Heyl Testomat ECO User manual

1
Testomat ECO®
Online analysis instrument
for residual total hardness
(water hardness)
Operating Instructions

Contents
2
Contents
Contents...............................................................................................2
Important safety information .............................................................4
Intended use .........................................................................................4
Qualification of the staff ........................................................................4
Warning notices in dthese instructions .................................................5
Further documents................................................................................5
Pay particular attention to..................................................................5
General instructions..............................................................................5
Properties of the measured water.........................................................5
Installation.............................................................................................6
Operation ..............................................................................................6
After switch-off and longer downtime....................................................6
Cleaning................................................................................................6
De-installation .......................................................................................6
Disposal ................................................................................................7
Scope of delivery ................................................................................7
Performance specifications...............................................................7
Indicators for Testomat ECO® instruments ...........................................8
Application instructions .........................................................................9
Installation.........................................................................................10
Operating Testomat ECO®in the pressure range 0.3 to 1 bar...........10
Installing Testomat ECO®...................................................................10
Connecting the water inlet and outlet .................................................11
Water inlet...........................................................................................11
Water outlet.........................................................................................11
Connecting the power supply and devices .........................................12
Block diagram Testomat ECO®...........................................................12
Internal design Testomat ECO®..........................................................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 ECO® on/off ........................................................18
Display functions.................................................................................18
Operating elements and function keys ...............................................20
Operating system................................................................................21
Entering basic program data...........................................................22
Selecting the indicator and the bottle size ..........................................22
Selecting the operating mode.............................................................22
Selecting the time control....................................................................22
Setting the analysis interval (interval pause) ......................................23
Selecting the quantity control..............................................................23
Selecting the type of water meter .......................................................23
Selecting the quantity control/time priority..........................................24

Contents
3
Selecting the display unit....................................................................24
Entering the flushing time ...................................................................24
Limit value monitoring.........................................................................25
Hysteresis ...........................................................................................25
Switch functions of the limit value outputs LV1 and LV2....................26
Switch function 0, duration..................................................................26
Switch function 1, impulse ..................................................................26
Switch function 2, interval...................................................................26
Switch function 3, two-point................................................................26
BOB operation (operation without permanent supervision)................27
Description of the signal inputs/outputs........................................28
Stop input............................................................................................28
Water meter input ...............................................................................29
Current interface 0/4 - 20 mA..............................................................29
Calculating the output currents...........................................................31
Description of the relay outputs......................................................32
LV1 and LV2 limit value outputs .........................................................32
Alarm/Message (fault message output)..............................................33
Information menu "i" ........................................................................34
Program menu "M" ...........................................................................35
Structure of the basic program............................................................37
Error messages/Troubleshooting ...................................................38
Further information..............................................................................39
Maintenance ......................................................................................39
Description of maintenance work........................................................40
Service instructions.............................................................................41
Testomat ECO® spare parts and accessories ................................42
Accessories.........................................................................................44
Check List Testomat ECO®.................................................................45
Technical data...................................................................................47
Conformity Declaration .......................................................................48
Product overview Testomat 2000®-Instruments ............................48

