Lenntech Testomat 2000 PO4 Operating Instructions Manual Download Page 48

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Testomat 2000® spare parts and accessories

Testomat 2000

spare parts and

accessories

Art. no.

Pressure controller

40125 Controller / Filter receiver, complete

40120 Controller / Filter receiver

40129 Controller plug T2000, complete

11225 Flow controller valve body

11230 Retaining pin 3x38

11217 Inlet filter

11218 Spring for inlet filter

40121 Inlet connector

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

40157 Angled plug-in connector G 1/8"

Measuring chamber

40378 Measuring chamber PO4, SP

40358 Sight-glass PO4 with seal, SP

40176 Sight-glass holder

33253 Bolt M3x40

40032 Latch fastener TL-17-201-52

11210 Plug for measuring chamber

Measuring chamber holder

40382 Measuring chamber holder DUO

40050 Magnetic stirrer

40186 Screw-in connector 3/8" -10

40018 Solenoid valve, 2/2-way

Dosing pump PERIClip

270430 Dosing pump PeriClip, complete

40362 Pump head PeriClip SP

Bottle connection/Suction device

37644 Screw cap with bottle insert for 500 ml

bottle

37645 Screw cap with bottle insert for 100 ml

bottle

Art. no.

Instrument spare parts

31582 Fuse M4A

40294 Base circuit board T2000 complete

230 V

40092 Control circuit board T2000 complete

40091 Plug-in circuit board driver/receiver SE-

T2000 (6)

40190 Cable gland 5-7

40191 Cable gland 7-10

31713 Ribbon cable 10 pole with EMI filter

clamp

40096 Ribbon cable 26 pole with EMI filter

clamp

40060 Cable loom 2V complete (for valves)

40062 Cable loom 2P complete (for max. 2

dosing pumps)

40200 Cable loom complete with mains switch

and cap

31596 Fuse T0.08A

31585 Fuse T0.315A

31595 Fuse T0.1A

31622 Fuse T0.16A

31592 Fuse T1.0A

Spare parts requirements for 2 - 3 years of

operation

11217 Inlet filter

40124 Gasket set T2000 (according to

maintenance requirements)

31585 Fuse T0.315A

31592 Fuse T1.0A

Summary of Contents for Testomat 2000 PO4

Page 1: ...hotometer for Phosphate 0 10 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: ...ting the power supply and devices 11 Block diagram Testomat 2000 PO4 11 Internal design Testomat 2000 PO4 12 Connecting the mains voltage 13 Connecting the plant components 14 Connecting the inputs and outputs 15 Commissioning 16 Inserting the reagent bottles 16 Extracting the reagent 16 Input reagent level 16 Opening the water inlet 17 Instrument settings and data input 17 Functions of the operat...

Page 3: ...ts 34 Calculation of output currents 35 Serial interface RS232 35 SD card data logger 36 Description of the relay outputs 36 Flushing external flush valve 36 LV1 and LV2 limit value outputs 36 Measuring points 1 or 2 measuring point switch over 37 AUX programmable function output 37 Alarm fault message output 38 Maintenance output for maintenance message 38 Information menu i 39 Program menu M 40 ...

Page 4: ...ect 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 require fundament...

Page 5: ...NOTE indicates important information If this information is not observed it may result in an undesirable result or state Further documents Testomat 2000 PO4 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 Adhere to health and safety regulations electri...

Page 6: ...malfunctioning occurs The warranty will be void if you tamper with or attempt to repair Testomat 2000 PO4 Repairs must be carried out by authorised service staff Cleaning Only use a dry lint free cloth for cleaning 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 retrac...

Page 7: ... range of 0 7 mg l 0 25 mg l in the range of 7 10 mg l Limit of detection 0 1 or 0 25 mg l depending on range Accuracy 10 at end of measuring range Simple menu driven operating and programming via a plain text display Freely selectable unit in ppm or mg l Analysis initiation Automatic interval operation Interval pause adjustable from 0 to 255 minutes External control Volume controlled water meter ...

