Lenntech Testomat 2000 Polymer Operating Instructions Manual Download Page 44

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Maintenance

Maintenance

Required maintenance measures



Regular maintenance is necessary to ensure trouble-free

operation 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 interval exceeded")



the instrument displays the following error messages:

"Mf. dirtiness" or "Low Reagent low 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 longer

period of time, a coloured film may form on the sight-glass
windows. Use alcohol to remove this sticky film.



Regularly check the sight-glass windows. For difficult water types,

the film must be removed from the sight-glass windows every 1 to
2 weeks in order to prevent measurement errors.

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 manually-operated valve of the branch line to Testomat

2000

Polymer.



Unhook the toggle type fastener

, tip 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 (measuring range exceeded!), a hard-to-remove film may

CAUTION

NOTE

Summary of Contents for Testomat 2000 Polymer

Page 1: ...cess Photometer for Polyacrylate 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: ... devices 11 Block diagram Testomat 2000 Polymer 11 Internal design Testomat 2000 Polymer 11 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 operating and display e...

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

Page 4: ...rrect 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 fundame...

Page 5: ...TE indicates important information If this information is not observed it may result in an undesirable result or state Further documents Testomat 2000 Polymer 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 elect...

Page 6: ...bles parallel to power cables Operation Ensure that the maximum electrical load capacity of the relay outputs is never exceeded Immediately switch off Testomat 2000 Polymer and contact service staff if malfunctioning occurs The warranty will be void if you tamper with or attempt to repair Testomat 2000 Polymer Repairs must be carried out by authorised service staff Cleaning Only use a dry lint fre...

Page 7: ... from 0 01 to 99 99 a measuring range from 0 5 to 4 999 5 mg l ppm is achieved The factor must be checked on site see page 24 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 Two independent limit ...

Page 8: ...colorimetric TESTOVAL test kit 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 Has the use by date of the indicator expired Are the hose connections of the dosing pump free of leaks Is there any air inside the dosing hoses Are all the water connections free of leaks Are th...

Page 9: ... bar 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 I...

Page 10: ...nnection 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 Polymer 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 ...

Page 11: ...magnetic fields If Testomat 2000 Polymer 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: ...00 Polymer 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 Flow controller 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: ...lay output max 240 VAC 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...

Page 15: ...tion 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 I...

Page 16: ...he 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 must be filled with indicator from the pump up to the measu...

Page 17: ...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 Polymer display shows operating statuses and measured values The input keys for programming cursor block and the function keys are located u...

Page 18: ...red value for measuring point 1 M1 and 2 M2 is displayed in line 2 and 3 e g M1 17 0 mgl l Value exceeds the measuring range e g M1 50 0 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 components line S...

Page 19: ...cursor block to navigate in 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 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 analysi...

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: ...ogram appears You can now enter the plant specific data Selecting the operating mode Under the menu item it is possible to select the type of analysis controller Testomat 2000 Polymer 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 betwe...

Page 22: ...imum 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 Press ENTER to con...

Page 23: ...ontact 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 each 21 sec reagent A and reagent B The stirring mechanism is switched off Allow a reaction time of 7 minutes 4 Display the measuring result 5 Drain the measuring chamber 6 Waiting time until...

Page 24: ...to a wrong reading Checking the factor The customer is to check this factor during ongoing operation after commissioning Proceed as follows Perform 3 5 analyses with the Testomat device Record the measurement results and calculate the average value Draw samples of the process water from the supply line to the Testomat device Have the extracted samples analysed by a laboratory If the results deviat...

Page 25: ...onds 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 inte...

Page 26: ... 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 27: ...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 28: ...nitoring 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 relays are deactivated and both LEDs illuminate green If this function has been selected no other function can be selected for limit value LV2 ...

Page 29: ...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 ALARM MESSAGE it is not registered in the error history Up to 20 error messages can be stored A list of these errors can be opened in the information menu The information stored per event is the time day mont...

