Gebruder Heyl Analysentechnik Testomat 2000 DUO User manual

1
Testomat 2000® DUO
Online analysis instrument for
water hardness, carbonate hard-
ness, p-value or minus m-value
Operating Instructions

Contents
2
Contents
Contents...............................................................................................2
Important safety information .............................................................4
Intended use .........................................................................................4
Qualification of the staff ........................................................................4
Warning notices in these instructions ...................................................5
Further documents................................................................................5
Pay particular attention to..................................................................5
General instructions..............................................................................5
Installation.............................................................................................6
Operation ..............................................................................................6
Cleaning................................................................................................6
De-installation .......................................................................................6
Disposal ................................................................................................6
Scope of delivery ................................................................................7
Performance specifications...............................................................7
Indicators for Testomat 2000® DUO instruments..................................8
Application instructions.....................................................................9
Installation.........................................................................................10
Operating Testomat 2000®DUO in the pressure range 0.3 to 1 bar..10
Installing Testomat 2000® DUO ..........................................................10
Connecting the water inlet and outlet .................................................11
Water inlet...........................................................................................11
Water outlet.........................................................................................11
Connecting the power supply and devices .........................................12
Block diagram Testomat 2000®DUO ................................................12
Internal design Testomat 2000®DUO.................................................13
Connecting the mains voltage.............................................................14
Connecting the plant components ......................................................15
Connecting the inputs and outputs .....................................................16
Commissioning.................................................................................17
Inserting the indicator bottle................................................................17
Extracting the indicator .......................................................................17
Opening the water inlet.......................................................................17
Instrument settings and data input......................................................18
Functions of the operating and display elements.........................18
Switching Testomat 2000® DUO on/off...............................................18
Display functions.................................................................................19
Operating elements and function keys ...............................................20
Operating system................................................................................21
Password protection and basic program.......................................22
Entering basic program data...............................................................22
Selecting the indicator and the bottle size ..........................................22
Selecting the operating mode.............................................................23
Selecting the display unit(s)................................................................24
Measuring point or parameter selection .............................................24
Entering further basic program data ..............................................25
Internal flushing...................................................................................25
External flushing .................................................................................25
Interval pause .....................................................................................26

Contents
3
Limit value monitoring.........................................................................26
Hysteresis ...........................................................................................27
Switch functions of the limit value outputs LV1 and LV2....................28
Switch function 0, duration..................................................................28
Switch function 1, impulse ..................................................................28
Switch function 2, interval...................................................................28
Function IN1........................................................................................28
Water meter ........................................................................................28
Alarm / Message.................................................................................29
Function AUX......................................................................................29
Service II.............................................................................................30
Reset operating time...........................................................................30
Maintenance interval...........................................................................30
Description of the signal inputs/outputs........................................31
Interfaces (optional) ............................................................................33
Monitoring a measuring point..............................................................33
Monitoring of two measuring points....................................................33
Calculating the output currents...........................................................34
Serial interface RS232........................................................................35
Description of the relay outputs......................................................35
Flushing (external flush valve)............................................................35
LV1 and LV2 limit value outputs .........................................................35
Measuring points 1 or 2 (measuring point switch-over)......................36
Alarm (fault message output)..............................................................37
Maintenance (output for maintenance message) ...............................38
Information menu "i" ........................................................................39
Program menu "M" ...........................................................................40
Structure of the basic program............................................................42
Error messages / Troubleshooting .................................................43
Further information..............................................................................44
Maintenance ......................................................................................45
Description of maintenance work........................................................45
Service instructions.............................................................................46
Testomat 2000®spare parts and accessories................................47
Accessories.........................................................................................48
Technical data...................................................................................49

Important safety information
4
Important safety information
Please read these operating instructions carefully and completely
prior to working with the instrument.
Ensure that these operating instructions are always available for all
users.
These operating instructions must always be passed on to the new
owner should Testomat 2000®DUO change hands.
Always adhere to hazard warnings and safety tips when using
reagents, chemicals and cleaning agents. Please adhere to the
respective safety data sheet! Download the safety data sheets for
the supplied reagents at http://www.heyl.de .
Intended use
Testomat 2000®DUO is used for the automatic determination and
monitoring of residual total hardness (water hardness), residual car-
bonate hardness, as well as the minus m-value and the p-value in
water. The measurement parameters and the respective measuring
range are determined by the indicator selection and according to the
user programming.
Always adhere to the performance limits stated in the section enti-
tled “Technical data”.
Always observe the application areas/application limits of the indi-
cators and the requirements of the medium being measured.
To ensure correct and intended usage, always read and understand
these instructions, especially the section entitled “Important safety
information”, prior to use.
The instrument is not used as intended if
it is used in areas not specified in these instructions,
it is used in areas which do not correspond to the ones described
in these instructions.
Qualification of the staff
Assembly and commissioning require fundamental electrical and
process engineering knowledge as well as knowledge of the respec-
tive technical terms. Assembly and commissioning should therefore
only be carried out by a specialist or by an authorised individual su-
pervised 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.

