Lenntech Testomat 2000 Fe User manual

1
Testomat 2000®Fe
Process Photometer for
Iron (Dissolved) 0 –1.0 mg/l
Operating Instructions
Lenntech
Lenntech
[e-mail] Tel. [phone]
www.lenntech.com Fax. [phone]
[e-mail] Tel. [phone]
www.lenntech.com Fax. [phone]
Lenntech

Contents
2
Contents
Contents...............................................................................................2
Important safety information.............................................................4
Intended use .........................................................................................4
Qualification of the staff ........................................................................4
Warning notices in these instructions ...................................................5
Further documents................................................................................5
Pay particular attention to .....................................................................5
General instructions..............................................................................5
Installation.............................................................................................6
Operation ..............................................................................................6
After switch-off and longer downtime....................................................6
Cleaning................................................................................................6
De-installation .......................................................................................6
Disposal ................................................................................................6
Scope of delivery ................................................................................7
Performance specifications...............................................................7
Application instructions.....................................................................8
Installation...........................................................................................9
Operating Testomat 2000®Fe in the pressure range 0.3 to 1 bar........9
Installing Testomat 2000®Fe................................................................9
Connecting the water inlet and outlet .................................................10
Water inlet...........................................................................................10
Water outlet.........................................................................................10
Connecting the power supply and devices .........................................11
Block diagram Testomat 2000®Fe .....................................................11
Internal design Testomat 2000®Fe ....................................................12
Connecting the mains voltage.............................................................13
Connecting the plant components ......................................................14
Connecting the inputs and outputs .....................................................15
Commissioning.................................................................................16
Inserting reagent bottles .....................................................................16
Filling the reagent ...............................................................................16
Opening the water inlet.......................................................................16
Instrument settings and data input......................................................17
Functions of the operating and display elements.........................17
Switching Testomat 2000® Fe on/off...................................................17
Display functions.................................................................................18
Operating elements and function keys ...............................................19
Operating system................................................................................20
Password protection and basic program.......................................21
Entering basic program data...............................................................21
Selecting the operating mode.............................................................21
Selecting the displayed unit................................................................24
Entering further basic program data ..............................................25
Internal flushing...................................................................................25
External flushing .................................................................................25
Interval pause .....................................................................................26
Limit value monitoring.........................................................................26
Hysteresis ...........................................................................................27

Contents
3
Switch functions of the limit value outputs LV1 and LV2....................28
Switch function 0, duration..................................................................28
Switch function 1, impulse ..................................................................28
Switch function 2, interval...................................................................28
Switch function 3, two-point................................................................28
Function IN1........................................................................................29
Water meter ........................................................................................29
Plant monitoring..................................................................................29
Alarm / Message.................................................................................30
Function AUX......................................................................................30
Service II.............................................................................................31
Calibration...........................................................................................31
Resetting the operating time...............................................................33
Maintenance interval...........................................................................33
Water quantity RESET.......................................................................33
Plant control RESET..........................................................................33
Description of the signal inputs/outputs........................................34
Interfaces (optional) ............................................................................35
Installing the interface cards SK910/RS910.......................................35
Monitoring of one measuring point .....................................................36
Monitoring of two measuring points....................................................36
Calculating the output currents...........................................................37
Serial interface RS232........................................................................37
SD card data logger............................................................................38
Description of the relay outputs......................................................38
Flushing (external flush valve)............................................................38
LV1 and LV2 limit value outputs .........................................................38
Measuring point 1 or 2 (measuring point switch-over)........................39
AUX (programmable function output) .................................................39
Alarm (fault message output)..............................................................40
Maintenance (output for maintenance message) ...............................40
Information menu "i" ........................................................................41
Program menu "M" ...........................................................................42
Structure of the basic program .......................................................44
Error messages / Troubleshooting .................................................45
Further information..............................................................................46
Maintenance ......................................................................................47
Description of maintenance work........................................................47
Service instructions.............................................................................48
Testomat 2000®Fe spare parts and accessories ..........................49
Accessories.........................................................................................50
Reagents.............................................................................................50
Technical data...................................................................................51
Conformity Declaration .......................................................................52
Product overview Testomat 2000®instruments ............................52
Check List Testomat 2000®................................................................54

