Lenntech TESTOMAT 2000 THCl User manual

GB
TESTOMAT®2000 THCl
Combined Process-Photometer for total chlorine 0 - 2.5ppm
and Process-Titrator for water hardness 0.25 - 2.50°dH
Operating Instructions
Lenntech
Lenntech
[e-mail] Tel. [phone]
www.lenntech.com Fax. [phone]
[e-mail] Tel. [phone]
www.lenntech.com Fax. [phone]
Lenntech

Contents
Introduction ..................................... 1
Short description ................................ 1
Notes for the user ................................ 2
Notes about the operational reliability ............... 2
Safety notes .................................... 2
Installation and commissioning .................... 3
Installation ..................................... 3
Electrical connection ............................. 3
Mains water supply .............................. 3
Water to drain ................................ 3
Commissioning ................................. 4
Installation diagram (example) ................... 4
General description .............................. 5
Internal construction ............................. 5
Description of the electrical connections .............. 6
Terminal block identification ..................... 6
Description of displays and operating features ......... 7
Display functions ................................ 7
Status of limit value displays ..................... 7
Measured value display ......................... 7
Limit value display ............................. 7
Alarm and maintenance message ................. 7
Status display .................................. 8
Description of the relay outputs ..................... 8
(Flush) External flush valve ...................... 8
LV1 and LV2 Limit value outputs ................. 8
1 or 2 Measuring points switch-over ............... 8
AUX Programmable function output ............... 9
Alarm fault message output ..................... 9
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 ouput (optional) .................. 10
Function characteristics ......................... 11
Mode of operation .............................. 11
Analysis cycle ................................. 11
Displayed unit ................................. 11
Measuring points switch-over ..................... 11
Setting the timer ................................ 12
Monitoring of limit value .......................... 12
Hysteresis .................................... 12
Logic functions ................................. 13
Function IN1 .................................. 13
Alarm / Message ............................... 13
Function AUX .................................. 14
Service II ..................................... 14
Reset operating time .......................... 14
Maintenance interval .......................... 14
Interfaces (optional) ............................. 14
Structure of the menu ........................... 15
Selection and input ............................. 15
Start menu .................................. 15
Selection ................................... 15
Input ...................................... 15
End menu .................................. 15
Information menu "i" ............................ 16
Structure of the "i" menu ......................... 16
Call .......................................... 16
Customer service ............................... 16
Operating values ............................... 16
Program values ................................ 16
Error registration ............................... 16
Maintenance .................................. 16
Program menu "M" .............................. 17
Service I ...................................... 17
Input reagent ................................ 17
Manual operation ............................. 17
Confirm maintenance ......................... 18
Diagnosis .................................. 18
Date/time of day ................................ 18
Basic program ................................. 18
Program values ................................ 18
Structure of the basic program .................... 19
Error messages / trouble shooting ................. 20
Further information ............................. 21
Maintenance ................................... 21
Description of maintenance work ................... 21
Cleaning the measuring chamber & sight-glass windows 21
Cleaning the filter housing ....................... 21
Notes on unit care .............................. 21
Spare parts list Testomat®2000 ................... 22
Technical appendix ............................. 23
Block diagram "Testomat®2000" ................... 23
Technical data ................................. 23

