Testomat EVO TH CAL Operating Instructions Manual
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Testomat EVO TH CAL Operating Instructions Manual

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Operating Instructions
®
Testomat
EVO TH CAL
Online analysis instrument
for residual total hardness
with calibration function

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Summary of Contents for Testomat EVO TH CAL

  • Page 1 Operating Instructions ® Testomat EVO TH CAL Online analysis instrument for residual total hardness with calibration function...

  • Page 2: Table Of Contents

    Assembling the Testomat EVO TH CAL ........... 13 ® Use of the Testomat EVO TH CAL within a pressure range of 0.3 to 1 bar ....................13 Connecting the water intake and discharge ........14 Water intake ................... 14 Water drain ..................15 Connect mains and devices ..............
  • Page 3 Content Getting started .................. 31 Input basic programming data ............32 Select operating mode ................ 32 Select timing control............... 32 Select quantity control ..............32 Select quantity control/time priority ..........33 Configure interval (interval pause) ............33 Select indicator type and container size ..........34 Calibration ...................
  • Page 4 Care instructions ................. 70 Replacing the backup battery ............. 70 Replacing fuses .................. 71 ® Checklist Testomat EVO TH CAL ............. 75 ® Spare parts and accessories for Testomat EVO TH CAL.... 77 Accessory .................... 78 Technical Data ................... 79 Equipment options ................

  • Page 5: Important Safety Information

    PDF file. ® If transferring the Testomat EVO TH CAL device to third parties, ensure these operating instructions are always included. Observe the safety precautions and safety recommendations when using reagents, chemicals and cleaning agents. Observe the relevant safety data sheet! For reagents we supply, the relevant safety data sheets are available online at http://www.heyl.de.

  • Page 6: Warnings In This Manual

    Additional documentation ® The Testomat EVO TH CAL device is a system component. Accord- ® ingly, you should also observe the Testomat EVO TH CAL mainte- nance manual and the system documentation of the system manu- facturer.

  • Page 7: Requirements Of Cable For Mains Voltage And System Components And Installed Lines

    Important safety information  The installation site is at altitudes under 2000 m.  The maximum relative humidity is 80% at temperatures of up to 31°C (linear declining up to 50% relative humidity at 40°C).  The device must always be protected against wetness and mois- ture.

  • Page 8: During Assembly

    4A.  In the event of any malfunctions, immediately switch off the Tes- ® tomat EVO TH CAL device and inform the service personnel. ® Never attemt to repair the Testomat EVO TH CAL device your- self.

  • Page 9: During Cleaning

    Important safety information During cleaning  Only use a dry and lint-free cloth.  Maintenance and care instructions are included in the section ® maintenance” and in the Testomat "Servicing and EVO TH CAL maintenance manual Malfunctions/repairing a defective device ...

  • Page 10: Operating Requirements

     Problem-free operation of the Testomat ® device is only possible when using Heyl Testomat indicators and only within the pH range CAUTION of 4 – 10.5! Using external indicators may invalidate the guarantee.  Only operate the device within the scope of parameters specified under "Technical...

  • Page 11: Delivery Includes

    The operating instructions apply to both colours, as the functionality is the same. Service description ® The scope of use of the Testomat EVO TH CAL is the automatic determination and monitoring of the residual total hardness (water hardness) in water. In the process, the required measurement scope is determined based on the selected indicator and corresponding user programming.

  • Page 12: Available Indicators For Testomat Evo Th Cal Devices

    0/4 - 20 mA for analog transfer of measurement data – Serial RS232 interface to transfer measurement data and no- tifications/alarms ® Available indicators for Testomat EVO TH CAL devices Parameter/indicator type Water hardness TH 2005 TH 2025 TH 2100 TH 2250 °dH...

  • Page 13: Assembly

    Assemble the Testomat EVO TH CAL device vertically and with- NOTE out mechanical stresses. ®  Assemble the Testomat EVO TH CAL device in a location free of vibration. ® Assembling the Testomat EVO TH CAL Requirements for the installation site NOTE Select an installation site at which the length of the water inlet hose can be minimized (max.

