WACON AquaInform Sycon 2500 User manual

on-line water hardness monitor
DocomentCode:: Wacon_Sycon 2500_oprerational manual_2010-10-01_GB
OP E R A T I O N M A N U A L

INTRRODUCTION
PAGE 3
INTRODUCTION
We appreciate your purchase of the on-line water hardness Limit Analyser based
on Sycon 2500 series.
The on-line water hardness Limit Analyser is part of a water treatment plant.
Distribution of this manual is intended for the manufacturer and the owner of this
plant.
This user’s manual covers instructions for the use of your Limit Analyser. Please
read through this manual and understand the contents before using the system.
We also recommend that the manual be kept nearby for reference when
operating the Limit Analyser system.
Operate the system only in accordance with the instructions given in this manual.
Under no circumstances whatsoever will we be liable for damages arising from
the user’s failure to follow the instructions given in this manual.
•Some details of the instructions contained in this manual may be
different from the actual system purchased. The instructions are also
subject to change without prior notice.
The Limit Analyser system on basis of Sycon 2500 series is a hardness
leakage monitoring system that monitors the total and residual hardness of
water and issues a hardness leakage alarm.
It is not a system that remedies hardness leakage itself.
WARNING

LIMIT ANALYSER H
ON-LINE WATER HARDNESS ANALYSER
TABLE OF CONTENTS
PAGE
SUMMARY SYCON 2500 SERIES
6
CHAPTER 1
SAFETY WARNINGS /PRECAUTIONS /SYMBOLS USED
7
CHAPTER 2
SPECIFICATION AND OVERVIEW
2.1 SPECIFICATION AND INTENDED USE
→GENERAL SPECIFICATION
→PHYSICAL DATA
→MONITORING CAPABILITIES
→WATER FEED AND DRAIN
→AVAILABLE INDICATORS
→ACCESSORIES
2.2 OVERVIEW AND CONFIGURATION
2.3 DISPLAY AND CONTROL BUTTONS
2.4 SPARE PART LIST
2.5 OPERATION PRINCIPLE
2.6 FUNCTIONS
11
11
13
14
15
16
17
CHAPTER 3
INSTALLATION AND COMMISSIONING
3.1 INSTALLATION REQUIREMENTS
3.2 INSTRUCTION FOR INSTALLATION
3.3 MOUNTING IN 4STEPS
→TERMINAL CONNECTION TABLE
→INSTRUCTION FOR WIRING AND CONNECTION
→MOUNTING DIMENSION
3.4 CONNECTING RELAY-OUTPUT
3.5 CONNECTING DIGITAL INPUTS
19
19
19
20
25
26
CHAPTER 4
OPERATION OF LIMIT ANALYSER
4.1 SUMMARY OF SYCON 2500 SYSTEM
4.2 BEFORE INITIAL OPERATION
4.3 SETTING OF PARAMETERS
→FLUSHTIME
→MONITORING INTERVAL
→RE-TRY CYCLE
→RELAY-FUNCTION
→WATER-PARAMETERS
4.4 TAKING INTO OPERATION IN 5STEPS
4.5 OPERATION OF THE SYSTEM
→OPERATING DISPLAY
→AUTOMATIC MONITORING
4.6 OPERATION OF THE SYSTEM
→MANUAL MONITORING
27
27
28
29
33
34
37

LIMIT ANALYSER H
ON-LINE WATER HARDNESS ANALYSER
CHAPTER 5
MAINTENANCE AND SERVICE
→CHANGING PERISTALTIC INDICATOR PUMP
→CLEANING OF MIXING CHAMBER
→CHANGING OF SPARE PARTS
→CHANGING OF INDICATOR BOTTLE
→CHANGING OF REPLACEMENT PARTS
38
CHAPTER 6
DIAGNOSTIC FUNCTION
TEST OF →LED
→CONTROL-BUTTON
→DIP SWITCH
→POTENTIOMETER
→RELAY 1+2
→SOLENOID VALVE
→AKTOR LED
→INDICATOR PUMP
→MAGNETIC AGITATOR
→IN CONTACT
→ZERO-TRANSMISSION
→COLOUR DETECTION
44
NOTES
CONVERSION TABLE OF
CONVENTIONAL WATER HARDNESS UNITS
50

