Process photometer for
chromium vi 0 - 5 ppm / chromate 0 - 11,15 ppm (54 pages)
Summary of Contents for Heyl Testomat PRO Ca SELF CLEAN
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1.1.1.1.1 Operating Instructions ® Testomat PRO Ca SELF CLEAN Process titrator for calcium hardness Gebr. Heyl Analysentechnik GmbH & Co. KG Orleansstr. 75 b D 31135 Hildesheim www.heylanalysis.de Testomat_Pro_Ca_SelfClean_EN_240115 Original manual...
Content General information .......................... 1 Use and storage of the instruction manual ................1 Symbols ........................... 1 1.2.1 Warnings and safety instructions in this manual ..............1 1.2.2 Pictograms ........................... 2 1.2.3 Typographical highlights ...................... 2 Limitation of liability ......................... 2 1.3.1 Failure to comply with the instructions.................
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4.6.4 Water meter input ......................16 4.6.5 Measuring point switch-over ....................17 Current interface 0/4 – 20 mA ....................17 4.7.1 Calculation of output currents .................... 17 Serial interface ........................18 Description of the SD card functions ..................20 4.10 Operating elements of the MicroClip micro dosing pump .............
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Select operating mode ......................42 Configure interval pause ......................43 Select measurement value unit ..................... 44 Set limit value monitoring ...................... 44 6.10 Input operating mode of LV1 and LV2 limit value outputs ............. 44 6.10.1 Switching functions, multiple limit value exceedance ............ 45 6.11 Set programmable switching output AUX ................
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Operational monitoring: Alarm/Message ................59 Firmware update ........................60 8.3.1 Menu-driven firmware update .................... 60 8.3.2 Manual firmware update ....................61 8.3.3 Firmware update Ethernet converter ................. 62 Troubleshooting and repair ....................62 8.4.1 Further possible errors....................... 66 8.4.2 Error messages after self-test ................... 67 8.4.3 Firmware update error list ....................
General information - Use and storage of the instruction manual 1 General information Use and storage of the instruction manual The operating instructions form part of the equipment. Therefore, observe the following principles: Read the operating instructions carefully and in full before working with the device.
General information - Limitation of liability Note indicates a potentially harmful situation. If not avoided, the equipment itself or something in the vicinity may become damaged. 1.2.2 Pictograms The following pictograms are used in these operating instructions: Danger signs for ESD-hazardous components: Electrostatic discharges (ESD) are voltage punctures caused by large potential differences.
Use of non-approved spare parts The equipment’s trouble-free operation is only guaranteed when using original Heyl Testomat ® PRO reagents and original Heyl spare parts. The use of other reagents or spare parts will invalidate the equipment’s guarantee. 1.3.5 Unauthorised conversions Do not make any changes (or otherwise manipulate the equipment in any way) that go beyond the handling described in these instructions;...
Your safety - Personal injury 2 Your safety The following safety instructions are intended to help you avoid hazards to yourself and bystanders when handling the equipment. They also serve to prevent material damage to the equipment. The measures to avert any and all dangers always apply, irrespective of specific actions.
This can potentially invalidate the warranty! • Only use original Heyl reagents that are specially adapted to the requirements for the measuring equipment, and thus guarantee perfect measuring results.
Technical Data - Property damage 3 Technical Data specifications 100 – 240 VAC Power supply: ± 10%, 50/60 Hz Complete protection T4A including user power supply Power consumption: 230 V (100-240 V) / 4 A max. 230 V (100-240 V) / 1 A without external load Protection class: Protection type:...
If the test water contains more than 20 mg/I CO (carbonic acid), erroneous evaluations cannot be ruled out. In this case, use an irrigator (e.g. optional accessory from Gebr. Heyl). The concentrations of disruptive ingredients can be determined with ®...
