Lenntech Testomat 2000 PO4 User manual

1
Testomat 2000®PO4
Process Photometer for
Phosphate 0- 10 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

Content
2
Content
Content.................................................................................................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
Cleaning................................................................................................6
After switch-off and longer downtime....................................................6
De-installation .......................................................................................6
Disposal ................................................................................................6
Scope of delivery ................................................................................7
Performance specifications...............................................................7
Application instructions.....................................................................8
Installation...........................................................................................9
Operating Testomat 2000®PO4 in the pressure range of 0.3 to 1 bar.9
Installing Testomat 2000®.....................................................................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®PO4..................................................11
Internal design Testomat 2000®PO4 .................................................12
Connecting the mains voltage.............................................................13
Connecting the plant components ......................................................14
Connecting the inputs and outputs .....................................................15
Commissioning.................................................................................16
Inserting the reagent bottles ...............................................................16
Extracting the reagent.........................................................................16
Input reagent level ..............................................................................16
Opening the water inlet.......................................................................17
Instrument settings and data input......................................................17
Functions of the operating and display elements.........................17
Switching Testomat 2000®PO4on/off................................................17
Display functions.................................................................................18
Operating elements and function keys ...............................................19
Operating system................................................................................20
Password protection and basic program.......................................21
Selecting the operating mode.............................................................21
Selecting the display unit....................................................................23
Entering further basic program data ..............................................24
Internal flushing...................................................................................24
External flushing .................................................................................24
Interval pause .....................................................................................25
Limit value monitoring.........................................................................25
Hysteresis ...........................................................................................26

Content
3
Switch functions of the limit value outputs LV1 and LV2....................26
Switch function 0, duration..................................................................26
Switch function 1, impulse ..................................................................26
Switch function 2, interval...................................................................26
Switch function 3, two-point................................................................27
Switch function 4, Duration/inverse ....................................................27
Switch function 5, range LV1-LV2 ......................................................27
Measuring points.................................................................................27
Function IN1........................................................................................28
Water meter ........................................................................................28
Alarm/Message...................................................................................28
Function AUX......................................................................................29
Service II ............................................................................................30
Calibration...........................................................................................30
Reset operating time...........................................................................30
Maintenance interval...........................................................................31
Description of the signal inputs/outputs........................................32
Interfaces (optional) ............................................................................33
Installing the interface cards SK910/RS910.......................................34
Monitoring a measuring point..............................................................34
Monitoring of two measuring points....................................................34
Calculation of output currents.............................................................35
Serial interface RS232........................................................................35
SD card data logger............................................................................36
Description of the relay outputs......................................................36
Flushing (external flush valve)............................................................36
LV1 and LV2 limit value outputs .........................................................36
Measuring points 1 or 2 (measuring point switch-over)......................37
AUX (programmable function output) .................................................37
Alarm (fault message output)..............................................................38
Maintenance (output for maintenance message) ...............................38
Information menu "i" ........................................................................39
Program menu "M" ...........................................................................40
Structure of the basic program............................................................42
Error messages/Troubleshooting ...................................................43
Further information..............................................................................44
Maintenance ......................................................................................45
Description of maintenance work........................................................45
Service instructions.............................................................................46
Maintenance message pump head.....................................................47
Replacing the pump head...................................................................47
Testomat 2000®spare parts and accessories................................47
Accessories.........................................................................................49
Technical data...................................................................................50
Conformity Declaration .......................................................................51
Check List Testomat 2000®................................................................52
Product overview Testomat 2000®-Instruments ............................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®PO4 change hands.
Intended use
The process photometer Testomat 2000® Phosphate is a robust wet-
chemical online monitor for monitoring the phosphate content from 0
to 10 mg/l (ppm) using the photometric analysis principle. The feed
water must be clear, colourless and free of undissolved particles. It is
used for monitoring the process water, e.g. in the fields of industry /
treated wastewater / online environmental analysis.
Always adhere to the performance limits stated in the section
entitled “Technical data”.
Always observe the application areas/application limits of the
indicators and 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
respective technical terms. Assembly and commissioning should
therefore only be carried out by a specialist or by an authorised
individual supervised 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
appropriate safety measures. A specialist should always adhere to
the relevant technical regulations.
Always adhere to hazard warnings and safety information 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
potential dangers to individuals and property resulting from incorrect
handling 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
damage.
“NOTE” indicates important information. If this information is not
observed, it may result in an undesirable result or state.
Further documents
Testomat 2000®PO4 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
Adhere to health and safety regulations, electrical equipment
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 modifications 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!
WARNING
!
WARNING
!
CAUTION
!
NOTE
DANGER
!