LIMIT ANALYSER H
ON-LINE WATER HARDNESS ANALYSER
With limit Analyser, WACON offers a very compact and easily operated water
analyser for automatic on-line detection of hardness leakages and quality control
of water softeners. The system controls selectable limit values according to the
colorimetric principle. A broad range of functions (incl. BOB) guarantee reliable
field-operation. Units will be supplied in standard as well as tailor-made housings.
Application:
→Detection of Hardness Leakages
→Limit monitoring
• Analysis START
a) manually
pushing START –button
b) automatically
in programmable intervals 5, 10, 20 or 30 minutes
→via remote input signal (flow- or level-control switch)
automatic starts can be switched on/off
• Analysis Cycle
→Programmable rinsing phase 30 sec –10 min.
→Zero compensation without indicator injection (Self calibration)
→Dosed injection of indicator via peristaltic pump and stirring of water sample
→Monitoring and evaluation according to the colorimetric method
→LED status indication of evaluation result
→Rinsing and cleaning of mixing chamber / solenoid valve stops flow of sample water
• Retry Cycle
→Control monitoring 4 min. after first detection of hardness leakage
• digital Input
Potential free
switch
e.g. for connecting timer or flow monitor
-> no analysis if break-contact is open
• digital Outputs
•2 x potential
free Relays
→REL 1
Limit value alarm (Permanent or Impulse)
→REL 2
Failure
• lack of Indicator (BOB-operation)
• fouling or electronic failure
• lack of water(pressure) or
incomplete reagent injection
• Reset-Functions
→ RELAY 1
•Quit “Limit value alarm”
→ RELAY 2
•Quit „Failure“ „Alarm“
•Quit “Indicator refilled”
•Interruption/Stop of Analysis
• Dimension
W: 300mm
H: 300mm
D: 190mm
Weight ca. 2 kg
• Power Supply
85 –264 V 47-63 Hz , Protection Category IP 54
• Indicator à 500 ml
•Consumption app. 0.10 ml/Analysis (5000 each bottle)
•shelf life 24 month
• Maintenance Interval
app. 2-3 times a year cleaning of mixing chamber
Once a year exchange of wearing parts
•Annual-Service-Set
Order Numbers
SYCON 2500 30-010120
Standard Housing 33-099005
Limit Value-Indicator
1 mg/l
2 mg/l
4 mg/l
6 mg/l
10 mg/l
20 mg/l
40 mg/l
60 mg/l
100 mg/l
200 mg/l
Residual Hardness °dH H25
0,05
0,1
0,2
0,3
0,5
1
2
3
5
10
Order Number
32-084125
32-084135
32-084145
32-084155
32-084165
32-084175
32-084185
32-084195
32-084205
32-084215
Carbonate Hardness °dH C25
1
1,5
2
3
Order Number
32-086125
32-086135
32-086145
32-086155

CHAPTER 1
LIMIT ANALYSER
SAFTY INSTRUCTIONS
PAGE 7
CHAPTER 1 SAFETY WARNINGS /PRECAUTIONS
This Chapter explains the danger and precautionary signs and notes that apply
to the handling, installation, wiring and maintenance of the SYCON 2500 series
Limit Analyser.
This manual describes the installation and operation of the on-line water-
hardness analyser of type Limit Analyser H based on SYCON 2500 series.
Installation and taking into operation must be performed only by authorized
personnel.
Operate the system only in accordance with the instructions given in this
manual: In particular, the system has to be protected against humidity and
moisture. Avoid direct contact with splash or condenser water. The device may
only be used for the specified purpose. When installing and operating the
equipment, the relevant standards (e.g. EN, DIN, VDE, UVV) and applicable
national regulations must be complied with.
The analyser is used only to determine a total or residual hardness or carbonate
hardness in the process water. Proper operation can only be guaranteed with
the manufacturer's recommended indicators and spare parts.
Changes to the electrical connections and the programming should only be
performed by an authorized specialist.
If connecting cables for the sensors are necessary they should be kept as short
as possible and not run together with power cables. The vicinity of strong
electromagnetic emitters may lead to deviations of evaluation and measurement
results. In such cases, appropriate measures must be taken to suppress
interferences. EMC-directives are especially applicable.
When working with this manual, it is recommended to have access to the
operational instrument to understand the functions described immediately. Read
the chapters in the order given.
If you have questions regarding the operation of the instrument, or when
problems occur, please contact us or one of our distributors. Try to locate
problems as accurately as possible. Also describe what actions you have taken,
which conditions lead to the problem. We can help you better and more
focused.
Labour protection
Rules for
accident
prevention
of
government
and industrial
safty
organisations
Operating Manual

