Xycalb LClOlmics BV

Zuiddij k 4, 5705 CS
IIc:lmond
Chamber of Co mmcn: c
Ilr. 1704600 1
Net herlands
Tel 1-) I 492 573 7o.t
Fax 1-3 I 492 53 4 135

MABAT EUROPE

MABAT CHEMICAL SYSTEMS

Corporate Graphics and Docwnentation

--
t!1

w_

&,- -

SDI-2200-2
Silt Density Indexing Unit
Serial No.: 080173

COHPOHATE (;H,\I'IIICS AND i)OCli",lENTATI()N

Operating Manual

May 2009
Revision No.: 1.00

T\Iabat Europe
J lead Office: Zuiddijk 4,5705

('S,

Ileimond 17046001. Netherlands'

TeL +31 492 578 704

E-mail: [email protected]\vw.mabat-systcms.com

 2003 "IABAT EUROPE

Malial EUROPE, Logo is trademarb of Attl/wl EUROPE. Company in EUROPE and other countries.

This doclunent contains proprietary information that is protected by

copyright. No part ofthis docllment may be photocopied, reprodllced,
or translated to another language withollt the prior written consellt of
Mabat EUROPE Ltd.

List of marking description and notation legend used in this manual:

I CON

KEY

VALUABLE INFORMATION -

manner indicates providing

information for reference onl y.

(?:'J Valuable

Text set off in this

general and helpfhl

lnfonnation

ICON

Computer

ICON

KEY

hnlx)ltant

ICON

IZ9

KEY

KEY

Caution

ICON

KEY

\Vaming

COMPUTER: Text set off in this manner indicates

general notation in reference to compnter program's
insttuctions and/or its operations.

IMPORTANT: Text set off in this manner indicates that

failure to follow directions could result in damage to
production process or loss of information.

CAUTION: Text set off in this manner indicates that

failure to follow directions could result in damage to
equipment.

Text set off in this manner indicates that

failure to follow directions could result in bodily harm or
loss oflife.

WARNING:

III

SDI-2200-2

Table of Contents
General Instructions

v;

3.1.2.

Check Step

23

1.

Introduction

3.1.3,

Clean Step

24

1.1.

General Description

3.2.

Preliminary Settings

2S

1.2.

PrincIpals of Operation

3.2.1.

Channel Operation Settings

2S

1.3.

System and Product Specifications

10

3.2.2.

Flush Setting

2S

1.4.

SOl Analyzer Type and description:

11

3.2.3,

Check Setting

26

1.4.1.

Analyzer Configuration

12

3.2.4.

Walt Setting

26

2.

Installation

13

3.2.5.

Alarm Setting

26

2.1.

System Layout

13

3.2.6.

Analog Output Range Setting

27

2.2.

Site Preparation

14

3.2.7.

Digital Output Option Setting

27

2.2.1.

Power Supply

14

3.2.B.

Pre Start Up setting

28

2.2.2.

all Free Dry Air Supply (OFA)

14

3.3.

Operating HMI Screen Program

2.

2.2.3.

Water Sample Supply

14

3.3.1.

Introduction

29

2.2.4.

3.3.2.

MAIN SCREEN:

30

Drain Line

1S

2.3.

Installation Process

1S

3.3.3.

LOGIN & LOGOUT

32

2.3.1.

Open Boxes

15

3.3.4.

P & 10 Screen

33

2.3.2.

SOl System PositionIng

15

3.3.5.

Operate Screen

34

2.3.3.

Power Supply

16

3.3.6.

Setting Screen

36

2.3.4.

Oil Free Dry Air (OFA) Supply:

16

3.3.7.

INFO Screen

38

2.3.5.

Water Sample Supply:

17

3.3.8.

Monitor Screen

40

2.3.6.

Drain LIne:

18

Alarm Screen

41

Install Filter Paper

,.

3.3.9.

2.3.7.

3.3.10.

Trend Screen

42

2.3.8.

Turn Valves and Switches ON

19

3.3.11.

Operation Modes

44

2.3.9.

Analog Outputs (Option)

19

3.3.12.

Start and Stop Button

4S

2.3.10.

Digital Output Status Information

19

3.3.13.

Memory RetrievefErase

46

2.3.11.

Remote Enable/Disable Input

20

3.3.14.

Filter Paper Advance

47

2.3.12.

Remote Start for Each Input

20

3.3.15.

Plant Stop (Option)

47

2.4.

Wiring Connection Table

20

3.3.16.

Date & Time Setting

47

3.

Operation

22

3.3.17.

Alarm & Fault Messages

47

3.1.

Sequence of Operation

22

4.

Maintenance

4.

3.1.1.

Flush Step

23

4.1.

Filter Paper Replacement

4.

Page Iv

OPERATING

MANUAL

4.1.1.

Pre Start-Up List

51

4.2.

Failure Messages Definitlon

51

4.2.1.

Major Failures (15)

51

4.2.2.

Plant Stop (6)

51

4.2.3.

Temporary Failures (7-8)

52

4.2.4.

Channels Alarms (1057)

52

4.3.

Failure Description and corrective action

52

4.3.1.

PLC Failure (1)

52

4.3.2.

Piston Failure (2)

52

4.3.3.

No Paper (3)

53

4.3.4.

Used Paper (4)

53

4.3.5.

Inlet Valve Leak (5)

53

4.3.6.

Monitored Plant (6)

53

4.3.7.

Protectlve Cover (7)

53

4.3.8.

Low Air Pressure (O)

53

4.3.9.

Pressure Low (912)

54

4.3.10.

Chamber Unclean (i3i6)

54

4.3.11.

Flow Low (1720)

54

4.3.12.

Level High (21.24)

54

4.3.13.

Fast Flow (25.28)

54

4.3.14.

No H/L Check Done (2932)

54

4.3.15.

No Flow (33-36)

55

4.3.16.

High SOl (3740)

55

4.3.17.

Paper Almost Finish (41)

55

4.4.

Alarm and Fault Messages

55

5.

Warranty Policy

57

5.1.

GENERAL

57

5.2.

WARRANTY PERIOD

57

5.3.

INSTALLATION AND OPERATION

57

6.

Repair Policy

58

6.1.

REPAIR POLICY

58

6.2.

EXCLUSIONS FROM WARRANTY:

58

7.

Appendix

60

7.1.

501-2200 System Drawings

60

7.1.1_

P&ID Schematic Drawings

61

7.1.2_

Electrical I Control Drawings

62

7.2.

Recommended Spare Part List

72

7.3.

Component List

73

7.4.

Change Order Form

75

7.5.

List of Figures

76

7.6.

List of Tables

76

Page v

General Instructions
abal EUROPE designs, manufactures and tests its products to
ensure they meet with national and international standards.
However, in order for these products to operate within their
normal specifications, they must be installed, used and maintained
correctly. '111C following instructions must also be adhered to and integrated
with your safety program when installing, using, and maintaining L'1a/Jat
EUROPE products.

Read and save all instiuctions prior to installing, operating, and servicing
the product

If you do not understand any of the instructions, contact your l\1a/Jat

EUROPE distributor for clarification.

l':"ollow all warnings, cautions, notes, and instll.1ct1ons marked on and

supplied with the product.

Inform and educate your personnel on the proper installation, operation

and maintenance of the product.

Install yOUl' equipment as specified in the Mabai EUROPE installation

instructions and also adhere to all applicable local! national codes.
Connect all products to the proper electrical and/or pressure sources.

Handle, n10ve and install each product using the appropriate nlU11ber of
personnel and moving devices/equiptl1cnt (dolly, forklift, crane, etc.).
Failure to do so could cause serious personnel injury.

To ensure proper performance, usc qualified personnel to install,

operate, update, program, and maintain products.

\\1hen replacement parts are rc(}uired, ensure that qualified scrvice

technicians usc replacement parts specified by Mabai EUROPE.

Unauthorized substitutions rnay result in f1fc, electrical shock, other

hazards, or impropcr equipment operation.

Ensure that all equipment doors arc closed and protective covers arc in
place, except when maintcnance is being performcd by qualified
persotmel, to prevent electrical shock and personal injmy.

All safety related issues appearing in this manual do not replace or alter
any customer safety procedures. In case of conflict in te1111s, d1e
custolller safety instruction should supersede those writtcn in the
manual.

Page vi

OPERATING MANUAL

1" introduction
1.1.

General Description

jy[,tlti COC/I/lle/ Ol/-Ulle Q//{//ity 1f7c,ter

/ll/{/I)'zel; SDI-2200

he SOl 2200 Automatic, On Line,

Silt Density Index
Ivlonitoring System is a unique on-line control system, designed
for continuous, unattended operation in desalination and other
watcr treaUnent plants.

The SOl 2200 is used in critic..ll water quality applications, where precise
control is essential for safe and economic operation. It replaces the manual,
error prone, conventional procedure with an automatic, precise and infallible
routine.

The SDI2200 is a complete self-contained system meant for unattended

operation with extensive reliability and with advanced fault analysis and
warmng.
The SOl 2200 has the follo\\1ng features:
Fully complies with the ASTM 04189-95
Up to 90 cycles (to complete one paper filter roll) without operator
interference
PP cabinet
Up to 4 sampling points
Automatic sampling pipes flw;h process prior to measurement
Automatic water draining and self cleaning process at the end of
each cycle
Standard modc test for LOW SOl watcr Oess than 5.0 for 15
minutes) or tlAuto Timetl mode tetit for HIGH SOl water (greater
then 5.0 for 15 minutes

Page 7 of 76

Rev. 1.00

SDI22002 OPERATING MANUAL (PP BOX, GE, 230VAC) 1.00 EUROPE

5DI22002

Automatic data logging to include trend's graphic representations

with SOl results, Check Time, and Plugging rae tor variables
Individual progranunable channel capability with Hush 11me, Check
Time, and \\lait 'l'imc variables
Three built-in operational modes:

1. l'vIANUAL (One-Cycle only)

2.

AUTO (progrrulill1able time interval)

3.

REtvIO'm (pre-started selected channel from [emote station)

Five programmable dray-contacts outputs per the following

indication status:

1. Analyzer Faults
2.

COll1111on

3.

Alarm Per Input

Alarms

4. Operating Channel
5. Ready to Start
Five-Digital Inputs for inter1ce with the plant main processor (plant
ON-Orr, Start any Input)
Optional Analog Output (range progranunable) per channel for
remote control and tllonitoring putposes
Color, touch screen operational panel

1.2.

Principals of Operation

Standard Test Mode

Silt Density Index (SOl) is measured by comparing the flow rate of a
known (Juan tit)' of water, where the water quantity is kept under constant
pressure. The flow rate is measured twice, once where the water flows
through a standard fliter, as a reference, when the filter is unused, and
the second time after the filter is exposed for I-IS minutes, and the
water sample flow is kept always under constant pressure.

The drop in flow rate is a direct measure of the silt build-up on the filter.
The flow rate is derived from quan tities and titning information:

Page 8 of 76

Mau2009
Mabat EUROPE Ltd.

OPERATING

MANUAL

SDI
ti:

initial time required to collect 500 [mL] of sample,

tp

time required to collect sao [mL] of sample after test time t

t:

total elapsed flow time, min. (usually Standard Measured Time')

The SDl 2200 provides the same type of measurement both in automatic
and in on-line mode for up to four independent sampling points.
The pressure is kept constant by precisely regulated air pressure applied on
the water surface without the need of any mechanical device.

Auto Time Test Mode

In cases where the silt density index (SOl) reading is unstable and
readings arc higher then 5 (i.e. Plugging Factor is higher then 75%),
during the 15 l1UllUtcs check time, the Analyzer can be progranullcd to
work in AUTO TlJ'vlE TEST lITOOE based on the following test
tllcthod automatically:
The 0/oP311 (Plugging Pactor) calculations will proceed and
recorded in intervals of one-minute elapsed.
Calculations will stop once %P" (Plugging Factol) 75% has been
reached.
New SOl' readings will be displayed based on the last calculated
plugging factor at the last measured time also check time will be
displayed.
All SOl test readings arc on 0-\00 scale where the exact check
time figure has no valuable meaning as in the Standard Test
Mode. In general, the higher the SOl reading the more silt is in
the water. \,'hen the plugging factor after IS minutes is
calculated to be lower then 75% , the Analyzer will switch and
calculale the test results based on the Standard Method.