Page 8: ... indicator expired Are the hose connections of the dosing pump free of leaks Are all the water connections free of leaks Are the doors of the instrument closed properly Is the instrument heavily soiled Are the measuring chamber and the drain duct drain hose clean Trouble free operation is only possible when maintenance is carried out on a regular basis For more information please refer to the sect...

Page 9: ... Remove the flow controller valve body to operate the instrument in the operating range of 0 3 to 1 bar e g when using an aerator type R This involves removing the retaining pin from the controller filter receiver Subsequently use the metal bracket to remove the controller plug from the borehole Then remove the flow controller valve body and reinsert the controller plug and the retaining pin Insta...

Page 10: ...nection is laid vertically upwards in order to prevent dirt particles from entering the instrument from the main water line Install a manually operated shut off valve in the branch to Testomat 2000 PO4 Use an opaque plastic hose 6 4 x 1 max length 5 m for the water inlet Flush the inlet to remove any dirt particles When operating within a pressure range of 0 3 to 1 bar or with a supply via a boost...

Page 11: ...ctromagnetic fields If Testomat 2000 PO4 or the connecting cables are installed parallel to power cables or in close proximity to electromagnetic fields the instrument may be damaged or measurements incorrect 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 230 115 VAC Pr...

Page 12: ...O4 Terminal strip for inputs Start Stop IN1 IN2 and output OUT Mains switch Terminal strip for power input and power output Terminal strip for relay outputs Dosing pump Water connections inlet and outlet Controller Filter receiver Measuring chamber ...

Page 13: ...ls PE N L or for 24 V instruments 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 Terminal Type Function Comment PE IN Protective earth conductor 5x Only for mains 115 230 V N U L V IN Mains N neutral conductor U 24 V Mains L phase V 24 V Mains input 24 V 1...

Page 14: ...4 A 3 4 5 LV1 OUT Limit value output 1 N C Limit value output 1 N O Limit value output 1 Common Isolated relay output max max 240 VAC 4 A 6 7 8 LV2 OUT Limit value output 2 N C Limit value output 2 N O Limit value output 2 Common Isolated relay output max 240 VAC 4 A 9 10 11 M point 1 2 OUT Measuring point 1 N C Measuring point 2 N O M point switch over Common Isolated relay output max 240 VAC 4 A...

Page 15: ...on of the signal inputs outputs No Terminal Type Function Comment 20 21 Start IN External analysis start common earth for inputs Only connect isolated normally open contact 22 23 Stop IN External analysis stop common earth for inputs Only connect isolated normally closed open contact 24 25 IN1 IN Universal input 1 common earth for inputs Only connect isolated normally closed open contact 26 27 IN2...

Page 16: ...mp Observe correct allocation of the reagents A and B to the dosing pumps A left B right Push the intake hose hand tight onto the hose connector of the insert Extracting the reagent Switch the instrument on and press the STANDBY key During operation the pump PERIClip automatically extracts reagent To ensure that reagent is available for the initial analyses the intake hose and the transport hose m...

Page 17: ... take 2 to 6 seconds to fill the measuring chamber Instrument settings and data input Please read the following information before carrying out settings and entering data for operating the instrument Functions of the operating and display elements The Testomat 2000 PO4 display shows operating statuses and measured values The input keys for programming cursor block and the function keys are located...

Page 18: ...ogramming data 2a The current measured value for measuring point 1 M1 and 2 M2 is displayed in line 2 and 3 Value exceeds the measuring range e g M1 10 mgl 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 co...

Page 19: ...e 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 Press the manual key to start an analysis by hand Press the STANDBY key to put the instrument into standby mode automatic analyses are not carried out analysis stop Press the Horn key to a...

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: ...the plant specific data Selecting the operating mode Under the menu item it is possible to select the type of analysis controller Testomat 2000 PO4 provides numerous selection options Time control quantity control via water meter and external analysis start Shortest interval 0 minutes between analyses Largest interval 255 minutes The analysis interval time between two analyses is determined by the...

