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Lenntech Testomat 2000 Fe Operating Instructions Manual Download Page 47

Maintenance 

 

 

47 

Maintenance 

 

Required maintenance measures 

 

 Regular maintenance is necessary to ensure trouble-free opera-
tion of the instrument! 

 

Please regularly carry out the maintenance work described in the 
following section when 

 

the programmed maintenance date has been reached (display 
"maintenance date exceeded") 

 

the instrument displays the following error messages: 

    "Mf. soiling" or "Low reagent level" 

 

the last maintenance was carried out max. 6 months ago 

 

Cleaning measures 

 

Never use organic solvents to clean the measuring chamber or 
other plastic parts! 

 

Please observe the safety regulations when handling cleaning 
agents! 

 

If the measuring range of the instrument is exceeded over a long-
er period of time, a coloured film may form on the sight-glass win-
dows. Use alcohol to remove this sticky film. 

 

Description of maintenance work 

Please refer to the "Maintenance manual Testomat 2000

®

/Testomat 

ECO

®" 

for a detailed description of maintenance work. The measures 

described here only provide a brief overview. 

 

Cleaning the measuring chamber and sight-glass windows 

 

Switch off the instrument or press the "STANDBY" key. If required, 
remove any water from the measuring chamber. 

            

 

 

 

 

 

 

 

Close the manually-operated valve of the branch line to Testomat 
2000

®

 Fe. 

 

Unhook the toggle type fastener 

, tilt the measuring chamber 

upwards and remove it. 

 

Release both sight-glass window holders 

; remove and clean 

the sight-glass windows. 

 

Use alcohol to clean off the film on the sight-glass windows. If the 
instrument has been used with hard water for a longer period of 
time, a hard-to-remove film may have formed on the sight-glass 
windows. If this is the case, clean the sight-glass windows as de-
scribed below for cleaning the measuring chamber. 

 

       

CAUTION 

 

! 

NOTE 

        

Summary of Contents for Testomat 2000 Fe

Page 1: ...ometer for Iron Dissolved 0 1 0 mg l Operating Instructions Lenntech Lenntech info lenntech com Tel 31 152 610 900 www lenntech com Fax 31 152 616 289 info lenntech com Tel 31 152 610 900 www lenntech com Fax 31 152 616 289 Lenntech ...

Page 2: ...cting the power supply and devices 11 Block diagram Testomat 2000 Fe 11 Internal design Testomat 2000 Fe 12 Connecting the mains voltage 13 Connecting the plant components 14 Connecting the inputs and outputs 15 Commissioning 16 Inserting reagent bottles 16 Filling the reagent 16 Opening the water inlet 16 Instrument settings and data input 17 Functions of the operating and display elements 17 Swi...

Page 3: ...o measuring points 36 Calculating the output currents 37 Serial interface RS232 37 SD card data logger 38 Description of the relay outputs 38 Flushing external flush valve 38 LV1 and LV2 limit value outputs 38 Measuring point 1 or 2 measuring point switch over 39 AUX programmable function output 39 Alarm fault message output 40 Maintenance output for maintenance message 40 Information menu i 41 Pr...

Page 4: ... To ensure correct and intended usage always read and understand these instructions especially the section entitled Important safety information prior to use The instrument is not used as intended if it is used in areas not specified in these instructions it is used in areas which do not correspond to the ones described in these instructions Qualification of the staff Assembly and commissioning re...

Page 5: ... NOTE indicates important information If this information is not ob served it may result in an undesirable result or state Further documents Testomat 2000 Fe is a plant component Therefore always observe the maintenance manual of Testomat 2000 Testomat ECO and the documentation of the plant manufacturer Pay particular attention to General instructions Please adhere to health and safety regulations...

Page 6: ... 2000 Fe Repairs must be carried out by authorised service staff After switch off and longer downtime Ventilate the indicator leads as described in the start up because longer downtimes more than 6 hours can cause the indicator in the leads to retract Do not switch off the appliance for longer periods e g over the weekend via the start stop output The indicator can retract from the leads This resu...

Page 7: ...ston dosing pump Range I 0 0 65 mg l resolution 0 01 mg l Range II 0 7 1 0 mg l resolution 0 1 mg l Analysis initiation Automatic interval operation interval pause can be set from 0 99 minutes External control Dynamic exhaustion dependent interval operation Quantity dependent via impulse water meter Two independent limit values with hysteresis 1 2 or 3 bad anal yses and settable switch functions M...