Important safety information
6
Installation
Always completely disconnect the relevant plant part before
installing 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®PO4 requires an interference free and stable
power supply. If necessary, use a mains filter to protect Testomat
2000®PO4against interference voltages caused, e.g., by solenoid
valves or large motors. Never lay connecting cables parallel to
power cables.
Operation
Ensure that the maximum electrical load capacity of the relay
outputs is never exceeded.
Immediately switch off Testomat 2000®PO4 and contact service
staff if malfunctioning occurs. The warranty will be void if you
tamper with or attempt to repair Testomat 2000®PO4. Repairs
must be carried out by authorised service staff.
Cleaning
Only use a dry, lint-free cloth for cleaning.
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.
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.
Disposal
Dispose of the instrument in accordance with national regulations.
WARNING
!
NOTE

Scope of delivery
7
Scope of delivery
1x Testomat 2000®PO4
1x plastic bag containing the screw caps with a hole and an insert for
the screw cap of the reagent bottles
1x operating instructions
Performance specifications
The process photometer Testomat 2000® Phosphate is a robust wet-
chemical online monitor for monitoring the phosphate content from 0
to 10 mg/l (ppm) using the photometric analysis principle. Analysis is
carried out by adding two reagents and the analysis result is
displayed after a reaction time of ten minutes.
Measuring range: 0 –10 mg/l with a resolution of:
- 0,1 mg/l in the range of 0 –7 mg/l
- 0,25 mg/l in the range of 7 –10 mg/l
Limit of detection: 0,1 or 0,25 mg/l depending on range
Accuracy: < 10% at end of measuring range
Simple, menu-driven operating and programming via a plain
text display
Freely selectable unit in ppm or mg/l
Analysis initiation:
- Automatic interval operation
(Interval pause adjustable from 0 to 255 minutes)
- External control
- Volume controlled (water meter)
Two independent limit values with hysteresis (1, 2 or 3 bad
analyses) and adjustable 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
optional
Interface (0/4-20 mA or 0/2-10 V) or
Interface RS 232 for a log printer
SD card data logger

Application instructions
8
Application instructions
Wait at least 5 seconds before switching the instrument on and
then off again at the main switch.
In order for Testomat 2000®PO4 to operate reliably, use Heyl
Testomat 2000®reagents.
Make sure that the water is not more acidic than pH 4. At lower
pH values, the hose connections and other plastic parts of the
device can be damaged.
If the measuring water contains more than 20 mg/I CO2(carbonic
acid), incorrect evaluations cannot be excluded.
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:
–Has the use-by-date of the indicator expired?
–Are the hose connections of the dosing pump free of leaks?
–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
carried out on a regular basis! For more information, 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
messages/Troubleshooting".
Dosing of high viscosity fluids
Fluids with a high viscosity can cause problems with the dosage. The
amount of liquid which is dosed may be too small.
At a high viscosity, check if enough liquid is dosed.
Watch out for a constant temperature in the measuring room, since
different temperatures can lead to different dosages.
NOTE

Installation
9
Installation
Risks resulting from incorrect installation!
Install Testomat 2000®PO4at 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.
Information for trouble-free operation
Install Testomat 2000®PO4vertically and without mechanical
stress.
Install Testomat 2000®PO4at a vibration-free site.
Operating Testomat 2000®PO4 in the
pressure range of 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 of 1 to
8 bar. Remove the flow controller valve body to operate the
instrument in the operating range of 0.3 to 1 bar (e.g. when using an
aerator type R). This involves removing the retaining pin from the
controller/filter receiver . Subsequently use the metal bracket to
remove the controller plug from the borehole. Then remove the
flow controller valve body and reinsert the controller plug and the
retaining pin.
Installing Testomat 2000®
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
instrument 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
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 5 °C and
30 °C
For temperatures above 40 °C, the KCN type cooler should be
installed in the branch line of Testomat 2000®PO4.
Water inlet
The measuring water is taken from the main water line of the water
treatment plant and fed to the inlet connection of Testomat 2000®
PO4. The instrument is equipped with a plug connector for plastic
hoses 6/4 x 1 (external diameter 6 mm/ internal diameter 4 mm, wall
thickness 1 mm) as standard.
Install the connection for the branch line of Testomat 2000®PO4
directly at the main water line directly after the water treatment
plant
It is important that the branch line connection is laid vertically
upwards in order to prevent dirt particles from entering the
instrument from the main water line .
Install a manually operated shut-off valve in the branch to
Testomat 2000®PO4.
Use an opaque plastic hose 6/4 x 1 (max. length 5 m) for the water
inlet .
Flush the inlet to remove any dirt particles.
When operating within a pressure range of 0.3 to 1 bar or with a
supply via a booster pump, please remove the valve body from the
controller and the filter housing. The pump should have a feeding
capacity 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®PO4.
Water outlet
The feed water flows through the measuring chamber to the drain via
the outlet hose.
Connect the outlet connection of Testomat 2000®PO4 to an outlet
hose(internal diameter 12 mm).
Lay this hose without backwater development and any
syphoning effect, e.g. via an open funnel, to the drain.






NO !!
"Sagging"
causes
backwater!
CAUTION
!
NOTE