Page 22: ...n the left Minimum interval 1 litre maximum interval 9999 litres The analysis 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 Selecting the volume control In select Press ENTER to confirm the selection The menu on the left appears Enter the respective flow rate in litres Pres...

Page 23: ... be interrupted by triggering a contact at the stop input Typical analysis cycle 1 Flush the measuring chamber and line 2 Fill the measuring chamber 3 Check the sample water for soiling The stirring mechanism is switched on Dose the reagents A and B Allow a reaction time of 10 minutes 4 Display the measuring result 5 Drain the measuring chamber 6 Waiting time until the next analysis Selecting the ...

Page 24: ...econds s Press ENTER to confirm the entry Setting the internal flushing time For connections longer than 3 m and with an internal hose diameter of 6 mm a minimum internal flushing time of 10 seconds is required 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 in...

Page 25: ... programmed independently of each other If the unit is used for monitoring two limit values the limit value outputs 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 Measuring point 1 2 LV2 Measuring point 2 If the limit val...

Page 26: ...our of switch function 4 is inverse With switch function 5 hysteresis occurs if limit value LV1 is exceeded and LV2 is not achieved The basic setting for LV1 and LV2 is 1 In select Enter the number of analyses Press ENTER to confirm the entry Switch functions of the limit value outputs LV1 and LV2 Switch function 0 duration If the limit value LV1 or LV2 has been exceeded the output relay LV1 or LV...

Page 27: ... two point only for LV1 Enter the time only for switch function 1 and 2 Press ENTER to confirm the entry Switch function 5 range LV1 LV2 Monitoring the range between limit values LV1 and LV2 If limit value LV1 is exceeded relay LV1 switches and LED LV1 illuminates red If limit value LV2 is not achieved relay LV2 switches and LED LV2 lights up red If the measured value is within the range both rela...

Page 28: ...quipped with an alarm relay output for signalling faults The events which mean a fault at the instrument or are intended to trigger a message can either trigger an alarm A continuous contact or a message M 2 second impulse The faults are recorded and stored in the error history if the event has been programmed as an alarm or message For example if a low reagent level has not been programmed as an ...

Page 29: ... function output for the contact with programmable duration prior to and or during the analysis or after an analysis For example it is possible to control the cooling water inlet of an upstream cooler via a solenoid valve This ensures that the cooling water only flows when required i e when an analysis is being carried out In select Select the program step at which the AUX contact is to be activat...

Page 30: ...he measured value displayed nevertheless deviate from the target value of a measured standard solution you can adjust the instrument with the calibration factor You can calculate the calibration factor as follows Target value Calibration factor Actual value The calibration factor can be between 0 9 and 1 1 Should the calibration factor vary from 1 0 by more than 10 send the instrument back to the ...

Page 31: ... the maintenance intervals is monitored and displayed by Testomat 2000 PO4 Program the desired maintenance interval in days here 0 days equals no maintenance interval In select Enter the maintenance interval in days d Press ENTER to confirm the entry ...

Page 32: ...contact at the input is open or closed An active Stop input prevents an analysis start e g via a current 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 chamber is already full ...

Page 33: ...ecording for analysis start and plant monitoring Function Connection Action OUT Programmable current interface 0 20 mA or 4 20 mA Max load 500 Ohms OR Programmable voltage interface 0 10 V or 2 10 V OR Serial interface RS 232 Serial bus 2 wire cable See description of interface card RS 910 Refer to the section entitled Interfaces for a detailed description Interfaces optional Current interface 0 4...

Page 34: ...current profile in the 0 20 mA range for one measuring point In select Select the desired current range Press ENTER to confirm the selection In 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...

Page 35: ...ent 2 x 10 mA 10 mA Maximum value Measured value 1 Current 1 x 8 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 the value shown on the display in the selected unit Maximum value the end value of the applied reagent 10 mg l Serial interface RS232 Testomat 2000 PO4 can also be connected to a log printer via the serial interface ...