Page 8: ...metric TESTOVAL test kits Only use Testomat 2000 Fe for its intended purpose Careful handling of the instrument increases both its operational reliability and service life Therefore carry out a visual inspection at regular intervals as described below Are the hose connections of the dosing pump free of leaks Is there air inside the dosing hoses Are all the water connections free of leaks Are the d...

Page 9: ...ating range 1 to 8 bar Remove the flow controller valve body to operate the instru ment in the operating range 0 3 to 1 bar e g when using a type R aerator This involves removing the retaining pin from the control ler filter receiver Subsequently use the metal bracket to remove the controller plug from the borehole Subsequently remove the flow controller valve body and reinsert the controller plug...

Page 10: ...ater line It is important that the branch line connection is laid vertically up wards in order to prevent dirt particles from entering the instru ment from the main water line Install a manually operated shut off valve in the branch line to Testomat 2000 Fe Use an opaque plastic hose 6 4 x 1 max length 5 m for the wa ter inlet Flush the inlet to remove any dirt particles When operating within a pr...

Page 11: ...ctromagnetic fields If Testomat 2000 Fe or the connecting cables are installed paral lel to power cables or in close proximity to electromagnetic fields the instrument may be damaged or measurements may be incor rect Ensure that connecting cables are as short as possible Always install connecting cables and power cables separately Connect the instrument to the protective earth conductor for 230 11...

Page 12: ... 1 Terminal block for inputs Start Stop IN1 IN2 and output OUT 2 Mains switch 3 Terminal block for mains inputs and mains outputs 4 Terminal block relay outputs 5 Dosing pumps 6 Water connections inlet and outlet 7 Flow controller 8 Measuring chamber ...

Page 13: ...24 V instru ments to terminals U V Connect the conductor to the terminal block as shown on the left Ensure that the leads are held securely in the terminals Proceed as shown in figure to loosen the connection Terminals Terminal description Type Function Comment PE IN Protective earth conductor 5x Only for mains 115 230 V N U L V IN Mains N neutral conduc tor U 24 V Mains L phase V 24 V Mains input...

Page 14: ... Limit value output 1 Normally open Limit value output 1 Common Volt free relay output max 240 VAC 4 A 6 7 8 LV2 OUT Limit value output 2 Normally closed Limit value output 2 Normally open Limit value output 2 Common Volt free relay output max 240 VAC 4 A 9 10 11 Measuring point 1 2 OUT Measuring point 1 Normally closed Measuring point 1 Normally open Measuring point switch over Common Volt free r...

Page 15: ...ription of the signal inputs outputs No Terminal description Typ e Function Comment 20 21 Start IN External analysis start Common earth for inputs Only for volt free normally open 22 23 Stop IN External analysis stop Common earth for inputs Only for volt free normally closed normally open 24 25 IN1 IN Universal input 1 Common earth for inputs Only for volt free normally closed normally open 26 27 ...

Page 16: ...into the reagent bottle Now screw the screw cap with hole hand tight onto the rea gent bottle Filling the reagent Switch the instrument on and press the STANDBY key During operation the pumps DOSIClip automatically extract the reagents To ensure that reagent is available for the initial analyses the intake hose and the transport hose must be filled with rea gent from the pump up to the measuring c...

Page 17: ... carrying out settings and entering data for operating the instrument Functions of the operating and dis play elements The Testomat 2000 Fe display shows operating statuses and meas ured values The input keys for programming cursor block and the function keys are located underneath the display Switching Testomat 2000 Fe on off 1 Mains switch Use this switch to switch the instrument on or off 2 Ins...

Page 18: ...isplayed in line 2 and 3 Value exceeds the measuring range e g M1 1 0 mg l 2b The set limit values LV1 and LV2 are displayed in line 4 3 Alarm red Indicates malfunctioning error message or warning message 4 Maintenance message yellow Indicates current maintenance requests 5 Status display of the active instrument components line Six displays indicate the current instrument and analysis status Canc...

Page 19: ... the menu to select the desired functions and to enter necessary instrument and plant specific data Press the ENTER key to select the submenu item and to confirm and accept the selection or data input Function keys Manually start an analysis via the Manual key 1 Set the instrument to standby mode via the STANDBY key 2 automatic analyses are not carried out analysis stop Acknowledge error and warni...