PAGE 8
SAFTY INSTRUCTIONS
CHAPTER 1
LIMIT ANALYSER
Safty instructions and symbols used
In this manual you will find specific safety instructions to indicate the
unavoidable residual risks when operating the unit. These residual risks imply
dangers to
●People
●Product / Plant / Machinery
●Environment
The symbols used in the instructions should draw attention in particular to the
safety instructions!
The main objective of the safety precautions is to prevent personal injury.
The symbol used in each case can not replace the text of a safety warning.
Therefore, the text must always be read completely
This symbol indicates a potential danger to persons.
→mortal danger
→risk of injury
●A safety notice with warning triangle DANGER points out that risks to plant,
machinery, materials, environment and people are not excluded
This symbol indicates a potential danger to product, plant and machinery
●A safety notice with warning triangle WARNING points out that risks to
plant, machinery, materials and/or environment are not excluded.
Danger to persons are not necessarily to be expected
This symbol points to hydraulic and pneumatic systems and indicates
pressurised systems.
This symbol points to electric and electronic systems and indicates electrical
systems.
This symbol indicates no safety information, but information to better
understand the plant or machine processes
NOTE
DANGER
WARNING
PRESSURE
ELECTRICY

CHAPTER 1
LIMIT ANALYSER
SAFTY INSTRUCTIONS
PAGE 9
Work on hydraulic and pneumatic equipment
●Maintenance and repair of hydraulic and pneumatic equipment shall be
carried out by specially trained personnel !
●Before all maintenance and repair work, the pneumatic and hydraulic
equipment of the system / machine must be depressurised !
●Hose pipes in preventive maintenance should be changed regularly, even
if here is no visible damage (Please note the information provided by the
manufacturer)
●Before starting up after maintenance or repair work:
→Check the screw connections for a tight fit.
→Ensure that the container lid, screens or filters are reinstalled in the
correct order.
●After completion of the maintenance and repair services, and before the
resumption of production, make sure that…
→…all the materials, tools and other equipment required for the execution
of maintenance or repair work are removed from the work area!
→…any leaked fluids were removed !
→…all safety devices of the system work properly again !
Transport
Use appropriate equipment to transport the system to prevent damage during
transport.
●Transport equipment carefully and do not throw !
●Choose a cool and dry storage location.
●Pay attention to the permitted ambient temperatures !
●Check the entire delivery immediately upon receipt for completeness and
shipping damage
●Devices are packed in a transport-safe packaging. Nevertheless, it can
lead to damage in transit. Please tell the transport company and the
manufacturer in writing IMMEDIATELY - no later than eight days after
receiving the goods - of the details of the damage. In this case, you must
keep the instrument and the packaging for inspection for the further
processing of the complaint.
WARNING
NOTE
PRESSURE

