

Continuous alarm or message

impulses

S Standby

• Plug-in circuit board defective

• Error at the optic component

(Transmitter or Receiver

defective)

Replace plug-in circuit board

Replace measuring chamber

sealing rings

Mf. ANALYSIS

CANCEL WITH HORN-KEY S After programming:

Continuous alarm or message

impulses

S Standby

Incorrect analysis, e.g.

• Air in the dosing capillary

• incomplete blending

• Reagent too old or use of third-

party reagent

Tighten connections of the dosing

pump

Replace stirring mechanism

Replace suction insert in the bottle

Replace reagent, only use HEYL

Testomat® 2000 reagent

Ff. DOSING FAULT CANCEL WITH HORN-KEY S After programming:

Continuous alarm or message

impulses or no message

S LED and output "maintenance"

on

S Continue measurements

• Dosing inaccuracy of the

dosing pump

Replace dosing pump or return to

the supplier for calibration

MAINTENANCE INTERVAL EXCEEDED

XXX DAYS

CANCEL WITH HORN-KEY S After programming:

Continuous alarm or message

impulses or no message

S LED and output "maintenance"

on

S Continue measurements

• Programmed maintenance date

reached or exceeded

Carry out maintenance and finally

cancel or confirm

Ff.= Function fault Mf.= Measuring fault

Further Information

Fault

Possible causes

Remedies

Interface works incorrectly • incorrect measuring value at the output or no power supply S Replace fuse F7

S Replace the plug-in circuit board Although unit is switched "ON"No display

• Fuse F9, F5 or F2 (240 V: F1) defective • Power switch defective

•Multi-pin strap cable at display circuit board or base circuit board loose contact

• Fault on display circuit board or base circuit board

S Replace fuses

S Replace power switch S Check and reconnect

S Replace display or base circuit board

Maintenance

Regular maintenance is necessary in order to ensure trouble-free operation of the unit!Please carry out the maintenance work described in the following section when

S the programmed maintenance date has been reached (display "maintenance date exceeded")S the unit displays the following error messages:" Mf.dirtiness " or " Reagent low leve l"S the last maintenance was carried out more than 6 months ago

Never use organic solvents to clean the measuring chamber and other plastic parts!Please observe the safety rules when handling cleaning agents!

L

If the measuring range has been exceeded over an extended period, a coloured coating can form on the sight-glass windows. This stubborn coating can be easily removed with alcohol.

Description of maintenance work

Cleaning the measuring chamber and the sight-glass windows

1.Switch the unit 'off' or press the "STANDBY" key (drain measuring chamber completely !).

2.Close the hand-operated valve on the branch line to the TESTOMAT ® 2000.

3.Unhook toggle type fastener, tip the measuring chamber upwards and extract.

4.Slacken both sight-glass window holders, extract and clean the sight-glass windows.

5.This stubborn coating can be easily removed with alcohol.

6.Clean the measuring chamber with 10% hydrochloric acid and then rinse well.

7.After cleaning, replace the sight-glass windows and secure these with the sight-glass windows holder (do not forget the O-ring seals and check for correct seating in the recess).

8.Insert the measuring chamber by tilting it backwards until the slot engages with the rear guide bar and press down. Finally secure the chamber with the toggle type fastener.Cleaning the filter housing

1.Close the hand-operated valve on the branch line to the TESTOMAT ® 2000.

2.Undo the hose connections to the filter housing.

3.Unscrew inlet connection remove sealing ring, spring and filter strainer and clean.

4.Extract the retaining pin and withdraw the flow regulator and finally remove the valve body.

5.Clean filter housing with water or alcohol and and reassemble.Insert filter strainer point downwards!

6.Install the hose connections to the filter housing.

Water Leakage from of the seals can result in damage to parts of the unit

T Tip: Please check the unit for leaks before carrying out the first analysis

•switch the unit to STANDBY •manually fill the measuring chamber •manual reagent dosing (key "Manual")•check the connections and seals for leaks

Note on care for the unit

The surface of the unit has not been treated. Therefore, a contamination with reagent, oil or grease should be avoided.

Should the housing, however, be contaminated, please clean the surface with isopropanol (never use other solvents).

