Testomat 2000 SO3 2- Manuel utilisateur

TESTOMAT®2000 SO32-

Process Photometer for Sulphite 0 - 20mg/l

Operating Instructions

Table of Contents

Introduction

……………………………………… 1

Short description

…………………………… 1

Handling instructions

…………………………… 2

Operational reliability instructions

……… 2

Safety instructions

…………………………… 2

Installation and commissioning

………………. 3

Installation ……………………………………… 3

Electrical connection …………………………… 3

Mains water supply …………………………… 3

Water outlet …………………………… 4

Commissioning …………………………… 4

Installation diagram (example) ………………… 4

General description

…………………………… 5

Internal construction …………………………… 5

Description of the electrical connections ……… 6

Terminal block identification ………………… 6

Description of display and operating features …… 7

Display functions …………………………… 7

Limit value status displays …………………………… 7

Measured value display …………………………… 7

Limit value display …………………………… 7

Alarm and maintenance message ………………… 7

Status displays …………………………… 8

Description of the relay outputs ………………… 8

Flush external flush valve ………………… 8

LV1 and LV2 Limit value outputs ………………… 8

Measuring points 1 or 2 Measuring points

switch-over ……………………………………… 8

AUX programmable function output ……… 9

Alarm fault message output ………………… 9

Maintenance maintenance message ……… 9

Description of the signal inputs and outputs ……… 10

Start external analysis start ………………… 10

Stop external analysis stop ………………… 10

IN1 and IN2 universal inputs ………………… 10

OUT interface output (optional) ………………… 10

Function characteristics

………………… 11

Operating modes …………………………… 11

Analysis cycle ……………………………………… 11

Display unit ……………………………………… 11

Measuring points …………………………… 11

Parameter ……………………………………… 11

Time setting ……………………………………… 12

Limit value monitoring …………………………… 12

Hysteresis ……………………………………… 13

Logic functions ……………………………………… 13

Function IN1 ……………………………………… 13

Water meter ……………………………………… 13

Alarm / Message ……………………………………… 14

Function AUX ……………………………………… 14

Service II ……………………………………… 14

Calibration ……………………………………… 14

Reset operating time …………………………… 14

Maintenance interval …………………………… 14

Interfaces (optional) …………………………… 15

Menu structure

…………………………… 15

Selection and input …………………………… 15

Menu start ……………………………………… 15

Selection ……………………………………… 15

Input ………………………………………………… 15

Menu end ……………………………………… 15

Information menu "i"

…………………………… 16

Structure of the "i" menu …………………………… 16

Call ………………………………………………… 16

Customer service …………………………… 16

Operating values …………………………… 16

Program values ……………………………………… 16

Error history ……………………………………… 16

Maintenance ……………………………………… 16

Program menu "M"

…………………………… 17

Service I ……………………………………… 17

Input reagents ……………………………………… 17

Manual operation …………………………… 17

Confirm maintenance …………………………… 17

Diagnosis ……………………………………… 17

Date/Time ……………………………………… 18

Basic program

…………………………… 18

Program values ……………………………………… 18

Structure of the basic program ………………… 19

Error messages / Troubleshooting

……… 20

Further information

…………………………… 21

Maintenance

……………………………………… 21

Description of maintenance work ………………… 21

Cleaning the measuring chamber

& sight-glass windows …………………………… 21

Cleaning the filter housing …………………………… 21

Service instructions …………………………… 21

Monitoring/Calibration with standard ……… 22

Spare parts list Testomat

2000 SO

……… 23

Technical appendix

…………………………… 24

Block diagram Testomat

2000 SO

........... 24

Technical data ………………………………………. 24

1 / 24

Introduction

These operating instructions describe the installation, operation and programming of the process photometer

Testomat

2000 SO

We recommend that, while familiarising yourself with the operation of the unit aided by these operating instructions,

you have immediate access to the unit in order to perform the described functions and combinations. As certain

functions are interrelated, it is advisable to follow the instructions in the given order.

Should problems or questions arise while operating the unit which are not described in these operating instructions

and/or cannot be solved, our customer service is always at your disposal.

Try to identify the problem as accurately as possible and record the actions and conditions under which it occurred.

This will enable us to offer you swift effective assistance.

Symbols and abbreviations used in these operating instructions:

☞

Operator instructions

Always observe / warning

"M" = Press the menu key M

✔Tip: Helpful hint

➔SERVICE ➔MANUAL OPERATION ➔FLUSH = Sequence of the menu selection

"STANDBY" = STANDBY lamp is “ON”

Short description

The process photometer Testomat

2000 SO

is a robust wet-chemical online monitor for monitoring the sulphite

content SO

from 0 to 20 mg using the colourimetric analysis principle.