  • Page 14: Connecting The Water Intake And Discharge

     We recommend short intake lines (under 3m) to the Testomat EVO TH CAL. For intake lines longer than 3m, purge periods of longer than 60s must be configured. For cable lengths exceeding 5 - 10m, we recommend external flushing via the AUX input.

  • Page 15: Water Drain

    Use an appliance switch or a circuit breaker that meets the requirements of IEC 608947-1 and IEC 60947-3. ® The switch must be within easy reach of the user of the Testomat EVO TH CAL and clearly marked as a disconnecting device for the ® Testomat EVO TH CAL.

  • Page 16: Block Diagram Of Testomat Evo Th Cal

    Assembly  Shield the device from strong electromagnetic fields. ® Block diagram of Testomat EVO TH CAL Illustrated position of relays: Device without current, mains: 230 V...

  • Page 17: Internal Structure Of Testomat

    Assembly ® Internal structure of Testomat EVO TH CAL         Terminal strip for inputs/outputs  Terminal strip for mains inlets and outlets  Terminal strip relay outputs  Dosing pump  Water connections, intake and outlet (funnel) ...

  • Page 18: Cable Ducting

    Assembly Cable ducting To guarantee IP protection, the device is supplied with cable ductings and blanking plugs. If you wish to use a relay output, you must re- move the blanking plug from the cable ducting. Proceed as follows in this instance: ...

  • Page 19: Connect System Components

    Assembly Terminal designa- Type Function Note tion Mains protective conductor Only for mains supply of Mass/PE 230 V and 100 – 240V! (5x) Grid, N=Neutral conductor N (U) Power input 50-60 Hz (U=24V) L (V) 24 V / 100-240 V / 230 V Grid, L=Phase (V=24V) Neutral conductor, secured Grid for consumers, max.
  • Page 20 Assembly Terminal Type Function Note designation Limit value output 1 – root c Limit value output 1 – closing contact Floating relay output, max. 240 VAC, 4 A (limit value) Limit value output 1 – break contact NC Limit value output 2 – root c Limit value output 2 –...

  • Page 21: Connect Inputs And Outputs

    Assembly Connect inputs and outputs ® The Testomat EVO TH CAL device has the following sockets for control and monitoring functions. Proceed as follows for connection:  Loosen the strain relief of the cable ducting (union nut).  Take out the blanking plugs of the corresponding cable ductings.

  • Page 22: Rs232 Interface Terminal Assignment

    Assembly RS232 interface terminal assignment Sub-D 9 poles Terminal Function designation Data reception Output of measured values/alarms Ground...

  • Page 23: Connect Indicator Bottle

    Connect indicator bottle Connect indicator bottle ® Flawless operation of the Testomat EVO TH CAL device is only CAUTION ® guaranteed when Heyl Testomat 2000 indicators are used! The use of external indicators may invalidate the guarantee. Insert indicator bottle ...

  • Page 24: Device Settings And Data Input

    These fuses protect the device or outputs against overload and short circuit. Descriptions of the fuses are found in Replacing fuses and under Spare parts and accessories for the Testomat® EVO Switching on/off NOTE Wait at least five seconds after switching off before switching back...

  • Page 25: Display Functions

    Functions of the control and display elements Display functions All error and warn- ing messages are shown in rotation with the standard display in line 1! 1 Limit value status indications (red/green) When the limit values 1 are exceeded, indicator 1 lights up in red. Falling under the limit value results in the indicator 1 lighting up in green.

  • Page 26: Control And Function Keys

    Functions of the control and display elements 10 Pause (green) The flashing LED indicates the activated pause. 11 Service (yellow) The yellow LED indicates that the maintenance period has elapsed. 12 Alarm (red) Indicates a functional error/error message or warning message. Handling of error messages/warning messages NOTE ...