I Standard i\ll~l~llring Time (Si\n) i~ 15 ll1inllte~. '!lIe higher the expected SDI vallie, the lower
the SI\ITnlue. 'IlIt' Si\IT ~calc \'a!ue range~ from I-IS.
0
2 _ jf after 15 minute~ the readings are lower then 75 '0 re~ult~ are being ca1culatt'tl
St:lmhrd method. '!lIt hight'r the SDI re.Hlings the !llort" ~iltarc in the water.

Page 9 of 76

a~

per tile

Rev. 1.00

8DI22002 OPERATING MANUAL (PP BOX, GE, 230VAC) 1.00 EUROPE

5DI-2200-2

%P",

plugging factor at 30 [psij feed pressure,

ti:

initial time required to collect 100 [mL] of sample,

t f:

time required to collect 100 [mL] of sample at each intervals

of one-minute test time.

The SDI-2200 is set to perform in correlation to what is specified by the

AST]',,! designation: ])-1892-95 (2002) Standard.

1.3.

System and Product Specifications

TECHNICAL INFORMATION:
Dimensions (in 111m)
Dimensions (in In)
Weight

W= 525 D= 3lO 1-[= 1126

W= 20.6 D= 12.2 11= 44
50[Kg], or 106[Lb]

CONSTRUCTION MATERIAL:
\,Tet Parts
Construction Container

PVC
PI'

UTILITY SPECIFICATIONS:
S upl)' In:
\\/ater Pressure
Water How Rate
Air Pressure
Electtical
Slit Density Index (SDI) ranges
SDr Check time
Repeatability

2.4 to 6.0 [Bar] or 35 to 90

[psig]
1.5 [L/ min.] or 0.5
[Gal/min.]
5.2 to 8.0 [Bar] or 80-120
[psig]
110 - 230 [VAC],
50/60[Hz],4 [Amp]
0.00-99.99
1-15[Minutes]
Less than 0.1 SOl Units

Digital Output Sig!lal:

Pivc-progrrunmable outputs for status indication (see Table 3)
Digital Input Signal:
Analyzer remote enablc--{lisablc operation
Separate remote start for each input
Page 10 of 76

Mau2Q09
Mabal EUROPE Lid.

OPERATING MANUAL

Analog Output Signal:

Analog isolated output per channel

0-5 [Volt], I-S[Volts], 020[mA] and 4-20[mA].

Filter Paper Type

Rolls, lcngdl 6 [Meter] or 20

fFt], 90 111caSUfelnents per
roll.

Drain

3/8" Flexible Pipe

Environment protection:

IPX3

Rated environmental conditions:

Indcx::>f usc:
o max. altitude 2000m (6562 ft)
o ma..x. operating ambient 4CklegC
o max. relative humidity 80% for temperature up to 31dcgC
(87.&legf<)
o decreasing linearly to 50% relative humidity at 40degC
o mains supply fluctuations up to 10%
o Over voltage Category II ofIEC60364-4-443
o Pollution Degree II

1.4.

SDI Analyzer Type and description:

Analyzer format definition - SDI

220n-a

n:

Number of Channels (1 - 4).

a:

Number of Analog Outputs (1 - 4).

Specified ranges:

0-5 [Volts]

1-5 [Volts]

0-20 [mAJ

4-20 [mAl
1VO!f:

"JlJt AllrJ!og Olttplft is dirt't1b' rr/aled 10 th, SDl Il!l7rVlIl!, (.fft'- Jellillg lIN

(///('/og mllgf J2.7)

Pag811 of 76
Rev. 1.00
SDI220(l.2 OPERATING MANUAL (PP BOX, GE, 230VAC) 1.00 EUROPE

50122002

1.4.1. Analyzer Configuration

TIJJ .5D1-2:5)0

IVwi,tJ

0/ si/ric /IOII-/V//abft, IIlIil.

amnii

:')l,tOllllp/WlWlalioll alld rt!laikd lil'lw' ale .d){)/IIII LdOlIl:

In the Table I below, the Analyzer is presented in the center column with a
view of the front door open. Picture of the side view in the right column:

Analyzer
Name

Analyzer Views
Side

Front

SDI2200:

. -.
.

Table 1 - Subunit Configuration

Page 12 of 70

Mau 2009
M.bat EUROPE Ltd.

OPERATING

MANUAL

2. Installation

Introduction

Dlilillg site p/Fparatioll, olle Jho/tld deJigll a plVper locatioll

jor the SDJ-2200 IJJith pmiJ'e odm/atioll alld amI
pOJitiollillg. ]tof/illallom/ioll pl{1II JhoNid ('{J/uider ollemll
IlIIi/jillliYiollalif)l proximity to itJ dielltl-lille.l; alld the
10Ctltioll of .mppO/t "fllitieJ:

2.1.

System Layout
Below is a complete schematic, on-site, recommended SDI2200 illustration and analyzer arrangement as follows:

The layout drawing below (see Pigure 1) can be used as a

guideline to plan for the final installation and location. It shows

critical dimensions required and overall configuration (sec Site

Preparation section for further details). Please note that this
illustration should be used as a reference only. Each specific
location and site situation should he designed exclusively
according to site requirements.

Page 13 of 76
Rev. 1.00
SDI.22002 OPERATING MANUAL (PP BOX, GE, 230VAC) 1.00 EUROPE

5DI22002

m
0

]
]
~' ~'

~I
~I

"Il

""
""

{r
I
I

0
"

~:

I"

"1"1
::l

6;>0

flA CK

"I

GJ

~
5;>5

rno!>,

'" "I

JJ
~

]J
"1"1

000'

Tor VI I:.'

I'

Ie

UACK

000'

1I
[ I
I

I; e
I;
I;,

61.0

CJ

II

I:I I

I"

e I

Ire
1

"5

\1F.1I'

,, 1

DOITOII (OUTSmr.) V1F.1f

RIGIIT/ LF.n rn:T

Figure 1 - 5DI2200 Layout Configuration (in MM)

2.2.

Site Preparation

Oil Jill!, IIlilil),p"pflmliolljorplVper SDI2200

illJlallfllioll Jboilid be plVl!lded ill tbejollOlvillg IIHlllller:
2.2.1. Power Supply

'n, e SOl 2200 is operated by electrical supply of 110 .

230 V i\C, 4A

2.2.2. Oil Free Dry Air Supply (OFA)

'1he inlet OFA supply requires clean, oil free and cil)' air
at 5.2 to 8 ~lars] (80 to 120 Wsigl). Air supply tube o uter
diameter is ,/, [In].

2.2.3. Water Sample Supply

Page 14 of 76

111c inlet \'{/ater Sample supply pressure lit1Uts is 2. 1-6.0

[Ilar]. Wa ter Sample supply tube outer diameter is 3/8
[In]. However as the Analyzer is sensitive to inlet pressm e
and flow, some actions have 10 be considered during
installation. \X' hcll pressure is wit hin specifications but
flow is to o low, shor ter or larger diamdCL' sample lin es
Mau 2009
Mabat EUROPE Ltd.

OPERATING

MANUAL

have to be used. \\then flow is too high, sl11<1ller or

adjusting valve have to be used.

2.2.4. Drain Line

2.3.

Drrun outlet should be provided having no backprcssurc.

Drain line outer diameter 3/8 [In] should be connected
to the analy:t.cr. Open drain designed to collect the three
separate drain lines from the analyzer is prcfcrn.xl.

Installation Process

2 .3.1. Open Boxes

Upon receiving the package, carefully inspect all shipping

containers for damage, which may have been incurred
during shipping. If any part of the system is damaged,
notify the courier immediately.

Open boxes in the horizontal position.

Place contents in their final location.

Check the external cabinet (inventory versus packing list).

Record and report ,lilY ,~siblc damage to package and/ or
its contents.

2.3.2. SOl System Positioning

Position (hang) the SDI system using hanging holes located

in the back panel up & low position (sec Figut'c-2).

Upper Positioning

Lower Positioning

Holes

Holes

Figure 2 - SOl System Positioning Holes

Page 15 of 76

Rev. 1.00

SD I-2200-2 OPERATING MANUAL (PP BOX, GE, 230VAC) 1_00 - EUROPE

5DI-2200-2

2.3.3. Power Supply

Connect incoming 110 ~ 230V t\C power supply to Tfl 0

(sec Figures-3 & 4)

Notice.

Connect Standard Earlh Wire 10 Ihe TB

O-ground tehninal, to avoid damage in case of
eleclrie spikes (sec Figure-3) .

CAUTION: DO NOT TURN THE

ANALYZER POWER ON.

ICON

KEY

Cautio n

"L" 110 - 230 Volt

AC Conncction

"N" 110 - 230 Voll

AC Conncction

Grollnd
Conllection

Figure 3 - Power Supply Connection

2.3.4. Oil Free Dry Air (OFA) Supply:

Connect incoming Analyzer o rA suppl y. flexible PVC

1/4 0.0. nlbe, onto the air slIpply connection (scc I1Ai r
Supply" in Figure 4).
11

CAUTION: DO NOT TURN OFA

SUPPLY VALVE ON.

Page 16 of 76

ICON

KEY

Caution

Mau 2009
Mabat EUROPE Ltd.

OPERATING

MANUAL

OFA Connection

110 - 230 Volt AC

Connection

I1OV/230VAClHlET

Figure 4 - Power Supply & OFA Connection

2.3.5. Water Sample Supply:

Connect incoming water sample supply, flexible 3/8"

0.0 . tube, into the \V,Hcr sa mple suppl y connection
thought Input 1-4 (scc :'igurc 5).

CAUTION: DO NOT TURN TH E

WAT ER SAMPLE SUI'PLYVALVE ON.

Page 17 of 76

ICON

KEY

C:lU ti on

Rev. 1.00

80122002 OPERATING MANUAL (PP BOX, GE, 230VAC) 1.00 EUROPE

50122002

Input 1

Input2

-,

Input3

...,.,
Input-4

-,

-,

Drain-I

....,

Drain-2

Figure 5 -Input Water Sample & Drain

Connections

2.3.6. Drain Line:

Connect outgoing Drain lines, 3/8" 0.0., (marked

"Drain 1 & Drain 2") to the main drain. for all three
Drain connections, Drain-l and Drain-2 see Figure 5, fo1'
Drain-3 sec Figure 6.

CAUTION: DRAIN LINE SHOULD

BE PROVIDED HAVING NO BACK
PRESSURE. THE CONNECTION OF
THE THREE SEPARATE DRAIN
LINES FROM THE ANALYZER TO
AN OPEN DRAIN SYSTEM IS HIGHLY
RECOMMENDED.

Page 18 of 78

ICON

0"

Key

Caution

Mau 2009
Mabat EUROPE Ltd.

OPERATING

MANUAL

Drain-3

Figure 6 - Third Drain Line Connection

2.3.7. Install Filter Paper

Install the filter paper roll. Refer to the maintenance

section of this operation manual.

2.3.8. Tum Valves and Switches ON

Turn power supply switch ON.

Open the water sample lines

Regulate the air pressure as indicated by gauge PG 1 to 80

[psig] by PRI (for location sec Table 7 in Section 7.3) .

JUtei' approximately one minute, regulate the float

assembly pressure as indicated by gauge PG2 to 30 [psig]
(for location see Table 7 in Section 7.3).

Open the OFA supply valve.

2.3.9. Analog Outputs (Option)

2.3.10.

Page 19 of 76

Connect the optional analog output according to the

Wiring CoIUlection Table (sec Table 2 below).