Page 20: ...ENTER to confirm the entry The date has now been entered Exit the menu item in order to set the time Use the cursor block to select the desired menu item Press ENTER to confirm your selection The cursor flashes at the first position of the time Use the cursor keys to select the desired number Use the keys to move the cursor to the next input field Repeat this input process until the seconds have b...

Page 21: ...nu for the basic program appears You can now enter the plant specific data Entering basic program data Selecting the operating mode Under the menu item it is possible to select the type of analysis controller Testomat 2000 Fe provides numer ous selection options Time control quantity control via water meter dynamic analysis start and external analysis start Shortest interval 0 minutes between anal...

Page 22: ...addition of the AUX be fore after analysis Internal flush and External flush times and the measuring value dependent analysis dura tion see diagram on the left Minimum interval 1 litre maximum interval 9999 litres The analy sis is carried out once the programmed water quantity has been measured The line and the measuring chamber are flushed prior to the analysis observe the programmed flush times ...

Page 23: ... This involves the amount of water used by the plant being determined The start interval is reset when limit value 1 or 2 is exceeded or via a signal at input IN1 re generation message from the process controller filter controller Selecting dynamic start In the menu select Press ENTER to confirm the selection The menu on the left appears Enter the of the plant in m 3 Enter the start of dynamic mod...

Page 24: ...an be interrupted by triggering a con tact at the stop input Selecting the displayed unit It is possible to program the unit of the displayed value mg l and ppm can be selected All the following inputs and displays will be dis played in the programmed unit In the menu select Select the desired unit Press ENTER to confirm the selection External analysis start NOTE ...

Page 25: ...nds s Press ENTER to confirm the entry Setting the internal flushing time For connections longer than 3 m and with an internal hose diame ter of 6 mm a minimum internal flushing time of 10 seconds is re quired to ensure that a valid sample is taken from the sampling line The required quantity of flush water for one minute internal flushing is 0 5 litres External flushing If very short analysis int...

Page 26: ...red The functions of the allocated relay outputs can be programmed independently of each other If the unit is used for monitoring two limit values the limit value out puts are permanently allocated to these limit values 1 LV1 Limit value 1 2 LV2 Limit value 2 If the unit is used for monitoring two measuring points the limit value outputs are permanently allocated to these measuring points 1 LV1 Me...

Page 27: ... be set independently of each other A further analysis is carried out immediately after the limit value has been exceeded for a hysteresis of 2 The respective output is only switched after the limit value of this analysis has been exceeded for a second time With a hysteresis of 3 the respective output only switches when the limit value of this analysis has been exceeded for a third time This setti...

Page 28: ...n 2 interval If the limit value has been exceeded the respective output switches at intervals with the settable time t impulse or interval as long as the limit value is exceeded The switching on times and the intervals are the same Switch function 3 two point If the upper limit value LV1 has been exceeded the output relay LV1 switches If the value falls below the lower limit value LV2 the output r...

Page 29: ... water meter rating Press ENTER to confirm the entry Plant monitoring In order to monitor the plant it is possible to determine a specific quantity of water at which the limit value should not be exceeded LV1 or LV2 Example A GOOD quantity of 50 m 3 has been entered If the quan tity of water produced between two violations of the limit value is less than the programmed quantity of water either an ...

Page 30: ...e of monitoring A alarm M message or no ac tion for the individual menu items Press ENTER to confirm the respective entry Error messages All error messages are lost after a power failure Certain instrument faults always trigger an alarm or a message switching off is not possible Function AUX The AUX relay output can be programmed for the following control functions As a function output for the con...

Page 31: ...s A standard solution or the value of the sample water determined via a laboratory analysis is required for this You can either determine the correction factor and enter it directly or carry out calibration with a standard solution In the latter case the correction factor is calculated by the Testomat Input of the correction factor from 0 10 to 2 00 Carry out a current measurement and make a note ...

Page 32: ...mber until the output valve has closed OUT LED extinguishes When the IN LED lights up fill the measuring chamber with the standard solution until it overflows as long as the IN LED illumi nates The solution is then drained flushing the measuring chamber Once the output valve has closed OUT LED extinguishes refill the measuring chamber with the standard solution until it over flows The filling leve...