PAGE 10
SAFTY INSTRUCTIONS
CHAPTER 1
LIMIT ANALYSER
Storage
We recommend storing equipment not longer than a year, because you lose the
warranty. Store equipment under following conditions.
●Cool and dry location / ambient temperature between -5 and 45 °C
Scope of Delivery
Scope includes the following modules:
●Equipment in accordance with the delivery of the ordered form
●Operating Manual
Check that all parts were delivered.
Obvious damage and / or missing components must be reported in writing
within 8 days of receipt of goods. After that, no complaints will be accepted
Installation
The installation of the device includes the following:
►Install the system in accordance with the following sequence. So you
save time and avoid damaging the plant, which can lead to malfunction.
●Mounting of the device:
→Place device in a dry, easily accessible and conspicuous place.
→Drill holes in the wall according to template (typically, these are four
holes) and tighten the device by means of screws (usually four
screws).
●Connect the initiators (eg level sensor)
●Connecting the actuators (for example pumps, valves)
●Connect the power supply
Make sure the correct input voltage
for example : 230 VAC or 115 VAC or 24 VAC
For correct supply voltage, refer to the nameplate of the unit
●Program the device (setting of parameters and conditions).
→Note the information in the manual
NOTE
NOTE
WARNING

CHAPTER 2
LIMIT ANALYSER
SPECIFICATION
PAGE 11
CHAPTER 2 SPECIFICATION
The Limit Analyser is used for the automatic monitoring of hardness in water.
We recommend that the user read this chapter before installation of the device
for safety operation.
2.1 General specification
Power-supply
85 … 264 V AC 47… 63Hz
Power consumption
25 VA (on operation)
Protection Class
IP 54
Ambient operating
temperature
5C …45 C
Raw water temperature
5C … 40 C
Humidity
20%RH …90%RH
(without ice or dew condensation)
Feed water pressure
app. 0.5…5 bar (1…2 bar recommended)
Feed water condition
clear, colourless, free of suspended solids, no gas
bubbles
pH 4 ~ 10.5, Iron < 3 ppm, Coper < 0.2 ppm,
Aluminium < 0.1 ppm, Manganese < 0.2 ppm
Acid Capacity K S4.3 < 5mmol/l
→Physical data
Installation method
indoor wall mount
External dimensions
without enclosure: 280[W] 250[L] 140[D] mm
with enclosure 300[W] 300[L] 190[D] mm
Mass
app. 2.0 kg
→Monitoring capabilities
Evaluation method
via the colorimetric method
Limit value alarm is
defined by the indicator
used
→bottles volume
500 ml
Total Hardness Limit-Value-Indicators:
0.05 °dH , 0.10 °dH , 0.20 °dH , 0.30 °dH ,
0.50 °dH , 1 °dH , 2 °dH , 3 °dH , 5 °dH , 10 °dH
Carbonate Hardness Limit-Value-Indicators:
1 °dH , 2 °dH , 3 °dH , 5 °dH
Indicator comsumption
< 0.10 ml / monitoring
Remote alarm output
2 x Relay
250 V AC / V DC 4A
potential free outputs NC/NO
Indicator exchange
output
Remote signal input
No voltage contact input
（Contact A or Contact B）
Drainage
Approx. 1000ml／monitor
→Drainage volume may vary depending on feed water
pressure.and flush time
→Water feed & drain
Feed-water connection
diameter
For connecting 1/4” (6mm) external dia. pipe
Drain-water connection
diameter
→ atmospheric
pressure / open funnel
For connecting 1/4” (6mm) external dia. pipe
→Inlet and outlet tubes are not attached to the device. Please
use specified tubes. Using tubes other than specified tubes
may cause leakage. → Please contact our distributors.

