RLS Wacon LIMES PLUS User manual

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Operating instructions
LIMES
Hardness control device for automated monitoring
of total hardness in the process water

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Foreword 5
General 6
Brief description .......................................................................................................................................................................................... 6
Scope of delivery ....................................................................................................................................................................................... 6
Overview: LIMESBase and LIMESPlus.................................................................................................................................................. 8
Safety instructions and symbols used ................................................................................................................................................... 9
Transport..................................................................................................................................................................................................... 9
Storage......................................................................................................................................................................................................... 9
Disposal note.............................................................................................................................................................................................. 9
Performance features 10
Specifications 12
General specifications.............................................................................................................................................................................12
Signal input and outputs ........................................................................................................................................................................12
Technical data ..........................................................................................................................................................................................13
Analysis properties..................................................................................................................................................................................13
Maintenance intervals ............................................................................................................................................................................13
Installation 14
Installation requirements .......................................................................................................................................................................14
Wall mounting LIMES.............................................................................................................................................................................15
Wall-mounted junction box (optional) ................................................................................................................................................16
Establish supply line to the sample water and to the canal ............................................................................................................17
Device overview 18
Displays and front panel ........................................................................................................................................................................20
Overview of the configuration elements............................................................................................................................................21
Upgrade Kit from LIMESBase to LIMESPlus......................................................................................................................................21
Electrical installation 22
Overview of the electrical connections (main board): .....................................................................................................................22
Overview of the electrical connections (cables): ..............................................................................................................................24
Overview of the electrical connections (junction box): ...................................................................................................................25
Establishing the supply voltage (with junction box): ........................................................................................................................26
Establishing the supply voltage (without junction box): ..................................................................................................................26
Connecting the relay outputs................................................................................................................................................................27
Connection input contact ......................................................................................................................................................................29
Wiring example 1: Connection to control room (LIMESPlus only)................................................................................................30
Wiring example 2: Connection to a reverse osmosis system (connection potential free switch, LIMESPlus) .....................31
Wiring Example 3: Connection to external control (LIMESPlus only) ..........................................................................................32
Wiring example 4 and 5: Input contact INPUT (LIMESPlus only)..................................................................................................33
Wiring Example 6: LIMESBase..............................................................................................................................................................34
Operation and handling 35
Key functions ...........................................................................................................................................................................................35
Operating principle..................................................................................................................................................................................36
Analysis process.......................................................................................................................................................................................36
Before commissioning ............................................................................................................................................................................38
Device settings.........................................................................................................................................................................................39
Setting the flushing time LIMESPlus....................................................................................................................................................40
Setting the flushing time LIMESBase ..................................................................................................................................................40
Analysis interval LIMESPlus depending on the input contact INPUT...........................................................................................41
Analysis interval LIMESBase .................................................................................................................................................................42
Input contact LIMESPlus (INPUT, start or stop analysis interval)..................................................................................................42
Input contact LIMESBase.......................................................................................................................................................................44
First value suppression...........................................................................................................................................................................45
Trigger conditions for an analysis start ...............................................................................................................................................45
Commissioning.........................................................................................................................................................................................46
LED indicators ..........................................................................................................................................................................................47
LED display reagent level.......................................................................................................................................................................51
Content

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Maintenance and service 52
Inserting a full reagent bottle................................................................................................................................................................53
Install maintenance set / clean measuring chamber ........................................................................................................................54
Change peristaltic pump cash register ................................................................................................................................................55
Component exchange.............................................................................................................................................................................56
Diagnostic functions LIMESPlus...........................................................................................................................................................59
Diagnostic functions LIMESBase..........................................................................................................................................................64
Spare parts 65
Maintenance sets and accessories 67
Maintenance sets.....................................................................................................................................................................................67
Accessories ...............................................................................................................................................................................................68
Reagents 69
Reagents for monitoring total hardness .............................................................................................................................................69
Interesting facts about the reagents....................................................................................................................................................69
Troubleshooting 70
Notes 71
Appendix 72
Maintenance and service .......................................................................................................................................................................72
Setting en ..................................................................................................................................................................................................73
Document changes..................................................................................................................................................................................73
EU Declaration of Conformity 74
Content