Page 33: ...servance of the maintenance intervals is monitored and displayed by Testomat 2000 Fe Program the desired maintenance interval in days here 0 days equals no maintenance interval In the menu select Enter the maintenance interval in days d Press ENTER to confirm the entry Water quantity RESET Resets the currently stored water quantity This has a direct effect on the plant monitoring and the dynamic a...

Page 34: ...he input is open or closed no analyses are carried out An active Stop input prevents an analysis start e g via a completed interval This can be necessary if the plant does not supply water A current analysis is stopped when the input valve is opened while the measuring chamber is being flushed or filled The water which has already entered the measuring chamber remains there If the measuring chambe...

Page 35: ...20 mA max load 500 Ohms Programmable OR Serial interface RS 232 Serial bus 2 wire cable See description of inter face card RS 910 See Technical info T2000 FE RS232 Refer to the section entitled Interfaces for a detailed description Interfaces optional Current interface 0 4 20 mA Current interface load The maximum load of 500 Ohms should not be exceeded In case of possible faults and when using ver...

Page 36: ...rm the selection In the menu select Select the desired configuration Press ENTER to confirm the selection Monitoring of two measuring points The example on the left displays the current profile for 4 20 mA and the use of two measuring points Measuring point 1 and measuring point 2 are measured alternatively The measured value 1 is shown in display line 2 M1 and the meas ured value 2 in line 3 M2 T...

Page 37: ... mA 4 mA Maximum value Measured value 2 Current 2 x 8 mA 12 mA Maximum value The current is set to 20 mA Measured value Value displayed in the selected unit Maximum value Final value of the measuring range 1 0 mg l Serial interface RS232 Testomat 2000 Fe can also be connected to a log printer via the serial interface RS232 to enable the printout of measuring results and error messages Analyses can...

Page 38: ... for the programmed period allowing the line up to Testomat 2000 Fe to fill with measuring water Please ensure that the programmed flush time is sufficient Please refer to Entering further basic program data External flush for programming details LV1 and LV2 limit value outputs Two volt free relay contacts are available to signal that a limit value has been exceeded The limit values the hysteresis...

Page 39: ...3 2 way control valve of the corresponding sampling line have to be connected to this output The terminals are strictly allocated to the measuring points Terminal 9 Measuring point 1 Terminal 10 Measuring point 2 In the menu select Select 2 measuring points Press ENTER to confirm the selection AUX programmable function output The functioning of this volt free relay output is programmable 1 For rep...

Page 40: ...entered in the error history also see i menu There is no additional alarm via the fault message output when the limit value is exceeded Refer to Error messages Troubleshooting for a description of the error messages Maintenance output for maintenance message The Maintenance output is a volt free change over contact During trouble free operation without a programmed maintenance interval the contact...

Page 41: ... a parameter can be requested via ENTER An asterisk indicates the se lected functions There are no active lines Error history 5 Use the i and ENTER keys to open the error history The error history is a list of errors or statuses which have occurred during operation The list is deleted after a power failure and a new list is started If no errors have occurred since start up the last switch on time ...

Page 42: ... Re agent B filling level 0 100 via the ENTER key the value is preset to 100 If you have connected a full bottle press ENTER to confirm the value If the filling level of the bottle differs enter the corresponding value Manual operation 4 After confirming the information message 4 via the ENTER key it is possible to select and activate the desired function by using the arrow keys and pressing the E...

Page 43: ...urrent interface can be checked under OUT output Press the Enter key to toggle between minimum and maximum current Change over occurs between 000 and 200 at 0 20 mA Time Date 12 Set the time and date by selecting and activating the desired function via the arrow keys and the ENTER key Subsequently press the M key again to save the setting and to return to the display function Refer to Functions of...

Page 44: ...sic program 44 Structure of the basic program Call the basic factory program by simultaneously pressing and holding down the M and i keys while switching on the instrument CAUTION the last set of programming will be lost ...

Page 45: ...e oxidised Clean filter strainer Replace valve block Remove pressure control ler valve body Replace fuse F6 Ff OUTLET TO DRAIN CONFIRM WITH HORN KEY After programming Continuous alarm or message impulses Standby Water remains in the meas uring chamber although LED OUT illuminates Check water outlet Connector at the outlet valve oxidised Replace valve block REAGENT LOW CONFIRM WITH HORN KEY After p...