  • Page 27: Operating System

    Functions of the control and display elements Input programming data If you configure settings or wish to input data or when changes are required, you can call up the programming menu with the "M" button. Pressing this button in the menu brings you to the higher-level menu item or you can leave the programming menu.
  • Page 28 Functions of the control and display elements Inputting date and time   Press the "M" button Basic program "Ser- The following selection appears: " " or vice" PROGRAM MENU  Service Using the cursor block , select the menu option " "...
  • Page 29 Functions of the control and display elements Inputting of data (Example: interval pause/quantity interval) Interval Using the menu option " " you can program the interval pause between two analyses.  To adjust the interval pause, proceed as follows:  Press the "M"...

  • Page 30: Control Elements On The Control Board

    Control elements on the control board   Battery holder  : The battery holder houses a CR2032 lithium battery to retain the time setting even if the device is switched off.  Plug-in slot for SD card  : SD or SDHC cards with a maximum capacity of 32GByte are suitable.

  • Page 31: Getting Started

    Getting started Getting started Once you have completed the steps in the section Connecting indica- tor, you can switch on the device. Automatic venting NOTE After the device is switched on the indicator lines are automatically vented and the measuring chamber purged, until indicator is detected in the measuring chamber.

  • Page 32: Input Basic Programming Data

    "Operating mode" Under the menu option you can select the ® type of analytical control. The Testomat EVO TH CALgives you scope to control timing or quantity via water meter or a combination of both. Smallest pause interval = 0 minutes between analyses. Longest Timing control pause = 99 minutes.

  • Page 33: Select Quantity Control/Time Priority

    Input basic programming data Select quantity control/time priority The analysis is performed once the programmed quantity of water Quantity control Time priority has passed. An analysis is always prioritized once the programmed interval pause has elapsed. MODE OF OPERATION Select the function Time controlled ...

  • Page 34: Select Indicator Type And Container Size

    The correction factor is calculated automatically after ® measurement by the Testomat EVO TH CAL. You can also use a laboratory analysis to determine the correction factor and enter it in the device. Using the calibration function CAUTION ...
  • Page 35 Input basic programming data  Confirm the selection by pressing “OK”  Enter the correction factor determined using the arrow keys  Confirm the entry by pressing “OK” Calibration using standard solution  BASIC PROGRAM => Calibration CALIBRATION Select from menu => Setpoint 3.5°dH ...

  • Page 36: Select Measurement Value Unit

    Input basic programming data Select measurement value unit You can program the unit of the value shown. Your selection options include °dH, °f, ppm CaCO as well as mmol/l. All the following inputs and indications will then be shown in the programmed unit. ...

  • Page 37: Switching Functions Of The Lv1 And Lv2 Limit Value Outputs

    Input basic programming data Two-point operating mode (Output LV2 relay as a two-point controller) If the LV2 upper limit value is exceeded, the LV2 output relay is acti- vated. If the lower limit value LV1 is not attained, the LV2 relay is switched off.
  • Page 38 Input basic programming data Switching function duration If the limit value LV1 or LV2 is exceeded, the output LV1 relay or LV2 switches. If the limit value LV1 or LV2 is not attained, the correspond- ing relay is again deactivated. Switching function impulse If the LV1 or LV2 limit value is exceeded, the corresponding output switches for the set time (t).

  • Page 39: Input Purge Cycle

    60 seconds should be selected. The purging is performed by simultaneously opening the inlet and outlet valves of the Testomat® EVO TH. Duration of the analysis interval NOTE The analysis interval depends directly on the programmed purge cycle.

  • Page 40: Bob Operation (Operation Without Constant Supervision)

    Input basic programming data BOB operation (operation without constant supervision) The operation without constant supervision is safety-relevant when using the device to determine water hardness and monitor steam boiler systems in accordance with TRD 604. If the BOB function is programmed, the device continuously checks the available quantity of indicator.A calculation using the following data is performed to determine whether sufficient indicator exists for the next 72 h: purge cycles, current indicator fill level, interval pause...

