Heyl Neomeris Testomat 2000 V Manuale utente

Testomat 2000®V

Mixing controller for water

hardness 1.0-10.0 / 2.5-25.0 °dH

and carbonate hardness

1.0 –20.0 °dH

Operating Instructions

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

After switch-off and longer downtime....................................................6

Cleaning................................................................................................6

De-installation .......................................................................................6

Disposal ................................................................................................6

Scope of delivery ................................................................................7

Performance specifications...............................................................7

Indicators for Testomat 2000®V...........................................................8

Function ................................................................................................8

Analysis cycle and control process.......................................................8

Requirements........................................................................................9

Special setting options..........................................................................9

Reaction during fault.............................................................................9

Fault message input............................................................................10

Application instructions...................................................................11

Suitable valves....................................................................................11

Installation.........................................................................................12

Operating Testomat 2000®V in the pressure range of 0.3 to 1 bar ...12

Installing Testomat 2000®...................................................................12

Connecting the water inlet and outlet .................................................13

Mains water supply.............................................................................13

Water inlet...........................................................................................14

Water outlet.........................................................................................14

Connecting the power supply and devices .........................................15

Block diagram Testomat 2000® V .......................................................15

Internal design Testomat 2000® V ......................................................16

Connecting the mains voltage.............................................................17

Connecting the plant components ......................................................18

Connecting the inputs and outputs .....................................................19

Commissioning.................................................................................20

Inserting the indicator bottle................................................................20

Extracting the indicator .......................................................................20

Opening the water inlet.......................................................................20

Instrument settings and data input......................................................21

Functions of the operating and display elements.........................21

Switching Testomat 2000® V on/off.....................................................21

Display functions.................................................................................22

Operating elements and function keys ...............................................23

Operating system................................................................................24

Content

Password protection and basic program.......................................25

Entering basic program data...............................................................25

Selecting the indicator.........................................................................25

Selecting the operating mode.............................................................26

Selecting the display unit....................................................................27

Entering further basic program data ..............................................28

Internal flushing...................................................................................28

External flushing .................................................................................28

Interval pause .....................................................................................29

Limit value monitoring.........................................................................29

Switch functions of the limit value outputs LV1 and LV2....................30

Switch function 0, duration..................................................................30

Switch function 1, impulse ..................................................................30

Switch function 2, interval...................................................................30

Switch function 3, two-point................................................................30

Valve during fault ................................................................................31

Blending..............................................................................................32

Function IN1........................................................................................32

Water meter ........................................................................................33

Alarm/Message...................................................................................33

Function AUX......................................................................................33

Service II.............................................................................................34

Reset operating time...........................................................................34

Maintenance interval...........................................................................34

Description of the signal inputs/outputs........................................35

Current interface 0/4-20 mA................................................................36

Description of the relay outputs......................................................37

Flushing (external flush valve)............................................................37

LV1 and LV2 limit value outputs .........................................................37

AUX (programmable function output).................................................38

Alarm (fault message output)..............................................................39

Maintenance (output for maintenance message) ..............................39

Information menu "i" ........................................................................40

Program menu "M" ...........................................................................41

Structure of the basic program............................................................43

Error messages/Troubleshooting ...................................................44

Further information..............................................................................45

Maintenance ......................................................................................46

Description of maintenance work........................................................46

Service instructions.............................................................................47

Testomat 2000®spare parts and accessories................................48

Accessories.........................................................................................49

Technical data...................................................................................50

Conformity Declaration .......................................................................51

Product overview Testomat 2000®-Instruments ............................51

Check List Testomat 2000® V .............................................................53

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®change hands.

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 http://www.heyl.de .

Intended use

In connection with a 3/2-way motor valve with an 0/4-20 mA interface,

Testomat 2000®V is a convenient control system for the water

hardness and carbonate hardness of blending water. The selection of

the indicator determines the working range of the controller

(=measuring range) Testomat 2000®V.

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.

Important safety information

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®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

DANGER

WARNING

CAUTION

NOTE

Important safety information

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®V requires an interference free and stable power

supply. If necessary, use a mains filter to protect Testomat 2000® V

against 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®V and contact service staff

if malfunctioning occurs. The warranty will be void if you tamper

with or attempt to repair Testomat 2000®V. Repairs must be

carried out by authorised service staff.

After switch-off and longer downtime

Ventilate the indicator leads as described in the start-up, because

longer downtimes (more than 6 hours) can cause the indicator in

the leads to retract.

Do not switch off the appliance for longer periods (e.g. over the

weekend) via the start/stop output. The indicator can retract from

the leads. This results in measurement errors after the appliance is

switched on.

Cleaning

Only use a dry, lint-free cloth for cleaning.

De-installation

Prior to de-installing a defective instrument, always write down a

description of the error (failure effect). It is only possible to repair a

defective instrument (irrespective of the warranty period) if it has

been de-installed and returned to us with a description of the error.