PAGE 12
SPECIFICATION
CHAPTER 2
LIMIT ANALYSER
Oder numbers for device and indicator
device
SYCON 2500 30-010120
Option Housing 33-099005
limit value indicator
total hardness HG
0,05 °dH
0,1 °dH
0,2 °dH
0,3 °dH
0,5 °dH
1 °dH
2 °dH
3 °dH
5 °dH
10 °dH
order number
32-084125
32-084135
32-084145
32-084155
32-084165
32-084175
32-084185
32-084195
32-084205
32-084215
carbonate hardness HC
1 °dH
1,5 °dH
2 °dH
3 °dH
order number
32-082125
32-082135
32-082145
32-082155
→for convert units for water hardness used please refer to table in page 50
The System works with one-set-indicators for different limit values. Shelf-life of
indicators are 2 years if properly stored (→ not opened → cool →dark ). After
opening, bottles should be used within twelve months.
Sample waters with temperatures over 45°C must be chilled down before
analysis !
colour reaction in mixing chamber
→accessories SYCON CLEAN order no. 30-010 900
Cleaning set for acryl glass mixing chambers
→1000 ml cleaning solutionFIT 3000
→5 pairs of gloves
→2 brushes, funnel, container
→manual
FIT 3000 order no. 32-089 100
Cleaning solution for acryl glass mixing chambers
→1000 ml cleaning solution FIT 3000
→sample cooler PC 200 order no. 30-015 100
PC 400 order no. 32-015 200
For details please refer to our home page
www.wacon.eu
type of indicator
sample evaluated as
GOOD condition
limit not exceeded
sample evaluated as
BAD condition
limit exceeded
total hardness
Green
red
carbonate hardness
yellow
violet
plus M-value
orange
blue
NOT
E
WARNING

CHAPTER 2
LIMIT ANALYSER
SPECIFICATION
PAGE 13
FIG.2.1 2.2 Overview –limit analyser –configuration
INLET PRESSURE OF
SAMPLE-WATER
APP.0.5 …5.0 BAR
1.. 2BAR
RECOMMENDED
MAGNETIC
STIRRER
WATER TREATMENT
PLANT
E.G.SOFTENER
CONTROL-UNIT
INDICATOR
BOTTLE 500 ML
DOSING-PUMP
DOSING-PLUG
WATER-OUTLET-PLUG
OPTICAL PATH WITH
LIGHT SOURCE AND
RECEIVER
WATER-INLET-PLUG
SOLINOID VALVE
(BEHIND BOTTLE)
MIXING
CHAMBER
FLOW DIRECTION OF
SAMPLE-WATER
OPEN FUNNEL
(ATMOSPHERIC PRESSURE)

PAGE 14
SPECIFICATION
CHAPTER 2
LIMIT ANALYSER
FIG.2.2 2.3 LIMIT ANALYSER –DISPLAY-CONFIGURATION
CONTROL BUTTONS
START STARTING ANALYSIS
MANUALLY
FLUSH RINSING MIXING CHAMBER
MANUALLY
INDICATOR DOSING INDICATOR
MANUALLY
RESET QUIT ALARM
+
NEW INDICATOR BOTTLE
LED DISPLAY
EVALUATION RESULT
GREEN GOOD CONDITION /POWER ON
RED BAD CONDITION
YELLOW ANALYSIS ACTIV
BLUE LACK OF INDICATOR
RED ALARM