Digital Output Status Information

Select the reguil'cd information based on Table 3.
For wiring information, refer to Table 2 below.

Rev. 1.00

SDI22002 OPERATING MANUAL (PP BOX. GE, 230VAC) 1.00 EUROPE

501-2200-2

2_3_11.

Remote Enable/Disable Input

To enablc the rcmote input characteristic, remove the

cOlUlcction betwecn tcnninals 9 and 10 and connect
remo te dry contact indicating plant status (working/not
working). Par further information, refer to Table 2 below.

IMPORTANT:
THE ANALYZER IS
SHIPPED WITH THE PLANT STOP
TERMINALJUMPERED.

I CON

0'

KEY

Important

Remote Start for Each Input

2.3.12.

To allow the tcst initiation of each relevant input chalUlcl.

2.4.

Conncct the rcmo te start [or each available input rc(]uircd

(see Table 2 below).

Wiring Connection Table

,,
,

.j - ?OruA

CUSTO";: li

USE:D rr. R!.IINAL

~ -20ruA

' IZI
' IZI
' IZI

OUTPlJTS- )

OlJTPUT-2

.1Zl
'0

t .j 20rM

~ - 20mA

OUTI'UT:l

0", PU T

,' nu

, 0

CLOSE TO

STArn

JH: !.I On: SrAHT/~"lOP

9 t24VOC INPU1'3 COMMON

-.-.

"

srAJIT INPUT - I

~- -

START INPU1' - O?

~-

I ~

~ES ):r

0"

,,"

"

, "

S-rAHT INPUT 4

MANY

[ 0~
-<>"

I
I

C--

SrAHT INI'Ul'-:l

c--;;-

SLOT I
INPUT CA ll\)
TERM

"

' IZI
10

rzJ

11

[gJ

12

IZl

"n
"n
IX]

IlEMOTE

15

ALAH M

'I .h-i"--"

HI IXI
1'/ [X]

f :lJSTom :u

CHI

MAm<
SYSl U 1

t' Jf Z
t' H3

SI.OI'2
OUTPUT CARD
TER!.!.

I II IZI
"0
~U l2sJ
21

l2{]

n[ZJ

Table 2 - lMring Connection Table

Page 20 of 76

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Mabal EUROPE Ltd.

I
OPERATING MANUAL

See Appendix 7.1.2 for further electtical drawings

Tile SDI-2200 AnalyzeJ' is nolV 0peJ'ationaJ.

