Testomat CL Operating Instructions Manual Download | Manualshive

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Assembly

17

Internal design Testomat

®

Modul CL



Control circuit board,
Base circuit board with terminal strips for inputs and outputs is behind
it



Cable gland on both sides



Dosing pumps



Optical unit (sender right/receiver left)



Solenoid valve



Water connections, inlet and outlet



Controller / Filter receiver



Measuring chamber





















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Summary of Contents for CL

Page 1: ...Testomat Modul CL Process Photometer Module for Chlorine Operating Instructions ...

Page 2: ...lation 11 Assembly 12 Assembling the Testomat Modul CL 12 Use of the Testomat Modul CL within a pressure range of 0 3 to 1 bar 12 Connecting the water intake and discharge 13 Water intake 13 Water drain 13 Connect mains and devices 14 Block diagram of Testomat Modul CL 15 Connecting inputs and outputs 16 Internal design Testomat Modul CL 17 Commissioning 18 Select parameters 18 Inserting the reage...

Page 3: ...s 33 Serial interface 34 Notification format 34 Error messages and troubleshooting 35 Temporary faults 35 Error messages 35 Reagent shortage 37 Correct water level in the measuring chamber 38 Maintenance message 39 Maintenance 40 Cleaning intervals 40 Service instructions 40 Cleaning of the measuring chamber and the sight glass windows 41 Cleaning the filter housing 41 Changing an empty reagent bo...

Page 4: ...specified in the Technical data section on page 50 Observe the areas and limits of application of the indicators and the requirements imposed by the medium to be measured see page 9 The scope of intended use presumes that you have read and under stood the instructions and particularly the section Important safety in formation Improper use is deemed to occur if you use the device outside the applic...

Page 5: ... of information If this information is not heeded it may adversely affect operational procedures Additional documentation The Testomat Modul CL is a system component Accordingly you should also observe the system documentation of the system manu facturer Special attention is required at this point General Information During assembly and commissioning observe the specific national and local require...

Page 6: ...o 10 mm If you use other ducts the cable diameters must correspond to the ducts Optimum cross section of the cores If the core cross section is less than 0 5 mm2 jamming may occur when the cores are loosened from the terminal strip We therefore recommend using wires with cross sections greater than 0 5 mm2 Requirements for cable ducts The recesses in the housing are intended for M16 ducts The duct...

Page 7: ...asures to avoid electrostatic discharge onto the compo nents ESD safety Make sure you are earthed before opening the casing During operation The device has no on off switch Use an external switch to turn the unit on and off The switch must be installed next to the device and must be marked as power switch for the device for example with a label Ensure that the maximum electrical load capacity of t...

Page 8: ...ber the seal of which must remain undam aged If you send the device in for repair completely empty the measuring chamber and remove the indicator bottle and the drain funnel Before dismantling the type of error must be noted error number error effect log file of the SD card Once a protective device has been triggered safety fuse initially try resolving the cause of error e g by replacing a defecti...

Page 9: ...cannot be ruled out In this case use an irri gator e g optional accessory from Heyl Co The water to be measured must be clean and free of bubbles The concentrations of disruptive ingredients can be determined with colorimetric TESTOVAL test comparators from Gebr Heyl Careful handling of the device enhances the operational safety and the service life With this in mind perform a visual inspection of...

Page 10: ...riding control system The output of the measurement values occurs via a 4 20 mA inter face and via RS232 interface Optional Display for measured value display in ppm Analysis trigger o Measurement phase mode A start impulse triggers a sequence of analyses for the period of between 10 minutes and 12 hours o Continuous mode Analyses are continuously carried out at a set interval The analysis interva...

Page 11: ...he new measurement value after the subsequent analysis In measurement phase mode a current of 4 mA shall be output out side of the measurement phase When using the RS232 interface the Testomat Modul CL transfers its determined measurement result to the control system All meas urement data and error messages are always transferred to the RS232 interface even if they are not used Measurement calcula...

Page 12: ... avoid direct sunlight or strong incidence of light as this may impair the measurement Drill the mounting holes as specified in the accompanying sketches Secure the device with three screws in a suitable place in the switching cabinet or on the wall Use of the Testomat Modul CL within a pres sure range of 0 3 to 1 bar Before assembling please check whether adaptation to a lower work ing pressure i...