CHAPTER 2
LIMIT ANALYSER
SPECIFICATION
PAGE 15
SPAR-PART-LIST ILLUSTRATION 2.3
order no.
description
33-090 002
magnetic stirrer
33-0 90 0 38
33-0 00 2 18
33-0 90 0 07
33-0 90 7 16
33-0 90 7 10
33-0 90 7 00
33-0 90 7 01
33-0 90 0 02
33-0 90 0 13
33-0 90 7 13
33-0 90 7 12
33-0 90 2 10
33-0 90 2 10
33-0 90 0 16
33-0 90 0 14
33-0 90 0 08
3 3 0 9 0 0 3 9
3 3 -090 0 11
3 3 -0 9 0 2 1 0
3 3 -0 9 0 7 11
3 3 -09 0 01 0
3 3 -0 90 0 1 5
33-090 007
O-Ring 17x2
33-090 008
bottle connection
33-090 010
bottle cap
33-090 011
suction lance
33-090 013
inlet connection ¼"
33-090 014
solenoid valve 24V complete.
33-090 015
outlet connection 6mm
33-090 016
bulkhead fitting 6mm
33-090 038
cartridge of peristaltic pump
33-090 039
bottle adapter
33-090 210
O-Ring 9 x 1,5
33-090 218
O-Ring 3,2 x 2,5
33-090 700
measuring chamber complete
33-090002, 33-090701, 33-090711,
33-090712, 33-090713, 33-090716
33-090 701
measuring chamber
33-090 710
actuator of magnetic stirrer
33-090 711
inlet plug ¼"
33-090 712
outlet plug ¼"
33-090 713
aktor (LED)
33-090 716
dosing plug
SPARE-PARTS NOT PICTURED
33-090 001
MAINTENANCE –KIT 1
33-090 020
connecting cable solenoid valve
1x 33-090 038
cartridge of peristaltic pump
33-090 021
connecting cable aktor (LED)
1x 33-090 218
dosing-O-ring 3,2 x 2,5
33-090 022
display circuit board cpl.
33-090 028
MAINTENANCE –KIT 2
33-090 023
power supply circuit board 85-264 V cpl.
1x 33-090 038
cartridge of peristaltic pump
33-090 024
main circuit board complete
1x 33-090 008
bottle connector
33-090 025
control unit complete 85-264 Volt
1x 33-090 011
suction lance
33-090 026
peristaltic pump complete
1x 33-090 007
O-ring 17 x 2
33-090 027
housing for control unit with lid
3x 33-090 210
O-ring 9x1,5
1x 33-090 218
dosing-O-ring 3,2 x 2,5
33-090 029
MAINTENANCE –KIT 3
FOR TWO-YEAR-OPERATION
1x 33-090 710
actuator for magnetic stirrer
1x 33-090 014
solenoid valve 24V cpl.
1x 33-090 700
measuring chamber cpl.
1x 33-090 026
peristaltic pump cpl.

PAGE 16
SPECIFICATION
CHAPTER 2
LIMIT ANALYSER
2-5
Operation principle of Sycon 2500
A monitoring cycle of Sycon 2500 follows 5 steps
[1]
Washing and rinsing mixing chamber with
sample water.
Programmable rinsing time: 30 sec-10 min
The solenoid valve opens, washing and rinsing the
mixing chamber with sample water. Old sample water
remaining in the container is pushed out, and the
container is washed at the same time. Rinsing time is
programmable between 30 seconds and 10 minutes
and should be set in relation to length of sample
pipeline. Recommended values 1-2 min. (→ page 30)
↓
[2]
Filling mixing chamber with sample water.
Monitoring of zero transmission without
indicator-injection
The mixing chamber is filled with water sample to be
analysed. The solenoid valve closes. The light source
is activated to project light into the sample water
without indicator injection to define a zero transmission
and absorption respectively. In case of turbidity
detection in certain ranges of absortion the device
gives alarm.
↓
[3]
Stirring water sample and injecting indicator.
Homogenisation and reaction phase while
stirring
The injection pump injects a defined amount of
indicator into the sample water. The stirrer coil,
activated at the same time, homogenises the mélange
of water and indicator. The indicator causes coloration
of the sample water in accordance with the hardness
components of the water. Indicators are calibrated to
change colour at certain limit values. For a list of
available indicators please refer to page 12 or 27.
↓
[4]
Monitor light transmitted through the sample
water.
Evaluation of water hardness limit value alarm
Light receptors electronically monitor the light trans-
mitted through the sample water. The absorption
characteristic of transmitted light in water changes if
the water sample changes its colour (for example from
green to red) caused by a colour-reaction of indicator
with ions in water (e.g. calcium and magnesium). After
monitoring the mixing chamber is flushed.
↓
[4.1]
Flushing and rinsing mixing chamber. Start of
Intervall time 5/10/20 or 30 minutes.
Note: During Interval mixing chamber kept
filled with water.
The monitoring results in a BAD or GOOD-condition
evaluation. The status is displayed as LED code (→
page 12).
↓
[5]
Show result as LED light code.
In case of bad-condition-evaluation alarm is
issued
monitoring can start..
A automtically in 4 programmable
intervals: 5 / 10 / 20 / 30 minutes
B manually by pushing the Start-button
START
►Connecting an external no-voltage-contact-switch
or a timer may allow limit analyser monitoring only
while water softener is turned on or is suspend
monitoring while the water softener is in
regeneration.
The purpose of remote signal is to prevent a
monitoring while the water softener is regenerating
or the feed water is stopped ( → page 26).