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 ECO®change hands.
Always adhere to hazard warnings and safety tips when using
reagents, chemicals and cleaning agents. Please adhere to the re-
spective safety data sheet! Download the safety data sheets for
the supplied reagents at http://www.heyl.de.
Intended use
Testomat ECO®is used for the automatic determination and monitor-
ing of residual total hardness (water hardness) in water with a pH
level above 4. The required measuring range is determined by the
indicator selection and the respective 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 dthese 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 error
Description of the consequences resulting from non-obervance
Preventive measures. Always adhere to these preventive
measures.
“DANGER” indicates an immediate hazardous situation which, if not
avoided, will result in death or serious injury.
“WARNING” indicates a potentially hazardous situation which, if not
avoided, could result in death or serious injury.
CAUTION” indicates a potentially hazardous situation which, if not
avoided, could result in minor or moderate injuries or property dam-
age.
“NOTE” indicates important information. If this information is not ob-
served, it may result in an undesirable result or state.
Further documents
Testomat ECO®is a plant component. Therefore, always observe the
maintenance manual of Testomat 2000®/ECO®and the documenta-
tion of the plant manufacturer.
Pay particular attention to
General instructions
Adhere to national and local regulations during installation and
commissioning.
Adhere to national health and safety regulations as well as envi-
ronmental protection regulations in the country of use and at the
installation site.
Do not carry out any changes or actions at the instrument which
are not described in these instructions; failure to adhere to these
instructions will negatively affect any warranty claims that you
make thereafter.
Trouble-free operation of Testomat ECO®is only guaranteed when
using Heyl Testomat 2000®indicators in the pH-range 4 –10.5!
Properties of the measured water
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
SIGNAL WORD!
DANGER
!
WARNING
!
CAUTION
!
WARNING
!
NOTE

Pay particular attention to
6
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), erroneous evaluations cannot be excluded (if necessary, use
aerator type R) (See note in the Performance Specifications).
The concentration of influencing contents can be determined by
using our colourimetric TESTOVAL®test kit.
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 ECO®requires an interference free and stable power
supply. If necessary, use a mains filter to protect Testomat ECO®
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 ECO®and contact service staff if
malfunctioning occurs. The warranty will be void if you tamper with
or attempt to repair Testomat ECO®. Repairs must be carried out
by authorised service staff.
After switch-off and longer downtime
Ventilate the indicator leads as described in the start-up, because
longer downtimes (more than 6 hours) can cause the indicator in
the leads to retract.
Do not switch off the appliance for longer periods (e.g. over the
weekend) via the start/stop output. The indicator can retract from
the leads. This results in measurement errors after the appliance is
switched on.
Cleaning
Only use a dry, lint-free cloth for cleaning.
De-installation
Prior to de-installing a defective instrument, always write down a
description of the error (failure effect). It is only possible to repair a
defective instrument (irrespective of the warranty period) if it has
been de-installed and returned to us with a description of the error.
WARNING
!
NOTE

Scope of delivery
7
Disposal
Dispose of the instrument in accordance with national regulations.
Scope of delivery
1 Testomat ECO®
1 plasic bag with screw cap with a hole and an insert for the
screw cap of the indicator bottle
1 operating instructions
Performance specifications
Testomat ECO®is used for the automatic determination and monitor-
ing of residual total hardness (water hardness) in water with a pH
level above 4. The required measuring range is determined by the
indicator selection and according to the user programming.
Simple, menu-driven operating and programming via a plain
text display
Determinable measuring of total hardness (water hardness)
Freely selectable hardness unit in °dH, °f, ppm CaCO3or
mmol/
High measuring accuracy provided by a precise piston-
dosing pump
Extended operating periods due to 500 ml indicator storage
bottle
Analysis initiation:
- Automatic interval operation
(interval pause can be set from 0-99 minutes)
- Quantity dependent via impulse water meter/turbine
- External analysis stop
Two independent limit values with hysteresis (1, 2 or 3 bad
analyses) and settable switch functions
(two neutral change-over contacts)
Fault message output (neutral change-over contact)
Current output 0/4 - 20 mA
Deposits and corrosion in water with a pH level < 4.0
In water with a pH level < 4, deposits or corrosion can occur on the
magnetic valve in the valve block located on the measured chamber.
In this case, you can order the Testomat ECO®with a different valve
block (Art. No. 40018). This magnetic valve is not affected by media,
and improves the service life.
NOTE

Performance specifications
8
Indicators for Testomat ECO® instruments
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)