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Technical Data - Other operational requirements o Are the measuring chamber and drain channel/drain hose clean? Problem-free operation is contingent on regular maintenance! Maintenance and care instructions can be found in the chapter 9 Servicing and maintenance on page 71. Indications of problems can be found in the chapter Troubleshooting and repair...
Setup and function - Internal structure of Testomat® PRO Ca SELF CLEAN 4 Setup and function ® Internal structure of Testomat PRO Ca SELF CLEAN Figure 1 Description Terminal strip for inputs/outputs Terminal strip for mains inlets and outlets Terminal strip relay outputs Dosing pumps Water connections, intake and outlet (funnel) Controller/filter housing...
Setup and function - Product description Product description The scope of use of the Testomat ® PRO Ca SELF CLEAN is the automatic determination and monitoring of the calcium hardness in water. Simplified menu-driven operation and programming via OLED Free selection of hardness units in °dH, °f, ppm and mmol/l Analysis trigger: o Automatic interval operation (Interval pause can be configured from 0-99 minutes)
Setup and function - Functions of the control and display elements Functions of the control and display elements The operating modes and measurement values are shown on the display of the Testomat ® PRO Ca SELF CLEAN The input keys for the programming (cursor block) and function keys are underneath the display.
Setup and function - Functions of the control and display elements 4.3.2 Display functions Figure 2 Colour Name Description of LED Limit value When the limit values 1 are exceeded, indicator LV1 lights up in red. Falling status red/green under the limit value results in the indicator LV1 lighting up in green. The indications same function applies to limit value 2 and indicator LV2.
Setup and function - Functions of the control and display elements 4.3.3 Control and function keys Figure 3 Name Description Manual The Manual button is used to start manual analysis The Pause button puts the device into standby mode. There will be no automatic analysis performed: analysis stop.
Setup and function - Control elements on the control board 4.3.4 Meaning of the symbols in the menu In the menu, symbols are shown on the first line at the right-hand edge. These represent the function keys, which can be used to facilitate navigation at this point in the menu.
Setup and function - Relay outputs Relay outputs Danger of destruction due to excessive load! The relay outputs are designed for a defined maximum load (see chapter Technical Data on page 6). • Note the load capacity of the relay outputs. •...
Setup and function - Signal inputs and signal outputs STOP: Terminals 20, 21 Function Contact type Test Action period Stop Programmable: none There are no analyses while the contact at the External analysis break contact or input is open or closed stop (e.g.
Setup and function - Current interface 0/4 – 20 mA 4.6.5 Measuring point switch-over M1/2: Terminals 22, 23 The “Measuring point” input is only queried if, under the basic program menu Measuring points the function 2 measuring points via input is activated (see chapter 6.14 Measuring points on page 47).
Setup and function - Serial interface The current for a given measured value is calculated as follows: Figure 5 Measurement value = display value in the selected hardness unit Maximum value = final value 33.5°dH / 60°f Examples: Measured value 0.56°dH: 0,33mA (4,27mA) Measured value 1°dH: 0,6mA (4,6mA)
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Setup and function - Serial interface The baud rate can be set to 2400, 9600, 19200, 38400 and 115200 baud. For Ethernet, 9600 must be set! Alarms are transmitted via the serial interface, In the case of alarms that cannot be acknowledged because the device generates them automatically, the end of the alarm is also reported (alarm inactive).
Setup and function - Description of the SD card functions Description of the SD card functions The SD card can be used to record measurement values and errors as well as for importing and exporting the device settings. Error and measurement value files are separately placed in subfolders arranged by year and month: In the year folder, files including measurement values and errors are...
Setup and function - Operating elements of the MicroClip micro dosing pump Transferring settings onto other devices Configuring multiple devices with identical settings Remote maintenance / support via transfer of the basic programming data The filename is preset to "bdata00.ini" (for "Basic Data" / basic programming data).
Prepare the product for use - Installation 5 Prepare the product for use Installation 5.1.1 Remove the packaging material Remove the packaging material completely before starting assembly. Separate packaging materials according to type and size and send for further use or recycling if no other arrangements have been made with your distributor.