Page 46: ...e circuit board Response of a protective circuit After a protective circuit fuse has been tripped attempt to eliminate the cause of malfunctioning e g replace a defective valve before reactivating the protective circuit Frequent tripping is always due to an error which in certain circumstances may also cause damage to the instrument Malfunctioning Repairing a defective instrument The repair of a d...

Page 47: ...se alcohol to remove this sticky film Description of maintenance work Please refer to the Maintenance manual Testomat 2000 Testomat ECO for a detailed description of maintenance work The measures described here only provide a brief overview Cleaning the measuring chamber and sight glass windows Switch off the instrument or press the STANDBY key If required remove any water from the measuring chamb...

Page 48: ...pring and filter Remove the retaining pin and extract the flow controller subse quently remove the flow controller valve body Clean the filter housing with water or alcohol then reassemble the unit If required replace the seals Insert the filter strainer with the cone facing downwards Re attach the hose connections at the filter housing Important maintenance information Water leakage at sealed poi...

Page 49: ...easuring chamber 5 x 60 Dosing pump DOSIClip 40201 Dosing pump SP 40011 Suction hose complete 40016 Pressure hose complete 40040 Valve set 32046 Plastic cover CNH 45 N Art no Bottle connection Suction device 40131 Screw cap with bottle insert T2000 40130 Screw cap GL32 hole 40132 Bottle insert for screw cap with push fit suction tube Unit spare parts list 31582 Fuse M4A 40294 Base circuit board T2...

Page 50: ...nector at the controller and filter housing with a plug for the quick release coupling not included Reagents Art no Description 040123 Retrofit kit for water inlet T2000 270305 Interface card 0 4 20 mA SK 910 270310 Interface card RS232 RS 910 270315 Interface card 0 2 10 V UK 910 100490 SD card data logger for Testomat 2000 270410 Booster pump 270337 Maintenance lab T2000 Heyl Art no Reagents 156...

Page 51: ...ains water supply Operating pressure 1 to 8 bar 1x10 5 to 8x10 5 Pa or 0 3 to 1 bar 0 3x10 5 to 1x10 5 Pa After removing the valve body 11225 Water inlet Opaque pressure hose with an external diameter of 6 4x1 mm Water outlet Pressure hose with an internal diameter of 12 mm Water temperature 10 to 40 C When using Testomat 2000 at a pre pressure of 0 3 bar it must be ensured that the flow rate thro...

Page 52: ...l and drinking water control Testomat 2000 CrVI Chromate Chrome VI 0 2 0 mg l 0 1 0 mg l process control of waste water in galvanic industry Testomat 2000 Duo as Testomat 2000 as Testomat 2000 Controlling of two measuring points Testomat 2000 Fe Iron II and Iron III 0 1 0 mg l De Ironing plants Testomat 2000 Polymer Polyacrylate 0 50 mg l Monitoring of conditioning agents in the cooling and heatin...

Page 53: ...sk of backwater No syphoning effect Yes No Is the drain hose free of blockages Microorganisms caused by contamination etc Yes No Does the set flushing time quantity of flush water ensure that only freshwater is measured Yes No Flushing time Are the hoses at the dosing pump free from air bubbles Operate the pump manually Carry out a manual analysis Yes No CARRYING OUT A MANUAL ANALYSIS Does the wat...

Page 54: ... Measuring points TYPE OF WATER METER 1 Litre Impulse 2 5 Litres Impulse 5 Litres Impulse 10 Litres Impulse 100 Litres Impulse 500 Litres Impulse 1000 Litres Impulse PLANT CONTROL Min Res Quant Limit val 1 Limit val 2 FUNCTION LV1 Duration Impulse Interval Two point Time FUNCTION LV2 Duration Impulse Interval Time HYSTERESIS LV1 Analysis 1 2 3 HYSTERESIS LV2 Analysis 1 2 3 ALARM MESSAGE Reagent lo...

Page 55: ...Scan the code and visit us on our website Lenntech info lenntech com Tel 31 152 610 900 www lenntech com Fax 31 152 616 289 info lenntech com Tel 31 152 610 900 www lenntech com Fax 31 152 616 289 Lenntech ...

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