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Summary of Contents for Lenntech Testomat 2000
- Page 1 Operating Instructions ® Testomat 2000 Online analysis unit with cleaning function for water hardness, carbonate hardness, p-value or minus m-value...
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Page 2: Table Of Contents
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 ®... - Page 3 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...
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Page 4: Important Safety Information
® ® 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. -
Page 5: Warning Notices In These Instructions
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... -
Page 6: Installation
® NOTE 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 ... -
Page 7: Scope Of Delivery
Scope of delivery 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... -
Page 8: Indicators For Testomat 2000 Instruments
Performance specifications ® Indicators for Testomat 2000 instruments Parameter/Indicator type Water hardness TH 2005 TH 2025 TH 2100 TH 2250 0.05 – 0.50 0.25 – 2.50 1.0 – 10.0 2.5 – 25.0 °dH (resolution) (0.01) (0.05) (0.2) (0.5) 0.09 – 0.89 0.45 –... -
Page 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 ® indicators. Operate in the pH-range 4 – 10.5, Testomat 2000 when determining the total hardness! ... -
Page 10: Installation
Installation Risks resulting from incorrect installation! WARNING ® 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 ®... -
Page 11: Connecting The Water Inlet And Outlet
The measuring water is taken from the main water line of the water ® treatment plant and fed to the inlet connection of Testomat 2000 The instrument is equipped with a plug connector for plastic hoses 6/4 x 1 (external diameter 6 mm/ internal diameter 4 mm, wall thickness 1 mm) as standard. -
Page 12: Connecting The Power Supply And Devices
Only use tested cables with sufficient cross-sections for the connections. Risk of damages caused by electromagnetic fields! ® If Testomat 2000 or the connecting cables are installed parallel to NOTE power cables or in close proximity to electromagnetic fields, the instrument may be damaged or measurements incorrect. -
Page 13: Internal Design Testomat 2000
Installation ® Internal design Testomat 2000 Terminal strip for inputs Start, Stop, IN1, IN2, and output OUT Mains switch Terminal strip for power input and power output ... -
Page 14: Connecting The Mains Voltage
Installation 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 ... -
Page 15: Connecting The Plant Components
Installation Connection example Connecting the plant components Limit value contact LV 1 switches mains voltage Connect the plant components to the output terminals of relays 1 to 19 (e.g. valves). If the plant components require mains voltage, connect the ... -
Page 16: Connecting The Inputs And Outputs
Installation Connecting the inputs and outputs ® Testomat 2000 has the following connections for control and monitoring functions. Do not connect an 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 installation has been completed. -
Page 17: Commissioning
Commissioning Commissioning Handling of reagents/indicators Adhere to the respective safety data sheet! CAUTION ® Trouble-free operation of Testomat 2000 is only guaranteed when ® using Heyl Testomat 2000 indicators! Inserting the indicator bottle Open the lower housing door by pulling on the right-hand side. -
Page 18: Instrument Settings And Data Input
® Switching Testomat 2000 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 2000 and the outputs against overloads and short circuits. -
Page 19: Display Functions
Functions of the operating and display elements Display functions Inlet Analysis BOB- Analysis Outlet Dosing valve stop running mode valve message active 1 Limit value status displays (red/green) The display 1 illuminates red if limit value 1 has been reached or exceeded. -
Page 20: Operating Elements And Function Keys
Functions of the operating and display elements Operating elements and function keys Programming keys (cursor block) Function keys Press the "manual" key to start an analysis by hand Press the "STANDBY" key to put the instrument into standby mode (automatic analyses are not carried out: analysis stop) -
Page 21: Operating System
Functions of the operating and display elements Operating system Testomat instrument Instrument settings and data input (display) in display mode Date, time and weekday input Press the "M" key The basic menu " " appears Use the cursor block to select the desired menu item "... -
Page 22: Password Protection And Basic Program
(display) in display mode program A four-digit password is required to enter data and to carry out settings in the basic program. The password is the current time of ® Testomat 2000 in reverse order. Password entry ▼▲ Press the "M" key The basic menu "... -
Page 23: Selecting The Operating Mode
Selecting the operating mode Under the menu item it is possible to select ® the type of analysis controller. Testomat 2000 provides numerous selection options: Time control, quantity control via water meter, dynamic analysis start and external analysis start. Shortest interval = 0 minutes between analyses. Largest interval = 99 Time controlled minutes. - Page 24 Password protection and basic program Minimum interval = 1 litre, maximum interval = 9999 litres. The Volume controlled analysis is carried out once the programmed water quantity has been measured. The line and the measuring chamber are flushed prior to Start via water meter the analysis (observe the programmed flush times).