Important safety information
4
Important safety information
Please read these operating instructions carefully and completely
prior to working with the instrument.
Ensure that these operating instructions are always available for
all users.
These operating instructions must always be passed on to the
new owner should Testomat 2000®Fe change hands.
Intended use
The process photometer Testomat 2000®Fe is a robust wet-chemical
online monitor for monitoring the dissolved iron content (II)+(III) from
0 to 1.0 mg/l using a colourimetric analysis principle.
Analysis is carried out by adding two reagents. The analysis result is
displayed after a reaction time of approx. 7 minutes (absolute meas-
uring time without flushing times).
Applications include, e.g., the monitoring of de-ironing plants or the
monitoring of process or drinking-water flows.
Always adhere to the performance limits stated in the section entitled
“Technical data”.
Always observe 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 specified in these instructions,
it is used in areas which do not correspond to the ones described
in these instructions.
Qualification of the staff
Assembly and commissioning require fundamental electrical and
process engineering knowledge as well as knowledge of the respec-
tive technical terms. Assembly and commissioning should therefore
only be carried out by a specialist or by an authorised individual su-
pervised by a specialist.
A specialist is someone who due to his/her technical training, know-
how and experience as well as knowledge of relevant regulations can
assess assigned tasks, recognise potential hazards and ensure ap-
propriate safety measures. A specialist should always adhere to the
relevant technical regulations.
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 www.lenntech.com .

Important safety information
5
Warning notices in these instructions
The warning notices in these instructions warn the user about poten-
tial dangers to individuals and property resulting from incorrect han-
dling of the instrument. The warning notices are structured as follows:
Description of the type or source of danger
Description of the consequences resulting from non-observance
Preventive measures. Always adhere to these preventive
measures.
“DANGER” indicates an immediate hazardous situation which, if not
avoided, will result in death or serious injury.
“WARNING” indicates a potentially hazardous situation which, if not
avoided, could result in death or serious injury.
“CAUTION” indicates a potentially hazardous situation which, if not
avoided, could result in minor or moderate injuries or 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®Fe is a plant component. Therefore, always observe
the maintenance manual of Testomat 2000® /Testomat ECO®and the
documentation of the plant manufacturer.
Pay particular attention to
General instructions
Please adhere to health and safety regulations, electrical equip-
ment safety regulations, and environmental protection regulations
valid in the country of use and at the installation site.
Adhere to national and local regulations during installation and
commissioning.
Always protect the instrument against moisture and humidity. It
should never come into contact with condensation or splash water.
Do not carry out any changes or actions at the instrument which
are not described in these instructions; failure to adhere to these
instructions will negatively affect any warranty claims that you
make thereafter.
SIGNAL WORD
DANGER
!
CAUTION
!
WARNING
!
WARNING
!
NOTE

Important safety information
6
Installation
Always completely disconnect the relevant plant part before in-
stalling the instrument or connecting/disconnecting it to/from the
power supply. Secure the plant against reconnection.
Only connect the instrument to the mains voltage specified on the
rating plate.
Always observe technical data and ambient parameters.
Testomat 2000®Fe requires an interference free and stable power
supply. If necessary, use a mains filter to protect Testomat 2000®
Fe against interference voltages caused, e.g., by solenoid valves
or large motors. Never lay connecting cables parallel to power ca-
bles.
Operation
Ensure that the maximum electrical load capacity of the relay out-
puts is never exceeded.
Immediately switch off Testomat 2000®Fe and contact service
staff if malfunctioning occurs. The warranty will be void if you tam-
per with or attempt to repair Testomat 2000®Fe. Repairs must be
carried out by authorised service staff.
After switch-off and longer downtime
Ventilate the indicator leads as described in the start-up, because
longer downtimes (more than 6 hours) can cause the indicator in
the leads to retract.
Do not switch off the appliance for longer periods (e.g. over the
weekend) via the start/stop output. The indicator can retract from
the leads. This results in measurement errors after the appliance is
switched on.
Cleaning
Only use a dry, lint-free cloth for cleaning.
De-installation
Prior to de-installing a defective instrument, always write down a
description of the error (failure effect). It is only possible to repair a
defective instrument (irrespective of the warranty period) if it has
been de-installed and returned to us with a description of the error.
Please also inform us of the measured medium. Before you return
the instrument for repair work, remove the reagent bottles and en-
sure that the measuring chamber has been flushed out and is
empty.
Disposal
Dispose of the instrument in accordance with national regulations.
WARNING
!
NOTE

Scope of delivery
7
Scope of delivery
1x Testomat 2000®Fe
1x plastic bag with two screw caps with a hole and inserts for the
screw caps of the reagent bottles
1x operating instructions
Performance specifications
The process photometer Testomat 2000®Fe is used for automatically
monitoring the dissolved iron content (II)+(III) from 0 to 1.0 mg/l using
a colourimetric analysis principle. Analysis is carried out by adding
two reagents.
Simple, menu-driven operating and programming via a plain text
display
High measuring accuracy provided by a precise piston-dosing
pump
Range I: 0 - 0.65 mg/l, resolution: 0.01 mg/l
Range II: 0.7 –1.0 mg/l, resolution 0.1 mg/l
Analysis initiation:
- Automatic interval operation
(interval pause can be set from 0-99 minutes)
- External control
- Dynamic (exhaustion-dependent interval operation)
- Quantity dependent via impulse water meter
Two independent limit values with hysteresis (1, 2 or 3 bad anal-
yses) and settable switch functions
Monitoring of two measuring points (change-over via external
solenoid valves)
Internal error documentation
Programmable service address
Programmable maintenance interval for a maintenance request
Extended operating periods due to 500 ml reagent storage bottle
Optional
Interface card (0/4-20 mA or 0/2-10 V) or
Interface card RS232 (for a protocol printer)

