Lenntech Testomat 2000 User manual

1
Testomat 2000®
Online analysis unit
with cleaning function for water
hardness, carbonate hardness,
p-value or minus m-value
Operating Instructions

Content
2
Content
Content.................................................................................................2
Important safety information .............................................................4
Intended use .........................................................................................4
Qualification of the staff ........................................................................4
Warning notices in these instructions ...................................................5
Further documents................................................................................5
Pay particular attention to .....................................................................5
General instructions..............................................................................5
Installation.............................................................................................6
Operation ..............................................................................................6
Downtimes ............................................................................................6
Cleaning................................................................................................6
De-installation .......................................................................................6
Disposal ................................................................................................6
Scope of delivery ................................................................................7
Performance specifications...............................................................7
Indicators for Testomat 2000®instruments...........................................8
Application instructions.....................................................................9
Installation.........................................................................................10
Operating Testomat 2000®in the pressure range of 0.3 to 1 bar.......10
Installing Testomat 2000®...................................................................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®..........................................................12
Internal design Testomat 2000®..........................................................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® 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....................................................................25
Entering further basic program data ..............................................26
Internal flushing...................................................................................26
External flushing .................................................................................26
Interval pause .....................................................................................27

Content
3
Limit value monitoring.........................................................................27
Hysteresis ...........................................................................................28
Lock out...............................................................................................28
Switch functions of the limit value outputs LV1 and LV2....................29
Switch function 0, duration..................................................................29
Switch function 1, impulse ..................................................................29
Switch function 2, interval...................................................................29
Switch function 3, two-point................................................................29
Function IN1........................................................................................30
Water meter ........................................................................................30
Plant control........................................................................................30
BOB operation (operation without permanent supervision)................31
Alarm/Message...................................................................................32
Function AUX......................................................................................32
Cleaning function ................................................................................33
Service II.............................................................................................34
Reset operating time...........................................................................34
Maintenance interval...........................................................................34
Water quantity RESET ........................................................................34
Plant control RESET...........................................................................34
Description of the signal inputs/outputs........................................35
Interfaces (optional) ............................................................................36
Installing the interface cards SK910/RS910 .......................................36
Monitoring a measuring point..............................................................37
Monitoring of two measuring points....................................................37
Calculation of output currents.............................................................38
Serial interface RS232........................................................................38
SD Card Data logger...........................................................................39
Description of the relay outputs......................................................39
Flushing (external flush valve)............................................................39
LV1 and LV2 limit value outputs .........................................................39
Measuring points 1 or 2 (measuring point switch-over)......................40
AUX (programmable function output).................................................40
Alarm (fault message output)..............................................................41
Maintenance (output for maintenance message) ..............................41
Information menu "i" ........................................................................42
Program menu "M" ...........................................................................43
Structure of the basic program............................................................45
Error messages/Troubleshooting ...................................................46
Further information..............................................................................47
Maintenance ......................................................................................48
Description of maintenance work........................................................48
Service instructions.............................................................................49
Testomat 2000®spare parts and accessories................................50
Accessories.........................................................................................51
Technical data...................................................................................52
Conformity Declaration .......................................................................53
Check List Testomat 2000®................................................................54
Product overview Testomat 2000®-Instruments ............................56

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®change hands.
Always adhere to hazard warnings and safety information when
using reagents, chemicals and cleaning agents. Please adhere to
the respective safety data sheet! Download the safety data sheets
for the supplied reagents at http://www.heyl.de .
Intended use
The Testomat 2000®is used for the automatic measuring and
monitoring of the residual / total hardness (water hardness), the
carbonate hardness, the minus m-value and the p-value. The
parameter to be measured and the respective measuring range are
determined by the choice of the reagent and by the corresponding
user program.
Testomat 2000®self clean is a special version of Testomat 2000®
with an additional pump for dosing a cleaning agent after analysis.
This, e.g., helps to prevent possible soiling of the measuring chamber
and outlet hose.
Always adhere to the performance limits stated in the section
entitled “Technical data”.
Always observe the application areas/application limits of the
indicators and the requirements of the medium being measured.
To ensure correct and intended usage, always read and understand
these instructions, especially the section entitled “Important safety
information”, prior to use.
The instrument is not used as intended if
it is used in areas not specified in these instructions.
it is used in areas which do not correspond to the ones described
in these instructions.
Qualification of the staff
Assembly and commissioning require fundamental electrical and
process engineering knowledge as well as knowledge of the
respective technical terms. Assembly and commissioning should
therefore only be carried out by a specialist or by an authorised
individual supervised by a specialist.
A specialist is someone who due to his/her technical training, know-
how and experience as well as knowledge of relevant regulations can
assess assigned tasks, recognise potential hazards and ensure
appropriate safety measures. A specialist should always adhere to
the relevant technical regulations.