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Prepare the product for use - Installation Jamming of the cores with incorrectly selected cross-section! If cores with the wrong cross-section are used, there is a risk of them becoming jammed when they are released from the terminal strip. • Our recommendation to prevent jamming is, that you only use wires with cross-sections greater than 0.5 mm².
Prepare the product for use - Installation 5.1.5 Assembly of the micro-dosing pump on the ® Testomat PRO Ca SELF CLEAN Damage to the pump caused by dust! No dust is allowed to get into the pump because the threaded rod of the micro-dosing pump is greased.
Prepare the product for use - Installation 5.1.6 Connecting the water intake Damage due to measuring water that is too warm! Water above 40°C can cause burns and damage to the parts of the ® Testomat PRO CA that come into contact with water. •...
Prepare the product for use - Installation The test water is extracted from the sampling pipe and channelled to the ® supply nozzles of the Testomat PRO Ca SELF CLEAN The device comes with a plug connection for plastic hoses 6/4 x 1 as standard (external diameter 6 mm/ internal diameter 4 mm, wall thickness 1 mm).
(see specification plate). • The cable ducts installed by Gebr. Heyl in the device have a clamping range of 4.5 mm – 10 mm. This means that the external diameter of the laid cable must remain within the range of 4.5 mm –...
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Prepare the product for use - Installation • If you use other ducts, the cable diameters must correspond to the ducts. • The terminal strips on the circuit board require core cross- sections of between 0.08 mm and 2.5 mm according to the manufacturer.
Prepare the product for use - Installation ® Block diagram of Testomat PRO Ca SELF CLEAN Illustrated position of relays: Device without current, mains: 230 V Figure 12 5.1.10 Connect system components Danger to life due to electric shock! If you connect system components that do not operate using the device voltage, you can apply external voltages to the relay contacts.
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Prepare the product for use - Installation 7. For components with a protective conductor connection, connect them to the PE connection. 8. Ensure that the cores in the terminals are securely in place. Supply terminals Controller board with serial and Inputs Relay outputs network interface...
Prepare the product for use - Installation 5.1.11 Connect inputs and outputs Possible damage to the equipment due to incorrect connection of the inputs and outputs! Incorrect connection of inputs and outputs will damage the equipment. • Do not expose the connections to any external voltage! •...
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Prepare the product for use - Installation Connect relay outputs Terminal Function designation Alarm Fault signal output – root c Fault signal output – closing contact no Fault signal output – break contact nc Limit value output LV1 – root c Limit value output LV1 –...
Prepare the product for use - Installation 5.1.12 Connect current interface Screw Connection Clamp I1OUT- I1OUT+ I2OUT- I2OUT+ RS232 GND RS232 RX RS232 TX For micro dosing pump Table 17 View from the front, as the card is inserted The plug-in card provides two (including opposed) potential-separated 20mA current outputs, as well as an additional RS232 interface, which is used to control the micro dosing pump mounted on the side.
Interrupted operation possible when using unapproved reagents! ® Flawless operation of the Testomat PRO Ca SELF CLEAN device is only guaranteed when Heyl reagents are used! The use of external reagents may invalidate the guarantee. • Use only original Heyl reagents.
Prepare the product for use - Commissioning Watch out for air bubbles in the tubes as they can lead to incorrect measurements. If there is an air bubble in the tube, it must be vented. 12. To do this, press the Manual button on the pump or select the appropriate pump in the “Service”...
Instrument setting and data entry - Enter program values 6 Instrument setting and data entry In chapter 4.3 Functions of the control and display elements on page 11 the operating elements and displays required for the equipment settings are explained. Enter program values Since no settings in the programming menu can be configured while the analysis is underway, press the Pause button once the venting is...
