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Maintenance

45

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 indicator 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 win-
dows. 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.

SERVICE I

MANUAL OPERATION

Drain cham-

ber

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

2000

®

.

Unhook the toggle type fastener a, tilt the measuring chamber

upwards and remove it.

Release both sight-glass window holders b, 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
have formed on the sight-glass windows. If this is the case, clean
the sight-glass windows as described below for cleaning the
measuring chamber.

a

b

NOTE

CAUTION

!

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Summary of Contents for 2000 THCL

Page 1: ...Testomat 2000 THCL Combined process photometer for total chlorine 0 2 5 ppm and process titrator for water hard ness 4 47 44 7 ppm CaCO3 Operating Instructions ...

Page 2: ...ecting the power supply and devices 12 Block diagram Testomat 2000 THCL 12 Internal design Testomat 2000 THCL 13 Connecting the mains voltage 14 Connecting the plant components 15 Connecting the inputs and outputs 16 Commissioning 17 Inserting indicator bottles 17 Extracting indicators 17 Opening the water inlet 18 Instrument settings and data input 18 Functions of the operating and display elemen...

Page 3: ...asuring 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 Request options Customer service operating values program values error history maintenance 39 Program menu M 40 Programming of Indicator manual mode flushing flush chamber drain chamber fill chamber self test conf...

Page 4: ...ated in the section enti tled Technical data Always observe the application areas application limits of the indi cators and the requirements of the medium being measured 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 specifi...

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

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

Page 7: ...nt via titration of residual hardness and photometric determination of the total chlorine content Freely selectable hardness units in dH f ppm CaCO3 or mmol l and chlorine units in mg l or ppm High measuring accuracy provided by a precise piston dosing pump Analysis initiation Automatic interval operation interval pause can be set from 0 99 minutes External control Quantity dependent via impulse w...

Page 8: ...t 2000 THCL Water hardness Indicator type TH 2025 dH Resolution 0 25 2 50 0 05 f Resolution 0 45 4 48 0 1 ppm CaCO3 Resolution 4 47 44 7 0 9 Unit mmol l Resolution 0 04 0 45 0 01 Total chlorine Reagent CL2250A CL2250B CL2250C Unit mg l ppm Resolution 0 0 2 5 0 1 ...

Page 9: ...be determined by using our colourimetric 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 air inside the dosing hoses Are all the water connecti...

Page 10: ... j j to operate the instru ment in the operating range 0 3 to 1 bar e g when using an aerator type R This involves removing the retaining pin i i i i from the controller filter receiver g g g g Subsequently use the metal bracket to remove the controller plug k k k k from the borehole Subsequently remove the flow controller valve body j j j j and reinsert the controller plug and the retaining pin I...

Page 11: ... after the water treatment plant 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 to Tes tomat 2000 THCL 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 o...

Page 12: ...lectromagnetic fields If Testomat 2000 THCL or the connecting cables are installed parallel to power cables or in close proximity to electromagnetic fields the instrument may be damaged or measurements 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 230 115 VA...

Page 13: ...ock for inputs Start Stop IN1 IN2 and output OUT Mains switch Terminal block for mains inputs and mains outputs Terminal block relay outputs Dosing pumps DosiClip1 left DosiClip4 right Water connections inlet and outlet Controller Filter receiver Measuring chamber ...

Page 14: ...als PE N L or for 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 Terminal description Typ e Function Comment PE IN Mains protective earth 5x Only with mains 115 230 V N U L V IN Mains N neutral U 24 V Mains L live V 24 V Mains input 24 V ...

Page 15: ...imit 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 Measur ing points 1 2 OUT Measuring point 1 Normally closed Measuring point 2 Normally open Measuring point switch over Common Volt free r...

Page 16: ...iption 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 I...

Page 17: ...in intake hoses into the indica tor bottles Now screw the screw caps with hole hand tight onto the indica tor bottles Switch the instrument on and press the STANDBY key Enter the filling levels of all the indicator bottles in In the menu select SERVICE I INPUT REAGENTS INDICATOR TH FILLING 100 New Full bottle 100 filling level Press ENTER to confirm the entry Enter further filling levels according...

Page 18: ... 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 dis play elements The Testomat 2000 THCL display shows operating statuses and measured values The input keys for programming cursor block and the function keys are locat...

Page 19: ... measuring range e g 44 7 ppm CaCO3 The current measured value for measuring point 2 total chlorine is displayed in line 2 Value exceeds the measuring range e g 2 5 ppm 2b The set limit values GW1 water hardness and GW2 total chlorine are displayed in line 3 and 4 3 Alarm red Indicates malfunctioning error message or warning message 4 Maintenance message yellow Indicates current maintenance reques...