Parameter

Measuring range/Display

(Resolution)

0 – 9.9

(0.1)

10 – 20

(1)

Analysis is carried out by adding three reagents, the analysis result is displayed after a reaction time of approx. 3

minutes (absolute measuring time without flushing times). Applications include, e.g., the monitoring of boiler feed

water or condensation water in steam boiler plants.

Two independently programmable limit value contacts are available for various monitoring and control tasks. The

analysis result can be recorded using the optional printer board (interface SK910, Art. No. 270305) with a dotted or

continuous line printer (0/4-20mA).

☞

Trouble-free operation of the Testomat

2000 SO

units is only guaranteed when using the HEYL

Testomat

2000 reagents SO

reagent A (Art.No. 156240) and SO

reagent B (Art. No. 156241) !

Interferences:

The concentration of influencing contents can be safely and easily determined by using our colourimetric TESTOVAL

test kits.

2 / 24

Handling instructions

• Repeated switching on/off:

• Wait at least 5 seconds before switching the unit repeatedly either on or off at the main switch.

• Observance of the ambient conditions:

• In order to guarantee reliable operation, only operate the unit under the ambient conditions described in the

technical data section. Always protect the unit against moisture and humidity. It should never come into contact

with condensation or splash water.

• Safety seal:

• The original seals attached during manufacture (e.g. EPROM labels) must not be broken, otherwise all warranty

rights are void.

• Malfunctioning / Repairing a defective unit:

• The repair of a defective unit – irrespective of the warranty period - is only possible when the unit is dismantled

and returned to us with a description of the error. Please also inform us of the measured medium and the indicator

type. The warranty shall not apply if the controller is tampered with, altered, modified or repaired contrary to the

instructions described in this manual.

• Before you return the unit for repair work, remove the reagent bottles and ensure that the measuring chamber has

been flushed out and is empty.

• Electrical load capacity

• The maximum electrical load capacity of the relay outputs and the total power rating should never be exceeded.

• Only use the Testomat

2000 SO

for its intended purpose.

• Environmental protection regulations

• Please observe environmental protection regulations and collect any unused reagents and send them to us for

safe disposal in accordance with local statutory requirements.

Operational reliability instructions

Careful handling of the unit increases both its operational reliability and service life!

Therefore, carry out a visual inspection at regular intervals as described below.

• 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 the doors of the unit closed properly?

• Is the unit unduly soiled?

Maintenance and servicing instructions

(see chapter entitled Maintenance)

Safety instructions

• The unit must be installed and operated in compliance with relevant standards (e.g. DIN, VDE, UVV) or in

accordance with regulations laid down by the respective country.

• Some functions (e.g. diagnosis, manual operation) allow direct manipulation of the plant to be monitored without

locking or monitoring. Only trained staff should use these functions, which can only be accessed after entering a

password.

• If you notice that the device is malfunctioning, switch it off immediately. Subsequently shut off the water supply

and contact our service staff.

• Do not try to repair the unit (loss of warranty rights); always contact authorised service staff. This is the only way to

ensure reliable and safe operation of the plant.

• 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 tripping is always due to an error which, in

certain circumstances, may also cause damage to the unit.

• Always observe the safety instructions about working with reagents, chemicals and cleaning agents.

•Always adhere to hazard warnings and safety tips when using reagents, chemicals and cleaning agents. Please

adhere to the respective safety data sheet! Download the safety data sheets for the supplied reagents at

http://www.heyl.de .

Non-compliance with these instructions can damage the unit as well as the plant and may result in a loss of

warranty rights.

3 / 24

Installation and commissioning

Only authorised technicians should carry out installation and

commissioning!

Installation

Install the unit vertically!

Avoid twisting the housing!

The unit doors swing to the left when they are opened. Please

ensure that there is sufficient space to open them. This facilitates

electrical installation as well as future maintenance and service

work.

Electrical connection

Please observe the supply voltage specified on the rating

plate!

Basic requirements

External cables (e.g. water meter, interface) should be kept as

short as possible and clear of power cables.

Connection

Loosen both fastening screws and open the upper door. Pierce the required rubber

cable glands with a screwdriver and insert the cable (1). Subsequently pull back the

cable until the bush (2) has been turned over. Ensure that the leads are held securely

in the terminals, then close the upper door once installation has been completed using

the two fastening screws.

Mains water supply

The temperature of the sample water should be between 10 °C and 40 °C. Higher water temperatures can

damage the parts which come into contact with the water (e.g. filter housing, measuring chamber)!