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Page 25: Selecting The Display Unit
Password protection and basic program Dynamic analysis start: Depending of the exhaustion of the water Dynamic treatment plant, the interval period automatically decreases when the analysis start residual capacity of the plant decreases. This involves the amount of water used by the plant being determined. The start interval is reset Filter capacity dependent control of the analysis interval when limit value 1 or 2 is exceeded or via a signal at input IN1... -
Page 26: Entering Further Basic Program Data
® external flush valve should be installed upstream of Testomat 2000 The external flush valve has to be connected to the "Flush” outlet. If the unit is used for monitoring two measuring points, external flushing prevents incorrect measurements caused by sample mixing. -
Page 27: Interval Pause
Entering further basic program data Interval pause If the analysis is triggered via a timer, the interval between two analyses (plus flushing time) is determined by the interval pause. The shortest interval can be 0 minutes. In this case, analyses are carried out continuously. -
Page 28: Hysteresis
Entering further basic program data Hysteresis The respective limit value output only switches after the first, second Suppression of or third bad analysis (suppression of the first or the second measured bad analyses value). This increases the reliability of the analysis evaluation, e.g. after the measuring point has been switched over or if the sampling line has not been flushed sufficiently. -
Page 29: Switch Functions Of The Limit Value Outputs Lv1 And Lv2
Entering further basic program data Switch functions of the limit value outputs LV1 and LV2 Switch function 0, duration Schematic representation of logic functions If the limit value LV1 or LV2 has been exceeded, the output relay LV1 or LV2 reacts. If the measured value falls below the limit value LV1 or LV2 without locking, the relevant relay drops out again. -
Page 30: Function In1
Entering further basic program data Function IN1 For dynamic analysis control or programmed plant monitoring, the regeneration message from the controller of the water treatment plant must be connected to IN1 (isolated contact required!). The active status of IN1 has to be programmed according to the output function of the controller. -
Page 31: Bob Operation (Operation Without Permanent Supervision)
Entering further basic program data BOB operation (operation without permanent supervision) BOB (operation without permanent supervision) is a safety relevant feature when using the instrument as a water hardness monitoring unit for monitoring steam boiler plants in accordance with TRD 604. If the BOB function has been programmed, the instrument continuously checks the available amount of indicator. -
Page 32: Alarm/Message
Entering further basic program data Alarm/Message The instrument is equipped with an alarm relay output for signalling ▼▲ faults. The events which mean a fault at the instrument or are intended to trigger a message, can either trigger an alarm "A" (continuous contact) or a message "M"... -
Page 33: Cleaning Function
30-second reaction time. The measuring chamber is then flushed twice. To achieve the best possible cleaning results, we recommend: Testomat 2000 self clean cleaning solution, article number: 151105 Important safety information CAUTION Read the operating instructions carefully and thoroughly before... -
Page 34: Service Ii
The operating time "000000h" appears on the display Maintenance interval Observance of the maintenance intervals is monitored and displayed ® by Testomat 2000 . Program the desired maintenance interval in days here. (0 days equals no maintenance interval) In , select ▼▲... -
Page 35: Description Of The Signal Inputs/Outputs
Description of the signal inputs/outputs Description of the signal inputs/outputs Connecting the signal inputs CAUTION Only connect the signal inputs "Start", "Stop", "IN1" and "IN2" with volt-free contacts! The connection of external voltages would damage the instrument! Function Test Action period Start... -
Page 36: Interfaces (Optional)
Description of the signal inputs/outputs Function Test Action period Fixed, Start of plant maintenance Message from the process and capacity reset to 100% terminals 24,25 seconds controller for dynamic (regeneration finished) (Normally closed or normally open) In , select ▼▲... -
Page 37: Monitoring A Measuring Point
Insert the plug-in circuit board into the left-hand slot with the component side on the left. (Contact no.1 is at the top) ® Switch on Testomat 2000 Program the desired type of current (0/4-20mA) (for SK910). Monitoring a measuring point A printer can be connected to record the analysis results. -
Page 38: Calculation Of Output Currents
(e.g. indicator 2005 = 0.5 °dH) Serial interface RS232 ® Testomat 2000 can also be connected to a log printer via the serial interface RS232 to enable the printout of measuring results and error messages. Analyses can then be continuously logged. This option is only possible in connection with the RS-232 interface card for log printer, RS910 (Art. -
Page 39: Sd Card Data Logger
Immediately before each analysis the external flush valve is opened terminals 1, 2 ® for the programmed period allowing the line up to Testomat 2000 fill with measuring water. Please ensure that the programmed flush time is sufficient. Please refer to "Entering further basic program data" "External flush"... -
Page 40: Measuring Points 1 Or 2 (Measuring Point Switch-Over)
Description of the relay outputs Function Contact Action Volt-free Programmable: Limit value 2 change- terminals 6, 7, 8 - Continuous contact Relay switches when the over - Impulse (1-99 seconds/minutes) limit value is exceeded at: - Interval (1-99 seconds/minutes) contact Limit value 2 or - Hysteresis (limit value is exceeded measuring point 2... -
Page 41: Alarm (Fault Message Output)
Description of the relay outputs Alarm (fault message output) The "Alarm" output is a volt-free change-over relay contact. During trouble-free operation, the contact between the terminals 15 – 16 is Alarm closed and the one between terminals 14 – 16 is open. In case of a terminals 14, 15, 16 voltage breakdown, the contact between the terminals 14 –... -
Page 42: Information Menu "I
Information menu "i" Information menu "i" In the information menu, it is possible to request active settings and Customer service (2) statuses of the instrument, the error history, the date for the next maintenance and the customer service address. Display of the customer service address or, e.g., a service hotline. -
Page 43: Program Menu "M
Program menu "M" Program menu "M" Service I (2) Call: (1) Input indicator (3) Use the key to open the program menu "M". Enter the new filling levels after It is possible to call up all the functions without password protection each refill or indicator bottle except for the basic program. - Page 44 Program menu "M" Self-Test (9) ® Press "ENTER" to start the functional test of Testomat 2000 . The ▼▲ program checks all relevant instrument functions and carries out an analysis. A respective message appears after an error-free test. Press the "ENTER" key again to cancel this function and to return to the "MANUAL MODE"...