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Introduction
These operating instructions describe the installation, operation and programming of the combined process photometer
and titrator Testomat®2000 TH/Cl.
We recommend that, whilst familiarising yourself with the operation of the unit aided by this manual, you have
immediate access to the unit in order to perform the functions and combinations as described. As certain functions are
interrelated, it is advisable to follow the instructions in the given order.
Should problems or questions arise which are not described in this manual 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 conditions under which it has occurred. This will
enable us to offer you swift effective assistance.
Symbols and abbreviations used in these instructions:
LNote for the user "STANDBY" = STANDBY lamp is “ON”
Important to observe / warning note "M" = Press menu key M TTip: Helpful hint
ºSERVICE ºMANUAL OPERATION ºFLUSH = Sequence in a menu selection
Short description
The Testomat®2000 THCl is an online monitor for monitoring the concentration of total chlorine in the measuring range
0 - 2.5 mg/l (ppm) using the colorimetric analysis principle and determines the water hardness through titration.
The analysis of total chlorine is implemented by adding three reagents, after a reaction time of approx. 1 minute
(measuring time without flush time) the analysis result is shown.
Areas of use are, e.g. the protection of reverse osmosis membranes from blocking due to hardness and from
destruction due to a high content of chlorine. Two independent programmable limit value contacts are available for
monitoring. The analysis result can be recorded using the optional printer board (interface SK910, item no. 270305) and
a dotted or continuous line printer (0/4-20mA).
Parameter / Measuring range
water hardness
TH 2025 total chlorine
Unit
°dH
(Resolution) 0.25 - 2.50
(0.05) -
°f
(Resolution) 0.45 - 4.48
(0.1) -
ppm CaCO3
(Resolution) 4.47 - 44.7
(0.9) -
mmol/l
(Resolution) 0.04 - 0.45
(0.01) -
mg/l (ppm) -0.0 - 2.5
(0.1)
LAconsistently reliable result can be guaranteed by the Testomat®2000 units only with the use of
original HEYL Testomat®2000 indicators and reagents! Failure or problems which are caused by the use
of different indicators are not covered by the warranty or refund services.
Larger quantities of heavy-metal ions in the softened water can affect the colour reaction, especially iron above
0.5 mg/l, copper above 0.1 mg/l and aluminium above 0.1 mg/l (brownish-red colour indication).The measuring
is possible in a range of pH 4 - 10.5.
At a concentration of more than 100 mg/l of CO2(carbon dioxide) in the water the analysis can be affected.
Fault influences:
Concentration values of these ingredients can be determined safely and simply with our TESTOVAL®colorimetric test
comparators.

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Notes for the user
•Repeated switching 'on' and 'off':
Wait at least for 5 seconds before you switch the unit repeatedly 'on' or 'off' at the main switch.
• Observation of the environmental conditions:
In order to guarantee a reliable operation, the unit must only be used under the environmental conditions described
in the technical data. Protect the controller against excessive humidity, condensation and water-splash.
• Safety seal:
The original seals attached during manufacture (e.g. EPROM labels) must not be broken, otherwise all warranty
rights are lost.
• Malfunction / repair of defective units:
The repair of a defective unit is only possible when the unit is dismantled and returned to us with a description of the
fault. In addition, please inform your supplier of the reagent type used.
Before you return the unit for repair, remove the reagent bottle and ensure that the measuring chamber is flushed out
and empty.
• Electrical load capacity
The maximum electrical load capacity of the relay outputs and the total power rating must not be exceeded.
• Operate the Testomat® 2000 THCl strictly in accordance with the manufacturer's instructions.
• Environmental protection regulations
Please observe the environmental protection regulations, collect large amounts of any unused reagent which you can
no longer use and send this to us for correct disposal.
Operational checks
Careful handling of the unit increases both the operational reliability and the service life!
Therefore, the following visual inspection should be carried out at regular intervals.
•Are the hose connections with 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 properly closed? (Check door seals!)
•Is the unit unduly contaminated with dirt?
Maintenance and servicing notes
(See page 21)
Safety notes
• The unit must be installed and operated in compliance with the relevant standards (e.g. DIN, VDE, UVV), or in
accordance with the regulations laid down by the individual country.
• Some functions (e.g. the manual analysis) allow the direct manipulation of the installation without locking or
monitoring. These functions may only be used by trained staff and for this reason are only accessible after a
password has been entered.
• If you observe the unit malfunctioning, switch it off immediately. Then shut off the water supply and contact your
supplier.
•Do not attempt to repair the unit yourself (loss of warranty rights); instead always get in touch with authorised service
staff. This is the only way a reliable and safe operation of the unit can be ensured.
•After a protective circuit (fuse) has tripped, first of all, attempt to correct the cause of the malfunctioning (e.g. replace
the solenoid valve) before reactivating the protective circuit. Frequent tripping is always due to a fault which, in
certain circumstances, may also cause damage to the unit.
• Observe the safety notes about working with reagents, chemicals and cleaning agents.
Ignoring these notes can result in damage to the unit as well as to the installation and may result in a loss of
warranty rights.