Consult the Operation section of this m:lllual for further Ktions.

~~~~rn

~~1~

SDI.22002 OPERATING MANUAL (PP BOX, GE, 230VAC) 1.00 EUROPE

l
5DI-2200-2

Operation

Introduction

III thiJ' paragraph, thm iJ a (ollsidemble a)}/Ollllt of

illfomJtJtioll Idated to the Jy.,1ellJ operatio/l.l; alld IVlllille
pm,rdJllvs. Then' {/IV 1Ia/Ilt1ble e:x:plalltltiolls tiS to the logiml
seq"ella:s alld colJJjJIIlerpmgralJJI))illg steps. Also./or
COIJ)Jl)OIl opemtor IIsage, tlJe/~ is ell/ ill-depth, lIJaill (olltml
plvgram tllld all sarell illJt11ldiollJ'p,vllided to ell.fJllV
pmise, qllalifJ' opemti01lJ:

3.1.

Sequence of Operation
Below is the SDI-2200 test sequence of operations presented in

a step-by-step fashion:
I. Flush Step
2. Check Step
3. Clean Step

COMPUTER:
THE
LETTERS
AND NUMBERS IN THE BRACKETS
OF THIS SECI'JON INDICATE THE
FUNCTION AND ADDRESS OF
DIGITAL INPUTS OR OUTPUTS THAT
SHOULD
BE
ON
FOR
THE
DESCRIBED STEP, (I - FOR INPUT, 0FOR OUTPUl). FOR FXA"ll'LE (0, H3)

ICON

KEY

!C') Valuable
Tnt(lOllation

Computer

REI'ERS /\S TO TilE l.ED B3 ON TilE

DICITAI. ()lJ'!VUT CARD.

Page 22 of 76

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Mabat EUROPE Ltd.

OPERATING

MANUAL

3.1.1. Flush Step

On ti,e INFO SCREEN in the State section below, the FLUSH
indication should be turned ON.
The filter motor is activated for 2-3 seconds to replace the used

filter (0, B3).

The piston goes down and presses the filter paper. Piston lower

position switched on (I, A4). One of the inlet valves (0, A2-5)
opens to check for minimum inlet pressure. If the line pressure

is higher then 30 [Psi] water will flow into the float assembly and
activate the lower float (I, Ai). If the line pressure is lower then
30 {psi] alaons 9-12 will be displayed.
\,Then water reaches the lower float, air pressure supply valve

SV-O closes (Pg 2 = 0 {psi]) and drain valve V-5 (0, A6) opens.
\Vater sitnultaneously flows into dle float assembly and out

from d,e drain. \,\Ihen d,e water levd reaches the upper float (I,
A2) d,e pressure supply valve SV-O (0, AI) open Pg 2 = 30
{psi] and the water is forced out of the float assembly to d,e
drain until the level reaches the lower float.

SV-O closes, PG-2=0 {psi]. 'l11is step is performed repeatedly

for the time set in the program as the flush time. If during the
whole flush cycle dle water level does not reach the upper float

at least once alarms 13-16 will be displayed.

\\lhen flush time finish drain valve V-5 closes and the air

pressure supply valve SV-O open (pG-2 = 30 {psi]). Water level

raise in the float assembly to the upper float.
\\'hen water levels reach the upper float the water supply valve

to d,e filter V-7 (0, A8) and the filter drain valve V-6 (0, A 7)
opens and water flows from the cell throughout the filter to dle
drain for about 5 seconds, to take out all the trapped air above

the filter.

V-6 and V-7 valves closes and the water level rises to the upper
float. 'lhe inlet valve closes

3.1.2. Check Step

On d,e INFO SCREEN in the State section below, the FLUSI I
indication is turned OFF, and CIIECK indicator should be
turned ON.
The water supply valve to ti,e filter \'-7 (0, A8) opens. 'l11e
time Ti required for the water level to decline to the lower float

(for 500 Icc]) is measured and stored for the SDI calculation.

h~~~rn

~~1~

SDI.22002 OPERATING MANUAL (PP BOX, GE, 230VAC) 1.00 EUROPE

SDI-2200-2

The time re(juired to the level to decline from upper to middle

floats is measured for filter inspection. If the time is more then -

8 seconds it probably indicates plugged filter. The cycle is

stopped and alarm - "4" is display.
If the time is less then 2 seconds it probably indicates broken or

missing filter .11lC cycle is stopped and alarm _"3 11 is display.

\,!hcn the water level rcaches the active float Qowcr or middle),

the inlet valve is open again and water flows into the float
assembly. \',/atcr level should rise above lower float and
continue to risc slowly toward upper float. If during this phase
the water level remains under the lower float for morc than 10

seconds alarms 17-20 will be displayed. 11,e rate of flow into the
float assembly is checked by l11casuring the time required for the
level to rise from middle to upper floats. If tllls time is less then
0.7 seconds, the cycle is stopped and alarms 25-28 will be
displayed. Each time d,at the water level in the float assembly
rises to the upper float the inlet valve is closed for 10 seconds,
to control the water level in the float assembly during the check
time. TIle pressure in the float assembly and on the filter is kept

constant by applying 30 [psi) air pressure on top of the water.

About 6 seconds before the check time is finished the closing
period of the inlet valve is set from 10 to 1 second to allow

closer level control at d,e upper float level. If dlC level does not
reach the upper float during tills stage failure message 29-32 is
displayed.
\,\lhen the check time ftnishes and the water level reaches the
upper float, the inlet valve closes and the time t{ required for thc
same volume that was used to measure t, (100-500 [cc]) of water
to flow through the filter is measured and stored. l1le new SDI
value is now calculated and stored in the memory. If t f is highcr

then 300 seconds alarms 33-36 is displayed and the computed

SDI value will be lower than the actual one, because the
analyzer used the 300 sec as t{ instead of the real value.
\,\lhen tf measurement is completed the new test results can be
monitored and stored in the Analyzcr.
The analyzer is ready to statt the cleaning step.

3.1.3. Clean Step

On the INFO SCREEN in d,C State section below, the
CHECK indication is turned off, and the CLEAN indicator
should be turned on.

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Mobat EUROPE Ltd,

OPERATING MANUAL

First V-5 (0, A6) is open for 10 seconds to drain d,e water
from dle float assembly, and then V-6 (0, A7) for 10 seconds to
drain the water frol11 the filter holder.
After 10 seconds V-6 (0, A7) closes. TIle remaining water is
forced with the air pressure through the filter for the next 10

seconds. V-7 (0, A8) is closed and V-5 is open to release the
pressure fru111 the filter Holder.
The piston rises and the paper l11otOf is activatcxl after 30
seconds, with a series of very short pulses to release dlC paper.

Cycle is ended when CLEAN indication is turn OFF.

3.2.

Preliminary Settings
Prior to system stattup some of the operation parameters should
be checked and set as required:

3.2.1.

Channel Operation Settings

11,e SDI 2200 can handle up to four water-sampling channels.

On the OPERATE SCREEN, each channel operating modes,
can be programmed separately as needed eid,er to ON or OFF.
11,e AUTOMAT and A UTO TIME modes should be set on the
Analy,er OPERATE SCREEN accordingly:

On the l'vlAIN SCREEN, select LOGIN button. Insert

login password per level required (see section 3.3.3).

Verify START is shown on the l'vlAIN SCREEN (if

STOP is shown select d,e button so START is shown).

On the MAIN SCREEN, select OPERATE button.

Select A UTOI'vli\1TI and AUTO TIME button to set

either ON or OFF respectively.

Repeat setting for all d,e active channels. 11,e defaultpreset value is norrH.

3.2.2.

Flush Setting

At the beginning of each sampling cycle process, the analyzer

flushes the sample line and all the relevant internal parts that
contain water from previous analysis rw}, TIlls Rush value should

be set on d,e analyzer OPERATE SCREEN accordingly:

On the MAIN SCREEN, select OPERATE Button.

Select Rush button and insert value in minutes.

Page 25 of 76
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5DI-2200-2

Repeat setting for all the active channels, TIle default

preset value is "1" (for 1 [Minute]).

In general, for every 10 [m] of sample input supply line,

insert Im.inutc as flush time value.

3.2.3.

Check Setting

11,e CHECK time detennines the total Run Time (t,), from the
start of t; (Initial time) to ti,e st1tt of tf (pinal time). Normally,
CI lEeK time is dle Standard Measuring Time (SMT) equals to
15 minutes. However, when the expected SDl value is higher,
lower CHECK value Oess dlan 15) may be considered. CHECK
value should be set on d,e analyzer OPERATE SCREEN as
follows:

On the MAIN SCREEN, select OPERATE button.

Select CHECK value button and insert value in minutes.

Repeat setting for all the active channels. ~nlC default

preset value is "15" (for 15 [Minutes]).

ANALyzER------THE
COMPUTER:
ACCEPTS ONLY VALUES IN TH"E~_'--,c,--o-,---N_K_._Y__
RANGE OF 1-15. ANY OTHER VALUE PI Vn"',blc
WILL BE SWITCHED OFF TO THE
inform,'llion
PERMITTED RANGE.

3.2.4.

Computer

Wait Setting

time is defined as the delay time, in hours, required

prior to repeat a test procedure only during Automat mode, for
each active channel as needed. The \X/ait valuc should be set on
the analyzer OPERAill SCREEN acc01tlingly:

'111C \'{!ait

On the MAIN SCREEN, sclect OPERATE button.

Select \'\fait button and insert value in hours.

Repeat setting for all the active channels. 'l11c default

preset value is "1" (for 1 [Hour]).

3.2.5.

Alarm Setting

Each specific channel can be set for the highest acceptable value.
During test run when measured SDl exceeds such limit value an
alarm will show. 111e Alarm Sct valuc should be set on the
analyzer OPERAill SCREEN accordingly.

Page 26 of 76

On d,e l\lAIN SCREEN, select OPERATE button.

Selcct j\larm Set button and insert value button.

Mau 2009
Mabat EUROPE Ltd.

OPERATING

MANUAL

Repeat setting ror all the active channels. 'TIle defaultpreset value is "5.00 11
ICON

COMPUTER: TI-IE ALARM SEITING

VALUE IS IN XX.XX FORMAT.

Key

il1fo mntiC )11

3.2.6.

Computer

Analog Output Range Setting

Analyzer allows analog output settings, per selected channel, in

preset ran ges.
Desired values should be inserted in the
sr:r n NG SCRE EN.
E.'\'(I)))/)/r illl'crt the val ue 10 in to th e rC(luircd programmcd
analog, C hannel I in t he SETI'I NG SCREEN, l'ct the rangc
to 00.00 10.00 ("SOl valul''') -} 4-20 ImAI.

The system default preset value is "20" - on all channels.

3.2.7.

Digital Output Option Setting

'lhe Analyzer has five digital outputs 10 be used for stanIS

indication signals. Ihe functionality of each output can be
programmed according to Table 3 below, Any cooe numbers 1 to
5 can be selected from the Settings Screen Q)' accessing with the
login password permission code see Section 3.3.3) per required
terminal no. 16-20. Analyzer will normally be delivered with the
dcfault settings of Option Code 4, unless it was requested
clscwllcre.
CAUTION: WI-lEN USING TI-IE ANALYZER
EXTERNAL POWER SUPPLY (TERMINALS 921 CONNECrED), MAXIMUM POWER
SUPPLY PER OTPUT IS lOW

ICON

0'

KEY

C;1 l1tion

Terminal J6

Fault

lofluh

Pault

Fault +
Alarm

Fault +
Alarm

Terminal 17

J\I1!nput
A\arms

Input- !
Alarm

Input- )
AlanH

N/A

Input. I ON

TCfmi n 011 18

N/A

Input -2
Alarm

Input-2
Alaml

N/A

Inpllt-2 ON

TCfmill l.l1 19

N/A

Input3
Alarm

Inpllt-3
,\\ann

N/A

Input-30N

'['cfl11inal 20

Rc.'fldy

Input4
AI:u-m

Rc.'fldy

Rc..'ady

Inpllt-4 ON

Table 3 - Digilal Oulpul Option Settings (Term. 16-20)

Page 27 of 76

Rav.1.00

80122002 OPERATING MANUAL (PP BOX, GE, 230VAC) 1.00 EUROPE

SDI22002

TIle outputs can be wired for one or two commons. TIle

COll11non terminal is usually connected to the customer's power
supply and the output signals are used as input signals at dle
customees main processor. TIle common terminal eln be
connected to the internal +24 VDC power supply and can be
used as an operating signal as well (such as indication lamp,
solenoid valve, etc.). The internal-24 VDC power supply is at
tenninal 22.

3.2.8.

Pre StartUp setting

After installing the Analyzer as described in the earlier chapter,

check and correct the following parameters as presented on dle
INFO SCREEN, as follows:

Verify no active alarm is present - remove all active nl:1.t1n

messages by selecting ",I" on dlCALARM SCREEN.

Verify no active fault presented - remove all active fault

messages by selecting ",I" on the ALARl'vl SCREEN.

Verify READY indication is shown.

Valuable Information: EACH AND

ICON KEY
EVERY ONE OF THE FOLLOWING
CONDITIONS SHOULD OCCUR IN
l[~7 Valuable
ORDER FOR "READY" TO SHOW:
Information
1. ANALYZERON"START".
2. NO ACTIVE FAULT.
3. P&ID SCREEN IN "MONITOR".
4. TRANSPARENT PISTON COVER IN PlACE.
5. AIR PRESSURE WITHIN WORKING RANGE.
6. ANALYZER IN STANDBY POSITION.

Verify Hcorrect" real time local clock and date presented reset time and date when rrClickingHon the Time & Date
button on the bottom of the MAIN SCREEN.

The SDI-2200 Analyzet< is now ready for staN lip

Consult the Oper:ltion section of this mal1u.u for further actions.

Page 28 of 76

Mau2009
Mabat EUROPE Ltd.

OPERATING

3.3.

MANUAL

Operating HMI Screen Progra m

Introduction
3.3.1.
The program MAIN SCREEN contains an all times selection Keys
0JlI(tons) correlated with fi.1I1ccio nal keys to any required operation to
either perform prod uction, view system status, analyze specific
situations, make process adj ustJncnts and/or perform maintenance
to the sys tem.

T he flow diagram below (Figme 7) represents a sct of system