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Instrument setting and data entry - Enter program values Figure 21 Reagent (3) Input the new fill level for each refill or when changing the bottle of the reagent. If you select the menu item for the filling level entry Reagent with OK, you can select the reagent that was switched out.
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Instrument setting and data entry - Enter program values Language (4) Select the desired language for the display. Diagnosis (5) The diagnosis menu allows you to perform an automatic comparison for the amplifier of the receiver diode and the LEDs. You can also switch and reset EV, AV and all outputs as well as test the current loop.
Instrument setting and data entry - Enter program values 6.1.2 Structure of the Information menu i Select the information menu by pressing i. In this menu, you can query the current settings and states of the equipment. The following query options are available: Operating and program values, such as software status, operating mode, maintenance/operating hours counter (see figure 22).
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Instrument setting and data entry - Enter program values Figure 23 Testomat_Pro_Ca_SelfClean_EN_240115...
Independently thereof, a four-digit password can be set in the Basic Program on the equipment for data entry and settings. If you have have forgotten your password, contact your Heyl service partner or water supplier. Note that in exporting settings, the password is not saved. Set your desired password as follows: Press the M button.
Instrument setting and data entry - Select Language 6. Move with the arrows r/l to the desired position in the time/date field. 7. Select the desired figure by confirming with the arrows u/d. 8. Confirm the newly configured values for the time and date with OK. If you do not wish to change the values, press no buttons for 30 seconds.
Instrument setting and data entry - Configure interval pause Longest pause = 99 minutes. The analysis interval (interval between two analyses) is determined by the configured purge cycle, the programmed pause time (interval) and the duration of analysis. The duration of analysis is directly dependent on the measurement value.
Instrument setting and data entry - Select measurement value unit Select measurement value unit You can program the unit of the value shown. Your selection options include °dH and °f. All the following inputs and displays will then be shown in the programmed unit. 1.
Instrument setting and data entry - Input operating mode of LV1 and LV2 limit value outputs Range: Relays switch when leaving the preset range between LV1 and LV2: If the value falls below LV1, relay LV1 switches and the LED “LV1” lights up red. If LV2 is exceeded, relay 2 switches and LED LV2 lights up red.
Instrument setting and data entry - Set programmable switching output AUX limit value. Only after the limit value has been exceeded twice is the corresponding output switched. When the limit value has been exceeded “3” times, the corresponding output only switches after the limit value has been exceeded three times consecutively.
Instrument setting and data entry - Select water meter 2. Input in the menu option Time the time in seconds(s). The factory default setting is 00 seconds(s). 3. Confirm all entries with OK. Enter exceedance flush An additional flush time can be entered here after the limit value has been exceeded, if the internal flushing is not sufficient to flush out the intake.
Instrument setting and data entry - Program alarm (Fault signal output) o 0,09ml / 3 strokes for normal water samples with hardness values above 3°dH (standard setting) or o 0,06ml / 2 strokes for pure water samples with hardness values below 3°dH. 3.
Instrument setting and data entry - Set up signal inputs and outputs 6.17 Set up signal inputs and outputs Set up stop input 1. Select the menu Basic program => Function STOP. 2. Select the contact type. 3. Confirm the selection with OK. Set up external acknowledge 1.
Instrument setting and data entry - Set up the SD card functions 6.20 Set up the SD card functions Store measurement values The storing of measurement values on the SD card is activated in the menu: 1. Select the menu Basic program => Function SD-Card => Store measurement 2.
Do not dispense cleaning solution by hand. • Only use cleaning solution that has been approved by Gebr. Heyl. By selecting Clean the measuring chamber is first rinsed and then the agent is added to the water in the measuring chamber After the set application time, the contents of the measuring chamber are drained.
Connect to network - Perform network settings 7 Connect to network No network with incorrect setting on the control board In order for the data of the serial interface to be passed on to the network module, the correct setting of the plug-in field on the control board is necessary.
