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17. Operation and Maintenance of Neon pR

Dr. A. Kuntze

Gutes Wasser mit System

Robert-Bosch-Str. 7a

40668 Meerbusch

+49 (0) 2150-7066-0 / Fax -60

www.kuntze.com

17. Operation and Maintenance of Neon pR

17.1. Mode

Never carry out maintenance while the controller is set to automatic. Select either

manual mode or Hold.

In the manual mode only the controller is deactivated. All other functions such as the

alarm relay and the test functions are still active. This mode is ideally suited to test

the wiring to your PLC and to check the alarm functions.

With Hold, all alarm functions are deactivated. This mode is ideally suited to carry out

maintenance such as calibration without issuing an alarm. With Hold, the controller is

deactivated, and all analog and digital outputs are frozen to the last value, in case

you are using these outputs as inputs for an external control.

17.2. Maintenance of the measurement

Maintenance of the measurement comprises cleaning of the various components,

regular testing of safety features and gaskets, regular exchange of consumables, and

with pH the regular calibration of the measurement.

Note

Maintenance intervals depend on the application, the installation,
the accuracy requirements etc.

Operation

Interval suggestion

Cleaning of sensors and assemblies

2 weeks

Refilling the KCl vessel

Depends on vessel size

Cleaning of valves, filters, tubing etc.

2 weeks

Calibration of the pH measurement

Weekly

Checking the gaskets

Weekly

Testing the safety features

2 weeks

Exchange of consumables

Six months / yearly

Содержание Neon pR

Страница 1: ...Neon pR Dr A Kuntze manual...

Страница 2: ...and connections 11 2 1 Dimensions 11 2 2 Installation panel mounted housing 12 2 3 Installation wall mounted housing 13 2 4 Connections 14 2 4 1 Connection diagram 15 3 Operation 17 3 1 Desktop 17 3 2...

Страница 3: ...uts 40 10 Test menu 41 11 Memory 42 11 1 Store and upload settings 42 11 1 1 How to save settings 43 11 1 2 How to load settings 44 11 2 Software update 45 11 3 How to save the diagnosis file 46 12 Sy...

Страница 4: ...sensors 69 17 2 2 Refilling the KCl vessel with refillable sensors 69 17 2 3 Cleaning of assemblies filters etc 70 17 2 4 Calibration of the pH measurement 70 17 2 5 Checking the gaskets 70 17 2 6 Tes...

Страница 5: ...Content Dr A Kuntze I Gutes Wasser mit System Robert Bosch Str 7a 40668 Meerbusch 49 0 2150 7066 0 Fax 60 www kuntze com 18 8 Events with Popup messages 91 18 9 Reset 92 Index 93...

Страница 6: ...illumination is deactivated after an adjustable interval The Neon instruments have an SD card slot You can store and load instrument settings to duplicate software settings to additional instruments...

Страница 7: ...a on the SD card A PID controller with two control relays for concentration based dosing Volume based dosing with two relays and flow measurement Modbus RTU interface With the Neon you have certainly...

Страница 8: ...ned built and tested according to the directives for electronic devices and has left our company in perfect working condition To preserve this condition and to ensure safe operation follow all instruc...

Страница 9: ...eration conditions and settings according to this manual Warranty is void if any one of the conditions listed above is disregarded 1 2 1 Transport damages Please check for damages immediately after de...

Страница 10: ...ial waste water process water disinfection and process control As a safety precaution measurement and calibration are checked for failure by the instrument Failures are indicated on the display via te...

Страница 11: ...tion Make sure that the required measuring conditions such as flow pressure temperature etc are constantly maintained Install and operate the instrument according to this manual Carry out all steps de...

Страница 12: ...fferential sensors with high impedance reference Averaging Off low medium high selectable via menu Temperature measurement With Pt100 or Pt1000 2 wire or 3 wire connection Temperature compensation Aut...

Страница 13: ...set to N O or N C contact via menu Flow measurement for volume based dosing Analog output 1 0 4 20 mA galvanically isolated max load 500 Ohm 22 mA alarm current selectable via menu To read out measure...