functio n keys in a product-u'cc configlU"ation:

SDI-2200 MAIN
SCREEN
P&ID
OPE RATE

SETTING
INF O
MONITOR

;, CH3 - Trend (Option)

.J

. CH4-Trend (Opti~n) l
l

~~

LOGIN/LOGOUT

Figure 7 - Operating System Flow Diagram

Page 29 of 76
Rev. 1.0D
SDI22002 OPERATIN G MANUAL (PP B OX, GE, 230VAC) 1.00 EUROPE

l
5 DI22002

MAIN SCREEN:

3.3.2.

The 11M IN SCREEN is the opening main program display that

categoriz<,'d and divided into several oil-screen operational keys;
j\'lain Strut/Stop, Log In/out, process flo w diagram, Analyzer
sta tu s, test process, SYStCU1 characteristic setting, and alarm
sta Lus rcp01t (sec Figure R):

COMPUTER: WHILE PRESSING

ON THE OPERATIONAL Kill'S,
leo N K. Y
FOR CONFIRMATION PURPOSES, - iC'!
-'-\"-'ru-,-.b
- lc--TI-IE COLOR SYMBOL WILL
InfOlll1:'ltioll
CHANGE FROM "GREEN" TO
"RE D",
E Computer

COMPUTER: ON THE SCREEN

leo N KEY
DISPLAY, FOR ALL NUMERICAL - -::---- - VALUES ADJUSTMENTS, ONCE A
iC'! Vrum!>c
SPECIFIC DATA BOX IS SELECrED
lnfolll'tllion
AN ENTRY WINDOW WILL BE
Q Computer
OPENED TO ALLOW SUCH
INSERTION.

Figure 8 - MAIN SCREEN

Page 30 of 76

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Mabat EUROPE Ltd.

OPERATING MANUAL

Screen buttons and indication description:

P&ID

Analyzer process status flow diagram

screen.

OPERATE

I'vIanual/Automatic mode operation

selector and ullit parrunctcrs screen.

SEITING

1-1onitor system operation parameters

screen.

INFO
MONITOR

J _

Dctailed analyzer test data information

report screen
- Registers value and data alteration screen.

CH"lTren!l

Channel 1 Test
representation.

results

graphic

CH"2Trend

Channel 2 Test results

representation (Option).

gmphic

CH-3Trend

Channel 3 Test results

rcpresent1tian (Option).

graphic

CH-4Trend

Channel 4 Test results

representation (Option).

graphic

ALARMS

Shows stored list of all active or reset

alarm screen.

START/STOP

J'vIain start/ stop operation button. \\lhcn

START or STOP is shown ci,e Analyzer
is in disable or stand-by3 mode,
respectively.

LOGIN
LOGOUT

Initiate log into or out of the system

screen (see below).

Login Level

- Uscr allthor:i:mtion log in level indication

status.

Date + Time

- Show Analyzer local Date & Time.

I\nalyzt:r is in "H'ady" for any opl'mli(mal command pogjlion.

Page 31 of 76
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l
50122002

3.3.3.

LOGIN & LOGOUT

Three types of llSer levels arc permitted to log o nto th e
co mputer con trol system. Each one should be assigned a
password in th e designated area. Tn o rd er to per fo rm specific
activities, o ne can log onto the system by assigning one o f the
following selections:

Level
No.

Login

Description

P assword~

No password
re<:)lu[cd

SDI

S012200

~L-\nr\TSDI

INPUTS

General access for sc reen

viewing only
limited access to the

OPERATE SCREEN
Limited access to enter inl o the
OPERAIE nnd/or SrTrrNG
SCREEN
Unlimited access to all screens

limited access for output seu ing

option

Table 4 - Login Level Configuration

COMPUTER: ANALYZER WILL

LOGOUT AUTOMATICALLY WHEN
I-IMI SCREEN RE MAINS UNrOVCI-IED
FOR ABOUT 5 ~UNUTES.

ICON

Key

In fc)l'Ill.lti()ll

Q ComputlT

Page 32 of 76

Mau 2009
M abat EUROPE Ltd.

OPER A T IN G

3.3.4.

M A NU AL

P & ID Screen
The P&l D SCllliEN shows a detailed process flow diagram
and provides stlltus indication for given elements sllch as
vtllvcs, filter paper motuI', level indicators and positio ns. \'X /hen
selecting the Analyzer to operate in manual 111<xic, di splayed
valves can be selected each, and nlrned ON /OFF as required.
Please no te that when manual mode is selected , excessive air
pressure is released along with a s\,~tching sOllnd. '111cre is an
arrangement for two P&ID SCREENs; for screen vic:wing o nly
when the screen is in l'vlonitor s taniS (see Figure 8), and for
mamml componcnt Oil-screen selectio n when the screen is in
Mamlal status. Toggle between iv{onitor and IVIanual screens by
pressing o n {',,[onito r or r"lanuru button respectively. O n
MANUAL SCREEN selected elements will switch color from
Hwhi tc H to "green", On f\IONITOR SCREEN, same valves and
clements will show Ilgreen!! (see figure 9).

Fig ure 9 - P & ID Screen

Screen buttons and indication description:

Page 33 of 78

Main

- Navigate back to MAIN SCilliEN.

MAN

- Process line with valves or other

co mpol1ent idcntifiGltio l1\ allowing for
individual manual operation.

Rev. 1.00

SDI22002 OPERATI NG MANUAL (PP BOX, GE, 2 30VAC) 1.00 EU ROP E

5DI22002

3.3.5.

Monitor

- i'vlonitor screen for viewing statu s o nly.

Manual

- Mallllal screell for illdividual ON/OFF

ad juslIncn t.

Operate Screen
The OPERATE SCREEN permits IIsers to operate Allalyzer
either in ['' ' [anllal or ,\utol11atic mode. Operation screen
provides lists o f process parameters per each input ch:ulIlcl
tested. Each channel can be set individuall) to either r'v lanual or
Automatic mode to define the required IHlturc of the Analyzer
operatioll (see Figure 10),

COMPUTER: WHILE 1'llliSSING ON

I CON K. Y
THE OPEltAl10NAL CHANNEL KEYS'-E1
":'~\-="-',h'-~-I'::'c-=-'--
FOR CONFIRMATION PURPOSES, THE
Infonl1.1tklll
COLOR SYMDOL WILL CHANGE FROM
U\'(fHITE" TO "GREEN".
Q C..omptltcr

Figure 10 - OPERATE SCREEN

Page 34 of 76

Mau 2009
Mobat EUROPE Ltd,

OPERATING

MANUAL

Screen buttons and indication description:

- Analyzer identification input channel

number. \'\/hen selecting the active
channel box, the entire column
background color switches to green.
- \X1,en ON: Perform one specific input
channel test process to completion and
stop.
- \"hen ON: Perform entire set of input
channel test processes per time interval
set in \\fait box below.
- When ON: CHECK time is defined
automatically& by the system.
- Cleaning time, in minutes, required
prior to beginning test process.
- Test time, in minutes, requires the test
process to be completed. Default time
set to 15 minutes.
- Delay time, in hours, is required prior
to perform repeat test in the Automat
mode.
- Set limit for SDI value in which a
warning message is shown once
traversed (permitted value 1-100).
- Display last SDI tested value.
- Navigate back to MAIN SCREEN.

() - Analylef pnlhrtam calculate CHECK time

Page 35 of 76

hlH,d 011

the filtef p.lpefpluMing rate.

Rev. 1.00

SDI22002 OPERATING MANUAL (PP BOX, GE, 230VAC) 1.00 EUROPE

SDI22002

3.3.6.

Setting Screen
The SETTING SCREEN allows moni to ring several of th e
j\nalyzcr operation pam meters as describ ed below; filter paper
inro l1nation sraWS is ga thered on-line, Analogue out ranges
status per input channel and remove previolls tes t memo 1)' data
per selected channel as required. On sc reen buttons aUow to
reset a few sys tem parameters as detailed here (see Figure 11):

New Pape.Pape.AlarM

Set

P a pe.- Lef't
Pape.- U s ed

FOJI
.FOJI

Figure 11 - SETIING SCREEN

Screen buttons and indication descri ption:

Paper Section

New Paper

- Analyzer rescl butto n selector o nce

new paper filter is inse rted .

Paper Alarm

- Generates warning message based on

th e va lue set in Alarm Sct butto n.

Alarm Set

- Set value to gencmtc warning mcssngc

due to paper filter ending (permitted
valne 1-89).

Paper Left

Pa ge 36 of 76

- A mount of filer paper correlate:; to the

Humber tests remain ing in the <ll1alyzcr.

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M abat EUROP E Ltd.

OPERATING MANUAL

- Calculated amount of ftlter paper used

so far.

Analog Out Range Section

- SOl analog range aXIs per active
channel-I.
- SDl analog range axis per active
channcl-2 (Option)
- SDl analog range axis per active
channel-3 (Option)
- SDl analog range aXIs per active
channelA (Option)

CLEAR MEMORY Section

- Reset and clear all history memory
data' per Channel-I.
- Reset and clear all history memory data
per Channcl-2 (Option).
- Reset and clear all history memo1), data
per Channel-3 (Option).
- Reset and clear all hist01Y mem01), data
per ChannclA (Option).
- Navigate back to MAIN SCREEN.

7 _

data

~HANNEtS

- Unchanged number of channels.

OP'!'lQN

- Option Code Number; fefer to section

3.2.7 for full description.

pre~entl'd

Page 37 of 76

graphical!y on the "nmND

~ClmEN,

per channel

Rev. 1.00

801220(1..2 OPERATING MANUAL (PP BOX, GE, 230VAC) 1.00 EUROPE

5DI-2200-2

3.3.7.

INFO Screen
Thc INI 'O SCREEN represents detailed information rcgarding
th e last SDI test results performed pel' selected chan nel. TIle
lest data results arc SDT values, completed test lime ill minutes,
t il and If, and Plugging Factor (sec Pigurc 12).

Figure 12 -INFO SCREEN

Screen buttons and indication description:

SOl

- Display most recent SD] value.

Check min

- Display test time, in rninutes, required pe r

test process to be complete.

t, sec

- Display ini tial timc for 500 [ee] tcstcd

s~l.Inplc to pass thrll the filter papcL

tf sec

- Display final time for 500 [eeJ tested

sa mple to pass tllm the filter paper.

Plug %

- Filier paper plugging factor in pcrccnt [%J.

Alarm

- Indication to state the

active alarm messages
SCREEN.

Page 38 of 78

cxiStU1CC
011

or nlly

the ALA Ri\,1

Mau 2009
M.bat EUROPE Ltd.

OPERATING MANUAL

Fault

Ready

- Indication to state the existence of any

active falM messages on d,e ALARM
SCREEN.
- Indication to state dut the Analyzer is
standing by ready for Sll\RT prior to any

operational condition.

Flush

- During actual flushing procedure state

indication.

Check

- During actual testing procedure state

indica rion.

Clean

- During actual cleaning procedure state

MAIN

- Navigate back to MAIN SCREEN.

Total:

- Calculated total amount of time to

complete the test in minutes (the combined
Flush and Check procedures time).

Left:,

- Calculated time remaining to complete and

receive test results data.

indication.

COMPUTER: CALCULATED "TOTAL"

AND "LEFT" VALUE ARE NOT
SHOWN WHILE ANALYZER IS IN
"AUTO TIME" MODE PER ACTIVE
CHANNEL.

_c:"c:'C:.,::0c:'N=--:K:.:...::E'--Y'-_

r/VaI",blc
Infonnation

Computer

Page 39 of 76
Rev. 1.00
SDI22002 OPERATING MANUAL (PP BOX, GE, 230VAC) 1.00 EUROPE

SDI22002

3.3.8.

Monitor Screen
The MONITOR SCREEN allows access to Analyzer's registers
and permits setting alteration as rcclLUrcd by the USCI' (see Figure

13).

[HaTi; I

~10N !TOR

EJ

EJ
Ii

- -- '

Figure 13 - MONITOR SCREEN

Screen buttons and indication description:

. Navigate back to MtIIN SCREEN.

- To increase/ dccrctlse the font size.

- Add a new register.

VAL

- J\'iodify register valuc from list,

DEL

- Delete register from lis\.

- Navigate UP to the next register on

screen.
- Navigate DO\VN to the next register on
screen.

Page 40 of 76

Mau 2009
Mabat EUROPE Ltd.

OPERATING

3.3.9.

MANUAL

Alarm Screen

The A nalyzer has an in tcnsive on line diagnostic p rogram, which

detec ts operatio nal failure and displays a list of active and non-active
alarm lists as the), appear on the ALARM SCREEN when the),
occur. On scree n response, enables to resume Analyzer operations
after receiving rnl11t conditions and cease all A nalyzer operations (sec
Figure 14).

~I

oiJ
iJ
Figure 14 - Alarm Screen

Screen buttons and indication description:

ESC

. Navigate back to the 1111\ IN SCREEN.

. Silence cl,e hom and nash ing red lamp (Not

opemble in all uni ts).
- Reset all active t11a.nll and fault messages.
- Show/I lide details of times when ahlrlll and faull
messages appear 011 the screen.
- Navigate UP to the next register on screen.

- Navigate DO\VN to the next register on screen.

Acknowledge
messages,

specific

alarm

and/or

fault

Paga 41 of 76
Roy. 1.00
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SDI-2200-2

3.3.10.

Trend Screen
The 'IREND SCREEN stands for a graph prese ntation of a
given set of test results per input channel. TIle graph
presentation of all tes t result parameters showll all the screen
arc the SDI value, "CIIECK", and Plug%.

'l11cre arc. two l)'PCS of on-screen graphs thal Gln be

selected:

Real Time Trend - Clirrent set o f tes ted re sult data

presented in a predefined time axis (sec Figures 15,
and 16).

J listor}' Trend - all previous sels of tested result data

presented along the time axis.
ICON

COMPUTER: CLICK ON SCREEN TO

TOGGLE BE1WEEN REAL TIME AND
1-IlSTORYTREND GIW'I-IS.

1i1 ... ~
L y scttLl

SOX
CHECI( (

:..-::

HI N

>

PI
X :l

..JG
)

Figure 15 - Real Time TREND SCREEN (V Scale)

I~~~~ SCALLING

Key

Valuable

Computer

--

Figure 16- Real Time TREND SCREEN (Curves)

Screen buttons and indicalion description:

MAIN

- Naviga te back to l\MIN SCREEN

SOl

- GrOl ph representation of ClIlTc nt SOl value

pn.:scntcd in a predefined Lime axis (red curve)

CHECK

- Graph representation of current C HECK value

presented in a predefined time axis (black curve)

Page 42 of 78

Mau 2009
Mabat EUROPE Ltd.

OPERATING

MANUAL

%Plug(x5)

- Graph representation of current Plugging value

presented in a predefined time axis (green curve)

Scale MIN

- Define the minimum nyu axis value, default value

IS HOI! (permitted value 0-100 but less than Scale
MAX value)

Scale MAX:

- Define the maximum "yl! axis value, De'lUlt

value is "20" (permitted values 1-100)

Trend History Graph:

While clicking on the RealTime Trend Screen graph, a new