Page 13: ...d be avoided The measurement water temperature must be between 10 and 40 C For water temperatures exceeding 40 C a cooler must be in stalled in the intake of the Testomat Modul CL Water intake The test water is extracted from the sampling pipe and channelled to the supply nozzles of the Testomat Modul CL The device comes with a plug connection for plastic hoses 6 4 x 1 as standard external diam et...

Page 14: ...oduct or damage to system components Disconnect all power to the relevant system component before as sembling the Testomat Modul CL device When connecting use only verified cables with sufficient line cross section see Requirements of cable for operating voltage and system components and installed lines on page 6 Danger of damage due to electromagnetic fields If you assemble the Testomat Modul CL ...

Page 15: ...Assembly 15 Block diagram of Testomat Modul CL Illustrated position of relays Device without current ...

Page 16: ...rminal des ignation Type Function Note OUT OUT OUT Current loop 4 20 mA Galvanically isolated START GND IN External start stop of analysis Ground Only connect isolated break contacts closing contacts GND IN Ground RxD TxD IN OUT RS232 interface Not galvanically iso lated RxD currently not in use Terminal des ignation Type Function Operating voltage 24 VDC NO Alarm output NO contact floating relay ...

Page 17: ...uit board Base circuit board with terminal strips for inputs and outputs is behind it Cable gland on both sides Dosing pumps Optical unit sender right receiver left Solenoid valve Water connections inlet and outlet Controller Filter receiver Measuring chamber ...

Page 18: ...fferent reagent sets will lead to an incorrect measurement result Please therefore label which type of analysis is to be used via the la bel that is included with the device Do not change the type of analysis Inserting the reagent bottle Remove the cover of the Testomat Modul CL To do this raise the cover slightly and push it forward to remove it Remove the cap from the indicator bottle Remove the...

Page 19: ...nes During operation the pump PERIClip automatically extracts rea gent The pump s suction hose and transport hose must be filled with the reagent up to the measuring chamber so reagent is present for in itial analyses Switch the instrument on and press the Manual button on the cir cuit board Press the Manual key at the pump several times until the intake hose and the transport hose are filled up t...

Page 20: ...he key s light goes out A maintenance message the LED above the key lights up yellow is acknowledged when the maintenance work has been performed You can set the indicator stock to 100 with the 100 function key see section Changing an empty indicator bottle on page 42 Additional control elements on the circuit board RESET key To reset the controller proceed as for switching on and off BOOT key Use...

Page 21: ...erformed LEDs above Manual and Alarm light up yellow The USB interface is active for communication with the computer LED above Manual flashes yellow The device is in standby mode i e it does not per form further analyses Manual is on or flashes and the LED above Manual is on A measurement phase is running Manual button in dicates whether an analysis is currently being per formed flashing or not li...

Page 22: ...ocess Press the RESET key once Keep the function key pressed down until the yellow LED above the BOOT key lights up The device is now is selection mode Starting USB communication Connect the computer and the Testomat Modul CL with a USB cable Start the Service Monitor program on the computer Press the Manual function key Press the Alarm function key Confirm by pressing the BOOT key The LED over th...

Page 23: ... a signal on the stop start input Other functions in selection mode Importing basic programming data from the SD card into the de vice Press the Manual function key Press the 100 function key Press the BOOT key The yellow LED next to the SD card lights up briefly The device then returns to normal interval operation Exporting basic programming data from the device onto the SD card Press the Alarm f...

Page 24: ...d into spreadsheet programs and databases Column 1 indicates measured value ME or alarm AL Column 2 shows the indicator used to determine the measuring range The M1 column contains the designation of the measured quan tity CL for Chlorine The actual measured value and its unit follow after M2 The devices have no adjustable limit values and only one meas uring channel The columns M2 limit and limit...

Page 25: ... since month and day changes do not occur Functions of the USB connection Installing the USB driver Install the appropriate USB driver on the computer so you can use the USB interface You can find the VCP driver suitable for the oper ating system on the www ftdichip com internet page USB connection to several devices If the same computer is connected to other devices the driver de fines a new COM ...