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Page 45: Structure Of The Basic Program
Program menu "M" Structure of the basic program Call the basic factory program by simultaneously pressing and holding down the "M" and "i" keys while switching on the instrument. CAUTION, the last set of programming will be erased! -
Page 46: Error Messages/Troubleshooting
Error messages/Troubleshooting Error messages/Troubleshooting Displayed message (flashes at Instrument result functions Possible causes Remedies selected display) Replace fuse F4 or F8 - After programming: - Internal power failure of the Ff. POWER FAILURE 24 V 24 V supply Continuous alarm or message (The control lamp "Power"... -
Page 47: Further Information
Error messages/Troubleshooting Instrument result functions Possible causes Remedies Displayed message (flashes at selected display) Retighten dosing pump - After programming: - Air inside the dosing hoses Mf. ANALYSIS connections Continuous alarm or message - Incomplete mixing Replace intake insert in impulses - Indicator out of date or use the bottle... -
Page 48: Maintenance
Use alcohol to remove this sticky film. Description of maintenance work ® ® The maintenance manual Testomat 2000 /Testomat ECO contains a detailed description of maintenance work. The measures described here provide a brief overview. -
Page 49: Service Instructions
Cleaning the filter housing Close the manually-operated valve of the branch line to Testomat 2000®. ® Depressurise the lines of Testomat 2000 via the “Flush” function: Switch of the instrument and loosen the hose connections at the filter housing. -
Page 50: Testomat 2000 Spare Parts And Accessories
Testomat 2000® spare parts and accessories ® Testomat 2000 spare parts and accessories Art. no. Pressure controller Art. no. Instrument spare parts 40125 Controller / Filter receiver, complete 31582 Fuse M4A 40120 Controller / Filter receiver 40294 Base circuit board T2000 complete... -
Page 51: Accessories
SK 910 270310 RS-232 interface card for log printer, RS 910 270315 Voltage interface card 0/2 - 10 V, UK 910 100490 SD-Card Data Logger for Testomat 2000 270500 Log printer 270501 Power supply unit for log printer 270410 Booster pump 270335 Maintenance case T2000 Heyl *) Retrofit kit for water inlet (Art. -
Page 52: Technical Data
Pressure hose with internal diameter 12 Water temperature: 10 to 40 °C ® * When using Testomat 2000 at a pre-pressure of 0.3 bar, it must be ensured that the flow rate through the measuring chamber is at least 400 ml/min. -
Page 53: Conformity Declaration
Technical data Conformity Declaration... -
Page 54: Check List Testomat 2000
® Check List Testomat 2000 Dear customers and service technicians, This check list cannot replace your expertise or extensive experience in fault resolution. It is intended to support fast and systematic error diagnosis and error documentation. This list does not claim to be complete. We are therefore always grateful for any advice and information you may be able to provide. - Page 55 Technical data Instrument settings Caution! Your settings may be deleted if repairs are carried out. Therefore, note down your instrument settings in the table below before sending the instrument to our service team for repairs. Please enclose a copy of the table with the instrument. If you have noted down the settings, they can be easily re-entered by your service staff once any repairs have been completed.
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Page 56: Product Overview Testomat 2000 -Instruments
Product overview Testomat 2000®-Instruments ® Product overview Testomat 2000 -Instruments Model/Type Measuring Measuring Applications/Functions Parameter Range • Water hardness • Universal for water treatment ® Testomat 2000 0.05-25 °dH plants • Carbonate 0,5-20 °dH • allowed for boiler houses hardness 1-15 mmol/l •... - Page 58 Gebrüder Heyl Analysentechnik GmbH & Co. KG Orleansstraße 75b D 31135 Hildesheim Testomat_2000_selfclean_GB_140929.doc www.heyl.de Scan the code and visit us on our website!
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