Neomeris Testomat 2000 Especificaciones técnicas

Testomat 2000®

Testomat ECO®

Maintenance Instructions

Contents

Contents...............................................................................................2

Important safety information .............................................................3

Qualification of the staff ........................................................................3

Warning notices in these instructions ...................................................3

Further documents................................................................................4

General instructions...........................................................................4

Testomat2000®in steam boiler plants with BOB operation: ................5

Prior to carrying out maintenance work ................................................6

Permissible tools...................................................................................6

Carrying out maintenance..................................................................7

Cleaning the measuring chamber and the sight-glass windows...........7

Cleaning the receiver optics..................................................................7

Cleaning the filter housing ....................................................................8

Cleaning the housing ............................................................................8

Removing and installing the measuring chamber holder......................9

Re-adjusting the measuring chamber holder (Overflow detection) .....9

Replacing the EPROM (software update)...........................................10

Opening the factory programming ......................................................10

Installing the interface cards SK910, UK910, RS910 (only Testomat

2000®) .................................................................................................11

Position and function of the fuses.......................................................12

Repairing or replacing the dosing pump.............................................14

Checking dosing .................................................................................15

Special function “Adjust mode”......................................................15

Testing of the overflow detection........................................................16

Checking the automatic adjustment....................................................16

Water consumption ..........................................................................17

Indicator consumption .....................................................................17

Indicator TH2025, TH2100, TH2250...................................................18

Indicator TH2005 ................................................................................18

Manual measured value check........................................................19

Troubleshooting................................................................................20

Error message MST analysis..............................................................20

Switching on the real-time clock (only Testomat2000®).....................22

Low water level ...................................................................................22

Error message FST optics (Testomat 2000®).....................................23

Error message MST turbid..................................................................23

Error message Ff outlet to drain .........................................................23

Error due to defective hardware .........................................................23

Readjusting the current interface........................................................24

Spare parts lists ..................................................................................25

Component positions.......................................................................26

Check List Testomat 2000®................................................................29

Product overview Testomat 2000®-Instruments ............................32

Important safety information

Please read the operating instructions and maintenance instruc-

tions carefully and completely prior to carrying out maintenance

work at Testomat instruments.

Observe the warning notices in these maintenance instructions

and the operating instructions of the respective instrument.

Always adhere to hazard warnings and safety tips when using

reagents, chemicals and cleaning agents. Please adhere to the re-

spective safety data sheet! Download the safety data sheets for

the supplied reagents at http://www.heyl.de.

Qualification of the staff

Maintenance work requires fundamental electrical and process engi-

neering 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 ap-

propriate safety measures. A specialist should always adhere to the

relevant technical regulations.

Warning notices in these instructions

The warning notices in these instructions warn the user about poten-

tial dangers to individuals and property resulting from incorrect han-

dling 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 dam-

age.

“NOTE” indicates important information. If this information is not ob-

served, it may result in an undesirable result or state.

DANGER

WARNING

CAUTION

SIGNAL WORD!

NOTE

General instructions

Further documents

Testomat instruments are plant components. Therefore, always ob-

serve the documentation of the plant manufacturer.

General instructions

Regular maintenance is necessary to ensure trouble-free operation of

the Testomat instrument. Regular visual inspections also increase

operational reliability. Also refer to the notes in the operating instruc-

tions!

Fix errors by yourself.

Experience has shown that many errors that occur in day-to-day op-

erations you can fix by yourself.

This ensures that the instrument is soon working again. In this

maintenance manual you will find possible causes of malfunctions

and helpful hints for their elimination.

Overview of maintenance work to be executed

The maintenance intervals may vary depending on the water and

pipeline quality.

Maintenance work

Quarterly

Semi-

annually

Triquarterly

Annually

Biennially

/ Trienni-

ally

Page

Cleaning sight-glass

windows

Measuring chamber

Cleaning / Measuring

chamber holder

Cleaning the receiver

optics

Cleaning the control-

ler/filter housing

Cleaning the waste

water line

Checking

the dosing pump

incl. suction and

pressure hoses

Electrical and hy-

draulic connections

Renewing the sealing

kit (40124) and

sight-glass windows

Recommendation:

Allow the manufac-

turer to overhaul the

dosing pump

NOTE

General instructions

Clean the measuring chamber at regular intervals (approx. every 6

months) and, if possible, replace the two seals of the measuring

chamber holder and the sight-glass windows.