SPARE PARTS LIST Testomat® 2000

Item

No.

Pressure regulator

40125Regulator / filter housing complete

40120Regulator / filter housing

40129Regulator plug T2000, complete

11225Flow regulator valve (1 - 8 bar)

11230Retaining pin for regulator plug

11217Inlet filter

11218Spring for inlet filter

40121Inlet connector

40153Plug in connector - G 1/4" -6

11209Securing screw M3 x 42

Measuring chamber

40173Sight-glass window 30 x 3 with seal

40170Sight-glass window 30 x 3

40176Sight-glass retaining disc

33253Screw spindle M3 x 40

40032Latch fastener TL 800-7-1

11203Plastic plug

40022Measuring chamber complete T2000

Holding block for measuring chamber 40029Holding block complete (without valves)

40050Magnetic stirrer

40186Plug connector

40018Solenoid valve, 2/2-Way

40181Rear guide bar for measuring chamber 5 x 60

Dosing pump DOSIClip®

40201Jet pump complete ( for exchange)

40001Jet pump complete

40011Suction capillary complete

40016Pressure capillary complete

37232Base circuit board TI, complete

34668Magnet 24 VDC

32046Plastic cover CNH 45 N

Bottle connection / Suction tube 40131Screwed cap with bottle insert T2000

40130Screwed cap GL32 - only

40135Bottle insert for screwed cap with push-fit suction tube

Item

No.

Electrical components

31582Fuse M4A

37236Base circuit board T2000 complete 230V

40092Control circuit board T2000 complete

40091Plug-in circuit board Transmitter / Receiver T2000

40190Cable sleeve 5 - 7

40191Cable sleeve 7 - 10

40197Mains on / off switch T2000

40198Cover for Mains on / off switch

31713Multi-pin strap cable 10 pol. with EMI filter clamp

40096Multi-pin strap cable 26 pol. with EMI filter clamp

40060Cable loom 2V complete (For Valves)

40062Cable loom 2P complete (For max.2 Dosing pumps)

40200Cable loom for Mains on/off switch complete

31596Fuse T0.08A

31585Fuse T0.315A

31595Fuse T0.1A

31622Fuse T0.16A

31592Fuse T1.0A

Spare parts requirement for 2 - 3 years of operation 40173Sight-glass window 30 x 3 with seal2

11217Inlet filter 1 x

40124Gasket set T2000 ( after maintenance )X*

31585Fuse T0.315A1

31592Fuse T1.0A1

X*Accurate operation of the Testomat 2000 can be assured only with regular maintenance and replacements of seals / gaskets (see text on maintenance).

Accessories:

Order no.

040123 Optional adapter for water inlet

(Quick-acting plug and -coupling)

270305 Interface (plug-in card) SK 910

Reagents:

Order no.

152005TH2005Water hardness 0. - 8.93 ppm CaCO

3 152025TH2025Water hardness 4.47 - 44.7 ppm CaCO

3 152100TH2100Water hardness 17.9 - 179 ppm CaCO

3 152250TH2250Water hardness 44.8 - 448 ppm CaCO

3 152500TH2500Water hardness .5 - 5 ppm CaCO

3 153050TC2050Carbonate hardness

154005TM2005minus m-value

155100TP2100p-valueTechnical appendix

Block diagram Testomat® 2000

Technical data

Power supply:230 V or 24 V ± 10 %, 50 - 60 Hz, fuse M4A

Unit protection:230 V:T0.1A

24 V: T1.0A

Power consumption:max. 30VA

Degree of protection:IP 65

Protection class:I

Conformity:EN50081-1, EN50082-2, EN 61010-1

Ambient temperature:10 - 45 °C

Contact rating of the relay outputs: 4 A resistive load, fuse M4A

Measuring range:see page 1

Interface:0/4 - 20 mA, max. load 500 Ù (optional)

Water supply:0.1 - 8 bar = 104 - 8 x 105 Pa

Water temperature:max. 40 °C

Dimensions (W x H x D):380 x 480 x 280 mm

Weight:approx. 10.5 kg

We reserve the right to make technical changes without notice in the interest of constantly improving our products!

Art.-Nr. 49511KfT2000_GB020327.wpd