Page 26: ...necting the connection between the Testomat Modul CL and the computer Remove the USB cable to disconnect the connection Press the RESET key to return the device to its normal operating mode The device carries out ventilation after the reset press ...

Page 27: ...or the device must be connected to the computer that the program is running on via the USB interface see also Starting USB communication on page 22 Installing the Service Monitor The Service Monitor program consists of the TestomatModul exe file and the TestomatModul_CL cfg configuration file Copy both files to the target computer Start the TestomatModul exe file When USB communication is establis...

Page 28: ...time can be acti vated with the Summer winter time automatically check mark Date and time in messages The date and time must be set to provide a time stamp in the history of the error messages maintenance messages and measured val ues If the time is not set the timestamp records 01 01 2011 12 00 Version field The version number and the creation date of the software used boot loader and firmware ar...

Page 29: ...use after water shortage If the instrument detects a lack of water during an analysis the meas urement is repeated twice before an alarm is issued Set the time until the next repetition here You can enter values in the range from 0 to 180 minutes The fac tory default setting is 0 minutes 0 minutes means that there is no pause between repetitions Total operating hours display The display shows the ...

Page 30: ...rd or into the connected device with the Export Data button Se lect whether you want to load the data onto an SD card or straight into the device via USB communication The basic program data is written into the TestomatModul_CL cfg configuration file when using an SD card Saving and loading parameters a when programming a device via the USB After the variables have been imported from the device us...

Page 31: ... under Settings Set the desired measurement interval with the slider Select Device as a data target under the Export field and re store the data with the Export Data button Close the service monitor with the Close button Disconnect the USB connection Exit the selection mode with the RESET key 2nd option Using the SD card on the computer Remove the SD card from the device and insert it into the com...

Page 32: ... this case an analysis will start as soon as the input has opened Function Contact type Testing duration Action STOP START External analysis stop e g via flow monitor or process control Normally open isolated None While the contact is closed at the input no analyses are per formed If the control input is active an analysis is prevented from starting for example due to an interval having elapsed Th...

Page 33: ...t output 4 20 mA The current output supplies the measurement value to the current in put of the connected master controller Loading the current loop The maximum load of 500 Ohm must not be exceeded In the event of faults and very long lines around 20 m the use of a shielded cable is recommended Calculation of output currents How is the current calculated for a specified measurement value measureme...

Page 34: ...e stored in Comma Separated Value format Field separator is a comma Decimal separator is a full stop Each data set is started with the ASCII characters 02 STX and terminated with 03 ETX Notifications and measured values can be distinguished by evaluating the first characters If ME is read it is a meas ured value with AL it is an alarm or notification This corresponds to the format of the Testomat ...

Page 35: ...resent either by reading the SD card or by using a computer at the USB interface Only after the error has been eliminated the alarm is acknowledged and the device can perform analyses again Once an alarm has been acknowledged after an interval operation has been stopped the analysis can start Error number error message Description possible causes Reaction of the device Solution trouble shooting me...

Page 36: ...er mount ing 80 Fault optics Imin Automatic zero point ad justment at the lower stop not possible or automatic zero point ad justment at stop Interval opera tion is stopped Measurement phase is can celled Avoid extraneous light 81 Fault optics Imax Automatic zero point ad justment at the lower stop not possible or automatic zero point ad justment at stop Interval opera tion is stopped Measurement ...

Page 37: ...auto re move air Automatic venting has failed Interval opera tion is stopped Measurement phase is can celled Possible causes can be problems with the dosing pump optics cloudiness dirt con tamination analysis error or water short age Reagent shortage If the reagent stock is only sufficient for less than 50 analyses the 100 key flashes the Alarm key lights up and the alarm relay switches The interv...

Page 38: ...nd outputs 38 Correct water level in the measuring chamber Reagent quantity and water quantity must be correct Otherwise it will result in incorrect measurements Water level correct closing plugs Water level too high Water level too low ...

Page 39: ...n exceeded The de vice must undergo maintenance Interval opera tion is continued After you have per formed the maintenance acknowledge the mainte nance message A new maintenance interval is started 25 Change pump head 1 The operating time of pump head 1 has been exceeded It must be re placed Interval opera tion is continued After you have replaced the pump head acknowledge the mainte nance message...