Lower water temperatures can cause mist to form on the sight-glass windows.

☞

For temperatures above 40 °C the KCN type cooler should be installed in the branch line of the Testomat

2000 SO

Hot water can scald you!

The sampling line to the Testomat

2000 SO

should be equipped with a manually operated shut-off valve and kept

as short as possible (the max. length of 5 metres should not be exceeded). It is important that the branch line

connection is taken vertically from the top of the main water line in order to prevent dirt particles from entering the unit.

When operating the Testomat

2000 SO

within the pressure range of 0.3 to 1 bar or when it is supplied via a feed

pump, please remove the valve body from the controller/filter housing. The feed pump should have a feeding capacity

of between 25 and 35 litres/hour and be resistant to the medium being measured.

Plug connector

The unit is equipped with a plug connector for opaque plastic hoses 6/4 x 1 (external diameter 6 mm/ internal diameter

4 mm) as standard.

Quick-release coupling (accessory: Adapter for water inlet, Art. no. 40123)

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 for the quick-release coupling (not included).

4 / 24

Water outlet

The feed water flows through the measuring chamber to the drain via the outlet pipe (hose connection internal

diameter 14 mm). Make sure, e.g. by using an open funnel, that the water drains off freely and backwater to the

measuring chamber does not develop. An opaque hose should also be used for the drain pipe (to prevent algae

formation).

Commissioning

1. Always connect full reagent bottles prior to commissioning and switching on. Use the union nut to attach the

vacuum connection to the reagent. Observe correct allocation of the reagents A and B to the dosing pumps: A =

left, B = right.

2. Switch the unit 'on' and press the "STANDBY" key. This prevents an analysis from being carried out without

correct programming and thus an error or alarm message.

3. Subsequently bleed the dosing pumps and pipes by pressing the "Manual" key on the dosing pump. Ensure that

there is no air in the pipes! (If necessary, retighten the connections.)

4. Program the unit according to your requirements, e.g.: - Operating mode - Display unit

- Limit values - Flush times / interval

Refer to program menu“M” for a description of programming.

5. Enter the correct fill levels of the reagent bottles.

"M" ➔SERVICE I ➔INPUT REAGENTS ➔REAGENT A FILLING (100%)

"M" ➔SERVICE I ➔INPUT REAGENTS ➔REAGENT B FILLING (100%)

6. Subsequently bleed the unit’s water supply via manual flushing.

"M" ➔SERVICE ➔MANUAL OPERATION ➔FLUSH (press "ENTER" repeatedly).

7. Flush until there are no bubbles visible in the measuring chamber.

8. Check all connections for tightness.

9. Carry out the first analysis by pressing the "Manual" key.

Installation diagram (example):

5 / 24

General description

Internal construction

6 / 24

Description of the electrical connections

Terminal block identification

IN = input, OUT = output

No. Terminal Type Function Comment

- PE IN Mains – Protective earth (5 x) Only with mains 115 / 230 V !

LIN Mains, N = Neutral

Mains, L = Live

Mains input

230 - 240 V AC

lOUT Neutral, switched (8 x)

Live, switched (8 x)

Mains voltage, max. 4 A

2 Flush OUT External flush valve Volt-free relay output

max. load 240 V AC, 4 A

LV1 OUT

Limit value output 1 – Normally closed

Limit value output 1 – Normally open

Limit value output 1 – Common

Volt-free relay output

max. load 240 V AC, 4 A

LV2 OUT

Limit value output 2 – Normally closed

Limit value output 2 – Normally open

Limit value output 2 – Common

Volt-free relay output

max. load 240 V AC, 4 A

Measuring

points 1/2 OUT

Measuring point 1 – Normally closed

Measuring point 1 – Normally open

Measuring point switch-over - Common

Volt-free relay output

max. load 240 V AC, 4 A

13 AUX OUT Universal output Volt-free relay output

max. load 240 V AC, 4 A

Alarm OUT

Fault message output – Normally closed

Fault message output – Normally open

Fault message output – Common

Volt-free relay output

max. load 240 V AC, 4 A

Maintenance OUT

Maintenance message – Normally closed

Maintenance message – Normally open

Maintenance message – Common

Volt-free relay output

max. load 240 V AC, 4 A

Start

┴IN External analysis start

Common earth for inputs

Only for volt-free normally open

contact!

Stop

┴IN External analysis stop

Common earth for inputs

Only for volt-free normally

open/normally closed contact!

25 IN1

┴IN

External measuring point switch-over

Common earth for inputs

Only for volt-free normally

open/normally closed

contact!