Page 36: ...nal flush valve is opened for the programmed period allowing the line up to Testomat 2000 PO4 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 l...

Page 37: ...valves or one 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 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 fo...

Page 38: ...istory also see i menu There is no additional alarm via the fault message output when the limit value is exceeded The error messages are described under Error messages Troubleshooting 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 between the terminals 17 19 is ...

Page 39: ...arameter can be requested via ENTER An asterisk indicates the selected 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 of th...

Page 40: ...he outlet valve in order to drain the water from the measuring chamber Press the ENTER key again to cancel this function Service I 2 Input reagent 3 Enter the new filling levels after each refill or reagent bottle change Once you have selected the menu item for entering the filling level Reagent X Filling 0 100 via the ENTER key the value is preset to 100 If a full bottle has been connected confir...

Page 41: ...ress the M key again to save the setting and to return to the display function Refer to Functions of the operating and display elements Operating system for more details Confirm pump head change 13 After pump head change has been carried out confirm it by pressing the Enter key and exit this item via the M key The change interval for the pump head is resetted Confirm the change request in the M me...

Page 42: ... M 42 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 erased ...

Page 43: ...ET TO DRAIN CANCEL WITH HORN KEY After programming Continuous alarm or message impulses Standby Water remains in the measuring chamber although LED OUT illuminates Check water outlet Connector at the outlet valve oxidised Replace valve block LOW REAGENT LEVEL CANCEL WITH HORN KEY After programming Continuous alarm or message impulses or no message LED and output maintenance on Continue measurement...

Page 44: ... or base circuit board Tripping 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 triggering is always due to power overload which in certain circumstances may also damage to the instrument Malfunctioning Repairing a defective instrument The repa...

Page 45: ...s Use alcohol to remove this sticky film Description of maintenance work The maintenance manual Testomat 2000 Testomat ECO contains a detailed description of maintenance work The measures described here 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 ...

Page 46: ...g and filter Remove the retaining pin and extract the flow controller subsequently 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 points c...

Page 47: ...ump head To replace the pump head proceed as described below Remove the transparent cover Open the housing with a suitable screwdriver push down the snap on fastening on both sides Carefully pull out the pump head with a drive mounting bracket Loosen both screws at the pump head Pull the pump head from the motor shaft Place the new pump head on the shaft The short hose with the stopper must be on ...

Page 48: ...ay Dosing pump PERIClip 270430 Dosing pump PeriClip complete 40362 Pump head PeriClip SP Bottle connection Suction device 37644 Screw cap with bottle insert for 500 ml bottle 37645 Screw cap with bottle insert for 100 ml bottle Art no Instrument spare parts 31582 Fuse M4A 40294 Base circuit board T2000 complete 230 V 40092 Control circuit board T2000 complete 40091 Plug in circuit board driver rec...

Page 49: ...lug connector at the controller and filter housing with a plug for the quick release coupling not included Art no Description 040123 Retrofit kit for water inlet 040315 Discharge hopper for Testomat 2000 ECO 270305 Current interface card 0 4 20 mA SK 910 270310 RS 232 interface card for log printer RS 910 270315 Voltage interface card 0 2 10 V UK 910 100490 SD Card Data Logger for Testomat 2000 27...

Page 50: ...nstrument is non volatile Water connection 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 Remove flow controller valve body 11225 Water inlet Opaque pressure hose with external diameter 6 4x1 mm Water outlet Hose with internal diameter 12 mm Water temperature 5 to 30 C When using Testomat 2000 at a pre pressure of 0 3 bar it must be ensured that the flow ra...

Page 51: ... Plant pressure Does the drain hose prevent the risk 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 ...

Page 52: ...points internal 2 Measuring points external 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 FUNCTION LV1 Duration Impulse Interval Two point Range LV1 LV2 Time FUNCTION LV2 Duration Impulse Interval Time HYSTERESIS LV1 Analysis 1 2 3 HYSTERESIS LV2 Analysis 1 2 3 ALARM MESSAGE Reagent low level Low ...

Page 53: ...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 54: ...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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