Application instructions
8
Application instructions
Wait at least 5 seconds before switching the instrument on and
then off again at the main switch.
Trouble-free operation of Testomat 2000®Fe is only possible
when using Heyl Testomat 2000® reagents FE2005A and
FE2005B
!
Faults or problems resulting from the use of other rea-
gents will not be accepted as a warranty or fair dealing claim.
Larger quantities of heavy metal ions in the water influence the
colour reaction, especially copper above 0.01 mg/I and alumini-
um above 0.1 mg/l. Measurement is possible in the pH range 4 –
10.5. The concentration of influencing contents can be deter-
mined by using our colourimetric TESTOVAL®test kits.
Only use Testomat 2000®Fefor its intended purpose.
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:
- Are the hose connections of the dosing pump free of leaks?
- Is there air inside the dosing hoses?
- Are all the water connections free of leaks?
- Are the doors of the instrument closed properly?
- Is the instrument heavily soiled?
- Are the measuring chamber and the drain duct/drain hose
clean?
Trouble-free operation is only possible when maintenance is car-
ried out on a regular basis! For maintenance and service instruc-
tions, please refer to the section entitled “Maintenance” and the
"Maintenance manual of Testomat 2000®/Testomat ECO®".
If problems occur, please refer to the section entitled "Error mes-
sages/Troubleshooting”.

Installation
9
Installation
Risks resulting from incorrect installation!
Install Testomat 2000® Fe at a location where it is protected
against dripping or splash water, dust and aggressive substances
–e. g. in a switch cabinet or on a suitable wall.
Only authorised technicians should carry out installation and
commissioning!
Information for trouble-free operation
Install the instrumentvertically and without mechanical stress.
Install the instrumentat a vibration-free site.
Operating Testomat 2000®Fe in the pressure
range 0.3 to 1 bar
Prior to installation, please check whether lower operating pressure is
required. The instrument is factory set for the operating range 1 to 8
bar. Remove the flow controller valve body to operate the instru-
ment in the operating range 0.3 to 1 bar (e.g. when using a type R
aerator). This involves removing the retaining pin from the control-
ler / filter receiver . Subsequently use the metal bracket to remove
the controller plug from the borehole. Subsequently remove the
flow controller valve body and reinsert the controller plug and the
retaining pin.
Installing Testomat 2000®Fe
Select an installation site where the water inlet hose can be kept as
short as possible (max. 5 m).
Please leave sufficient space on the left-hand side of the instru-
ment to open the door.
Drill the mounting holes as shown in the drawing on the left.
Use three screws to attach the instrument at a suitable position in
the switch cabinet or on a wall.
Remove for
pressure
range 0.3 to 1
bar
4
3
2
1
WARNING
!
NOTE

Installation
10
Connecting the water inlet and outlet
Information for trouble-free operation
The water pressure must be between 0.3 bar and 8 bar.
Avoid strong pressure fluctuations.
The measuring water temperature must 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)!
For temperatures above 40°C, install the KCN type cooler in the
branch line of Testomat 2000®Fe.
Water inlet
Equip the sampling line to Testomat 2000®Fe with a manually oper-
ated shut-off valve and keep it as short as possible (the max. length
of 5 metres should not be exceeded). The instrument is equipped
with a plug connector for opaque plastic hoses 6/4 x 1 (external di-
ameter 6 mm/internal diameter 4 mm, wall thickness 1 mm) as stand-
ard.
Install the connection for the branch line of Testomat 2000®Fe
directly at the main water line .
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 line to
Testomat 2000®Fe.
Use an opaque plastic hose 6/4 x 1 (max. length 5 m) for the wa-
ter inlet .
Flush the inlet to remove any dirt particles.
When operating within a pressure range of 0.3 to 1 bar or with a sup-
ply via a booster pump, please remove the valve body from the con-
troller and the filter housing. The pump should have a feeding capaci-
ty of between 25 and 35 litres/hour and be resistant to the medium
being measured.
When using a cooler
The hot water can cause burns and damage wetted parts of
Testomat 2000®Fe.
Water outlet
The feed water flows through the measuring chamber to the drain via
the outlet hose.
Connect the outlet connection of Testomat 2000®Fe to an outlet
hose (internal diameter 12 mm).
Lay this hose without backwater development and any syphon-
ing effect, e.g. via an open funnel, to the drain .






NO !!
"Sagging“
causes backwa-
ter!
CAUTION
!
NOTE