Testomat CL Manuel utilisateur

Testomat®Modul CL

Process Photometer Module

for Chlorine

Operating Instructions

Content 
2 
Content 
Content................................................................................................2
Important safety information............................................................4
Intended use ........................................................................................4
Qualification of personnel ....................................................................4
Warnings in this manual.......................................................................5
Additional documentation.....................................................................5
Special attention is required at this point.............................................5
General Information .............................................................................5
Requirements for the installation site...................................................5
Requirements of cable for operating voltage and system components 
and installed lines ................................................................................6
Requirements for cable ducts..............................................................6
During assembly ..................................................................................6
During operation ..................................................................................7
During cleaning....................................................................................8
Repairing a defective device................................................................8
During disposal ....................................................................................8
Operating requirements.......................................................................9
Scope of delivery ............................................................................ 10 
Performance specifications........................................................... 10 
Interaction with the controller............................................................ 10 
Measurement calculation.................................................................. 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 reagent bottle............................................................... 18 
Opening the water inlet..................................................................... 19 
Venting reagent lines ........................................................................ 19 
Functions of the operating and display elements....................... 20 
Function keys.................................................................................... 20 
Additional control elements on the circuit board............................... 20 
Display elements of the function keys .............................................. 21 
Adjusting parameters in the device.............................................. 22 
Calling up selection mode on the device .......................................... 22 
Starting USB communication............................................................ 22 
Entering parameters via the Service Monitor program..................... 22 
Exiting selection mode...................................................................... 23 

 Content 
 
 3 
Start of measurements...................................................................... 23 
Other functions in selection mode .................................................... 23 
Functions of the SD card .................................................................. 24 
Storage of measured values and alarms.......................................... 24 
Functions of the USB connection...................................................... 25 
The Service Monitor program........................................................ 27 
Installing the Service Monitor............................................................ 27 
Selecting language ........................................................................... 28 
Adjusting, saving an loading parameters.......................................... 28 
Example: Changing the measurement interval in the Service Monitor 
for Testomat®Modul CL.................................................................... 31 
Description of the signal inputs and outputs .............................. 32 
Control input STOP/START.............................................................. 32 
Fault signal output “Alarm”................................................................ 33 
Current output 4-20 mA .................................................................... 33 
Calculation of output currents........................................................... 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 bottle.................................................... 42 
Replacing a reagent bottle without a shortage notification............... 43 
Maintenance message pump head................................................... 43 
Replacing the pump head................................................................. 43 
Firmware update ............................................................................. 44 
Firmware update error list................................................................. 44 
Optional display for measured value display .............................. 46 
Testomat®Modul CL spare parts and accessories ..................... 48 
Reagents........................................................................................... 49 
Additional accessories...................................................................... 49 
Technical data................................................................................. 50 
Conformity Declaration ..................................................................... 51 
 

Important safety information

Read the operating instructions carefully and in full before working

with the device.

Ensure that the operating instructions are accessible at any time for

all users. When an SD card is used in the device, it can also be

stored on the same as a PDF file.

If transferring the Testomat®Modul CL device to third parties, ensure

these operating instructions are always included.

Observe the safety precautions and safety recommendations when

using reagents, chemicals and cleaning agents. Observe the relevant

safety data sheet! For reagents we supply, the relevant safety data

sheets are available online at www.heylanalysis.de.

Intended use

The Testomat®CL module process photometer is a robust wet-chem-

ical online transmitter for monitoring the decay behaviour in cooling

towers after shock chlorination. The measuring range for total chlo-

rine or free chlorine is 0 to 5 ppm.

Comply with the output limits 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 applicable scope, as specified in these instructions,

•under operating conditions that deviate from the scope specified in

these instructions.

Qualification of personnel

The assembly and commissioning require basic electrical and process

engineering expertise as well as knowledge of the applicable specialist

terms. The assembly and commissioning must therefore be performed

only by a specialist or a properly trained person instructed and super-

vised by a specialist.