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Foreword
Thank you for purchasing a LIMES analyser for online monitoring of water hardness.
•The LIMES analyser for monitoring water quality is part of the water treatment plant.
•This manual is intended for the manufacturer and the operator of such a unit. It contains
instructions for the installation and operation of the unit.
•Please read this manual carefully before operating the unit.
•We recommend that you always keep the manual close at hand during operation.
•Operate the unit only in accordance with the instructions in this manual.
•Under no circumstances will we be liable for any damage caused by operating errors or
failure to follow the instructions in this manual.
•Some details and instructions in this manual may differ from your actual purchased unit.
We reserve the right to make technical changes without prior notice.
On our website www.rls-wacon.de you will always find the latest version of our documentation.
The LIMES analyser automatically detects hardness breakthroughs in a water treatment
system and issues a message when the limit value is exceeded. This message can be
used, for example, to trigger regeneration of the water softener.
The LIMES analyser is not a device that prevents hardness breakthroughs.
Conversion for the units of water hardness
°dH
°e
°fH
ppm
mval/l
mmol/l
German degrees
1 °dH =
1
1,253
1,78
17,8
0,357
0,1783
English degrees
1 °e =
0,798
1
1,43
14,3
0,285
0,142
French degrees
1 °fH =
0,56
0,702
1
10
0,2
0,1
ppm CaCO3(USA)
1 ppm =
0,056
0,07
0,1
1
0,02
0,01
mval/l Alkaline earth
ions
1 mval/l =
2,8
3,51
5
50
1
0,5
mmol/l Alkaline earth
ions
1 mmol/l =
5,6
7,02
10
100
2
1
The unit 1 ppm is used here contrary to the actual literal sense in the sense of 1 mg/l CaCO .3

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General
Brief description
With the LIMES analyser, RLS Wacon offers a compact and very easy-to-use analyser for the
automatic online monitoring of water treatment plants.
The measuring device works on the principle of "limit value monitoring with colour change" and
provides all important functionalities for reliable field use.
The LIMES analyser automatically carries out water analyses at regular intervals to determine the
total hardness.
Based on the reagent type used, a limit value is specified by the user. There are 4 reagents
available for monitoring the total hardness.
If the limit value is exceeded, the unit outputs a message on a potential-free relay output. This
message can be further processed by a softening control. In this way, functions such as
automatic regeneration triggering can be realised.
The LIMES analyser is characterised by low maintenance costs. Up to 10,000 analyses can be
carried out with a 750 ml reagent bottle. The input contact of the device can additionally be
used to connect a flow monitor to the device. In this way, the LIMES interrupts the analysis
interval during downtimes of the water softener and automatically resumes the analysis when
the unit is put back into operation.
To prevent disturbances due to the counter ion effect, a first value suppression is available. If the
limit value is exceeded, this first carries out another control measurement before a hard water
message is issued.
You will find in-depth and much more information about your new LIMES analyser in this
manual.
Scope of delivery
The scope of delivery for a new unit includes the following items:
•LIMES analyser with 1.75m connection cables
•Operating instructions
Optional accessories:
•Front cover for analyser (transparent)
•Junction box (for electrical installation)
•LIMES connection set (for water supply)
•Stopcock
Further information on accessories can be found from page 65.

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General
These operating instructions describe the installation and operation of the LIMES on-line
analyser. Installation and commissioning may only be carried out by an authorised specialist.
The unit may only be operated under the conditions described in these operating instructions.
The unit may only be used for the specified purpose. When installing and operating the analyser,
all locally applicable regulations (such as EN, DIN, VDE, UVV) must be observed.
The analyser is used for the automatic determination of the total water hardness in the process
water. Proper operation can only be guaranteed if the reagents and spare parts recommended by
us are used.
Changes to the electrical wiring and programming may only be carried out by a designated
specialist.
The water connection lines to the unit should be kept as short as possible and should not be laid
together with mains lines or in their immediate vicinity. In the vicinity of strong electromagnetic
radiators, interference with the analysis may occur; in this case, separate interference
suppression measures must be taken, in particular the EMC guidelines must be observed.
It is recommended to always have access to the analyser when familiarising oneself with the help
of these operating instructions in order to be able to understand the explained correlations and
functions immediately. Since certain areas build on each other, it makes sense to work through
the chapters in the given order.
If you have any questions about the use of the analyser, you will receive support from our
partners or from us. You can reach us by telephone during normal business hours or by e-mail.
The contact details of our technicians and our partners can be found on our website.