Page 40: ...o prevent measurement disruptions Cleaning intervals Maintenance work Monthly Quarterly Semi annually Annually Biennially Trienni ally Cleaning sight glass win dows X Cleaning measuring chamber measuring chamber holder X Cleaning the receiver optics X Cleaning the controller filter housing X Cleaning the waste water line X Checking the dosing pump incl suction and pressure hoses X Checking electri...

Page 41: ...ers Insert the O ring seals and be careful to ensure correct fitting in the groove Put the measuring chamber back in place by tilting the unit and se cure it with the spring lock Cleaning the filter housing Cleaning interval quarterly Connect the manual valve of the secondary line to the Testomat Modul CL Press the Manual key and wait until the current measurement has finished If a measurement is ...

Page 42: ...ommended here Changing an empty reagent bottle Replace a reagent bottle as described under section Inserting the re agent bottle on page 18 Set the reagent reservoir to 100 again Press the 100 function key and keep it pressed down The key that lights up when there is a shortage of reagent goes out after 1 sec When the yellow LED lights up the reagent reservoir is set to 100 The yellow LED goes out...

Page 43: ...r 81000 analyses Maintenance interval for the pump head We recommend replacing the pump head after 2 years as the perfor mance of the pump head can decrease due to wear and tear Always replace the pump head if the maintenance message 25 or 26 is dis played Replacing the pump head To replace the pump head proceed as described below Remove the transparent cover Open the housing with a suitable screw...

Page 44: ...t up simultaneously and then go out The firmware update is now complete The device starts automati cally with the new operating software The complete firmware update takes approx 1 minute Then check the settings you configured with the Service Monitor pro gram Firmware update error list Is there a firmware update error These errors can be distinguished by the red LED next to the SD card If the LED...

Page 45: ...e to resolve the error by repeating the update process The entire pro gramming process is repeated up to five times For each repeat the entire programming process is relaunched from the start If after five attempts it is still impossible to carry out a successful update the LEDs show an error matching the previous description The device or the control circuit board requires repair Also send partic...

Page 46: ...d on with the display plugged in the in stalled software version is displayed during the boot process This al lows you to visually check the current software version after a soft ware update After a measurement has been completed the measurement result is shown in the selected display unit The display value is retained until the end of the next measurement and is then updated to the new measured v...

Page 47: ...atus message Description Communication PC Testo module Connection successful Import OK Successful import of data from the device to the service moni tor Export OK Successful export of data from the service monitor to the de vice Set date and time OK Date and time sent from the service monitor to the device ...

Page 48: ... Measuring chamber holder 37856 Measuring chamber holder DUO 40050 Magnetic stirrer 40186 Screw in connector 3 8 10 40056 Solenoid valve 2 2 way Dosing pump PERIClip 270430 Dosing pump PERIClip SP 40362 Pump head PERIClip SP Bottle connection Suction device 37644 Screw cap with insert for 500 ml bottle Instrument spare parts 10843 Fuse GS M 5x20E 2 A 37855 Base circuit board T MU_GP_Chlor 37805 Co...

Page 49: ...isting installations please replace the plug connection on the controller and filter housing for a plug for the quick release coupling not included in the delivery scope A current device overview of the available accessories can be found in details in our delivery scope in the download section of our website www heylanalysis de Art No Designation 040187 Connector set Cock hoses reducers 130010 Min...

Page 50: ...USB 2 0 Full speed SD Card SD or SDHC cards with a maximum capac ity of 32GByte are suitable The card must be FAT or FAT32 formatted Relay contact load max 35 VAC 60 VDC max 4 A Battery Lithium CR2032 Dimensions W x H x D 270 x 350 x 147 mm Weight With Cover 5300 g Without Cover 4350 g Water connection Operating pressure 1 to 8 bar 1x105 to 8x105 Pa or 0 3 to 1 bar 0 3x105 to 1x105 Pa Remove flow ...

Page 51: ...Technical data 51 Conformity Declaration ...

Page 52: ...52 Gebrüder Heyl Analysentechnik GmbH Co KG Orleansstraße 75b D 31135 Hildesheim www heylanalysis de Testomat Modul_CL_GB_210303 docx Scan the code and visit us on our website ...

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