Страница 14: ...A Hysteresis Adjustable within the measuring range Proportional range XP Adjustable within the measuring range Integral time TN 0 2000 seconds Derivative time TV 0 2000 seconds Min pulse 0 2 9 9 secon...

Страница 15: ...56 mm Weight 0 6 kg 1 0 kg Connections Cable inlet 2x M16 2x M12 optionally 2x M12 and 1x M25 Terminals Basic function rigid flexible 0 2 2 5 0 2 2 5 mm Measurements rigid flexible 0 2 1 0 2 1 5 mm Pr...

Страница 16: ...2150 7066 0 Fax 60 www kuntze com 11 2 Instructions for installation and connections Attention Install the instrument in a place where it is not put under mechanical or chemical strain Note Mind the...

Страница 17: ...Installation panel mounted housing Prepare an opening of 138 x 138 mm Clip the installation frame into the opening Place the instrument inside the frame and secure it with the M4 x 25 screws Tighten t...

Страница 18: ...for as many cable glands as you wish to use and remove any remaining pieces from the openings Place the installation plate into the back frame and screw in the cable glands Drill two holes at 80 mm h...

Страница 19: ...cially apart from power lines For inputs and outputs use screened cables and connect the screens on one side only The measurements are interference sensitive Use only our special cables with a very hi...

Страница 20: ...1 4 1 measurement brown 2 measurement white 5 power supply 6V green 6 power supply 6V yellow pH differential sensor 1 3 1 GROUND 2 measuring electrode 3 high impedance reference ORP sensor 1 2 1 measu...

Страница 21: ...1 70 71 Controller control variable set point1 Volume based dosing control variable set point 1 Max 2 A AC 250 V 550 VA DC 30 V 60 W Relay 2 73 74 Controller control variable set point 2 with 3 point...

Страница 22: ...r approx 20 seconds the process is finished and the measured values are displayed 3 1 Desktop With factory settings the display shows at the top the instrument name and the time followed by the curren...

Страница 23: ...operated via four keys DOWN UP ESC one step back and OK enter Starting from the desktop display of the measured values enter the menu with key DOWN 3 2 1 Main menu With each symbol the four keys mean...

Страница 24: ...e the corresponding settings The dark background indicates your current position in the submenu If the submenu contains more parameters than can be shown a scroll bar on the right side gives access to...

Страница 25: ...until the instrument shows that the touch has been recognized In the desktop display of the measured values touching various areas of the screen gives access to different functions and submenus Touch...

Страница 26: ...nu Press the triangle on the left side of the bottom line of the desktop to enter the main menu In the main menu select submenus by touching the corresponding symbols 3 3 3 Submenus In submenus you wi...

Страница 27: ...Drop down lists are indicated by a triangle on the right side of the parameter setting Move the cursor with the UP and DOWN keys in the submenu until the setting of the desired parameter turns black I...

Страница 28: ...ion turns black then press OK to tick the box or to remove the tick With touch screen instruments press the desired option with your finger to tick or untick its box Note Options that are not activate...

Страница 29: ...ey pad instruments with the UP and DOWN keys and OK with touch screen instruments by touching the settings box of the parameter On the right side of the keyboard four function keys are shown The upmos...

Страница 30: ...appears OK key three times c appears abc key three times c appears Touch OK when the input is complete Now the instrument checks if the input is within the allowed limits If it is the new value is sto...

Страница 31: ...3 Operation Dr A Kuntze I Gutes Wasser mit System Robert Bosch Str 7a 40668 Meerbusch 49 0 2150 7066 0 Fax 60 www kuntze com 26 3 5 Menu overview where to look...

Страница 32: ...3 Operation Dr A Kuntze I Gutes Wasser mit System Robert Bosch Str 7a 40668 Meerbusch 49 0 2150 7066 0 Fax 60 www kuntze com 27...

Страница 33: ...3 Operation Dr A Kuntze I Gutes Wasser mit System Robert Bosch Str 7a 40668 Meerbusch 49 0 2150 7066 0 Fax 60 www kuntze com 28...