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Connect to network - Perform network settings Often the IP address can be linked to a MAC address by the server so that the device is always reachable under the same IP address. The MAC address is printed on the module with the network connection under the barcode.
Is not required for function; relevant as a safety feature for remote access. Syslog System log messages. Inactive. System For restart. Do not use the firmware update because the Heyl network logger process runs differently! To export and import settings. Testomat_Pro_Ca_SelfClean_EN_240115...
Connect to network - Web interface configuration menus 7.2.1 Addresses of the web interface If 192.168.0.10 is set as the IP address of the Ethernet converter, the web interface can be reached at the following addresses: http://192.168.0.10 Ethernet converter setting The links below relate to the following pages.
Connect to network - Set up e-mail dispatch Set up e-mail dispatch The Ethernet converter does not send e-mails The Ethernet converter only supports dispatch via so-called open SMTP servers that do not require a password. Authentication is not used! •...
Connect to network - File access with web interface Monthly measured values (e.g. 07/2009) are stored in a file “ME0907.CSV”. Errors that occurred are stored in another file “AL0907.CSV”. Access is possible using Windows Explorer on Windows PCs: 1. Enter the ftp://<IP address of the Testomat Pro>.
Connect to network - Message forwarding to TCP/IP port Figure 30 Message forwarding to TCP/IP port All notifications and measured values can also be forwarded on in CSV raw data format to any TCP/IP port for linking with devices and SPS. You will find the settings in the menu Line, Line 1 Configuration: o Interface: RS232 o State: Enabled...
Operation - Normal operation 8 Operation Normal operation The device has no power switch. Use an external power switch to turn the unit on and off. The switch must be installed next to the device and must be marked as power switch for the device - for example with a label.
Implement the firmware update as follows: ® 1. Download the firmware update for the Testomat PRO Ca SELF CLEAN from the Heyl website. 2. Save the firmware in the root directory of the SD card to be inserted ® into the Testomat PRO Ca SELF CLEAN.
Operation - Firmware update Obtain the settings after the firmware update After a firmware update, the device may be in an undefined state. After a firmware update, basic programming should therefore always be performed. If the settings have been preserved, it is advisable to export the settings onto the SD card before the firmware update and after the firmware update, to import the saved settings.
To update, you need a PC with network access to the Testomat and its IP address. The process is as follows: 1. Download the update in the download section of the Heyl website. 2. Unzip the zip archive on the PC. 3. Start the executable program.
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Operation - Troubleshooting and repair card with the start and end times of the error. Regardless of the case, the analyses are continued. Access the error history as follows: Select Service => Error History to call up error history. 2. Select Show(OK), to show the list of error messages. 3.
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36 Fault analysis for damage • reagent expiry date exceeded − Replace stirring bar • Foreign reagent in the device − Replace reagent, only use Heyl ® Testomat reagent − Check reagent fill level • Reagent minimum quantity 10 % has 37 Reagent low −...
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Operation - Troubleshooting and repair Error number/error message Description, possible causes Solution, troubleshooting measures 91 Meas. fault • Too high content of Ca or interfering − Check water to be measured for titration3 bivalent ions. After reaching the ions. threshold value the Ca complex does not remain constant.
− Download the firmware file from The device does not function immediately after being switched on. firmware file was found on the the Heyl website and copy the file No display indication. inserted SD card onto the SD card. Two red LEDs on the control card flash quickly •...
Operation - Troubleshooting and repair 8.4.2 Error messages after self-test ® When switched on, the Testomat PRO Ca SELF CLEAN 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 errors in Table has occurred and can be identified by the LED signal.
Operation - Troubleshooting and repair 8.4.3 Firmware update error list Firmware update error und error after self test can be distinguished using the red LED next to the SD card. If the LED lights up, the bootloader is active, and the error concerned occurred during the firmware update. If the LED is inactive, it is an error after the self-test.