  • Page 41: Description Of The Relay Outputs

    Input basic programming data Description of the relay outputs All relay outputs are designed as neutral contacts. This means the full range of connection options is available to you. This facilitates the switching of mains power, external power and direct switching of inputs, e.g.

  • Page 42: Aux (Programmable Functional Output)

    Input basic programming data AUX (programmable functional output) Function Contact Action Isolated change-over Programmable with Terminals 7,8,9 contact time interval, see below Programmable Terminal 7: c / central contact function output Terminal 8: no / closing contact dependent on Terminal 9: nc / break contact the analytical sequence This isolated relay output lets you set various switching functions set,...

  • Page 43: Alarm/Message - How To Proceed When Errors Occur

    ACK. With the help of these inputs and outputs and the transmis- sion of measurement data (via 20mA current loop or serial RS232 interface), the Testomat can be operated at a master display. If the limit value is exceeded, there is no additional Alarm via the...

  • Page 44: Water Shortage

    Input basic programming data Water shortage The water shortage error is a special case, since one further setting can be configured for this error. In the menu, under Basic program Waterlow count => => the number of consecutively occurring errors before the alarm is trig- gered can be set.

  • Page 45: Description Of The Signal Inputs/Outputs

    Input basic programming data Description of the signal inputs/outputs Switching of the signal inputs CAUTION  Switch the signal inputs "Stop", "WM" and "Ext. Ack" only with isolated contacts! Switching with external voltage will damage the device! Stop input The stop input is intended for short-term suspension of operation, e.g.

  • Page 46: External Delete (External Acknowledge)

    Input basic programming data External delete (external acknowledge) Function Contact type Testing Action duration External delete Programmable: none Proceed as for Ext. Ack. Deleting / ac- horn button break contact or Terminals 15,16 knowledging exist- closing contact ing errors / alarms (isolated) Via these terminals, all error messages can be acknowledged re- motely.

  • Page 47: Calculation Of Output Currents

    Input basic programming data Monitoring the measurement point Connecting a recorder allows the analytical results to be document- ed. For this purpose the device includes a programmable current output (optionally 0-20 mA or 4-20 mA). The following example indicates the course of the current within the range of 0-20 mA.

  • Page 48: Serial Interface

    Notifications and measured values can be distinguished by evaluating the first characters: If “ME” is read, it is a meas- ured value; with “AL”, it is an alarm/notification.  ® This corresponds to the format of the Testomat 2000 data logger. Example of measured value: <STX>ME,TH2005,31.07.2013,08:09,0.050,°dH,limit val.1:,0.200,°dH,limit val.2:,0.300,°dH<ETX>...

  • Page 49: Lcd Settings

    Input basic programming data LCD settings ® The Testomat EVO TH CAL comes with a large-scale backlit graph- ic-enhanced LC display.  Basic program Adjust brightness and contrast in the menu => LCD settings => LCD SETTINGS Brightness brightness contrast...

  • Page 50: Storing Measurement Values

    Input basic programming data Link between time and correct data NOTE To ensure that the naming of the file and the time and date details in the file are correct, the time function must work properly. If the battery drains, the date is automatically set to 1.1.2011, 12:00 and the data is stored.

  • Page 51: Interim Storage For A Non-Inserted Sd Card

    => => FUNCTION SD CARD basic data  Store measurement all settings of the Testomat device can be stored in a file on the SD Store error Import basic data card. Export basic data This function is recommended for: Storing multiple configuration profiles for one device...

  • Page 52: Import Basic Programming Data

    Input basic programming data Import basic programming data  Select in the menu FUNCTION SD CARD Basic program Function SD-Card Import => => =>  Store measurement basic data Store error one of the files in the root directory of the SD card with the ending Import basic data "ini"...

  • Page 53: Change Password

    Menu-driven firmware update In the menu FIRMWARE UPDATE => Basic program => Firmware update Execute (OK) the operating software of the Testomat device is updated. For this purpose, you need an SD card. Implement the firmware update as follows:  ®...
  • Page 54 LED begins flashing. The process is repeated until all LEDs light up permanently. The firmware update is now complete. The Testomat is started auto- matically with the new operating software. The complete firmware update takes around 70 seconds.