A specialist is a person who can draw on professional training,

knowledge and experience as well as knowledge of applicable provi-

sions to assess work assigned to him/her, detect potential hazards and

implement suitable safety measures. A specialist must comply with the

applicable professional rules.

Important safety information

Warnings in this manual

These instructions include warnings against specified actions that in-

volve the risk of injury or property damage. Warnings are structured

as follows:

Description of the type or source of danger

Description of the consequences of non-compliance

Hazard prevention indications. Compliance with these hazard pre-

vention measures is imperative.

The signal word "RISK" refers to a significant danger that represents

a direct threat and will definitely result in severe injuries or even be

fatal if not avoided.

The signal word “WARNING" refers to a possible danger that may re-

sult in severe injuries or even be fatal if not avoided.

The signal word "CAUTION" refers to a potentially dangerous situa-

tion that could result in minor to moderate injuries or property dam-

age if not avoided.

The signal word "NOTE" refers to important pieces 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 requirements.

•Observe the accident prevention and conservation requirements in

the country of use and at the installation site.

•Make no changes or modifications to the device that go beyond the

scope of use specified in these instructions. Doing so will void the

warranty.

Requirements for the installation site

Ensure that the following conditions are met at the installation site:

•Use the device in indoor locations only.

•The ambient temperature is between 10 and 40 °C.

•The installation site is at altitudes under 2000 m.

•The maximum relative humidity is 80 % at temperatures of up to

31 °C (linear declining up to 50 % relative humidity at 40 °C).

SIGNAL WORD!

WARNING

CAUTION

DANGER

NOTE

WARNING

Important safety information

•The device must always be protected against wetness and mois-

ture. Under no circumstances may it be exposed to splashed water

or condensate.

•Surge category II

•Soiling degree II

Requirements of cable for operating voltage and

system components and installed lines

Use only cables and installed lines which meet the following require-

ments:

•The terminal strips on the circuit board require core cross-sections

of between 0.08 and 2.5 mm2. This applies to single-wire and fine-

wire cores with wire end ferrules without plastic collar.

For fine-wire cores with wire end ferrules and plastic collar, the

cross-section may be up to 1.5 mm2.

For single-wire cores, AWG28 –AWG12 can also be used.

•The cable ducts installed by the manufacturer in the device have a

clamping range of 4.5 to 10 mm. This means that the external di-

ameter of the laid cable must remain within the range of 4.5 to 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 ducts should have a smooth and rounded opening (to protect

against bending and abrasion).

•The duct should include a strain relief that prevents slippage of the

cable and that cannot be disengaged without a tool.

•You can order cable ducts from us as spare parts (see Testomat®

Modul CL spare parts and accessories on page 48).

During assembly

•Always disconnect the relevant system component from the power

source before assembling the device or connecting it to the power

supply or disconnecting it from the same. Prevent any inadvertent

reactivation of the device.

•Only connect the device to the operating voltage as specified on

the type plate.

•Observe the technical data and the environmental parameters.

WARNING

NOTE

Important safety information

•The connections for operating voltage and relay outputs must be

laid separately from each other, to guarantee corresponding insu-

lation between the cables.

Avoiding interference voltages

The Testomat®Modul CL device requires stable and uninterrupted

supply voltage. Where applicable, use a mains filter to shield the Tes-

tomat®Modul CL device from interference voltages, which may be

generated for example within the network by magnetic valves or

large-scale engines. Never lay the connecting cables in parallel to

mains cables.

Handling may cause damage or destruction of electrical compo-

nents!

If you need to open the upper door, you should take the necessary

safety measures 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 the switching

outputs is not exceeded, particularly for inductive loads. The power

supply for the user inclusive device is secured with a 1 A fuse,

which means the total of all loads must not reach 1 A.

•In the event of any malfunctions, immediately switch off the Tes-

tomat®Modul CL device and inform the service personnel. Never

attempt to repair the Testomat®Modul CL device yourself. Doing

so will invalidate the guarantee. Repairs must be performed by au-

thorized service personnel only.