If the water has high iron content, cleaning might be necessary

more often.

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

To carry out maintenance work after the error message “Mf. soil-

ing” or “Ff. optics”, always confirm the error message.

Only Testomat 2000®: If maintenance is carried out after an in-

strument maintenance message (maintenance interval), mainte-

nance must be confirmed. (In SERVICE I menu)

Wait at least 5 seconds before switching the instrument on and

then off again at the main switch.

The repair of a defective instrument –irrespective of the warranty

period - is only possible after the instrument has been dismantled

and returned to us with a description of the error. Furthermore,

please inform us of the indicator type being used and the meas-

ured medium. Before you return the instrument for repair work, re-

move the bottle and ensure that the measuring chamber has been

flushed out and is empty. Prior to dismantling, always write down a

description of the error (failure effect). For Testomat 2000®and

Testomat ECO®please download the respective checklist from our

website www.heyl.de.

Do not carry out any actions at the instrument which are not de-

scribed in these instructions; failure to adhere to the instructions

will negatively affect the warranty claims that you make thereafter.

Testomat2000®in

steam boiler plants

with BOB operation:

In accordance with the pro-

visions of TRD 604, Sheet 1

(new WÜ 100), Testomat

2000®must be regularly

maintained and, if neces-

sary, inspected. Mainte-

nance must be carried out

every six months by the

plant operator or an author-

ised service and mainte-

nance provider. Please con-

tact us if you require a regu-

lar maintenance service. We

will then provide you with an

offer.

Download of check list

General instructions

Prior to carrying out maintenance work

Carry out a visual inspection of the instrument:

Are the instrument doors closed properly?

Is the instrument heavily soiled?

Is there air inside the dosing hoses?

Are the hose connections of the dosing pump free of leaks?

Has the use-by date of the indicator expired?

Always make sure that the sight-glass windows are clean before in-

serting a new indicator bottle.

Cleaning agents

Never use organic solvents to clean the measuring chamber or

other plastic parts!

Use an acidic cleaning agent for cleaning.

Please observe the safety regulations when handling cleaning

agents!

Permissible tools

Always use suitable tools for the described tasks. Refer to the table

below for an overview of suitable tools, which can be purchased as

tool kit T2000 (Art. no. 40138).

Content of the tool kit T2000 (Art. no. 40138)

Size

Application

Art. no.

Adjustment pin

2 mm

Alignment of the overflow sensor

measuring chamber holder (only re-

quired up to device number 22899)

30990

Torx, TX 20x100

Measuring chamber, snap-on installa-

tion

30991

Torx, TX 10x80

Measuring chamber holder

30992

Torx, TX 8x60

Display circuit board, measuring cham-

ber holder

30993

CAUTION

Carrying out maintenance

Cleaning the measuring chamber and the sight-

glass windows

Proceed as follows:

Switch off the instrument or press the "STANDBY" key. If required,

remove any water from the measuring chamber:



Close the manually-operated valve of the supply line to Testomat

2000®.

Unhook the toggle type fastener , tilt the measuring chamber

upwards and remove it.

Release both sight-glass window holders , remove and clean the

sight-glass windows.

Use alcohol to clean off the film on the sight-glass windows. If the

instrument has been used with hard water for a longer period of

time (measuring range exceeded!), a hard-to-remove film may

have formed on the sight-glass windows. In this case, clean the

sight-glass windows as described below for cleaning the measur-

ing chamber.

The measuring chamber can be cleaned with a cleaning agent

suitable for decalcification and rust removal. Flush the measuring

chamber thoroughly after cleaning.

After cleaning, re-insert the sight-glass windows and secure them

using the sight-glass window holders b. (Do not forget the flat

seals, making sure they are fitted correctly in the groove).

Re-insert the measuring chamber and use the toggle type fastener

to secure it.

Cleaning the receiver optics

If you detect that the lenses of the receiver optics (left-hand side of

the measuring chamber holder) are soiled, please clean them using a

dry, lint-free cloth.

Carrying out maintenance

Cleaning the filter housing

Close the manually-operated valve of the supply line to Testomat

2000®.