Pay particular attention to
5
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
observed, it may result in an undesirable result or state.
Further documents
Testomat 2000®DUO is a plant component. Therefore, always ob-
serve the maintenance manual of Testomat 2000® / Testomat 2000
ECO®and the documentation of the plant manufacturer.
Pay particular attention to
General instructions
Please adhere to health and safety regulations, electrical equip-
ment safety regulations, and environmental protection regulations
valid in the country of use and at the installation site.
Adhere to national and local regulations during installation and
commissioning.
Always protect the instrument against moisture and humidity. It
should never come into contact with condensation or splash water.
 Do not carry out any changes or actions at the instrument which are
not described in these instructions; failure to adhere to these in-
structions will negatively affect any warranty claims that you make
thereafter.
SIGNAL WORD!
DANGER
!
WARNING
!
CAUTION
!
NOTE
WARNING
!

Pay particular attention to
6
Installation
Always completely disconnect the relevant plant part before in-
stalling the instrument or connecting/disconnecting it to/from the
power supply. Secure the plant against reconnection.
Only connect the instrument to the mains voltage specified on the
rating plate.
Always observe technical data and ambient parameters.
Testomat 2000®DUO requires an interference free and stable
power supply. If necessary, use a mains filter to protect Testomat
2000®DUO against interference voltages caused, e.g., by solenoid
valves or large motors. Never lay connecting cables parallel to
power cables.
Operation
Ensure that the maximum electrical load capacity of the relay out-
puts is never exceeded.
Immediately switch off Testomat 2000®DUO and contact service
staff if malfunctioning occurs. The warranty will be void if you tam-
per with or attempt to repair Testomat 2000®DUO. Repairs must
be carried out by authorised service staff.
Cleaning
Only use a dry, lint-free cloth for cleaning.
De-installation
Prior to de-installing a defective instrument, always write down a
description of the error (failure effect). It is only possible to repair a
defective instrument (irrespective of the warranty period) if it has
been de-installed and returned to us with a description of the error.
Disposal
Dispose of the instrument in accordance with national regulations.
WARNING
!
NOTE

Scope of delivery
7
Scope of delivery
1 Testomat 2000® DUO
1 Plastic bag with two screw caps with a hole and an insert for the
screw caps of the indicator bottles
1 operating instructions
Performance specifications
Testomat 2000®DUO is used for the automatic determination and
monitoring of residual total hardness (water hardness), residual car-
bonate hardness, as well as the minus m-value and the p-value in
water. The instrument can be used to alternately measure two pa-
rameters at one measuring point or two measuring points with differ-
ent (or the same) parameters. The measurement parameters and the
respective measuring ranges are determined by the indicator selec-
tions and according to the user programming.
Simple, menu-driven operating and programming via a plain
text display
Determinable measuring of residual hardness, total hard-
ness, carbonate hardness, minus m-value, p-value via indica-
tor selection
Freely selectable hardness unit in °dH, °f, ppm CaCO3or
mmol/l
High measuring accuracy provided by a precise piston-
dosing pump
Analysis initiation:
- Automatic interval operation
(interval pause can be set from 0-99 minutes)
- External control
- Quantity dependent via impulse water meter
Two independent limit values with hysteresis (1, 2 or 3 bad
analyses) and settable switch functions
Monitoring of two measuring points (change-over via external
solenoid valves)
Internal error documentation
Programmable service address
Programmable maintenance interval for a maintenance re-
quest
Extended operating periods due to 500 ml indicator storage
bottle
optional:
Interface card (0/4-20 mA or 0/2-10 V)
Interface RS 232 (for a protocol printer)