NOTE

ATTENTION

Important safety information

During cleaning

•Only use a dry and lint-free cloth to clean the device.

•Maintenance and care instructions are included in the section

Maintenance on page 40 and in the Testomat®Modul CL mainte-

nance manual.

Repairing a defective device

•A defective device, regardless of the guarantee period, can be ser-

viced only when the device is dismantled and the error is de-

scribed. Also inform us of the indicator type currently in use and

the measured medium. Make no changes or modifications to the

device that go beyond the scope of use specified in these instruc-

tions. Doing so will void the warranty. This applies particularly to

the measuring chamber, 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 defective

valve), before reactivating the protective device. Frequent trigger-

ing always signifies an error, which under certain circumstances

may also damage the device.

During disposal

•Dispose of the device in accordance with the regulations of your

country.

Batteries:

The device is built with a removable lithium battery (CR2032 / 3V)

made by VARTA or similar.

Batteries and devices must be disposed of separately! Dispose

of batteries in accordance with the guidelines in your country.

Important safety information

Operating requirements

•Wait at least 5 seconds before switching the instrument on and

then off again at the main switch.

•Problem-free operation of the Testomat®device is only possible

when using Heyl Testomat®regents and only within the pH range

of 5 –9.5! Using external products may invalidate the guarantee.

•Only operate the device within the scope of parameters specified

under section Technical data on page 50.

•When operating without the instrument cover (Art. No. 37798), only

protection class IP 40 is valid.

•Please note that oxidizing agents other than chlorine, e.g. ozone,

chlorine dioxide or hydrogen peroxide, are also recorded and in-

crease the measuring result!

•If the test water contains more than 20 mg/I CO2 (carbonic acid),

erroneous evaluations 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 the

device at regular intervals as follows:

oHas the expiry date of the indicator elapsed?

oAre the hose connections of the dosing pump leakproof?

oIs there any air in the dosing hoses?

oAre all water connections leakproof?

oIs the device excessively soiled?

oAre the measuring chamber and drain channel/drain hose

clean?

•Problem-free operation is contingent on regular maintenance!

Maintenance and care instructions can be found in the Mainte-

nance section on page 40.

•Indications of problems can be found in the Error messages and

troubleshooting section on page 35.

CAUTION

NOTE

Scope of delivery

1x Testomat®Modul CL

1x plastic bag including 2 screw caps with hole and 2 inserts for the

indicator bottles

1 package including 1 plastic bag with drain funnel

1 User manual

1 plastic bag with stickers for marking as CL-T or CL-F

Performance specifications

The process photometer Testomat®Modul CL is a robust, wet chemi-

cal online measuring converter to measure the concentration of total

chlorine and free chlorine in the measuring range 0 - 5 mg/l in cooling

circuits when applying the photometric analysis principle. Instrument

operation is based on the DPD method according to EN ISO 7393-2.

The analysis is carried out through the addition of two reagents and

the measurement result is obtained after a reaction time of approx.

15 seconds (pure measurement time without flush time).

•The device is connected to an overriding 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:

oMeasurement phase mode: A start impulse triggers a sequence

of analyses for the period of between 10 minutes and 12 hours.

oContinuous mode: Analyses are continuously carried out at a set

interval. The analysis interval can be set within the range from

10 to 60 minutes.

•Shared output for the alarm

Connect to the max. 35 VAC / 60 VDC relay.

•Parameterisation with the Service Monitor program (on the SD

card), logging of error and maintenance messages and a firm-

ware update with the SD card

•USB connection for service purposes and for parameterisation

with the Service Monitor program

•History for error and maintenance messages

•Built-in self-test with ongoing monitoring

Interaction with the controller

There are two operating modes for the device:

Measurement phase mode: With a single impulse, the controller

starts a sequence of measurements. The device carries out analyses

CAUTION

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