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General
Quick overview: LIMESBase and LIMESPlus
LIMESBase
LIMESPlus
Parameters:
Limit value reagents Total hardness
0.1 / 0.5 / 3.0 / 7.0 °dH
Bottle size reagent
750 ml
750 ml
Shelf-life reagent in months
24
24
Contacts:
Input contact
(INPUT, start or stop analysis interval)
Relay output 1
(Boundary value alarm)
Relay output 2
(Unit fault or reagent message BoB)
Functions:
Adjustable flushing time
Fixed 50 sec.
First value suppression
Adjustable analysis interval
Available analysis intervals
10 min
5 / 10 / 20 / 30 min
Diagnosis mode
Technical data:
IP protection class without front cover
IP43
IP43
IP protection class with optional front cover
IP54
IP54
Protection class
SKII
SKII
- Available
- Not available
For more information, see page 21 and 68.

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Safety instructions and symbols used
In this operating manual you will find various safety instructions that point out possible risks
when handling the analyser. This concerns in detail dangers for
•People,
•this product or associated equipment and installations,
•the working environment.
Various symbols in these operating instructions indicate special dangers to prevent personal
injury and damage to the appliance. Please read the entire text completely before starting work.
This symbol draws your attention to useful tips that contribute to a better
understanding of the unit.
This symbol is a general warning that indicates circumstances that must be
observed.
Pressure
This symbol is a warning that you must expect pipes under pressure.
Irritant
This symbol indicates the danger of harmful as well as irritating chemicals.
Avoid direct skin contact.
Voltage
This symbol indicates the danger of electric current and the danger to persons
and electronic components and assemblies.
Transport
Immediately after receipt, check that the unit is complete and has no transport
damage. The analyser is delivered in a transport-safe condition. Nevertheless,
damage may occur during transport. Immediately inform the delivery person
of any transport damage.
Protect the analyser from possible damage during transport. Remove any
liquids still in it beforehand. Remove the reagent bottle and close it to prevent
the reagent from leaking.
Storage
Store the analyser in a dry place at temperatures between 0 - 45 °C and out of
direct sunlight.
Disposal notes
The appliance must not be disposed of with residual waste. Take the appliance to a collection
point.
Alternatively, you can return the analyser to your dealer or to us for disposal.
General

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Performance features
Fully automatic
The unit detects hardness breakthroughs fully automatically when
the limit value of the reagent used is exceeded.
The analysis process is more reliable than manual methods and
more sustainable than other measurement methods. Compared to
swelling resin sensors or electrodes, no regeneration, calibration or
replacement of the sensor element is necessary.
Intelligent and self-sufficient
The device does not need to be calibrated. Due to the integrated
measurement technology and a two-stage analysis procedure with
zero-point measurement, external measurement influences due to
contamination of the measurement chamber, turbidity of the
sample and extraneous light influences is detected and eliminated
during the evaluation of the analysis.
The integrated full colour sensor is one of the central components
for the self-sufficient operation of the unit and does not need to be
maintained or replaced.
Selectable interval time (LIMESPlus)
The interval time between two measurements can be set in 4 steps:
Interval times of 5 / 10 / 20 / 30 minutes can be selected. The
analysis can also be started via an external switch or paused when
the system is at a standstill.
Self-calibrating
Hardness breakthroughs are reliably detected by using LHV limit
reagents. Our reagents are calibrated to a fixed limit value in
production. You choose the reagent to suit your requirements. No
further configuration or calibration is necessary.
First value suppression
After a bad measurement, a reference measurement is taken every
4 minutes to evaluate the result. This prevents false alarms due to
the counter ion effect after a system shutdown.
Extensive alarm functions
If the limit value is exceeded, an alarm is issued by switching a
potential-free relay. This alarm output can be connected to a
control room for signalling or used to activate a horn, close a valve
or control a programme for regeneration of a softening system.

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Performance features
Diagnostic programme (LIMESPlus)
If technical problems occur at the unit, a fault message is output by
switching a potential-free relay. The detailed diagnostic programme
in LIMESPlus enables step-by-step testing of all unit functions. In
this way, the unit is thoroughly checked, and the cause of the error
message is clearly identified.
Minimal maintenance effort
Depending on the set measuring interval or the frequency of the
measurements, the measuring chamber must be cleaned. The hose
pump cassette and sealing rings typically only need to be replaced
every 24 months.
Efficient reagent consumption
The reagent bottle is easy to replace. A freshly inserted 750 ml
bottle allows up to 10,000 analyses.
Digital input contact (INPUT, start or stop analysis interval) only with LIMESPlus
The potential-free switch of a flow monitor, a timer or another
status switch can be connected to this input, for example. When
the contact is open, no analyses are carried out in the programmed
interval.
Alternatively, this input can be used as a start input for analyses.
Two potential-free relay outputs
The potential-free relay outputs can be used to signal a limit value
alarm, a device fault or a reagent message BoB, e.g., to a control
room. Alternatively, signalling devices or service valves can be
switched.