CHAPTER 2
LIMIT ANALYSER
SPECIFICATION
PAGE 17
2.6 Functions
The SYCON 2500 system has the following features:
[1] Monitors hardness leakage automatically in accordance to limit value
indicator used.
The monitoring process is fully automated, saving a significant amount of
work by eliminating the need for complicated manual procedures.
[2] Requires no periodic calibration
The system needs no cumbersome periodic calibrations.
[3] Interval for each monitoring may be set in 4 programmable intervals: 5 / 10
/ 20 / 30 minutes
[4] Reliable detection of hardness leakages by use of limit value Indicators
1mg/L
2mg/L
4mg/L
6mg/L
10mg/L
20mg/L
40mg/L
100mg/L
200mg/L
0.05 °dH
0.10 °dH
0.20 °dH
0.30 °dH
0.50 °dH
1 °dH
2 °dH
5 °dH
10 °dH
[5] Evaluates hardness leakage at higher accuracy
When a BAD-condition is detected, monitoring may be repeated with a
delaytime of 4 minutes
[6] LED status display is independent on language areas
[7] Offers an alarm function
When it is evaluated that there is a hardness leakage, an alarm is issued
by switching a potential free relay. This remote alarm output may be used
to send an alarm remotely or sounds a buzzer for example.
[8] Offers a diagnostic-program. If a problem occurs in the system an alarm is
issued by switching a potential free relay. Technicians may run step by
step through the diagnostic program to check functions or find faulty parts
in the device (→ page 44).
[9] Requires minimal maintenance
Depending on measurement intervals and frequencies respectively the
measuring chamber has to be cleaned up and indicator hose pipes have to
be changed app. twice a year (→ page 38).
[10] Minimal indicator consumption
The indicator bottle may be replaced easily. The 500 ml bottle needs no
replacement for approximately three to four months in typical applications.
(Note that more frequent replacement may be necessary, depending on
the application.)
[11] Compact in design, easy to install
The main unit is installed easily on a wall.
Installation is a simple process (→ page 19).
Wacon provides the most compact designed devices of this type.

PAGE 18
SPECIFICATION
CHAPTER 2
LIMIT ANALYSER
[12] Remote signal input function
Connection the remote non-voltage signal for example from a flow- or
level-control-device or from regenerating water softener prevents a false
detection that can occur, for instance, while the water softener is
regenerating or no water flows, thus providing more accurate evaluation
(→ page 26).
Two Remote alarm outputs REL 1 / REL 2
Two potential free Relais alarm contact outputs may be used to transmit
hardness-leakage-alarm (REL 1) and mechanical-error- or mal-functions
to a remote location (→ page 25).
[12] BOB-operation
The abbreviation BOB comes from the German Betrieb ohne Beobachtung
(unattended operation) and follows a regulation of German TÜV (technical inspection
authority) especially for boiler houses, which requires reliability of instruments at
least for next 72 hours.
The REL 2 output may be used to transmit to a remote location when an
indicator storage needs to be replaced.
Analytical devices of type SYCON 2500 specially were designed for
BOB-operation (unattended operation). Boiler houses, running in BOB-
operation, require a qualitative monitoring of water hardness in boiler
feed water according to the technical guideline TRD 604 (`Technische
Regeln für Dampfkessel` published by German TÜV).
Analytical devices of type SYCON 2500 record the consumption of
indicator in order to ensure that in periods of unattended operation a
sufficient amount of indicator for reliable running of measurements is
available in bottle.
The sufficient amount of indicator should be calculated independent of
set analysis intervals for a next 72-hour operation.
If a very next 72-hour BOB-operation is no more reliably guaranteed an
alarm “lack of indicator” is issued via relay REL 2.
The indicator stocks can only be calculated correctly if the internal
counter is reset after installing a new 500 ml reagent bottle by pressing
the RESET key combination.
+
NEW INDIKATOR BOTTLE
●The device does not recognize the contents of the bottle, but resets
the counter of the metering pump, which then counts back starting
from 500 ml. You can reset the counter to zero only. If the keys
pressed on the fly, without a new, full bottle indicator is used, the
indicator stocks may not be properly calculated, and the alarm is not
issued on time or is wrong.
WARNING
NOTE