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360
266
Dimensioned sketch
Installation and commissioning
Installation and commissioning must be undertaken only
by authorised technicians!
Installation
The unit should be fixed vertically!
Avoid tension of the housing.
The unit doors swing to the left when they are opened. Please
ensure that there is sufficient space for opening them. In this
way, you facilitate the electrical installation and later
maintenance and service work.
Electrical connection
Check supply voltage on the rating plate!
Basic requirement
The 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). Then 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 after the installation is completed using the two fastening screws.
Mains water supply
The temperature of the sample water must be between 10 °C and 40 °C. Higher water temperatures can lead to
damage to all parts coming into contact with water (e.g. filter housing, measuring chamber)!
Lower water temperatures can cause misting on the sight-glass windows.
LIn the event of higher temperatures, the KCN type cooler must be installed in the branch line of the Testomat®
2000 THCl.
Hot water can cause scalding!
The sampling tube to the Testomat®2000 THCl must be equipped with a hand-operated shut-off valve and be kept as
short as possible (not longer than a maximum of 5 metres). It is important that the branch line connection is taken
vertically from the top of the main soft water line in order to prevent dirt particles from entering into the measuring
chamber. Remove the valve body out of the regulator/ filter housing when operating the Testomat®2000 THCl with a
pressure range of 0.1 to 1 bar.
Plug connector
The unit is equipped as a standard with a plug connector for opaque plastic hoses 6/4 x 1 (external diameter 6 mm/
internal diameter 4 mm).
Quick-acting coupling (accessory: optional adapter for water inlet, item no. 40123)
When 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-acting coupling (not included with the delivery).
Water to drain
The feed water flows through the measuring chamber then, via the outlet pipe, to the drain (hose connection internal
diameter 14 mm). Make sure, by using a funnel for example, that the water can run freely to drain and cannot back-up
into the measuring chamber. A hose impervious to light should also be used for the drain pipe (to discourage algae
formation).

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Commissioning
1. Full reagent bottles must be connected before commissioning and switching on. Attach the vacuum connection onto
the reagent bottle using the union nut. Please observe the correct allocation of the reagents A, B and C to the dosing
pumps: TH2025 = DOSIClip 1 (left), Cl2025A = DOSIClip 2, Cl2025B = DOSIClip 3, Cl2025C = DOSIClip
4 (right).
2. Switch the unit 'on' and press the "STANDBY" key. In this mode, an analysis is prevented from being carried out
before a correct program has been entered which could possibly result in an error or alarm message.
3. Then bleed the dosing pump and the capillary by repeatedly pressing the "Manual" key on the dosing pump. Ensure
all air is removed from the tubing! (If necessary tighten up the connections.)
4. Program the unit as applicable to your requirements, e.g.: - Mode of operation - Displayed units
-Limit values -Flush time / interval
For a description of programming see from page 17 onward.
5. Enter the correct fill status of the reagent bottles:
"M" ºSERVICE IºINPUT REAGENTS ºREAGENT TH FILLING (100%)
"M" ºSERVICE IºINPUT REAGENTS ºREAGENT A FILLING (100%)
"M" ºSERVICE IºINPUT REAGENTS ºREAGENT B FILLING (100%)
"M" ºSERVICE IºINPUT REAGENTS ºREAGENT C FILLING (100%)
6. Then remove all air from the water supply side of the unit by manual flushing.
"M" ºSERVICE ºMANUAL OPERATION ºFLUSH ("ENTER" press repeatedly).
Continue flushing until no bubbles can be seen in either the measuring chamber or the filter housing.
7. Check all connections for tightness.
8. Carry out the first analysis by pressing the "Manual" key.
Installation (example):