Important safety information
5
Warning notices in these instructions
The warning notices in these instructions warn the user about
potential dangers to individuals and property resulting from incorrect
handling of the instrument. The warning notices are structured as
follows:
Description of the type or source of danger
Description of the consequences resulting from non-observance
Preventive measures. Always adhere to these preventive
measures.
“DANGER” indicates an immediate hazardous situation which, if not
avoided, will result in death or serious injury.
“WARNING” indicates a potentially hazardous situation which, if not
avoided, could result in death or serious injury.
“CAUTION” indicates a potentially hazardous situation which, if not
avoided, could result in minor or moderate injuries or property
damage.
“NOTE” indicates important information. If this information is not
observed, it may result in an undesirable result or state.
Further documents
Testomat 2000®is a plant component. Therefore, always observe the
maintenance manual of Testomat 2000® / Testomat ECO®and the
documentation of the plant manufacturer.
Pay particular attention to
General instructions
Adhere to health and safety regulations, electrical equipment
safety regulations, and environmental protection regulations valid
in the country of use and at the installation site.
Adhere to national and local regulations during installation and
commissioning.
Always protect the instrument against moisture and humidity. It
should never come into contact with condensation or splash water.
 Do not carry out any changes or modifications at the instrument
which are not described in these instructions; failure to adhere to
these instructions will negatively affect any warranty claims that
you make thereafter .
SIGNAL WORD!
WARNING
!
DANGER
!
WARNING
!
CAUTION
!
NOTE

Important safety information
6
Installation
Always completely disconnect the relevant plant part before
installing the instrument or connecting/disconnecting it to/from the
power supply. Secure the plant against reconnection.
Only connect the instrument to the mains voltage specified on the
rating plate.
Always observe technical data and ambient parameters.
Testomat 2000®requires an interference free and stable power
supply. If necessary, use a mains filter to protect Testomat 2000®
against interference voltages caused, e.g., by solenoid valves or
large motors. Never lay connecting cables parallel to power cables.
Operation
Ensure that the maximum electrical load capacity of the relay
outputs is never exceeded.
Immediately switch off Testomat 2000®and contact service staff if
malfunctioning occurs. The warranty will be void if you tamper with
or attempt to repair Testomat 2000®. Repairs must be carried out
by authorised service staff.
Downtimes
If the Testomat 2000® is switched off for a longer period of time,
such as over the weekend, you need to vent the dosing pump
pipes once you have switched it back on. To do so, proceed as
described under “Extracting the indicator” on page 17.
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
1x Testomat 2000®self clean
1x plastic bag containing a screw cap with a hole and an insert for the
screw cap of the indicator bottle
1x operating instructions
Performance specifications
Testomat 2000®is used for the automatic determination and
monitoring of residual total hardness (water hardness), residual
carbonate hardness, as well as the minus m-value and the p-value in
water. The measurement parameters and the measuring range are
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 residual hardness, total
hardness, carbonate hardness, minus m-value, p-value via
indicator selection
Freely selectable hardness unit in °dH, °f, ppm CaCO3,
mmol/l
High measuring accuracy provided by a precise piston-
dosing pump
Analysis initiation:
- Automatic interval operation
(Interval pause justable from 0 to 99 minutes)
- External control
- Dynamic start (Exhaustion dependent)
- Volume controlled (water meter)
Two independent limit values with hysteresis (1, 2 or 3 bad
analyses) and adjustable 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
request
Extended operating periods due to 500 ml indicator storage
bottle
optional
Interface (0/4-20 mA or 0/2-10 V) or
Interface RS 232 for a log printer
SD Card data logger

Performance specifications
8
Indicators for Testomat 2000®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)
Parameter/Indicator type
Carbonate hardness
minus m-
value
p-value
TC 2050
TC 2100
TM 2005
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)
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®to operate reliably, use Heyl
Testomat 2000®indicators. Operate in the pH-range 4 –10.5,
when determining the total hardness!
With Testomat®instruments for water hardness monitoring, larger
quantities of heavy metal ions in the softened water might
influence the color reaction, especially iron above 0.5 mg/I,
copper above 0.1 mg/I and aluminum above 0.1 mg/l (brownish-
red color 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 colorimetric 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 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?
- Are the measuring chamber and the drain duct/drain hose
clean?
Trouble-free operation is only possible when maintenance is
carried out on a regular basis! For more information, please refer
to the section entitled “Maintenance” and the "Maintenance
manual of Testomat 2000®/Testomat ECO®".
If problems occur, please refer to the section entitled "Error
messages/Troubleshooting".
No opening of the measuring chamber holder!
Do not open the measuring chamber holder. You cannot carry out
any repairs in this area, but damage the device. If you open the
measuring chamber holder, your warranty will expire.
CAUTION
!

Installation
10
Installation
Risks resulting from incorrect installation!
Install Testomat 2000® 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® vertically and without mechanical stress.
Install Testomat 2000® at a vibration-free site.
Operating Testomat 2000®in the pressure
range of 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 of 1 to
8 bar. Remove the flow controller valve body to operate the
instrument in the operating range of 0.3 to 1 bar (e.g. when using an
aerator type R). This involves removing the retaining pin from the
controller/filter receiver . Subsequently use the metal bracket to
remove the controller plug from the borehole. Then remove the
flow controller valve body and reinsert the controller plug and the
retaining pin.
Installing Testomat 2000®
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
instrument 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