  • Page 55: Manual Firmware Update

    Input basic programming data Manual firmware update The manual firmware update facilitates the recovery of software after Observe ESD safety failed firmware updates. The indicator and device buttons are not precautions! See the used in the process. information on page 8 NOTE An SD card with a firmware file must be inserted in the device.

  • Page 56: Information Menu "I

    Information menu "i" Information menu "i" The information menu gives you scope to query current settings and states of the device. Call (1) Call (1) The button allows you to call up the information menu. Remote access in the infor- mation menu to check or query Scope for queries: Operating values and program values, such as the settings and operating...

  • Page 57: Service Menu

    Service menu Service menu Service (2) Call: (1) Indicator fill level (3) The button allows you to call up the program menu. Use the Input the new fill level for each Service refill or when changing the cursor keys to select the menu option " ".
  • Page 58 Service menu Language (9) English Deutsch Select the desired language for the indicator. The number of installed languages may vary. Français Nederlands Espanol Diagnosis (10) Türkçe The diagnosis menu allows you to perform an automatic comparison 中文 for the amplifier of the receiver diode and the LEDs. You can also Czech switch and reset EV, AV and all outputs as well as test the current loop.

  • Page 59: Structure Of Basic Programming

    Structure of basic programming Structure of basic programming...

  • Page 60: Error Messages/Troubleshooting

    Error messages/troubleshooting Error messages/troubleshooting Errors will be recorded in the error history as far as capacity allows (after which the oldest message will be deleted). In addition, error messages can be stored on the SD card, if in the menu =>...
  • Page 61 Error messages/troubleshooting Error number/error message Description, possible Solution, troubleshooting measures causes 01 Power failure   Prior power failure (also Check power supply when switching off) 02 Power failure 24V   Failure of the internal Replace 24V fuse 24V power supply ...
  • Page 62 Check suction and pressure hose for dam-  Indicator expiry date  exceeded Replace stirring bar   Foreign indicator in the Replace indicator, only use Heyl Testomat ® device 2000 indicator 37 Indicator low   Indicator minimum quan-...

  • Page 63: Further Possible Errors

    Error messages after self-test ® When switched on, the Testomat EVO TH CAL performs a self-test automatically and then monitors its own state continuously. If the LEDs on the control card flash quickly after switching on, one of the above errors has occurred and can be identified by the LED signal.
  • Page 64 Error messages/troubleshooting Error number/text Solution, troubleshooting measures LED1 LED2 LED3 LED4 LED5 in alarm log on SD card 500 CTRL-FRAM 1. Defective component. Repair/exchange ☼ ○ ○ ○ ○ required. ☼ 501 MB-IC12 See 1. ☼ ☼ ○ ○ ○ 502 HMI-IC1 See 1.

  • Page 65: Firmware Update Error List

     One LED flashes quickly: Problem with SD card (Write protec- Control card tion, formatting).  For the Testomat® EVO TH, the filename should correspond to the following format: "100M001S00.UPD", where 001 is the version number, which increases incrementally as new versions are re- leased.
  • Page 66 Error messages/troubleshooting Error number/text LED1 LED2 LED3 LED4 LED5 in update.txt Solution, troubleshooting measures On SD card 900 No SD-Card in- ☼ ○ ○ ○ ○ Insert SD card, restart firmware update serted 901 SD-Card write Confirm write-protect tab on the side of ○...
  • Page 67 Error messages/troubleshooting Error number/text in LED1 LED2 LED3 LED4 LED5 Solution, troubleshooting measures update.txt on SD card 916 UPD sec invalid Start info in update file defective: Re- ☼ ☼ start download 917 UPD sect invalid Length info in update file defective: Re- ☼...

  • Page 68: Servicing And Maintenance

    A detailed description of the maintenance work can be found in the maintenance manual. The measures described here only constitute an overview. For all additional maintenance instructions, please refer ® to the Testomat EVO TH CALmaintenance manual. Cleaning measures ...