Performance specifications
9
Application instructions
Switching on/off
Wait at least 5 seconds before switching the instrument on and
then off again at the main switch.
Ambient conditions/Installation site
Always protect the instrument against moisture and humidity. It
should never come into contact with condensation or splash wa-
ter.
Malfunctioning/Repairing a defective instrument
The repair of a defective instrument –irrespective of the warranty
period - is only possible after the instrument has been dismantled
and returned to us with a description of the error. Furthermore,
please inform us of the indicator type being used and the meas-
ured medium. Do not carry out any actions at the instrument
which are not described in these instructions ; failure to adhere to
these instructions will negatively affect any warranty claims that
you make thereafter . Before you return the instrument for repair,
write down a description of the error (failure effect). Repair work
repair work, remove the bottle and ensure that the measuring
chamber has been flushed out and is empty. Prior to dismantling,
always (irrespective of the warranty period) is only possible when
the instrument is dismantled and returned to us with a description
of the error.
After a protective circuit (fuse) has been tripped, attempt to elimi-
nate the cause of malfunctioning (e.g. replace a defective valve)
before reactivating the protective circuit. Frequent tripping is al-
ways due to an error which, in certain circumstances, may also
cause damage to the instrument.
Operating safety instructions
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:
- Are the hose connections of the dosing pump free of leaks?
- Is there any 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?
Maintenance and servicing instructions
(For more information, please refer to the section entitled
“Maintenance” and the "Maintenance manual of Testomat 2000® /
Testomat ECO®)

Installation
10
Installation
Risks resulting from incorrect installation!
Install Testomat ECO® 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 ECO® vertically and without mechanical stress.
Install Testomat ECO® at a vibration-free site.
Operating Testomat ECO®in the pressure
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 ECO®
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.
Remove for
pressure
range 0.3 to 1
bar
WARNING
!
NOTE

Installation
11
Connecting the water inlet and outlet
Information for trouble-free operation
The water pressure must be between 0.3 bar and 8 bar
Avoid strong pressure fluctuations
The measuring water temperature must be between 10 °C and 40
°C
For temperatures above 40°C, the KCN type cooler should be in-
stalled in the branch line of Testomat ECO®.
Water inlet
The measuring water is taken from the main water line of the water
treatment plant and fed to the inlet connection of Testomat ECO®.
The instrument is equipped with a plug connector for plastic hoses
6/4 x 1 (external diameter 6 mm/ internal diameter 4 mm, wall thick-
ness 1 mm) as standard.
Install the connection for the branch line of Testomat ECO® direct-
ly at the main water line directly after the water treatment plant
It is important that the branch line connection is laid vertically up-
wards in order to prevent dirt particles from entering the instrument
from the main water line
Install a manually operated shut-off valve in the branch to Tes-
tomat ECO®.
Use an opaque plastic hose 6/4 x 1 (max. length 5 m) for the water
inlet 
Flush the inlet to remove any dirt particles
When using a cooler
The hot water can cause burns and damage wetted parts of
Testomat ECO®.
Water outlet
The feed water flows through the measuring chamber to the drain via
the outlet hose.
Connect the outlet connection of Testomat ECO®to an outlet hose
(internal diameter 12 mm)
Lay this hose without backwater development and any syphoning
effect, e.g. via an open funnel, to the drain.






NO !!
"Sagging"
causes back-
water!
CAUTION
!
NOTE

Installation
12
Connecting the power supply and devices
Risk of electric shocks during installation!
If the power supply is not disconnected prior to installation, it may
result in personal injuries, destruction of the product or damage to
plant parts.
Always disconnect the relevant plant parts before installing Tes-
tomat ECO®.
Only use tested cables with sufficient cross-sections for the con-
nections.
Risk of damages caused by electromagnetic fields!
If Testomat ECO®or the connecting cables are installed parallel to
power cables or in close proximity to electromagnetic fields, the in-
strument may be damaged or measurements incorrect.
Ensure that connecting cables are as short as possible.
Always install connecting cables and power cables separately.
Connect the instrument to the protective earth conductor (for
230/115 VAC).
Protect Testomat ECO® against interference voltages –e.g. via a
mains filter.
Shield the instrument against strong electromagnetic fields.
Block diagram Testomat ECO®
Drawn relay positions: Instrument de-energised, mains: 230/115 V
WARNING
!
NOTE