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Terminal block for inputs
Start, Stop, IN1, IN2 and output OUT
F7 T0,08A F5 T0,2A F6 T0,315A
F8 T1A
F1 T0,1A/ 240V
F4 T0,16A
230 V
F1 T0,1A
230 V
F9 T4A
H 250 V
J6
J4 DOSI 3
J3 DOSI 2
J2 DOSI 1
J5 DOSI 4
J11
J13J8J7
E-Ventil A-Ventil 24 V
Steckplatz Flexkabel
Messkammer
17
21
18
*
2
14 13 *
Mains water supply:
Inlet with primary filter and pressure regulator,
outlet
Valve
block
Dosing pump 1
TH2025
Plug-socket holder J4 = Dosing pump 3
Plug-socket holder J5 = Dosing pump 4
Dosing pump 2
Cl2250A
TH2025
TESTOMAT
2000
Dosing pump 4
Cl2250C
Plug-socket holder J2 = Dosing pump 1
Plug-socket holder J3 = Dosing pump 2 Dosing pump 3
Cl2250B
CL2250C
TESTOMAT
2000
General description
Internal construction

6 / 23
Description of the electrical connections
Terminal block identification
IN = input, OUT = output
No. Terminal Type Function Note
-PE IN Mains-Protective earth (5 x)
-
-N LIN Mains, N = Neutral Mains, L = Live Mains-input 230 - 240 V AC (or 24V AC)
-
-n lOUT Neutral switched (8 x) Mains switched (8 x) Mains voltage, max. 4 A
1
2Flush OUT External flush valve Volt-free relay output max. load 240 V AC, 4 A
3
4
5LV1 OUT Limit value output 1 - Normally closed
Limit value output 1 - Normally open
Limit value output 1 - Common
Residual hardness
Volt-free relay output
max. load 240 V AC, 4 A
6
7
8LV2 OUT Limit value output 1 - Normally closed
Limit value output 1 - Normally open
Limit value output 1 - Common
Chlorine
Volt-free relay output
max. load 240 V AC, 4 A
9
10
11
Measuring point
1/2 OUT Measuring point 1 - Normally closed
Measuring point 2 - Normally open
Measuring point switch-over -Common
Volt-free relay output
max. load 240 V AC, 4 A
12
13 AUX OUT Universal output Volt-free relay output max. load 240 V AC, 4 A
14
15
16 Alarm OUT Fault message - Normally closed
Fault message - Normally open
Fault message - Common
Volt-free relay output
max. load 240 V AC, 4 A
17
18
19 Maintenance OUT Maintenance message - Normally closed
Maintenance message - Normally open
Maintenance message - Common
Volt-free relay output
max. load 240 V AC, 4 A
20
21 Start 2
IN External analysis start
Common earth for inputs Only for volt-free normally open contact!
22
23 Stop 2
IN External analysis stop
Common earth for inputs Only for volt-free normally open/ normally closed contact!
24
25 IN1 2
IN External measuring point switch
Common earth for inputs Only for volt-free normally open/ normally closed contact!
26
27 IN2 2
IN Universal input 2 (Water meter)
Common earth for inputs Only for volt-free normally open contact!
28
29 OUT OUT 0/4 - 20 mA or serial interface Potential output ! 28 = 0/4 - 20 mA, 29 = 2