Page 20: ...igate 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 Manually start an analysis via the Manual key Set the instrument to standby mode via the STANDBY key automatic analyses are not carried out analysis stop Acknowledge error and w...

Page 21: ...t the menu item DATE in order to set the time Use the cursor block to select the desired menu item TIME Press ENTER to confirm your selection The cursor flashes at the first position of the time 0 00 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 been entered Press ENTER to confirm the entry ...

Page 22: ... Entering basic program data Selecting the display units In BASIC PROGRAM menu select PROGRAM VALUES DISPLAY UNIT TH Press ENTER to confirm the selection The DISPLAY UNIT TH menu shown on the left appears Select the desired unit dH is factory set Press ENTER to confirm the selection An asterisk appears at the end of the line In BASIC PROGRAM menu select PROGRAM VALUES DISPLAY UNIT CI The DISPLAY U...

Page 23: ... at the end of the line TIME CONTROLLED is preset Enter the interval pause and the flush times In BASIC PROGRAM menu select PROGRAM VALUES FLUSH TIMES INTERVAL INTERVAL PAUSE Enter the INTERVAL PAUSE in minutes m 1 minute is preset Enter the INTERNAL FLUSH TIME in seconds s 00 seconds s is preset Enter the EXTERNAL FLUSH TIME in seconds s 00 seconds s is preset Press ENTER to complete all the entr...

Page 24: ...lect external analysis triggering External analysis triggering occurs via a contact at the start input Note The current analysis interval can be interrupted by triggering a contact at the stop input In BASIC PROGRAM menu select PROGRAM VALUES OPERATING MODE EXTERNAL START Press ENTER to confirm the selection An asterisk appears at the end of the line Quantity control Start via water meter External...

Page 25: ...al 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 intervals are required or if a very long several metres sampling line or a line with a large diameter is used an ex ternal flush valve should be installed upstream of Te...

Page 26: ...o cated relay outputs can be programmed independently of each other The instrument monitors two measuring points Water hardness is measured at measuring point 1 and total chlorine at measuring point 2 The measuring points are strictly allocated to the limit value out puts 1 LV1 Measuring point 2 LV2 Measuring point 2 water hardness total chlorine If the limit value LV1 has been exceeded the limit ...

Page 27: ... this analysis has been exceeded The respec tive output is only switched after the limit value of this analysis has been exceeded for a second time With a hysteresis of 3 the re spective output only switches when the limit value of this analysis has been exceeded for a third time This setting is only reactivated once the value has fallen below the limit value The basic setting for LV1 and LV2 is 1...

Page 28: ...alue is exceeded The switching on times and the intervals are the same In BASIC PROGRAM menu select PROGRAM VALUES FUNCTION LV1 or FUNCTION LV2 Select duration impulse interval Enter the time only for switch function 1 and 2 Press ENTER to confirm the entry Function IN1 For dynamic analysis control or programmed plant monitoring the regeneration message from the controller of the water treatment p...

Page 29: ...or 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 month year and hour and the type of the error In BASIC PROGRAM menu select PROGRAM VALUES ALARM MESSAGE Select the type of monitoring A alarm M message or no action for the individual menu items Press ENTER to confirm the respective entry Error messages All error ...

Page 30: ...ion of the instrument Programming the maintenance interval editing reset the operating time Use of the Service II menu The functions in the service II menu directly influence the operation and monitoring functions of the unit These tasks should only be carried out by trained and qualified staff Reset operating time After replacing a dosing pump or the measuring chamber holder it is possible to res...

Page 31: ...monitored and displayed by Testomat 2000 Program the desired maintenance interval in days here 0 days equals no maintenance interval In BASIC PROGRAM menu select SERVICE II MAINTENANCE INTERVAL Enter the maintenance interval in days T Press ENTER to confirm the entry 000d MAINTENANCE INTERVAL ME ME ME ME ...

Page 32: ... 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 the analysis is executed Manual start has priority over the Stop inp...

Page 33: ...one Quantity recording for start ing an analysis Function Connection Action OUT Programmable interface 0 20 mA or 4 20 mA max load 500 Ohms Interface supplies a meas ured value proportional current OR Programmable voltage interface 0 10 V or 2 10 V Interface supplies a meas ured value proportional voltage OR Serial interface RS 232 Serial bus 2 wire cable See description of inter face card RS 910 ...