trend screen called HISTORY SCREEN is shown. 11,e
HISTORY SCREEN is identical to d,e Real-Time TREND
SCREEN test results parameters; in addition, there is a nc\v
set of operating buttons that appear on the bottom of the
screen as described below.

Screen buttons and indication description:

- Fast travel backward along the time axis.

<

- Travel backward along the time axis.

- Zoom In along the time axis .

- RctlUn to current time on the time axis.
- /..00111

Out along the time axis.

>

- Travel forward along the time axis.

- Fast travel forward along the time axis.

MemoryFul~

lfHistOli' of information C.'Ul be presented on the graphs

until memory is filled. In such a situation, a message
"I'v!E1\,10RY PULL" is shown on the screen. Purther usage,
wlliIe l11cmory message is on, will erase oldest registered test
results and wm be deleted, in the order it was received
(FIFO). To free up rnemory space for new test results to be
stored clear McmOLY button in d,C SETTING SCREEN pe,specified input channel and erase all "history" dat.'l (for
further details see section 3.3.13).
Page 43 of 76
Rev. 1.00
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SDI22002

Operation Modes

3.3.11.

The analyzer C<ln operate in two modes Automatic or 1:vIanu1l.

Automatic Mode:

On the MAIN SCREEN sdcct Operate button.

While in ci,e OPERATE SCREEN, per active channel,

select the box next to the Automat line and turn it to ON.

Reselect Aut01nat box per each active channel as required.

COMPUTER:
TIME
COUNT
STARTED ONCE AUTOMATIC BOX IS
PRESSED TO ON.

COMPUTER: TIME COUNT CAN BE

RESET
BY
REPRESSING
THE
AUTOMAT BOX TO OFF AND
SWITCHING FROM OFF TO ON
MiAIN.

ICON

Infonl1ation

Q Computcr

ICON

KEY

int{mn.1.!:i()!1

INPUT CHANNEL
COMPUTER:
WITH ZERO "WAIT", WILL BE
CONTINUOUSLY SCANNED. OTHER
ACTNE
CHANNELS
WILL
BE
SCANNED PER THEIR ORIGINAL
SETI1NGS.

Key

Computer

ICON

KEY

If'; V"'tuble
Intflnn.'lti(lIl

Q Computer

Select MAIN button to navigate back to the MAIN

SCREEN.

Select START button.

Manual Mode:

On ci,e I'vIAIN SCREEN, select START button (please

note, STOP button is shown for confirmation).

On the MAIN SCREEN, select OPERATE button to open

the OPERATE SCREEN.

Page 44 of 76

Mau 2009
Mabat EUROPE Ltd.

OPERATING

MANUAL

While in the OPERATE SCREEN, per tested channel,

select the button next to the MANUAL box and turn it to
ON as rcquired 8,

Rcsc1ect rvlANUAJ, button pet each channel as rC(luircd.

COMPUTER: THE MANUAL C Y C L E - - - - - - MAY BE ACTIVATED EVEN WHEN THE_:'-'c::C-'O::,:-:N----"K,,"=-y'-_

ANALYZER IS IN AUTOMA11C MODE b Vrumble
WITHOUT ANY EFFECT ON THE
Infonnation
AUTOMATIC SCHEDULE.
Q Computet

3.3.12.

Select IIIAIN button to navigate back to the MAIN

SCREEN.

start and Stop Button

By pressing the STOP button, the analyzer will stop aU operations at

any moment. \,\/hen using the STOP command when the analyzer is
performing a test procedure it will proceed immediately to Cleaning
process and cease all operations once completed,
When STOP button is selected during Automatic mode, rl,e WAIT
value remains stored in the system and can be operable effectively
once rcselecting START again.
COMPUTER: IN OPERATE SCREEN
WHEN
RESELECTING
AUTOMAT
MODE FROM ON TO OFF WILL RESET
WAIT TO ZERO.

ICON

KEY

L! Vall~ble
Infomm.tion

~ Computet

COMPUTER: WHEN USING THE STOP - - - - - - ICON KEY

BUTTON, THE ANALYZER WILL
UNDERGO
THE
CLEANING
Villu.'1blc
SEQUENCE
AND
STOP
ONCE
InfOOlL'ltion
COMPLETED.

~ Computer

COMPUTER: WHILE PRESSING ON - - - - - - THE OPERATIONAL BUTTON, FOR

, CON KEY
CONFIRMATION
PURPOSES,
THE - - 0 - - ' - - - - - - - v j V;umble
COLOR SYMBOL WILL CHANGE FROM
int<mnation
"WHITE" TO "GREEN".
~ Computer

_ Analyzer will start testing the fir~t selected channel and continue nl':.:t to all tJther ~dl'cteJ
channels S('ljllCl1tially.

II

Page 45 of 76
Rev. 1.00
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S DI220 02

Memory Retrieve/Erase

3.3.13.

The Analyzer stores Hhistory" data readings for each input sampled
channel. Current data however, shown on the INFO SCREEN. In
order to read the ClUTcnt test results of a specific input channel, press
the following sequence below:

On d,e l'vlAIN SCREEN select INFO button.

While in the INFO SCREEN, per active channel read out

data related to SDI, CI lECK, Plug, t, and tf .

Select lvlAIN button to navigate back to dlC lvlAIN

SCREEN.

To view real-time data shown on the graph representation follow the

sequence below:

On the MAIN SCREEN select cid,er CH-l Trend, CH-2

Trend, CI-I-3 Trend, or CHA Trend button.

Select MAIN button to navigate back to the J'vIAIN

SCREEN.

To retrieve IIhistorytl data shown on the graph representation follow

the sequence below:

On the MAIN SCREEN select either Cll-l Trend, CH-2

Trend, CI-I-3 Trend, or CHA Trend button.

ItClick ,r on the open TREND SCREEN window in order to

vicw the "history" data.

Select Main button to navigate back to the MAIN

SCREEN.

To crase the stored

below:

'~listOly"

data readings, follow the sequence

On the lvlAIN SCREEN select Setting button.

While on the SETTING SCREEN, per active channel,
select Clear i\kmory Channel-I, Channcl-2, Channe1-3, or
Channel-4 button to reset channel history data to zero.

Select MAIN button to navigate back to the MAIN

SCREEN.

Page 46 of 76

Mau 2009
Mabat EUROPE Ltd.

OPERATING MANUAL

3.3.14.

Filter Paper Advance

The filter paper is programmed to advance itself automatically at the

conclusion of each operation cycle by a stllall electric motor. In order
to save paper usage the operation time of the motor can be reduced
based on the calculated number of test rWl-cycles to be completed

by each particular paper roll.

The NEW PAPER button resets the test cycle count to zero and it
should be pressed, ONI X after a new filter roll has been installed.

On the MAIN SCREEN, select Setting button.

While on the SETTING SCREEN, press and hold the New
Paper button (NEW'), until Paper Used equals zero.

Select Main button to navigate back to the MAIN

SCREEN.

3.3.15.

Plant Stop (Option)

The plant Stop - Start option is a digital input activated by a city

contact at the monitored plant. It is closed when the pl1nt is working
and opened when not working.
The plant Stop option is effective only in the automatic mode and is
used to stop the analyzer when the sample line pressure is low. It has
no effect on thc schedule time that was programmed for cycle time.
If the contact is opened during the waiting time for the next cycle
nothing will happen and the analyzer will resume operations when
the contact is closed again.

If the contact is opened during operation, the analyzer will go to

cleaning step and stop operation. \\fhen the contact is closed the
analyzer will start at the same input that was interrupted. '111is option
has no effect on the manual mode, and the analyzer can be operated
on in manual mode whenever needed.

3.3.16.

Date & Time Setting

Adjust Anal)",er local Time and Date is displayed on dlC MAIN

SCREEN by pressing on the Date & Time button to open d,e RealTime-Clock (RTC) window. In the RTC window insert the required
time and/ or date, press Enter and close the window.

3.3.17.

Alarm & Fault Messages

There are three ways in this Analyzer to display the output alarms
and fault messages to a remote station Q)lcase refer to List of Faults

and Alarms in Table 5):

h~~~n

b~1~

SDI22002 OPERATING MANUAL (PP BOX, GE, 230VAC) 1.00 EUROPE

5DI-2200-2

1.

One common dry contact output for Alarm and

Pault that is !!open!! when any alanll or fault
message is active.

2. Two separate dry contact outputs for Alarm and

Pault that are f!openlf when any alarm or 'lUlt
message is active.

3.

One separate dry contact output for each channel

ala11115 and one for common Fault.

COMPUTER: FAULT MESSAGES ARE - - - - - - RELATED

TO THE OPERA'IlON __'_C_D_N_K_"_Y_ _
STATUS OF THE ANALYZE. ANALYZER
D Vrumble
CEASE ALL OPERATIONS WHEN
Infonnatioll
ACI'NE FAULT IS PRESENT. TO
RESUME OPERATIONS ACTIVE FAULTS
g Computer
SHOULD BE RESET FROM THE ALARM
SCREEN.
COMPUTER: ALAHM MESSAGES ARE
RELATED TO THE INPUT STATUS OF
EACH TESTED CHANNEL. WHEN
ACTIVE ALARM IS PRESENT ONLY
CInUUlNT CYCLE IS STOPPED AND
TEST PROCESS CONTINUE TO THE
NEXT AVAILABLE INPUT CHANNEL.

Page 48 of 76

Y_ _
_.:'-.:C,-D::....c:N-'.K:..;E::...c

VJVruuable
infomJation

Q Cornputcr

Mau2009
Maba! EUROPE Ltd.

OPERATING

MANUAL

4. Maintenance

Introduction

III this ptlragmph, theiP iJ a comidemble alllollllt ql

illfol'll/atioll Irklted to the Alla/y'(Cr IIJ(Jillte/lalll'e, Cllld
rolltillC pro,rdllm: Their CII? wlll(/ble e"'1'irllltltioIlJ tlJ to
the 10ti",1 JeqlleJ/l'eJ alld coII!jJllterplvgmllJlllillg ,Ilep": AI.ro
.for <VIIlII/OII opemtor lI,rage, thel? is all ill,depth, llJaill
colltrolprogmlll alld 011 JCll'etI illJtntdioll,r pro/lided to
etlJIIIV pmiJe, qllality opemtiom:
COMPUTER: ON mE SCREENI-_ _ _ _ _ __
DISPLAY, FOR ALL NUMERICAL
leo N K. Y
VALUES ADJUSTMENTS, ONCE A-:::'-':""::'-"-.='-'--SPECIFIC DATA BOX IS SELECTED AN 0 V,,]mblc
ENTRY WINDOW WILL BE OPENED
Infonnatinn
TO ALLOW SUCH INSERTIONS,
~ Computer

4.1.

Filter Paper Replacement

Open the analyzer cabinet door

Unscrew the two Screw Covers while they remain

attached to the tran::.varcnt Inner Piston Cover (see

Figure 16), For proper disassembling the Inner Piston

Cover, both screws need to be unscrewed
simultaneously.
CAUTION: FOR SAFE'lY REASON
REMOVAL
OF TRANSPARENf
INNER PISTON COVER WILL
THE
SYSTEM
AIR
CAUSE
PRESSURE TO BE RELEASED,

ICON

KEY

[2S] Caution

lC'J Valmbk
lnt(lllnatlon

Release
the
Tension
Cylinder fr0111 dlC collecting reel. Pull out used paper
with ti,e adjacent reel (see Figure 18).

Page 49 of 76
Rev. 1.00
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5DI22002

Transfer the empty reel to the collecting Qeft) side.

r.oad a New Reel in the right sid e; in sert the Pilter
Paper through the cylinders and the pi ston as shown

in the diagmm.
[ Screws Cover

Transparent
Piston Cover

Figure 17 - Piston Cover

Fasten the paper edge to the Collecting Reel using Ole

adllcsivc tape.

Close Ole Tension Cylinder on the Collecting Reel

side .

.Mount the transparent Inner Pisto n Cover in place.

Tighten the two screws o n the tmnsparent Inner

Piston Cover. For proper assembly of the Inner
Piston Cover, both screws need to be screwed
simultatlco llsly.

Close off the analyzer cabinet door.

[ Collecting Reel

E mp ty Reel
Tension Cylinder

Pivot

Filter Paper

Piston

Figure 18 - Filter Paper Installation

Paga !l0 of 76

Mau 2009
Mabat EUROPE Ltd.

OPERATING MANUAL

4.1.1. Pre Start-Up Ust

111c three indication lights on the PLC power supply;

P\\IR, OK, RUN, is ON.

COMPUTER: THE LETTERS AND\o...._ _ _ _ __

NUMBERS IN TIlE BRACKETS OF
leo N K. Y
THIS SECTION INDICATE THEu----'--'--'''-''--'-'--=--:'----FUNCTION
AND
ADDRESS
OF E7 Vnlmble
DIGITAL INI'UT OR OUTPUT THAT
Infonnatiu!l
SHOULD BE DISPLAYED FOR THE
DESCRIBED STEP, (I - FOR INI'UT, 0 - ~ Computer
FOR OUTI'U1).

PG-I on the inlet air regulator should read 80-90 [psi].

Air pressure switched O.K (I, A3).

Piston cover in place (I, A6).

Monitored phUlt operable (I, A 7)

Piston on upper position (0, B I)

Piston upper position switched ON (I, AS)

30 [psi] to float assembly SV-O is ON (0, AI)

PG-2 indicate 30 [psi] (Adjustable)

No fault nor alarm (0, B5, B4)

Ready ON (0, !l8, only when STOP button is sho\\",
on the 1\hin Screen).

Start operation.

4.2.

Failure Messages Definition

4.2.1. Major Failures (1-5)
A major failure will stop the analyzer until the failure is
removed and ti,e RESET PAULT button is pressed on the
ALARlI! SCREEN. If the fault occurs when tile analyzer is
operating, it will pcrfonn the cleaning cycle and stop.

4.2.2. Plant Stop (6)

\"'(fhen the monitored plant is stopped the analyzer will stop
its test cycle. If this occurs when the analyzer is operating, it
will perform the cleaning cycle and stop. \,'hen the plant
resumes operations, the analyzer will restart checking the
Page 51 of 76

Rev. 1.00

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5DI-2200-2

intclTupted channel without any need of external

intelvention. It allows starting the ~[ANUAL mode if such
an operation is desired.

4.2.3. Temporary Failures (7-8)

A temporary failure will cause the Analyzer to stop
immediately and closc all the valves. After the failure is
removed the analyzcr will pcrfonn a cleaning cyclc and
restart checking the interrupted channel without any need
for cxternal intervcntion.

4.2.4. Channels Alarms (10-57)

These failures are related to specific input and have no
effect on the operation for thc other input. \\/hen a failure
occurs, the analyzer will perfonll dlC cleaning cycle and
continue to the next channel. TI1C warning message will
remain on display lIDtil RESET ALARl'vl button is pressed.

4.3.

Failure Description and corrective action

4.3.1. PLC Failure (1)

Check d,e power supply to the PLC (24 [volt]).
Verify the three green indicator lights for POWER, O.K.,
and RUN arc on. Turn power off and on again. O.I<. lamp
should blink several times and then goes on. RUN lamp
should turn on when O.K. stops blinking.