Страница 34: ...o enter another code and the other to stop the controller When the code is set to 1612 to give full access to all functions the main menu shows all functions of the instrument In the entry level versi...

Страница 35: ...file and view various settings Full access code 1612 On this level you can enter and change all functions and settings If the full access code is set the CODE symbol in the main menu shows an open lo...

Страница 36: ...active Data log active mA outputs active Controller OFF Modbus RTU active Desktop display active Alarm relay deactivated Test functions deactivated Limits deactivated Data log on HOLD mA outputs on HO...

Страница 37: ...ORP and back activate a suitable averaging level and define the connection for pH differential sensors Measure To select the parameter select pH or mV ORP Averaging To activate the averaging function...

Страница 38: ...cannot be used Correction If the sensor is connected with a 2 wire cable slight deviations might occur between measured and real temperature Check the temperature once during installation and calibrat...

Страница 39: ...e display and given out via the various interfaces and the pH measurement is automatically compensated to the reference temperature Note The compensation compensates only the temperature effect on the...

Страница 40: ...e compensation for ORP measurements Therefore the parameter reference is inaccessible with ORP measurements However temperature measurement is still possible and the measured temperature can be displa...

Страница 41: ...t value and the alarm relay is deactivated Mind the temperature compensation For automatic compensation the temperature sensor has to be put in the calibration buffers together with the pH sensor If t...

Страница 42: ...fer solutions are pH 4 and pH 7 If you want to use other buffer solutions you have to change the calibration settings The automatic buffer recognition starts When it is finished the right window shows...

Страница 43: ...appears With OK you execute the second calibration point and reach the info screen showing the results of the calibration With the SAVE button you store the results With DISCARD you reject the results...

Страница 44: ...L you see the current settings for buffer solutions and internal buffer and can change the settings if you want to use other solutions or a sensor with a special internal buffer Note The internal buff...

Страница 45: ...s will appear for them Contact For both inputs you can define whether the input should work as a normally open NO or normally closed NC contact Event You can select one of three text messages that wil...

Страница 46: ...tivated in your instrument In the entry level version this means only relay 3 Set the mode to manual Select the symbol TEST in the submenu IN OUT In the submenu TEST you can switch all available relay...

Страница 47: ...activated 11 1 Store and upload settings You can save all settings on the SD card for safekeeping or to duplicate the settings into another instrument of the same type This way you can easily restore...

Страница 48: ...gs Make sure that an industry standard SD card max 2 GB with free storage space is plugged into the instrument In the menu IN OUT MEMORY select the symbol SAVE Select the symbol SETTINGS Acknowledge w...

Страница 49: ...ect the symbol LOAD In the submenu select the symbol SETTINGS Acknowledge with OK The display shows the name of the file that will be loaded The name consists of the parameter and the date for example...

Страница 50: ...es on an industry standard SD card directly use no subfolder Plug the SD card into the instrument In the submenu MEMORY select the symbol LOAD Select the symbol SOFTWARE Acknowledge with OK The displa...

Страница 51: ...current values To collect all the information and maybe have it ready for a contact person you can save a diagnosis file on the SD card In the submenu MEMORY select the symbol SAVE Select the symbol D...

Страница 52: ...e System settings can only be changed with the full access code 12 1 Language For the menu a variety of languages are available The entry level version contains English and German To change the langua...

Страница 53: ...enu the symbol TIME When you select the field of either time or date a keyboard appears to enter the desired time or date For your convenience the instrument adds zeros automatically If you enter 6 fo...

Страница 54: ...CONTRAST you can adjust the brightness of the display between 0 and 100 Desktop This submenu contains a drop down list of various desktop designs The selection is activated as soon as you leave the m...

Страница 55: ...ever you enter any menu Selection If you select the line the desktop remains in its previous design Note Text time the triangle and the event messages are part of all desktop designs Selection default...

Страница 56: ...ree relays and the mode Active relays are shown white on black and the symbol shows whether the relay is open or closed See relay 3 in the example shown Selection Flow add on Volume based dosing This...