Page 34: ...e 0 20 mA range The range of the current interface is divided The range 0 10 mA is available for the meas ured value from measuring point 1 and range 10 20 mA for the measured value from measuring point 2 If the 4 20 mA range is selected the ranges are divided as 4 12 mA and 12 20 mA The measured value 1 is shown in display line 2 M1 and the meas ured value 2 in line 3 M2 The currently analysed me...

Page 35: ...is set to 20 mA Measured value Value displayed in the selected measuring unit Maximum value Final value of the used indicator e g indicator type TH 2025 44 7 ppm CaCO3 Serial interface RS232 Testomat 2000 THCL 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 then be continuously logged This option is o...

Page 36: ...vailable to signal that a limit value has been exceeded The limit values the hysteresis and the function can be freely programmed for both contacts Function Contact Action LV1 Relay switches if limit value 2 Limit value 1 resdidual hardness measuring point1 Volt free change over contact programmable Continuous contact Impulse 1 99 seconds minutes Interval 1 99 seconds minutes Hysteresis 1 2 or 3 l...

Page 37: ...ve Measurements only from measuring point 1 AUX programmable function output The functioning of this volt free relay output is programmable 1 For reporting a current analysis and or 2 For contact prior to an analysis e g to operate a cooler or 3 Contact after an analysis In BASIC PROGRAM menu select PROGRAM VALUES FUNCTION AUX Select the program step at which the AUX contact is to be acti vated Un...

Page 38: ... history 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 Trouble shooting 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 ...

Page 39: ...o request the current setting of a parameter An asterisk indicates the se lected functions There are no active lines Error history 5 Open the error history by pressing the i and ENTER key The error history is a list of the errors or statuses which have occurred during current operation This list is lost after a power failure and the re cording is restarted If no errors have occurred since start up...

Page 40: ...n to cancel this function Flush chamber 6 Press the ENTER key to flush the measuring chamber once Drain chamber 7 Press the ENTER key to open the outlet valve in order to drain the water from the measuring chamber Press the ENTER key again to cancel this func tion NOTE Service I 2 Input indicator 3 Enter the new filling levels after each refill or indicator bottle change Once you have se lected th...

Page 41: ...ly 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 Oper ating system for more details Basic program This menu item can only be accessed after entering the password After entering the password and confirming it via the ENTER key it is possible to carry out basic programming of the instrument and to select vario...

Page 42: ...nu 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 ACHTUNG die letzte Programmierung geht verloren ...

Page 43: ...let valve oxidised Clean filter strainer Replace valve block Extract pressure control ler valve body Replace fuse F6 Ff OUTLET TO DRAIN CANCEL 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 LOW INDICATOR LEVEL CANCEL WITH H...

Page 44: ...tive Ribbon cable at display circuit board or base circuit board is loose Error at display circuit board or base circuit board Replace fuses Replace power switch Reconnect ribbon cable Replace display or base 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 reactivat...

Page 45: ...ticky 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 SERVICE I MANUAL OPERATION Drain cham be...

Page 46: ...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 housing Important maintenance information Water leaka...

Page 47: ...ck processed bottom part 40201 Jet pump exchange instrument 40001 Jet pump ET 40011 Suction hose complete 40016 Pressure hose complete 37232 Base circuit board TI 3 34668 Solenoid 24 VDC 32046 Plastic cover CNH 45 N Bottle connection Suction device 40131 Screw cap with bottle insert T2000 40130 Screw cap GL32 hole 40135 Bottle insert for screw cap with push fit suction tube Art No Unit spare parts...

Page 48: ...t for water inlet Art no 040123 If 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 fort he quick release coupling not included Art no Description 040123 Retrofit kit for water inlet T2000 040315 Outlet funnel for Testomat 2000 ECO 270305 Interface card 0 4 20 mA SK 910 270310 Interface card ...

Page 49: ...0 4 20 mA max load 500 Ohm Protocol printer See section Accessories Dimensions W x H x D 380 x 480 x 280 mm Weight Approx 9 5 kg Others The unit 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 After removing the valve body 11225 Water inlet Opaque pressure hose with an external diameter of 6 4x1 mm Water outlet Opaque hose wi...

Page 50: ...CLT Total chlorine 0 2 5 mg l DPD method for swimming pools and drinking water Testomat 2000 CrVI Chromate Chromium VI 0 2 0 mg l 0 1 0 mg l Monitoring of process and waste water for electroplating Testomat 2000 Duo same as Testomat 2000 same as Testomat 2000 Monitoring 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 M...

Page 51: ...51 Gebrüder Heyl Analysentechnik GmbH Co KG Orleansstraße 75b D 31135 Hildesheim www heyl de Testomat_2000_THCL_GB100519_B3 doc Ma 2011 ...

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