Depressurise the lines of Testomat 2000®via the function:



Switch off the instrument and loosen the hose connections at the

filter housing.

Unscrew the inlet connection using an open ended spanner (size

22).

Remove the seal, spring and filter and clean them.

Remove the retaining pin and extract the flow controller, subse-

quently remove the flow controller valve body.

Clean the filter housing with water or alcohol; then reassemble the

unit.

If required, replace the seals.

Insert the filter strainer with the cone facing downwards!

Re-attach the hose connections at the filter housing.

After assembly

After assembly, make sure the connections are leak-free.

Leaking water at sealed points can damage unit components.

How to check the unit for leaks:

Switch the instrument to "STANDBY" .

Manually fill the measuring chamber:



Manually dose the indicator ("Manual" key).

Check the connections and seals for leaks.

Drain the measuring chamber.

Cleaning the housing

The surface of the instrument housing is untreated. Therefore, avoid

any soiling caused by indicators, oil or grease. However, if the hous-

ing becomes soiled, please clean the surface with alcohol (never use

other solvents).

Inlet

connector

Regulator/filter

CAUTION

Carrying out maintenance

Removing and installing the measuring chamber

holder

(Required tool: Torx 10x80)

Please stop the water supply to the instrument and drain the

measuring chamber.

Switch off the instrument.

Unhook the toggle type fastener, tilt the measuring chamber up-

wards and remove it.

Remove the stirring bar.

Loosen the pressure hose (1).

Loosen the four fastening screws of the measuring chamber holder

(2).

Loosen the valve block (3) from the measuring chamber holder

(two fastening screws).

Disconnect the plug from the flexible cable connection (4) on the

base circuit board by pressing together and raising the two lateral

levers. Unplug the flexible cable.

Remove the measuring chamber holder from the front. To achieve

this, remove the drain pipe (5) from the hose connection of the

measuring chamber holder (see fig. push locking ring upwards).

Install the new measuring chamber holder in reverse order.

Ensure that the plug is locked into position after inserting the flexi-

ble cable connection.

Re-adjusting the measuring chamber holder

(Overflow detection)

(Required tool: Adjustment pin 2 mm, Art. no. 30990)

Testomat2000®/ ECO instruments have been factory set. Therefore,

instrument adjustment during start-up is not required.

All instruments from instrument number 222.899 and higher are

equipped with a self-adjusting electronic circuit.

Adjustments are no longer required and no longer possible!

If the re-adjustment of instruments with a serial number below

222.899 is required after replacing the measuring chamber holder

(error message "low water level" in spite of noticeable filling process),

carry out the re-adjustment as follows:

Switch off the instrument, press and hold the "DOWN" key and

switch on the instrument again (Call the special function “Adjust

mode”).

Push locking

ring upwards

NOTE

Carrying out maintenance

Use a suitable adjustment pin to turn the potentiometer on the

base of the measuring chamber holder A(hole in the base) clock-

wise until the "Analysis" LED (overflow detection) illuminates.

Subsequently turn the potentiometer anti-clockwise by an approx.

1/8 turn.

Check correct functioning of the overflow detection circuit via the

key = input valve: The "Analysis" LED must illuminate while

water is overflowing. Press key again for quitting. The LED

must extinguish once the overflow has finished.

Back to normal operation: Press the “LEFT” and “DOWN” keys

simultaneously.

Checking water recognition

Use the key to check the water recognition function for in-

struments equipped with a self-adjusting electronic circuit.

Replacing the EPROM (software update)

(Required tool: Torx 8x60)

Switch off the instrument.

Loosen the six fastening screws of the display circuit board

Avoid static charges during installation/de-installation and ob-

serve the direction of installation!

Non-adherence can result in damage to or destruction of the elec-

tronic components on the circuit board or of the EPROM.

Carefully remove the EPROM from the socket (please make a

note of the direction of the marking).

Insert the new EPROM.

Fasten the display circuit board.

Switch on the instrument.

Opening the factory programming

After replacing the EPROM, carry out basic programming.

Switch on the instrument by simultaneously pressing the and

keys. Your programmed settings are lost and the factory set-

tings are reset (also see the operating instructions!).

CAUTION

NOTE

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