Disposal

Dispose of the instrument in accordance with national regulations.

WARNING

NOTE

Scope of delivery

1x Testomat 2000® V

1x plastic bag containing a screw cap with a hole and an insert for the

screw cap of the indicator bottle

1x operating instructions

Performance specifications

Testomat 2000®V is used for the automatic determination of residual

hardness and carbonate hardness and controlling a set point value

using a motor valve with an 0/4-20 mA input. The measurement

parameters and the respective measuring range are determined by

the indicator selection.

Simple, menu-driven operating and programming via a plain

text display

Determinable measuring of residual hardness, total

hardness, carbonate hardness via indicator selection

Freely selectable hardness unit in °dH, °f, ppm CaCO3,

mmol/l

High measuring accuracy provided by a precise piston-

dosing pump

Analysis initiation:

- Automatic interval operation

(Interval pause adjustable from 0 to 99 minutes)

- Volume controlled (water meter)

Two independent limit values with adjustable switch functions

Internal error documentation

Programmable service address

Programmable maintenance interval for a maintenance

request

Extended operating periods due to 500 ml indicator storage

bottle

Interface 0/4-20 mA

Performance specifications

Indicators for Testomat 2000®V

Range / Type of reagent

TH 2100

TH 2250

TC 2100

Unit

dH

(Resolution)

1,0 - 10,0

(0,1)

2,5 - 25,0

(0,1)

1,0 - 20,0

(1,0)

f

(Resolution)

1,79 - 17,9

(0,2)

4,5 - 44,8

(0,1)

1,79 - 35,8

(1,79)

ppm CaCO3

(Resolution)

17,9 - 179

(1,8)

44,7 - 447

(0,9)

mmol/l

(Resolution)

0,18 - 1,79

(0,01)

0,4 - 4,5

(0,01)

0,36 - 7,16

(0,36)

Function

After each analysis, the current for the blending valve is recalculated

and output. If the measured value is within the target range, the next

analysis is carried out after the set interval time. If it is outside this

range, the analysis is carried out after 30 seconds.

Analysis cycle and control process

(example with schematic cycle diagram)

1 Interval break

2 Supplementary program AUX before analysis (see page 38)

3 Flush branch line and measuring chamber

(note flush time of the sampling line)

4 Analysis:

–Fill measuring chamber

–Check the sample for dirtiness

–Measure out reagents (stirring mechanism is "ON")

–Display measuring value

–Drain measuring chamber

5 Set point value comparison

a. Set point value reached: Waiting period until next analysis

(Time- or quantity analysis interval, further with 1)

b. Set point value not reached yet: then further with 6

6 Readjust mixing valve and start next analysis (4)

Performance specifications

Requirements

The control function realised in Testomat 2000®V requires that the

hardness of the mixed water changes proportionally to the position of

the mixing valve. The total characteristic curve of the system (mixing

valve plus pipeline system) should therefore have a linear

characteristic. This must be observed when selecting the mixing

valve.

To ensure a linear control characteristic, the pressure at the hard

water connection and the pressure at the soft water connection must

be the same. Furthermore, the water quantity in the control valve

should not be too low. In order to increase the water quantity, it may

be wise to select a mixing valve with a smaller diameter than the

piping. In case of doubt, contact a valve manufacturer who will

recommend a suitable valve type (see page 11).

Furthermore, to guarantee correct control, it must be ensured that the

Testomat measures the “correct” water. To achieve this, hard and

soft water must be fullly mixed before being fed to the instrument.

Therefore, the sampling line to the Testomat must be installed at

least 1 m (but no further than 5 m) downstream of the mixing valve. It

is beneficial to install the sampling line downstream of a water meter

as it whirls the water.

Special setting options

Enter the values for hard and soft water as well as the set point

values and the control range. Two special setting options are

available to adapt the instrument to difficult conditions: Maximum

change in current and maximum adjustments.

Maximum change in current

This is a restriction of the change of current. It offers the possibility to

gradually adjust the valve to the set point value.

Maximum adjustments

Adjustment means the current calculated after an analysis and the

respective valve position achieved. If the measured value is still

outside the target range after several analyses (set point value+/-

control range), an error message is output.

Reaction during fault

In case of a fault, the valve moves to one of four possible positions.

Performance specifications

Fault message input

Input IN1 is provided for the fault message of a superordinate

process controller. If a signal is pending, the blending valve moves to

the programmed position “Valve during fault” and remains there. The

controller is blocked and no analyses are carried out.

Example:

If the soft water supply fails, e.g. due to a fault at the softening plant.

By using an external fault message it is possible to prevent the

controller moving the blending valve to the final position B (soft

water), thus ensuring there is still water available at the blending

output. Testomat 2000®V outputs the error message “External fault”,

switches the alarm contact and moves the valve to a position in which

water can still be supplied. If the fault has been eliminated and there

is no longer a signal at IN1, the controller is released again.

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