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STANDBY
Description of displays and operating features
(1) Power switch
The 'ON'/'OFF' switch is located on the right-
hand side panel. Use it to switch the unit on
and off.
(2) Unit fuse (inside the unit)
Protects outputs against overload and short
circuit.
3Status of limit value displays
Displays the status of the limit values of
residual hardness LV1 (1) and chlorine LV2 (2).
4Text display
Displays the current analysis, all important
status results and programming data in a 4-line
LC-Display.
5Alarm
Displays a function fault.
6Maintenance message
Displays a maintenance request.
7Status display
6LEDs signal the current status (analysis and unit
status) of the Testomat®2000 THCl.
8Programming keys (Cursor block with ENTER)
These keys are used to enter all values and
programming data.
Function keys:
9Manual" = manual start of analysis
10 STANDBY = manual analysis stop/standby
11 "Horn" = cancels alarm message
12 i-key
Call-up all unit information (see i-Menu).
13 M-Taste
Call-up the programming menu for user and specific unit
settings (see M-Menu).
Display functions
Status of limit value displays 1 and 2
The display signals the status of the limit values.
1: The red display lamp lights up if the limit value 1 (residual hardness) is reached or exceeded.
Lights up green if the measured value falls below the set limit value.
2: The red display lamp lights up if the limit value 2 (chlorine) is reached or exceeded.
Lights up green if the measured value falls below the set limit value.
Measured value display
The current measured value for the residual hardness (TH:) and for the total content of chlorine (CI:) are shown in line
2 and 3, e.g. TH: 0.37 °dH or Cl: 0.73ppm
When the measured value exceeds the measuring range ">" is displayed, e.g. TH:>2.50 °dH or Cl: > 2.5 mg/l
Limit value displays
The set limit values are shown in the bottom display lines 3 and 4.
1: residual hardness, 2: total chlorine
Alarm and maintenance message
Display of present error messages (red) and of present maintenance request (yellow).
LError messages are displayed alternately with the normal display text and can only be deleted by cancellation and
correction of the fault.

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Status display
The display indicates active
unit components.
Description of relays outputs
Flush external flush valve
We recommend the fitting of a programmed flush valve upstream of the unit if, when installing the unit, the use of a long
sampling tube is unavoidable
Also, in cases where the unit is used for monitoring two measuring points, an external flush valve should be installed in
order to prevent faulty measurements caused by mixing of the samples.
Immediately before each analysis the external flush valve is opened for a programmed period, thereby allowing the tube
up to the Testomat®2000 THCl to fill with the water to be measured. Please ensure that the programmed flush time is
sufficiently long.
The flush time is set with menu item
"M" ºBASIC PROGRAM ºPROGRAM VALUES ºFLUSH TIMES/INTERVAL ºEXTERNAL FLUSH TIME
LV1 and LV2 Limit value outputs
Two volt-free relay contacts are available for reporting that a limit value has been exceeded. For both contacts the limit
values, the hysteresis and the function can be independently programmed:
Function Type of contact Action
LV1
Sactive at
limit value in excess of
limit value 1 (residual hardness)
(Measuring point 1)
volt-free
change-over contact
programmable:
SContinuous contact
SImpulse (1 - 99 seconds/minutes)
SInterval (1 - 99 seconds/minutes)
SHysteresis (1, 2 or 3 limit value in excess)
LV2
Sactive at
limit value in excess of
limit value 2 (total chlorine)
(Measuring point 2)
volt-free
change-over contact
programmable:
SContinuous contact
SImpulse (1 - 99 seconds/minutes)
SInterval (1 - 99 seconds/minutes)
SHysteresis (1, 2 or 3 limit value in excess)
Menu values:
"M" ºBASIC PROGRAM ºPROGRAM VALUES ºLIMIT VALUES
"M" ºBASIC PROGRAM ºPROGRAM VALUES ºFUNCTION LV1
"M" ºBASIC PROGRAM ºPROGRAM VALUES ºFUNCTION LV2
"M" ºBASIC PROGRAM ºPROGRAM VALUES ºHYSTERISIS LV1
"M" ºBASIC PROGRAM ºPROGRAM VALUES ºHYSTERISIS 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 distributing
valve) must be connected to the corresponding sampling tubes. The switch-over can occur automatically: The analyses
are carried out alternately from measuring point 1 or 2.
Or via an external request: Inlet IN1 active = next analysis from measuring point 1 (hardness)
It is important that the terminals are strictly allocated to the appropriate measuring points and to the parameter to be
measured:
Terminal 9 = Measuring point 1= Residual hardness
Terminal 10 = Measuring point 2 = total chlorine
IN1 active = measurements only from measuring point 1
"M" ºBASIC PROGRAM ºPROGRAM VALUES ºMEASURING POINTS 1/2