4.3.2. Piston Failure (2)

If the piston is not in the required position dID1ng any of
the analysis phases, the analyzer will stop and display failure
no. 2. Check the piston operation. Disconnect the electric
socket SV-8, and by pressing the red button on the top of
the electric valve move the piston up and down to check
the position indicators. Replace the failed component.

Page 52 of 76

Mau 2009
Mabat EUROPE Ltd.

OPERATING MANUAL

4.3.3. No Paper (3)

Remove the Transparent Piston Protective Cover and
install a new roll of paper.

4.3.4. Used Paper (4)

TIle filter paper did not move at the end of the previous
analysis. Open the protective cover. Check whether the roll
has reached the end. If yes, replace it. If not operate the
motor manually by applying +24 [volt] to terminal No. 14
(Output 11) on the output card of the PLC. Obselve ti,e
paper movement. Correct the wure and retum the cover.

4.3.5. Inlet Valve Leak (5)

'111is failure is detected between measurement cycles, when
water level reaches the low-level switch. \\lhen detected the
analyzer \-vill drain the water and will not proceed with the
next analysis cycle, until reset fault is done. First check the
inlet water sampling pressures and make sure that they do
not exceed 6 bar (90 [psigJ). Disconnect the sample valve
lines and locate the one that is leaking. Repair or replace it
as reguired.

4.3.6. Monitored Plant (6)

\\lhen the monitored plant is stopped the analyzer will stop
its cycle. \\lhen the plant resumes its operations, the
analyzer will restart without any need of external
intervention.

4.3.7. Protective Cover (7)

'Illis failure is detected when the protective cover is not in
place. If this failure appears even when the cover is in
place, check the operation of the proximity switch with a
magnet.

4.3.8. Low Air Pressure (8)

Check the air supply pressure. It should be higher then
70[psi]. If high enough check the calibration of the pressure
switch PS (set to 50 [Psi]). Calibrate or replace as required.
Page 53 of 76
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SDI-2200-2

4.3.9. Pressure Low (9-12)

Check the inlet water pressure and correct as required (It
should be higher then 30 [Psi]).

4.3.10.

Chamber Unclean (13-16)

111i8 f.'1ilure results from low inlet flow of water together
with low water pressure, usually due to long sample tubing.
Tn order to avoid this failure throttle the measuring tank
drrun line (e.g. insert a 1/411 pipe section) or raise it above
the tank elevation.

4.3.11.

Flow Low (17-20)

1111S failure is detected during the check titne, indicating
that the water quantities flowing out arc larger than those
flowing in.

4.3.12.

Level High (21-24)

1l,is failure is detected during the test cycle if d,e high-level
float is activated for more than 7 seconds, Usually it will
indic.1te plugged filter, caused from velY high SOl. If this is
the case, reduce the test time.

4.3.13.

Fast Flow (25-28)

1111S failure is detected after ~ is measured, if the water level
is rising too fast in the float chrunber. J ..ower the inlet water
pressure or decrease the size of the srunple line.

4.3.14.

No H/L Check Done (29-32)

111is wure is detected during the test cycle, if after 15
minutes the water does not reach the high-level float. In
order to resolve this problem raise the water inlet pres..<;ure
or increase the size of the sample lines.

Page 54 of 76

Mau2009
Mabat EUROPE Ltd.

OPERATING MANUAL

4.3.15.

No Flow (33.36)
'I1lis 1.ilure is detected during dlC memmretncnt of If,
indicating dlal the rate of flow through the filter is vcry
low, and the expected SDI reading is very high (>6.4) 11,e
analyzer is not measuring the real tf time, usc the value of
300 [Sec] as t, for the calculation.

4.3.16.

High SDI (37-40)

111is alarm message indicate that the last reading of the
channel is higher then the progratntned value. It is used as
a warning and it is not an Analyzer failure.

4.3.17.

Paper Almost Finish (41)

TIlls alarm message is show11 when Paper Used value is
equal to Paper Set value (refer to SETl'ING SCREEN in
section 3.3.6).

In order to remove the above alann message increase the

Alarm Set value to a higher value then the Paper Used one.

4.4.

Alarm and Fault Messages

11,e following table shows all Ule analyzer f"ilure and ala1m
description messages. TIle corresponding code description
related to fault 111CSsages will cause analyzer to shut down;
alarm message conditions will stop analyzer current test
operations.

Item
1
2
3
4

5
6
7

8
9
10
11
12
13

Description
P.L.C. Failure
Piston Failure
No paper
Used Paper
Inlet Valve Leaks
Monitored Plant
Protective Cover
Low Air Pressure
Pressure Low (Ch-1)
Pressure Low (Ch-2)
Pressure Low (Ch-3)
Pressure Low (Ch-4)
Chamber Unclean (Ch-1)

h~u~rn

Fault
Message

Alarm
Message

./
./
./
./
./
./
./
./
./
./
./
./
./

~~1~

5DI-2200-2 OPERATING MANUAL (PP BOX, GE, 230VAC) 1.00 - EUROPE

5DI22002

Item
14
15
16
17
18
19
20
21

Chamber Unclean (Ch2)

Chamber Unclean (Ch-3)
Chamber Unclean (Ch-4)
FION Low (Ch-1)
FION Low (Ch-2)
FION Low (Ch-3)
FION Low (Ch-4)
Level High (Ch -1)
Level High (Ch -2)
Level High (Ch -3)
Level High (Ch -4)
Fasl Flow (Ch-1)
Fast Flow (Ch-2)
Fast Flow Ch-3)
Fast Flow (Ch-4)
No H/L Check Done (Ch-1)
No H/L Check Done (Ch-2)
No H/L Check Done (Ch-3)
No H/L Check Done (Ch-4)

22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41

Description

No Flow (Ch-1)
No Flow (Ch-2)

....

Fault
Message

Alarm
Message
.,f
.,f
.,f
.,f
.,f
.,f
.,f
.,f
.,f
.,f
.,f
.,f
.,f
.,f
.,f
.,f
.,f
.,f
.,f
.,f
.,f

No Flow (Ch-3)
No Flow (Ch-4)
High SOl (Ch-1)
High SOl (Ch-2)
High SOl (Ch-3)

.,f

HlghSDI(CIi~4r

.,f

Paper Almost Finish

.,f
.,f
.,f
.,f

.,f

Table 5 - System Alarms

Page 56 of 76

Mau2009
Mabat EUROPE Ltd.

OPERATING MANUAL

Warranty Policy
5.1.

GENERAL

abat EUROPE Ltd. warrants that its products

arc free from defects in
workmanship, and will have

described
proposal.

5.2.

in

the

Mabat

material and
the functions

EUROPE

Ltd.

WARRANTY PERIOD
The terms of this warranty shall be for a period of one (1)
year after the product is placed in service, but not
exceeding fifteen (15) months after shipment.

5.3.

INSTALLATION AND OPERATION

This warranty remains in effect only if the products arc
used in accordance with instructions in manuals and

instruction sheets furnished by Mabat EUROPE Ltd.

with regard to safety, installation, maintenance, startup
and operation. This warranty shall not be effective if

Buyer fails to adequately protect the goods from adverse

environmental conditions, before and after startup. and
to act in accordance with instructions furnished by

Mabat EUROPE Ltd ..

h~~~re

~.1~

SDI22002 OPERATING MANUAL (PP BOX, GE, 230VAC) 1.00 EUROPE

SDI22002

6" Repair Policy

6.1.

REPAIR POLICY

he buyer may return to Mabat EUROPE Ltd.

any part or unit for repair, freight and insurance

pre-paid. Mabat EUROPE Ltd. will repair

part or unit and return part or unit to the Buyer,

paying for return shipping and insurance only. If part or
unit was covered by warranty then repair will be at no

charge to the Buyer. If Buyer wishes to engage Mabat

EUROPE Ltd. field service technician for repair
services, then the following conditions apply:

All travel and living expenses will be paid for by

the Buyer.
Standard rates for Mabat EUROPE Ltd. field
personnel.
A purchase order must be issued by the Buyer
before a technician wlll be dispatched,

Mabat EUROPE Ltd. will determine by accepted

engineering criteria whether the unit or part was covered

by \,(Iarranty. If the repair is covered by Warranty then

Mabat EUROPE Ltd. will deduct the cost of cile part(s)
and the labor charge for the standard repair time from
the invoice.

6.2.

EXCLUSIONS FROM WARRANTY:

"In no event shall Mabat EUROPE Ltd. be liable [or
indirect, incidental or consequential damages nor shall the

liability of Mabat EUROPE Ltd. arising in connection

with any products sold hereunder (whether such liability
arises from a claim based on contract, warranty, or
otherwise) exceed the actual amount paid by Buyer to

Mahat EUROPE Ltd. for the products delivered

hereunder."

Page 58 of 76

Mau 2009
Mabat EUROPE Ltd.

OPERATING MANUAL

'1'111': liOR"C;OING WARRANTY IS IN LIEU OF AND

EXCl.UDES Al.l. OTHER EXPRESSED OR I~IPLI"D
WARRANTIES OR J\IERCIIANT ABIl.I'JY. OR FITN"SS, OR
Cl'llll-:RWISli.

Page 59 of 76
Rev. 1.00
5DI2201).2 OPERATING MANUAL (PP BOX, GB, 230VAC) 1.00 EUROPE

SDI22002

7. Appendix

7.1.

Page 60 of 76

5012200 System Drawings

Mau 2009
M.bat EUROPE Ltd.

OPERATING

MANUAL

7.1.1. P&ID Schematic Drawings

--===========-;-

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c.: ONTIW I. BOX

Figure 19 - P&ID, overall Schematic Drawing

Paga 61 of 76

Rev. 1.00

SDI22002 OPERATING MANUAL (PP BOX, GE, 230VAC) 1.00 EUROPE

SDI-2200-2

7.1.2. Electrical I Control Drawings

3~O

?36

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Page 62 of 76

Mau 2009
Mabat EUROPE Ltd,

OPERATING

MANUAL

1/,
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Figure 21 - Control Box (Inside View)

h~~~n

~~1_

8DI-2200-2 OPERATING MANUAL (PP BOX, GE, 230VAC) 1,00 EUROPE

..

o~

0..1

'Co..

N Ul

MAI)J CIRCUIT
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Figure 26 - 810t1, Digital Inputs (Cant.)

Page 68 of 76

Mau 2009
Mabat EUROPE Ltd.

ow

I
SLOT 2 -

AI - AS

Al
2

::;)

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z
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C)

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}.'V- 4

XV - 5

},,'V - S

XV - 7

I:-lPUT 2

lKPUT 3

l"PCT 4

DRAIN 1

JRAIl\ 2

FLOAT

REGULA:'E

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OPERATING

MANUAL

- ---V'//
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Figure 29 - Slol3, Analog Outputs (Current)

h~"~n

~~1~

8DI22002 OPERATING MANUAL (PP BOX, GE, 230VAC) 1.00 EUROPE

5DI22002

7.2.

Item

1
2
3
4
5

6
7
8
9
10
11
12
13
14
15
16
17
18
19

ParI No.

2106
2403
3172
3203
4050
4435
4090
4220
4224
4230
4642
4436
4289
8855
8857
8850
8852
8853
8854

Recommended Spare Part List

Description
Motor
O-Ring VAITON
Filter Support Screen
Pneumatic Diaphragm Valve
Pressure Regulator
Two Solenoid Valve 3/2
Pressure Regulator Delicate
Pressure Switch
Switch Magnet with LED
Switch Magnet HAMLIN
Magnet
Solenoid Valve 5/2
Float assembly
Pivot With Disk
Disk
Plate (Holder)
Screen Holder
Pivot
Pivot Direct

Qty

1
1
1
7
1
4
1
1
2
1
1
2
1
1
1
1
1
1
4

Recotntnended

Spare Qty.
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1

Table 6 - Recommended Spare Part List

Page 72 of 76

Mau 2009
Mabat EUROPE Ltd.

OPERATING MANUAL

7.3.

Component List

'fag

Item No.

PattNo.

1
2
3
4
5
6
7
8

3203
3203
3203
3203
3203
3203
3203
4435

Pneumatic Diaphragm
Pneumatic Diaphragm
Pneumatic Diaphragm
Pneumatic Diaphragm
Pneumatic Diaphragm
Pneumatic Diaphragm
Pneumatic Diaphragm
Solenoid Valve 3/2

4435

Solenoid Valve 3/2

10

4435

Solenoid Valve 3/2

11

4435

Solenoid Valve 3/2

12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37

4436
4436
4215
4215
4215
2106
2403
3172
4016
4017
4018
4018
4019
4029
4050
4434
4090
4216
4217
4220
4223
4224
4224
8853
8854
8854
8854
8854
8855
8857
9009
8850

Solenoid Valve 5/2

Solenoid Valve 5/2
Level Switch
Level Switch
Level Switch
Motor
O-Ring VAITON
Filter Support Screen
D.1. Module
D.O. Module
A.O. Module
A.O. Module
Power Supply
Base
Pressure Regulator
Manifold
Pressure Regulator Delicate
Pressure Indicator
Pressure Gauge
Pressure Switch
Piston
Switch Magnet with LED
Switch Magnet with LED
Pivot
Pivot Direct
Pivot Direct
Pivot Direct
Pivot Direct
Pivot With Disk
Disk
Vertical Plate
Holder

38
39
40
41
42
43

Description

No.
Valve
Valve
Valve
Valve
Valve
Valve
Valve

XV-1
XV-2
XV-3
XV-4
XV-5
XV-6
XV-7
SV-O
SV-1
SV-2
SV-3
SV-4
SV-5
SV-6
SV-7
SV-8
SV-9
LS-1
LS-2
LS-3
M-1
ORV-1
SC-1
DI-1
DO-1
AO-1
AO-2
PS-1
CPU-1
PR-1
MF-1
PR-2
PG-2
PG-1
PRS-1
PIS-1
LlS-1
LlS-2
PD-5
PD-2
PD-3
PD-4
PD-1
PWD-1
D-1
P-1
SHU-1

Page 73 of 76
Rev. 1.00
8DI-2200-2 OPERATING MANUAL (PP BOX, GE, 230VAC) 1.00 - EUROPE

SDI22002

Item No.

PattNo.

44
45
46
47

8851
8852
4230
4289
4642
4057

48
49

Description
Paper Holder Plate
Screen Holder
Switch Magnet HAMLIN
Float assembly
Magnet
Data Panel

Tag
No.
PHP-1
SHl-1
SM-1
FA-1
SM-2
DP-1

Table 7 - System Component List

Page 74 of 76

Mau 2009
Mabat EUROPE Ltd.

OPERATING MANUAL

7.4.

Change Order Form

Mabat EUROPE Ltd.

COli/Pail)'
Document No.:
Revision No.:

Pril!i/eged & COlljlde!ltia/

I Date,

I Subject: Change Order FOhn

Project: SDI-2200 Serial No.

I File:

Change Order (CO) Log No.:

0 Product/Component

SerialJPart Number:

0 Document (drawinglspec./procedure)

Document Number:

Reason for Change:

Description of Change:

Documents affected by change":

Item
Document No.
No.
1
2
3
4
SUJl]lliers/Subcontractors to be notified:
Item
Name
No.
1
2
3
-.-'--- Authorization Signature:
. -

~-

Title

. - . -

Name

Title

Current
Rev.

New Rev.

Date

Done

..

-.-----.-~.-

Signature

~-.

Date

~ - For changes other then documentation changes (excluding labeling) - attach information on the effect of the
change on the regulatory status ortll(! product.
~~~~n