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Operation - Troubleshooting and repair Error number/text in LED1 LED2 LED3 LED4 LED5 Solution, troubleshooting measures update.txt on SD card ☼ ○ ○ ○ ○ 900 No SD-Card inserted Insert SD card, restart firmware update Confirm write-protect tab on the side of the card, ○...
Operation - Troubleshooting network connection Troubleshooting network connection Error pattern Possible causes Solution, troubleshooting measures • Wrong user or wrong password − The factory set username “admin” has The network connection via web the password “PASS”. browser works, but it asks for an unknown login: •...
Servicing and maintenance - Leak resistance test 9 Servicing and maintenance Risk of (chemical) burns from cleaning agents! Contact with the cleaning agents used may cause (chemical) burns. • Ensure to observe the safety instructions when handling the cleaning agents! Danger of soiling! The surface of the equipment is untreated.
Servicing and maintenance - Replacing reagents Replacing reagents Risk of (chemical) burns from reagents! Contact with the reagents used may cause (chemical) burns. • Use protective goggles and gloves before handling reagents containing acids and alkalis. With the error message Reagent low or if the maximum shelf life of the reagent is exceeded, it must be replaced.
Servicing and maintenance - Cleaning the filter housing 6. Remove the sight glasses for cleaning. 7. Remove the film on the sight glasses with isopropanol. 8. Clean the measuring chamber with 10 percent hydrochloric acid. 9. Rinse the measuring chamber thoroughly. 10.
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Servicing and maintenance - Replacing fuses • Make sure you are earthed before opening the casing. Device fuses (internal) ® These fuses protect the Testomat PRO Ca SELF CLEAN device or outputs against overload and short circuit. All fuses are pluggable. The main fuses F1 (1) and F6 (2) (4 A MT) for outputs and equipment are located on the motherboard (see figure 38).
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Servicing and maintenance - Replacing fuses Exchange If not all three green LEDs on the motherboard light up, at least one fuse is defective (see figure 39). The supply voltage unit is next to the LED, which indicates its status. You will need the following to switch out a fuse: A Phillips-tip screwdriver Flat-tip screwdriver 24 V...
Servicing and maintenance - Replacing the backup battery Step LED / lamps Action − Disconnect device from the mains! 24V does not light up − The fuse F4 is located at the top edge of the power supply board. Change the plug-in fuse F4 (T2A). −...
Servicing and maintenance - Maintenance of pump head Maintenance of pump head 9.7.1 Replacing the pump head To replace the pump head, proceed as described below: 1. Remove the transparent cover. 2. Open the housing with a suitable screwdriver (push down the snap- on fastening on both sides).
Standard SD card 2GByte 040123 Conversion kit for water intake *) 270337 Maintenance case T2000 Heyl Table 28 *) Conversion kit for water intake, Art. No. 040123 When using fabric pressure hoses (e.g. for existing installations), replace the plug connection on the controller and filter housing for a plug for the quick-release coupling (not included in the delivery scope).
Information on the repair of products and exchange of parts - Consumables 11 Information on the repair of products and exchange of parts The repairing of defective equipment is – regardless of the warranty period – only possible in a dismantled state and with a description of the fault.
Required information when the product is no longer needed - Consumables 12 Required information when the product is no longer needed Dispose of the device in accordance with the regulations of your country. Batteries The unit contains a removable lithium battery (CR2032 / 3V) from VARTA or an equivalent.
Check list Testomat® PRO CA self clean ® Check list Testomat PRO Ca SELF CLEAN Dear customers and service technicians, The following checklist is no substitute for your expertise and experience applied to the process of troubleshooting. It should assist you and facilitate swifter and more systematic detection and logging of errors.
Check list Testomat® PRO CA self clean ® Device settings Testomat PRO Ca SELF CLEAN Caution! Your settings may be deleted in the event of a repair. There are several ways to save the settings: • Export your equipment settings to an SD card before sending the equipment to our service team for repair. The settings can be imported again after the repairs have been completed •...
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