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Specifications
General specifications
Parameter
Value / Range
Power supply
100 - 240 VAC (50/60 Hz)
Protection class
II
Power consumption
15 VA (in operation)
Load capacity of the relay
outputs
2.5 A per relay
IP protection class
without front cover
IP43
with optional front cover
IP54
Storage temperature
0 °C - 45 °C
Ambient temperature
10 °C - 45 °C
Measured water temperature
5 °C - 40 °C
Humidity
20 - 90 % RF (without ice or condensation)
Inlet water pressure
min: 0.5 bar - max: 5 bar / recommended 1 - 2 bar
Inlet water in general
clear, colourless, free of solids, without gas bubbles
Water quality requirements for
the measurement of water
hardness
pH:
4 - 10
Iron:
< 3 ppm
Copper:
< 0.2 ppm
Aluminium:
< 0.1 ppm
Manganese:
< 0.2 ppm
Acid capacity:
KS 4.3 < 5 mmol/l
Note on oxidising agents:
Oxidising agents such as calcium hypochlorite, chlorine, chlorine dioxide, sodium hypochlorite or
ozone above the limits permitted in "TrinkwV 2012" attack the dye contained in the reagent and
interfere with the measurement. This means that an exact determination of the water hardness is
no longer guaranteed. An activated carbon filter connected upstream of the analyser can remove
these oxidants from the sample water and thus enable the correct determination of the water
hardness.
The capacity of an activated carbon filter is consumed during operation. Therefore, the activated
carbon filter must be replaced at regular intervals. The effectiveness of the activated carbon filter
can be checked with the help of Caldur® test sets.
Signal input and outputs
Parameter
Value / Range
Relay outputs
2 Relay
2.5 A / 250 VAC
2.5 A / 100 VDC
as potential-free outputs NC/NO
The relays provide the following functions:
•Limit value alarm (relay output 1)
•Device fault or reagent message BoB (relay output 2)
Input contact
(INPUT, start or stop
analysis interval)
only with LIMESPlus
Galvanically isolated input contact for connection of a potential-
free contact
•Start analyses (external analysis interval)
•Flow monitor (analysis interval interruption during system
standstill)

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Specifications
Technical data
Parameter
Value / Range
Installation
Wall mounting in closed rooms
Dimensions
without lid:
250 x 330 x 60 mm (W x H x
D)
with lid:
250 x 330 x 90 mm (W x H x
D)
Weight
without lid:
approx. 1.8 kg
with lid:
approx. 2.1 kg
Inlet/outlet connection
Plastic hose with 1/4-inch outer diameter
Analysis properties
Parameter
Value / Range
Measuring principle
Colorimetric method
The limit value alarm is
defined by the reagent
used
•Total hardness limit reagents:
Reagent Limit value
LHV - 0.1 0.1 °dH
LHV - 0.5 0.5 °dH
LHV - 3 3 °dH
LHV - 77 °dH
For more information, see page 69
Reagent consumption
•< 0.10 ml / analysis
•Up to 10,000 analyses per 750 ml reagent bottle
Accuracy
Measurement accuracy:
•± 10 % of the limit value of the respective reagent used
Durability of the reagents
24 months from date of manufacture
Water consumption
•Approx. 2 L / analysis
•The water consumption varies depending on the inlet
pressure and the set flushing time
Maintenance intervals
Interval
Maintenance work
every 6 months
Cleaning the measuring chamber
In case of high ambient and water temperatures or water with a
high organic load, the cleaning intervals may have to be
shortened.
After 24 months of
operation
Installation Maintenance kit: Changing the hose pump cassette
and the seals
Further information can be found on pages 52 and 67