IN2

┴IN Universal input 2 (water meter)

Common earth for inputs

Only for volt-free normally open

contact!

OUT

┴OUT 0/4 - 20 mA or serial interface Non floating output!

28 = 0/4 - 20 mA, 29 = ┴

7 / 24

Description of display and operating features

(1) ON/OFF switch

The ON/OFF switch is located on the right-

hand side panel of the unit. Use this switch to

switch the unit on or off.

(2) Unit fuse (inside the unit)

The fuse protects the outputs against

overloads and short circuits.

3 Limit value status displays

Displays the status of the limit values LV1 (1)

and LV2 (2).

4 Text display

Displays the current analysis result as well as

all important status results and programming

data via a 4-line LCD.

5 Alarm

Indicates malfunctioning.

6 Maintenance message Function keys:

Displays a maintenance request. 9 "Manual" = manual start of an analysis

10 STANDBY = manual analysis stop/standby

7 Status display 11 "Alarm" = confirms an alarm message

Six LEDs signal the current status (analysis

and unit status) of the Testomat

2000 SO

. 12 i-key

Call-up all unit information (also see i menu).

8 Programming keys

(cursor block with ENTER) 13 M-key

Use these keys to enter all the values and Call-up the programming menu for user and unit-

programming data. specific settings (also see M menu).

Display functions

Limit value status displays 1 and 2

The displays signal the status of the limit values.

1: The display is red if limit value 1 has been reached or

exceeded. The display is green if the measured value

has fallen below the set limit value.

2: The display is red if limit value 2 has been reached or exceeded.

The display is green if the measured value has fallen below the set limit value.

Measured value display

The current measured value for measuring point 1 (M1:) and 2 (M2:) are displayed in lines 2 and 3, e.g. M1: 5.6 mg/l

If the measured value has exceeded the measuring range, ">" is displayed: e.g. M1: > 20 mg/l

Limit value displays

The set limit values are displayed in the bottom display line.

Alarm and maintenance message

Display of present error messages (red) and maintenance requests (yellow).

Error messages are displayed alternately with the normal display and can only be deleted via confirmation and

elimination of the fault.

8 / 24

Status displays

The displays signal active unit components.

Description of the relay outputs

Flush external flush valve:

If a long sampling line is unavoidable for installation, we recommend the installation of a flush valve upstream of the

unit.

If the unit is used for monitoring two measuring points, also install an external flush valve to prevent incorrect

measurements caused by sample mixing.

Immediately before each analysis the external flush valve is opened for the programmed period allowing the line up to

the Testomat

2000 SO

to fill with measuring water. Please ensure that the programmed flush time is sufficient.

Set the flush time under menu item

"M" ➔BASIC PROGRAM ➔PROGRAM VALUES ➔FLUSH TIMES/INTERVAL ➔EXTERNAL FLUSH TIME

LV1 and LV2 limit value outputs

Two volt-free relay contacts are available 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 Type of contact Action

LV1

- active when

limit value 1 or measuring point 1

have been exceeded volt-free change-over contact

programmable:

Continuous contact

Impulse (1 - 99 seconds/minutes)

Interval (1 - 99 seconds/minutes)

Two-step controller (only for one measuring

point)

Hysteresis (1, 2 or 3 limit values exceeded)

LV2

- active when

limit value 2 or measuring point 2

have been exceeded

volt-free change-over contact

programmable:

Continuous contact

Impulse (1 - 99 seconds/minutes)

Interval (1 - 99 seconds/minutes)

Hysteresis (1, 2 or 3 limit values exceeded)

Menu values:

"M" ➔BASIC PROGRAM ➔PROGRAM VALUES ➔LIMIT VALUES

"M" ➔BASIC PROGRAM ➔PROGRAM VALUES ➔FUNCTION LV1

"M" ➔BASIC PROGRAM ➔PROGRAM VALUES ➔FUNCTION LV2

"M" ➔BASIC PROGRAM ➔PROGRAM VALUES ➔HYSTERISIS LV1

"M" ➔BASIC PROGRAM ➔PROGRAM VALUES ➔HYSTERISIS LV2

Measuring points 1 or 2 Measuring points switch-over

If the unit 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 input. The switch-over can occur automatically:

The analyses are carried out alternately from measuring point 1 or 2.

Or via an external request: Input IN1 active = analysis of measuring point 2

The terminals are strictly allocated to the measuring points.

Terminal 9 = Measuring point 1

Terminal 10 = Measuring point 2

"M" ➔BASIC PROGRAM ➔PROGRAM VALUES ➔MEASURING POINTS 1/2

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