Installation
13
Internal design Testomat ECO®

Terminal strip for inputs Stop, IN2, output OUT, +12 V for turbine

Mains switch

Terminal strip for power input and power output

Terminal strip for relay outputs

Dosing pump

Water connections, inlet and outlet

Controller / filter receiver

Measuring chamber









Installation
14
Connecting the mains voltage
Only connect the instrument to the specified mains voltage. Refer to
the rating plate for the appropriate mains voltage. Connect the cables
as follows:
Loosen both fastening screws and open the upper door. The
terminal box is now accessible.
Pierce the required rubber cable glands with a screwdriver and
insert the cable through the bush into the terminal box (1)
Subsequently pull back the cable until the bush has been turned
over (2)
Connect the power supply to terminals PE,N,L or for 24 V instru-
ments to terminals U,V.
Ensure that the leads are held securely in the terminals.
Terminal
description
Typ
et
Function
Comment
PE
IN
Mains –protective earth (3x)
Only with mains
115/230 V !
N (U)
L (V)
IN
Mains, N=neutral (U=24 V)
Mains, L=live (V=24 V)
Mains input
24 V / 115 V / 230 V
n
l
OUT
Neutral, switched (3x)
Live, switched (3x)
Mains for consum-
ers, max. 4 A




Installation
15
Connecting the plant components
Connect the plant components to the output terminals of relays 9
to 17 (e.g. valves).
If the plant components require mains voltage, connect the
switched mains voltage (l) to the common contact of the re-
spective relay (see the connection example for 230 VAC on the
left).
Connect the neutral conductor of the plant component to one of the
terminals (n)
For components with a protective earth conductor connection,
connect it to the PE connection.
Ensure that the leads are held securely in the terminals.
(Drawn relay positions: Instrument de-energised, mains: 230/115 V)
No.
Terminal
description
Type
Function
Comment
9
10
11
LV1
OUT
Limit value output 1 –Normally closed
Limit value output 1 –Common
Limit value output 1 –Normally open
Isolated relay output,
max. 240 VAC, 4 A
12
13
14
LV2
OUT
Limit value output 2 –Normally closed
Limit value output 2 –Common
Limit value output 2 –Normally open
Isolated relay output,
max. 240 VAC, 4 A
15
16
17
Alarm
OUT
Fault message output –Normally closed
Fault message output –Common
Fault message output –Normally open
Isolated relay output,
max. 240 VAC, 4 A
Connection example:
Limit value contact LV 1
switches mains voltage

9
10
11
l
n
e.g.
solenoid
valve
PE

Installation
16
Connecting the inputs and outputs
Testomat ECO® has the following connections for control and moni-
toring functions.
Do not connect external voltage to these connections!
Ensure that the leads are held securely in the terminals
Use the two fastening screws to close the upper door once installa-
tion has been completed.
* From serial number 227474
For more information, please refer to the section entitled "Description
of the signal inputs/outputs".
No.
Terminal
description
Type
Function
Comment
18
19
Stop
IN
External analysis stop
Common earth for inputs
Only for isolated normally
closed/normally open!
20
21
IN
IN
Water meter input
Common earth for inputs
Only for isolated normally
closed/normally open; or
observe the technical data
of the turbine!
22
23
OUT -
OUT +
OUT
Current interface 0/4 - 20 mA
Galvanically separated *
24
+
OUT
+12 V for Hall sensor (turbine)
Observe the technical
data of the turbine! Max.
output current 20 mA!