~-

~~1~

SDI22002 OPERATING MANUAL (PP BOX, GE, 230VAC) 1.00 EUROPE

SDI22002

7.5.

List of Figures

FIGURE 1 - SDI2200 LAYOUT CONFIGURATION (IN MM)

FIGURE 2 - SDI SYSTEM POSITIONING HOLES
FIGURE 3 - POWER SUPPLY CONNECTION
FIGURE 4 - POWER SUPPLY & OFA CONNECTION
FIGURE 5 -INPUT WATER SAMPLE & DRAIN CONNECTIONS
FIGURE 6 - THIRD DRAIN LINE CONNECTION
FIGURE 7 - OPERATING SYSTEM FLOW DIAGRAM
FIGURE 8 - MAIN SCREEN
FIGURE 9 - P & ID SCREEN
FIGURE 10 - OPERATE SCREEN
FIGURE 11 - SETTI NG SCREEN
FIGURE 12 -INFO SCREEN
FIGURE 13 - MONITOR SCREEN
FIGURE 14-ALARM SCREEN
FIGURE 15 - REAL TIME TREND SCREEN (Y SCALE)
FIGURE 16 - REAL TIME TREND SCREEN (CURVES)
FIGURE 17 - PISTON COVER
FIGURE 18 - FILTER PAPER INSTALLATION
FIGURE 19 - P&ID, OVERALL SCHEMATIC DRAWING
FIGURE 20 - CONTROL BOX (OUTSIDE VIEW)
FIGURE 21 - CONTROL BOX (INSIDE VIEW)
FIGURE 22 - MAIN CIRCUIT DIAGRAM
FIGURE 23 - WIRING CONNECTION
FIGURE 24 - TERMINAL BLOCKS
FIGURE 25 -SLOT1, DIGITAL INPUTS
FIGURE 26 - SLOT1, DIGITAL INPUTS (CO NT.)
FIGURE 27 - SLOT.2, RELAY OUTPUTS
FIGURE 28 - SLOT2, RELAY OUTPUTS (CONT.)
FIGURE 29 - SLOT3, ANALOG OUTPUTS (CURRENn

7.6.
TABLE 1 TABLE 2 TABLE 3 TABLE 4 TABLE 5 TABLE 6 TABLE 7 -

14
15
16

17
18
19

29
30
33

34
36
38
40

41
42
42
50
50
61

62
63

64
65
66
67

68
69
70
71

List of Tables
SUBUNIT CONFIGURATION
WIRING CONNECTION TABLE
DIGITAL OUTPUT OPTION SETTINGS (TERM. 1620)
LOGIN LEVEL CONFIGURATION
SYSTEM ALARMS
RECOMMENDED SPARE PART LIST
SYSTEM COMPONENT LIST

Page 76 of 76

12
20
27
32
56
72
74

Mau 2009
Mabat EUROPE Ltd.

coc
We herein to declare that the manufacture of the

Automatic Analyzer SDI-2200

Model 2202

SIN 080173
Is consistent with MABAT's high
Standards of quality,
and product specifications.

MABAT Europe industrial control systems Ltd.

September, 2010

CHECK LIST SDI ANALYZER 080173

Customer: Degremont SA
Address:

Date: September, 2010

SDI Analyzer Model: 2202
Serial Number: 080173
Voltage: 1101230VAC

France

[S] SDI Analyzer

.......a . .

Number of channels (1-4)

Number of analog outputs (1-4)
~
Range of analog outputs (volts/mA)
.. ~.~ ..?r.!hI
Options:
Output Contact
~ Common Alarm

........ ...... A

G Common Fault
~ Ready

D Alarm pel' Input

Input Signal

B Common Remote START/STOP

8] Remote START pel' Input

Accessories

Enc. Documcnts

J0.03/4(9/98)

IS!] Operation Manual

... A.... Pcs.

I'-J I Spare Compression Nuts

.......... Pcs.

D Filter Rolls

....... Rolls

~ Chcck List

O.K.

~ Operation test

O.K.

~ Alarm & Fault detection test

0.](.

Lj

@ Operation tcst
1.
2.
3.
4.

Check for water leaks.

Check for Air leaks.
Check ifPLC is in RUN position.
Remove the piston cover and notice input 6 turn off.
Change the piston position up and down by hand and noticc piston up input 5
goes on, piston down input 4 goes on, ifnot adjust limit switch locations.
5. Dccrease the Air Pressure by the inlet pressure regulator, as indicated on PO I
to 50 Psi. Input 3 will turn off, ifnot adjust PSI.
6. Adjust the pressure on PO I to 90 Psi.
7. Return piston cover, adjust the pressure on P02 to 30 Psi by the chamber
regulator.
8. Check all the valves by pressing the red buttons on the solenoid valve and
notice that the red indicator on the valvcs goes up, and no air leaks.
(SV 1-7 operates valve V 1-7 accordingly)
9. Install a new roll of paper according to the manual, and return the piston
cover.
10. Program the Analyzer fi'om the Touch Screen, according the instruction
manual for automatic and manual operation. If you have more than one input
program different check timc for each input.
11. Start the Analyzer for manual operation, and notice that the analyzer checks
the fU'st active input. Check for watcr leaks.
12. Check that the line flush and the membrane air venting is performed
acco rding to the instruction manual.
13. Prepare a 500ec funnel. When the analyzer is checking Ti, check the volume
of water between the high and low float to be exactly 500ec, ifnot adjust the
position ofthe float. Measure the distance between the floats and writc it
down. FLOAT DISTANCE: 1) From Lower to Uppcr CiJ2 Milimctcr.
2) From Upper to Middlc
Milimeter
14. Complet e the cycle, after receiving the SOl value check that the analog output
(if avai lable) is O.K. in consideration with the check time (page 3 in the
manual).
15. After thc piston is raised check that the paper motor is working properly,
meaning first releasing the paper by a series of short pulses and when ncw
cyclc is started pulling thc right amount of paper for the next check. (if not
change rcgister No. 228 and check again, until the right movement is found
and writc down the register value). REG ISTER 228 VALUE .;) ~-r
16. Complete all checking of the active channel and notice that the sequence of
checking is in the right order.
17. Program the analyzcr for automatic operation, if you have more than one
input, program different cycle times for each input.
18. Operate the analyzer in automatic mode and notice that thc sequence of
operation is according the program.

\I"

10.03/4(9/98)

@ Alarm & Fault dctcction test

Description
Piston failurc

Remove piston cover change piston position by hand wait 5 seconds to get
the alarm on the display.
No Paper
Pertorm operation without filter paper and wait for the alarm after Ti
measurement.
Old Paper
Pertorm operation with blocked paper and wait for the alarm after Ti
measurement.
Manually open one of the inlet valves by pushing the red button on the SV.
Inlet Valve Leal<
until the water is reaching the low float and notice that the analyzer drains
the waler and that the alarm is displayed.
Monitorcd PLANT Remove the plantstop jumper and notice the alarm.
Remove the piston cover and notice the alarm.
Protectivc Covcr
Low Ail' Prcssure
Close the air supply, let the pressure decrease and wait for the alarm at
50 Psi.
Decrease water pressure under 30 Psi. start the analyzer and notice the
P"essurc Low
alarm (perform this test tor each channel.)
Chambcr Unclean
Adjust water pressure to a value so that the water will not reach the upper
float at the flush stage, notice the alarm.(pertonn this lest for each channel).
Adjust water pressure to a value so that the water will not reach the upper
Flow Low
float during the checking stage, notice the alarm (perform this test for each
channel).
No H/L Chccl< Done Adjust water pressure to a value so that the water will not reach the upper
tloat at the end of the checking stage, notice the alarm
(perform this test for each channel).
Increase water pressure to a value so that the water is raising li'OIn the
Fast Flow
low float to the high float in less then 5 seconds, notice the alarm
(perform this test for each channel).
Manually open the inlet valve while the instrument is in the checking stage
Level High
to have water at the high float tor more than 5 seconds, notice the alarm
(perform this test for each channel).
No Flow
Unplug SV -7 while the analyzer is on Tf measuring stage for more than
300 seconds, notice the alarm (perform this test for each channel).
Set the SDl alarm value to a low value (0.5), start the analyzer and notice
High SOl
the alarm after receiving a new value (perform this test for each channel).

TI,is certifies that the abOl'e al/alyzer was tested aI/(/ operated to ourfitll satisjactOl:V
alld that IlO.~~:::;~:::~~~ could be detected.
Sigllature Mabat testillg Ellgill eer
10. 03/4(9/98)