  • Page 69: Setting Indicator Fill Level

    Switch off the device or press the "Pause" button  Check that the measuring chamber is completely emptied. ®  Connect the manual valve of the secondary line to the Testomat EVO TH.  Release the spring lock, tilt the measuring chamber upwards and take it out.

  • Page 70: Care Instructions

    Servicing and maintenance  Remove the locking pin and pull it out of the flow regulator.  Remove the flow governor core.  Clean the filter housing with water or alcohol and reconstruct it.  Ensure that you insert the filter sieve with the top facing down! ...

  • Page 71: Replacing Fuses

    Replacing fuses Motherboard Device fuses (internal) These fuses protect the Testomat® EVO TH CALdevice or outputs against overload and short circuit. All fuses are pluggable. The main fuses F1 and F6 (4A MT) for outputs and equipment are located on the motherboard.
  • Page 72 Servicing and maintenance Multi-range power supply board 100 – 240V 12V/3,3V Primary F2: 1 A/T F3: 0.5 A/T Secondary F4: 2 A/T F5: 2 A/T...
  • Page 73 Servicing and maintenance Exchange If not all three green LEDs on the motherboard light up, at least one fuse is defective. The supply voltage unit is next to the LED, which indicates its status. You require: Observe ESD safety precautions! See the ...
  • Page 74 Use a flat-tip screwdriver to turn and rotate the safety cov- Replace safety fuse 4A Put safety cover back in place. When switching on the Testomat device, check whether all three green LEDs light up. Otherwise, restart from Step 1. Fuses on the power supply Disconnect device from the mains! board defective.

  • Page 75: Checklist Testomat Evo Th Cal

    Are the configured limit values correct? (Within the measurement Limit values: range/corresponding to the performance limit of the system?) Is the Testomat continually supplied with mains voltage – except during maintenance work/emergency cases? (Intermediate switching off only with "PAUSE" button or "Stop”! input) More details of error messages and possible causes of errors can be found in the operating instructions under "Error messages / Help dealing...
  • Page 76 ® Device settings for Testomat EVO TH CAL Caution! Your settings may be deleted in the event of a repair. Accordingly, export your device settings onto an SD card before sending the device for repair to our service team. The settings can be re-imported after the repair.

  • Page 77: Spare Parts And Accessories For Testomat Evo Th Cal

    Spare parts and accessories for Testomat® EVO TH CAL Spare parts and accessories for ® Testomat EVO TH CAL Art. No Pressure regulator Art. No Device spare parts 40125 Controller / filter mounting, complete 31582 Fuse GS-M 5x20E 4A MT...

  • Page 78: Accessory

    Spare parts and accessories for Testomat® EVO TH CAL Accessory Accessory Indicators Indicator Range Quantity Art. No.: type TH2005 Water hardness 0.05 - 0.5 °dH 500 ml 152005 TH2005 Water hardness 0.05 - 0.5 °dH 100 ml 151005 TH2025 Water hardness 0.25 - 2.5 °dH 500 ml...

  • Page 79: Technical Data

    < 20 mg/l ® * When using the Testomat EVO TH CAL with an upstream pres- sure of 0.3 bar, it must be ensured that a minimum flow quantity of 400 ml/min can traverse the measuring chamber. ** see also notes on page 10...

  • Page 80: Equipment Options

    (see details of the version on the rear of the instruc- tions), you can find the most recent version of the operating instructions on our homepage www.heyl.de under Download. Equipment options ® You can select the following options for the Testomat EVO TH CAL: Option Description Power supply 230 V –...

  • Page 81: Declaration Of Conformity

    Declaration of conformity Declaration of conformity...
  • Page 82 Gebrüder Heyl Analysentechnik GmbH & Co. KG Orleansstraße 75b D 31135 Hildesheim www.heyl.de Testomat_EVO_CAL_GB_181106.docx Scan the code and visit us on our homepage!

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