Commissioning
17
Commissioning
Trouble-free operation of Testomat ECO®is only guaranteed
when using Heyl Testomat® indicators!
Inserting the indicator bottle
Open the lower housing door by pulling on the right-hand side.
Remove the cap from the indicator bottle.
Remove the plastic bag from inside the lower housing door. The
plastic bag contains the screw cap with hole and the insert 
for the screw cap.
Connect the parts as shown on the left.
Screw the hose connector of the intake hose hand-tight into
the insert .
Place the insert with the screwed-in intake hose into the indicator
bottle.
Now screw the screw cap with hole hand-tight onto the indica-
tor bottle. 
Extracting the indicator
Switch the instrument on and press the "STANDBY" key
During operation, the pump (DOSIClip) automatically extracts
the indicator
To ensure that indicator is available for the initial analyses, the
intake hose and the transport hose must be filled with indi-
cator from the pump up to the measuring chamber.
Press the "manual" key several times until the intake hose 
and the transport hose are filled with indicator up to the measur-
ing chamber.
If necessary, manually tighten the hose connectors of the intake
and transport hose slightly in case of bubble formation.
Opening the water inlet
Open the lower housing cover.
Slowly open the manually operated shut-off valve to prevent the
measuring chamber overflowing. The flow regulator requires a few
seconds to function correctly.
Make sure that the water conducting parts are not leaky.








CAUTION
!

Functions of the operating and display elements
18
If water sprays from the tube of the measuring chamber ,
reduce the amount of inlet water via the manually operated shut-off
valve. It should take 2 to 6 seconds to fill the measuring chamber!
Instrument settings and data input
Please read the following information before carrying out settings
and entering data for operating the instrument.
Functions of the operating and dis-
play elements
The Testomat ECO® display shows operating statuses and measured
values. The input keys for programming (cursor block) and the func-
tion keys are located underneath the display.
Switching Testomat ECO® on/off
(1) Mains switch
Use this switch to switch the instrument on or off.
(2) Instrument fuse (inside the instrument)
This fuse protects Testomat ECO®and the outputs against
overloads and short circuits.
(1)
(2)



Functions of the operating and display elements
19
1
2
3
4
2a
2b
5
Display functions
1 Limit value status displays (red/green)
The display 1 illuminates red if limit value 1 has been reached or
exceeded. The display 1 illuminates green if the value falls below
the limit value. The same principle applies to limit value 2 and dis-
play 2.
2 Text display (2 lines)
Displays the current analysis result as well as all important status-
es and programming data.
2a = The current measured value is displayed in line 1
Value falls below the measuring range = "<" e.g.: < 0.05 °dH
Value exceeds the measuring range = ">" e.g.: > 10.0 °dH
If the current analysis interval (analysis stop) is interrupted,
"STANDBY" is displayed alternately with the measured value.
2b = The set limit values LV1 and LV2 are displayed in line 2.
3Alarm (red)
Indicates malfunctioning/error message or warning message.
4 Analysis message (yellow)
The yellow LED indicates a current analysis.
5"BOB operation"
The symbol "╘╛" is displayed.
Cancelling error messages/warning messages
Eliminate the fault and acknowledge the message via
the "Horn" key.
All error and
warning
messages are
alternately shown
in line 1 of the
standard display!
╘╛
NOTE

Functions of the operating and display elements
20
Operating elements and function keys
If you wish to carry out settings or enter data, or if alterations are
necessary, press the "M" key to open the programming mode. Use
this key when in the menu to go to the higher order menu items or to
exit the programming mode.
Programming keys (cursor block)
Use the programming keys (cursor block) to navigate in the menu, to
select the desired functions and to enter necessary instrument and
plant specific data. Press the "ENTER" key to select the submenu
item and to confirm and accept the selection or data input. The se-
lected menu items are displayed in capital letters.
Function keys
Manually start an analysis via the "Manual" key
Set the instrument to standby mode via the "STANDBY"
key (automatic analyses are not carried out: analysis
stop)
Acknowledge error and warning messages via the
"Horn" key
Open the program menu for user-specific and instrument-
specific settings via the "M" key
Retrieve all instrument information and settings via the
"i" key
Cursor block
(M)enu key






Program-
ming keys
(cursor
block)
ECO®