Page 30: ...minutes m and seconds s Press ENTER to confirm the entry Service II The service II menu contains various functions for monitoring the operation of the instrument Programming of the maintenance interval operation reset internal data setting e g water quantity and plant monitoring Use of the Service II menu The functions in the Service II menu directly influence the operation and monitoring function...

Page 31: ...ot yet running Function Test period Action Stop External analysis stop e g via flow controller or process controller None There are no analyses while the 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 meas...

Page 32: ...d 500 Ohms Programmable Measured value measuring point 1 or 2 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 20 mA Current interface load The maximum load of 500 Ohms should not be exceeded In c...

Page 33: ...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 measured alternatively The measured value 1 is shown in display line 2 M1 and the measured value 2 in line 3 M2 The cu...

Page 34: ...range is divided for two measuring points The value from measuring point 1 is displayed in the lower half 0 10 mA or 4 12 mA and the value for measuring point 2 in the upper half 10 20 mA or 12 20 mA Measured value Current x 20 mA Maximum value Measured value Current x 16 mA 4 mA Maximum value Measured value 1 Current 1 x 10 mA Maximum value Measured value 2 Current 2 x 10 mA 10 mA Maximum value M...

Page 35: ...ER to confirm the selection Description of the relay outputs All relay outputs are neutral contacts This ensures that all connection options are available The switching of mains voltage and external voltage and the direct switching of inputs e g a process controller can be realised Flushing external flush valve Immediately before each analysis the external flush valve is opened for the programmed ...

Page 36: ... Switch functions of the limit value outputs LV1 und LV2 for more details and programming Measuring points 1 or 2 measuring point switch over If the instrument is used for monitoring two measuring points the solenoid valves individual 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 poin...

Page 37: ... 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 closed and ...

Page 38: ...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 39: ...er to drain the water from the measuring chamber Press the ENTER key again to cancel this function Service I 2 Input indicator 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 A filling level 0 100 or Reagent B filling level 0 100 via the ENTER key the value is preset to 100 If you have connected a...

Page 40: ...ntly press 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 150 hours of operation the maintenance message for the pump head is displayed Change the pump head and confirm the change by pressing the Enter key Exit the screen via the M key The change i...

Page 41: ... M 41 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 42: ...y Replace fuse F6 Ff OUTLET 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 maintenanc...

Page 43: ...ttempt 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 repair of a defective instrument irrespective of the warranty period is only possible when the instrument is d...

Page 44: ... this sticky film Regularly check the sight glass windows For difficult water types the film must be removed from the sight glass windows every 1 to 2 weeks in order to prevent measurement errors 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 meas...

Page 45: ...connection using an open ended spanner size 22 and remove the seal spring 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 ho...

Page 46: ...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 47: ...0430 Dosing pump PeriClip SP 39902 Pump head PeriClip SP 40359 PeriClip conversion kit for tube connection at measuring chamber Bottle connection Suction device 37644 Screw cap with insert for 500 ml bottle 37645 Screw cap with 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...

Page 48: ... existing installations are used please replace the plug 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 U...

Page 49: ...her The instrument 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 Pressure hose with internal diameter 12 mm Water temperature 10 40 C When using Testomat 2000 at a pre pressure of 0 3 bar it must be ensured ...

Page 50: ...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 Yes No CARRYING OUT A MANUAL ANALYSIS Does the w...

Page 51: ...ints 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 Duration inverse Impulse Interval Two point Range LV1 LV2 Time FUNCTION LV2 Duration Duration inverse Impulse Interval Time HYSTERESIS LV1 Analysis 1 2 3 HYSTERESIS LV2 Analysis 1 2 3 ALARM MESSAGE Reagent low level ...

Page 52: ...CLT Total Chlorine 0 2 5 mg l DPD method for swimming pool 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 SO3 Sulphite 0 20 mg l Control of...

Page 53: ...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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