Страница 57: ...ff the display illumination after an adjustable interval If you set the interval to 0 eco mode is deactivated and the illumination remains on permanently Note The eco mode not only saves energy it als...

Страница 58: ...CAL to start the calibration The touch screen calibration texts are available in English only Note When started the calibration routine cannot be left until it is finished it has to be carried out com...

Страница 59: ...can store contact data of your contact person including company name personal name and phone number Select in the submenu SYSTEM the symbol CONTACT For each field a keyboard opens to enter the name or...

Страница 60: ...ubmenu SYSTEM EVENT provides information on the event and suggestions how to solve it Select in the submenu SYSTEM the symbol EVENT With touch screen instruments you can reach this submenu directly by...

Страница 61: ...erating hours of the instrument Eventlog The event log stores up to 100 events with the time they appear or leave Settings This submenu shows a complete list of all settings Press UP and DOWN to view...

Страница 62: ...actory settings except the time date and contact Activated add ons will remain activated of course Select the symbol SYSTEM in the main menu and in the submenu the symbol RESET Go DOWN as indicated Ac...

Страница 63: ...controller or volume based dosing Modbus RTU RS 485 needs additional hardware To activate add ons select the symbol SYSTEM in the main menu and in the submenu the symbol ADD ON A keyboard appears to...

Страница 64: ...lay This defines a delay time in case of an event the alarm relay switches only after a specified interval Display of the text message on the desktop and output of 22mA error current are not affected...

Страница 65: ...menu Select the symbol ACTION A list of all possible actions appears By activating the check boxes you can define actions as alarm actions If a box is marked with a tick the action or event will caus...

Страница 66: ...en activated Select the symbol IN OUT in the main menu and in the submenu the symbol MEMORY If the datalog add on is activated four symbols appear In the menu LOG PARA you define which parameters you...

Страница 67: ...removing the card Otherwise data loss might occur and an error message will appear Note Always use a card with sufficient storage space even with ring mode otherwise the logging will not start Interva...

Страница 68: ...date and the time for example pH060812_1322 csv for pH or mV060812_1345 for ORP measurements Each file starts with the device name the instrument number and the software versions followed by the log...

Страница 69: ...the mA output rises to 22mA whenever the measuring inputs receive no proper signals Range Select either 0 20mA or 4 20mA from the drop down list Note While 4 20mA gives slightly less resolution it hel...

Страница 70: ...s of a long bus connection should be terminated with termination resistors of 120 Ohm With Neon instruments you can activate the termination via menu Note Activate the bus termination only at the ends...

Страница 71: ...finition Read Holding Registers Request Function code 1 Byte 0x03 Starting Address 2 Bytes 0x0000 to 0xFFFF Quantity of Registers 2 Bytes 1 to 125 0x7D Response Function code 1 Byte 0x03 Byte count 1...

Страница 72: ...3 Register NEON provides the following information via RS485 Register Index Register Content from to Date time 0 1 10 12 Primary Value 20 24 Secondary Value 30 31 Raw Value 40 40 DIG I O Primary Value...

Страница 73: ...without issuing an alarm With Hold the controller is deactivated and all analog and digital outputs are frozen to the last value in case you are using these outputs as inputs for an external control 1...

Страница 74: ...raded Make sure not to scratch the glass membrane in the process Clean the metal electrodes of ORP sensors regulary to remove coatings and grease Use commercially available detergents and rinse thorou...

Страница 75: ...out use so the measurement has to be recalibrated at regular intervals The instrument checks the calibration results after calibration and displays an event message if the sensor has to be cleaned reg...

Страница 76: ...often contain organic acids providing nutrients for microbiological growth Never put used solution back into the bottle Nowadays a variety of single use sachets with certified accuracy are available T...

Страница 77: ...ple inlet and outlet open sampling point closed Check that all screw connections are sealed tight before applying pressure pH measurements have to be calibrated at the beginning Mind that the temperat...

Страница 78: ...solution preferably in 3M KCl never in deionized water or aggressive solutions We advise to use for storage the protective covers in which the sensors were delivered If you want to use other beakers u...