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Installation
Installation requirements
The LIMES analyser may only be used for determining the total hardness in water.
Changes to the electrical wiring and parameterisation may only be carried out by an
authorised and experienced specialist.
The installation to be monitored must fulfil the following conditions:
•The maximum permissible load capacity of the relay outputs and the total power of the
system must not be exceeded by the connected load.
•All inductive loads (valves, motors, contactors, transformers) in the system must be
equipped with suitable overvoltage protection (e.g., RC element, varistor, diode, etc.).
•If there are external devices with a high mains interference level in the vicinity of the
control unit, these must be reduced with suitable measures, or appropriate external
interference suppression measures (mains filters) must be taken at the supply voltage
input of the control unit.
Voltage

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Installation
Wall mounting LIMES
The LIMES analyser can be mounted directly. An additional front cover is optionally available for
protection against dirt and dust.
Illustration 1: LIMES - rear and side view (dimensions are in mm)
The unit is attached to a wall or suitable supporting structure using 3 screws (max. Ø 5 mm).
1. Select a suitable mounting location
2. First pre-mount a screw (A) on the wall.
3. Suspend the analyser, align
4. Finally, fix to the wall from the front with two screws (B).
Do not install the analyser under dripping pipes.
Voltage

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Installation
Wall-mounted junction box (optional)
The junction box is attached to a wall or suitable supporting structure using 4 screws (max. Ø 6
mm).
1. Select a suitable mounting location
2. First pre-mount on the wall with two screws (A).
3. Align junction box
4. Finally, fix it to the wall with two screws (B).
Do not install the junction box under dripping pipes.
Illustration 2: LIMES junction box - front and side view (dimensions are in mm)
Voltage

Safety reliably produced.
[e-mail]
Subject to change without notice
17
Installation
Establish supply line to the sample water and to the canal
The connections for inlet and outlet are designed for flexible plastic hose with 1/4-inch
outer diameter.
A manual shut-off valve must be provided between the preparation unit and the analyser. A
suitable valve can be found in the product catalogue or in the spare parts list. When connecting
to a drinking water pipe, the installation must take EN 1717 into account. The drain must lead
into an open channel via a short connection. The drainpipe must remain depressurised.
Make sure that the inlet and outlet are not interchanged. The inlet is located on the left
side of the inlet filter.
Pressure
The inlet pressure of the water sample must be between 0.5 and 5.0 bar.
The recommended inlet pressure of the water sample should be between
1 and 2 bar.
The hose length of the water drain must not be longer than 2 m and must
lead away vertically downwards. The system must be able to relax freely
against the atmospheric pressure (no counterpressure). The water drain is
pressureless into an open funnel or drain.
Water inlet
(Water inlet)
open hopper
Hand valve
(Install on site)
Softening
Water drainage
(Water outlet)
Illustration 3: Connecting the water inlet and outlet

Safety reliably produced.
[e-mail]
Subject to change without notice
18
Device overview
Position
Description
A
Control
B
LED display
C
Operating buttons
D
Cable gland
E
Dosing pump (peristaltic pump cassette)
F
Measuring chamber
G
Filter
H
Pressure regulator
I
Reagent bottle 750 ml
J
Solenoid valve
K
Water inlet / sample water
Push-in connection for plastic hoses
with 1/4-inch outer diameter
L
Water drainage
M
Measuring chamber drain
N
Measuring chamber inlet
In the housing / not visible
O
Magnetic stirrer
P
Stirrer blade
Q
Injector
R
Optical measuring path
S
Actuator board (LED)
T
RGB sensor
Illustration 4: LIMES analyzer with indicator bottle installed (l.),
schematic representation of the measuring chamber (r.)

Safety reliably produced.
[e-mail]
Subject to change without notice
19
Device overview
Observe the correct placement and flow direction when replacing components or
performing other work on the analyser.
Illustration 5: LIMES exploded view - assembling the components

Safety reliably produced.
[e-mail]
Subject to change without notice
20
Device overview
Displays and front panel
On the front of the LIMES analyser there are 4 LEDs to indicate the operating status and 4 keys
to operate the unit.
Illustration 6: LIMES - Unit overview / front foil
The LED display shows the operating status:
LED
Colour
Information
A
Green (two-colour LED)
Limit value undershot
A
Red (two-colour LED)
Limit value exceeded
B
Yellow
Analysis active
B
Yellow flashing
Input contact open, e.g., by flow monitor
C
Blue
Provide reagent
C
Flashing blue
BoB message
D
Red
Device fault
Further information can be found from page 35 and 47.