CHAPTER 3
LIMIT ANALYSER
INSTALLATION AND COMMISSIONING
PAGE 19
CHAPTER 3 INSTALLATION AND COMMISSIONING
OF LIMIT ANALYSER
3.1 Installation Requirements
The analyser shall be used only to determine a parameter in the process water.
A proper operation can only be guaranteed by use of indicators which were
tested and recommended by the manufacturer(→ page 12 or 27).
Changes to the electrical connections and the programming should be carried
out only by an authorized specialist.
The controlled system must meet the following conditions:
●The maximum allowable load capacity of the switching outputs and the
overall performance of the system must not be exceeded by the connected
load (note phase angle for inductive loads).
●All inductive loads (valves, motors, contactors, transformers) of the plant
must be equipped with suitable suppressors (e.g. RC element, varistor,
diode, etc.)
●If the analyser could be influenced by external devices with high electro-
magnetic interference levels, these effects should be reduced by appropriate
measures. On the supply voltage input of the offending equipment
appropriate external interference suppression (line filter) have to be fitted.
3.2 Instruction for Installation
During the assembly of printed circuit boards, the following guidelines must be
followed:
●Upon actuation of the clamping lever, only apply the force required.
Screwless terminals are capable to receive one- and finely-stranded
conductors (without core pods) to 0.5 mm ² (in sensor and analog output
terminals) or 2.5 mm ² (all other terminals). Using wire sleeves according to
the manufacturer is not require (only in case of screwless terminals)
●Observe all applicable electrical installation work rules.
●Work on electrical equipment of the plant / machinery must be performed by
a qualified electrician!
WARNIN
G
NOTE
ELECTRICY

PAGE 20
INSTALLATION AND COMMISIONING
CHAPTER 3
LIMIT ANALYSER
3.3 Installation in 4 steps
The analyser can be mounted with or without protective housing. The
manufacturer offers a standard housing; the mounting and dimensions are
described in this guide:
Custom-built or tailor made enclosures for the devices of the series aqua inform
LimitAnalyser / aqua inform TrendAnalyser / SYCON 2500 / SYCON 2800 and
SYCON 3000 as well as devices with custom names and labels that are
technically based on these ranges are not described in detail in this manual.
►step I a mounting without enclosure
Using 4 screws (max. 6 mm) to mount the unit on a wall or suitable support
structure. Hole spacing see page 24
or ►step I b mounting with enclosure
Using the included 4 brackets to mount the unit (→ page 24). The tabs can be
rotated by 45 degrees or 90 degrees outside. Alternatively, the unit can be
mounted without the brackets from the rear on a plate (M6). For hole spacing see
page 24
In both variants, avoid direct sunlight and strong artificial light sources
→ disturbance of the optical path in the measuring chamber
→electromagnetic interferences by artificial light source
Do not install under dripping pipes.
►step II eatablish sample and drain pipe line
Use flexible hose pipe 6x4. Between water treatment plant and analyser a
manual shutoff valve and particle filter (if necessary) should be installed.
Drainage should be lead via short connection into an open funnel → runoff to
atmospheric pressure.
Make sure that you connect the inlet and outlet properly
→ Figure 2.1 in page 13
►step III electrical connections
refer to information in figure 3.1 (terminal connection (→ page 21) and figure 3.2
(connection instructions (→ page 22).
Work on electrical equipment of the plant / machinery must be performed by a
qualified electrician! Observe all applicable electrical installation work rules
→applicable supply voltage 85 … 264 V AC 47 …63Hz
NOTE
NOTE
ELECTRICITY
WARNING