Страница 79: ...configuration software and then load the settings into the instrument via SD card The configuration software is available free of charge 17 5 2 Software update via SD card With the SD card you can als...

Страница 80: ...est sensors check cables and test instrument functions On the next pages you will find detailed information on when and how to use the PH T Short circuit wire With pH meters a simple wire bridge allow...

Страница 81: ...t off first Nowadays a variety of buffers are available as single use sachets They can be stored until needed and pack quite small ORP buffer For ORP sensors buffer solutions are available as well The...

Страница 82: ...s with the times of their appearance and disappearance Further details are supplied on the following pages Settings This menu lists all settings In case of trouble check if all settings are as you had...

Страница 83: ...ayed only if the functions have been activated 18 5 Event messages In case of trouble the instrument displays an event message on the desktop If there are more than one message they are displayed alte...

Страница 84: ...appearance and disappearance times allow to check what other events had happened at that time for example the start up of a dosing pump frequency inverter etc Note You can save the eventlog by saving...

Страница 85: ...ers or the sensor that you used Note The internal buffer is the buffer filled into the pH glass bulb The pH of this buffer represents the zeropoint of your sensor You can find the pH of the internal b...

Страница 86: ...fferent cable Use more mV values to check the response of the instrument If the error is not caused by the instrument or the cable it might be caused by the sensor This might be due to a worn out or p...

Страница 87: ...ensor emits 50 60mV per pH at room temperature If you keep in mind that pH 7 is your zeropoint giving 0mV then each pH unit that you move away from pH 7 will give you 50 60mV positive for acidic solut...

Страница 88: ...ot of energy Deactivate the test after some seconds If these causes can be ruled out then the focus turns towards the sensor especially towards the pH membrane which might be coated or worn out Check...

Страница 89: ...instrument in the menu SYSTEM INFO VIEW Deviations up to 5mV are irrelevant If you find large deviations repeat the test with a different cable Also check if the signal changes abruptly if the cable i...

Страница 90: ...for examination If the examination shows a defect that you could not have caused you will receive a replacement free of charge and if not then at least you will know the cause of the trouble and be ab...

Страница 91: ...ge If the measured value gets so high that it can no longer be processed the message check measuring input will appear Event message Cause Suggested remedies Upper limit or lower limit respectively Th...

Страница 92: ...nnection The digital input allows connection of a flow sensor or level sensor or an external switch According to its intended function you can assign the digital input one of three different texts Low...

Страница 93: ...outputs and change the settings if necessary Event message Cause Suggested remedies RS 485 off Bus communication does not work Check bus connection and address This message appears if the master of y...

Страница 94: ...check monitors only those times when the controller is dosing with 100 If your proportional range is higher than the maximum possible difference between set point and measured value this condition ca...

Страница 95: ...amental problems that you cannot solve on site Event message Cause Suggested remedies Communication error The internal communication between instrument parts does not work Contact your supplier Unknow...

Страница 96: ...at the files are available on the SD card directly and not in a subfolder Delete and restore the files if necessary If you want to store settings on the SD card check if there is enough storage space...

Страница 97: ...to 3 point controller If you have selected a 3 point controller for set point 1 then both control relays are used for this set point one to open the actor and one to close it so you cannot use set po...

Страница 98: ...5 Code 29 30 Communication error 90 Communication parameters 66 Connection 32 Connection diagram 15 Contact data contact person 54 Contact digital input 40 Contrast display 49 Correction temperature 3...

Страница 99: ...ging 91 Menu overview 26 Modbus RTU 65 bus address 65 bus termination 65 communication parameters 66 read holding registers 66 register 67 Mode data log 62 Mode operation mode 31 68 Mode temperature c...

Страница 100: ...load 74 store and upload 42 Slope 82 Software update 45 74 Software version 56 System functions 47 T Technical Data 10 Temperature compensation 33 34 reference temperature 33 Temperature measurement...

Страница 101: ...Robert Bosch Str 7a I D 40668 Meerbusch I Germany Fon 49 0 2157066 0 I Fax 49 0 21507066 60 info kuntze com I www kuntze com...

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