Performance specifications
8
Indicators for Testomat 2000® DUO instru-
ments
Parameter/Indicator type
Water hardness
TH 2005
TH 2025
TH 2100
TH 2250
Unit
°dH
(resolution)
0.05 –0.50
(0.01)
0.25 –2.50
(0.05)
1.0 –10.0
(0.2)
2.5 –25.0
(0.5)
°f
(resolution)
0.09 –0.89
(0.02)
0.45 –4.48
(0.1)
1.8 –17.9
(0.4)
4.5 –44.8
(1.0)
ppm
CaCO3
(resolution)
0.89 –8.93
(0.2)
4.5 –44.8
(0.9)
18 - 179
(3.8)
45 - 448
(10)
mmol/l
(resolution)
0.01 –0.09
(0.002)
0.04 –0.45
(0.01)
0.18 –1.79
(0.04)
0.45 –4.48
(0.1)
Parameter
/Indicator
type
Carbonate
hardness
minus m-
value
p-value
p-value
TC 2050
TC 2100
TM 2005
TP 2010
TP 2100
Unit
°dH
(resolution)
0.5 –5.0
(0.5)
1.0 –20.0
(1.0)
-
-
-
°f
(resolution)
0.90 –8.96
(0.9)
1.8 –35.8
(1.79)
-
-
-
ppm
CaCO3
(resolution)
8.9 –89.5
(8.9)
18 - 358
(18)
-
-
-
mmol/l
(resolution)
0.18 –1.79
(0.18)
0.36 –7.16
(0.36)
0.05 –0.50
(0.01)
0.1 –1.5
(0.1)
1 - 15
(1)
Display, if measuring value is outside of range (for example TH2005):
At falling below: < 0,05°dH
At exceeding: > 0,50°dH

Application instructions
9
Application instructions
Wait at least 5 seconds before switching the instrument on and
then off again at the main switch.
In order for Testomat 2000®DUO to operate reliably, use Heyl
Testomat 2000®indicators in the pH-range 4 –10.5!
With Testomat®instruments for water hardness monitoring, larger
quantities of heavy metal ions in the softened water might influ-
ence the colour reaction, especially iron above 0.5 mg/I, copper
above 0.1 mg/I and aluminium above 0.1 mg/l (brownish-red colour
display).
If the measuring water contains more than 20 mg/I CO2(carbonic
acid), incorrect evaluations cannot be excluded.
The concentration of influencing contents can be determined by
using our colourimetric TESTOVAL®test kit.
Careful handling of the instrument increases both its operational
reliability and service life! Therefore, carry out a visual inspection
at regular intervals as described below:
- Has the use-by date of the indicator expired?
- Are the hose connections of the dosing pump free of leaks?
- Is there air inside the dosing hoses?
- Are all the water connections free of leaks?
- Are the doors of the instrument closed properly?
- Is the instrument heavily soiled?
- Are the measuring chamber and the drain duct/drain hose
clean?
Trouble-free operation is only possible when maintenance is car-
ried out on a regular basis! For more information, please refer to
the section entitled “Maintenance” and the "Maintenance manual
of Testomat 2000® / Testomat 2000 ECO®"
If problems occur, please refer to the section entitled "Error mes-
sages/Troubleshooting”.

Installation
10
Installation
Risks resulting from incorrect installation!
Install Testomat 2000® DUO at a location where it is protected
against dripping or splash water, dust and aggressive substances
–e. g. in a switch cabinet or on a suitable wall.
Information for trouble-free operation
Install Testomat 2000® DUO vertically and without mechanical
stress.
Install Testomat 2000® DUO at a vibration-free site.
Operating Testomat 2000®DUO in the pres-
sure range 0.3 to 1 bar
Prior to installation, please check whether lower operating pressure is
required. The instrument is factory set for the operating range 1 to 8
bar. Remove the flow controller valve body to operate the instru-
ment in the operating range 0.3 to 1 bar (e.g. when using an aerator
type R). This involves removing the retaining pin from the control-
ler / filter receiver . Subsequently use the metal bracket to remove
the controller plug from the borehole. Subsequently remove the
flow controller valve body and reinsert the controller plug and the
retaining pin.
Installing Testomat 2000® DUO
Select an installation site where the water inlet hose can be kept as
short as possible (max. 5 m).
Please leave sufficient space on the left-hand side of the instru-
ment to open the door.
Drill the mounting holes as shown in the drawing on the left.
Use three screws to attach the instrument at a suitable position in
the switch cabinet or on a wall.
NOTE
Remove for
pressure
range 0.3 to 1
bar
WARNING
!