Testomat 2000 CAL

Summary

Product Identification

Testomat 2000® CAL is an online analysis unit for water, designed to measure and monitor:

• Residual total hardness (water hardness)
• Residual carbonate hardness
• Minus m-values
• p-values

Intended Use

The Testomat 2000® CAL is intended for use in water treatment sectors such as osmosis plants, water softening, and drinking water applications. The feed water must be clear, colourless, and free of undissolved particles. Measurement parameters and ranges are determined by indicator selection and user programming.

Performance Specifications

The instrument offers:

• Menu-driven operation and programming with a plain text display.
• Measurement of residual hardness, total hardness, carbonate hardness, minus m-value, and p-value selectable via indicator.
• Freely selectable hardness units: °dH, °f, ppm CaCO₃, mmol/l.
• High measuring accuracy due to a precise piston-dosing pump.
• Multiple options for analysis initiation:
  • Automatic interval operation (interval pause adjustable from 0 to 99 minutes).
  • External control.
  • Dynamic start (exhaustion dependent).
  • Volume controlled (via 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 with a maintenance request.
• Extended operating periods with a 500 ml indicator storage bottle.
• Optional interfaces: 0/4-20 mA or 0/2-10 V, or RS 232 for a log printer.

Indicators for Testomat 2000® CAL Instruments

The following indicators are supported for different parameters:

Water hardness:

• TH 2005: 0.05 – 0.50 °dH (0.01) / 0.09 – 0.89 °f (0.02) / 0.89 – 8.93 ppm CaCO₃ (0.2) / 0.01 – 0.09 mmol/l (0.01)
• TH 2025: 0.25 – 2.50 °dH (0.05) / 0.45 – 4.48 °f (0.1) / 4.5 – 44.8 ppm CaCO₃ (0.9) / 0.04 – 0.45 mmol/l (0.01)
• TH 2100: 1.0 – 10.0 °dH (0.2) / 1.8 – 17.9 °f (0.4) / 18 - 179 ppm CaCO₃ (3.8) / 0.18 – 1.79 mmol/l (0.04)
• TH 2250: 2.5 – 25.0 °dH (0.5) / 4.5 – 44.8 °f (1.0) / 45 - 448 ppm CaCO₃ (10) / 0.45 – 4.48 mmol/l (0.1)

Carbonate hardness, minus m-value, p-value:

• TC 2050: 0.5 – 5.0 °dH (0.5) / 0.90 – 8.96 °f (0.9) / 8.9 - 89.5 ppm CaCO₃ (8.9) / 0.18 – 1.79 mmol/l (0.18)
• TC 2100: 1.0 – 20.0 °dH (1.0) / 1.8 – 35.8 °f (1.79) / 18 - 358 ppm CaCO₃ (18) / 0.36 – 7.16 mmol/l (0.36)
• TM 2005: - °dH / - °f / - ppm CaCO₃ / 0.05 – 0.50 mmol/l (0.01)
• TP 2100: - °dH / - °f / - ppm CaCO₃ / 1 - 15 mmol/l (1)

Application Instructions

• Wait at least 5 seconds before switching the instrument off and then on again at the main switch.
• Use Heyl Testomat 2000® indicators in the pH-range 4 – 10.5 for reliable operation.
• Heavy metal ions (iron > 0.5 mg/l, copper > 0.1 mg/l, aluminum > 0.1 mg/l) and CO₂ (> 20 mg/l) may influence color reactions and evaluation.
• Regular visual inspections are recommended for operational reliability.
• Trouble-free operation requires regular maintenance.

Installation

General Requirements

• Install in a location protected against dripping or splash water, dust, and aggressive substances.
• Install vertically and without mechanical stress.
• Install at a vibration-free site.

Operating Pressure

The instrument is factory set for an operating range of 1 to 8 bar. To operate in the range of 0.3 to 1 bar, the flow controller valve body must be removed and the controller plug reinserted with the retaining pin.

Water Inlet and Outlet

• Water Pressure: 0.3 bar to 8 bar. Avoid strong pressure fluctuations.
• Measuring Water Temperature: 10 °C to 40 °C. For temperatures above 40 °C, a KCN type cooler should be installed.
• Water Inlet: Connect to the main water line directly after the water treatment plant using an opaque plastic hose (6/4 x 1, max. 5 m). Install a manually operated shut-off valve. The connection should be laid vertically upwards.
• Water Outlet: Connect to an opaque outlet hose (internal diameter 14 mm) and lay it to the drain without backwater or syphoning.

Electrical Connections

• Ensure the power supply is disconnected before installation.
• Use tested cables with sufficient cross-sections.
• Keep connecting cables short and install them separately from power cables.
• Connect to the protective earth conductor (for 230/115 VAC).
• Protect against interference voltages using a mains filter if necessary.
• Shield against strong electromagnetic fields.

Terminal Strip Functions:

• Terminals 1-19 (Outputs): For plant components, including flush valve, limit value outputs (LV1, LV2), measuring point switch-over, AUX, Alarm, and Maintenance messages. Relay outputs are isolated, max. 240 VAC, 4 A.
• Terminals 20-27 (Inputs): For control and monitoring functions including Start, Stop, IN1, and IN2 (water meter). Do not connect external voltage.
• Terminals 28-29 (Analog/Serial Output): For 0/4-20 mA or RS232 interface.

Commissioning

• Adhere to the respective safety data sheet for reagents.
• Trouble-free operation is guaranteed only when using Heyl Testomat 2000® indicators.

Indicator Setup

1. Open the lower housing door.
2. Remove the cap from the indicator bottle.
3. Assemble the screw cap with hole and insert.
4. Screw the intake hose connector hand-tight into the insert.
5. Place the insert with the hose into the indicator bottle.
6. Screw the screw cap with hole hand-tight onto the indicator bottle.

Indicator Extraction

1. Switch the instrument on and press "STANDBY".
2. The pump will automatically extract indicator.
3. Fill the intake and transport hoses by repeatedly pressing the "manual" key until indicator reaches the measuring chamber.
4. Ensure the instrument is switched on at the mains switch first.
5. Tighten hose connectors slightly if bubble formation occurs.

Water Inlet

1. Open the lower housing cover.
2. Slowly open the manual shut-off valve to prevent overflow.
3. Ensure water-conducting parts are leak-free.
4. The measuring chamber should fill in 2 to 6 seconds; adjust inlet water if spray emerges from the vent hole.

Instrument Settings and Data Input

Operating and Display Elements

• Display: Shows operating statuses and measured values.
• Limit Value Status Displays (Red/Green): Indicate if limit values are reached/exceeded or fallen below.
• Text Display (4 lines): Shows current analysis results, statuses, and programming data.
• Alarm (Red): Indicates malfunctioning/error or warning messages.
• Maintenance Message (Yellow): Indicates current maintenance requests.
• Status Displays: Six displays indicate current instrument and analysis status.
• Programming Keys (Cursor Block): Used for menu navigation, function selection, and data input.
• Function Keys: "M" (Programming Menu), "i" (Information), "manual" (Start Analysis), "STANDBY" (Standby Mode), "Horn" (Acknowledge Messages).

Switching On/Off

Use the mains switch (1) to turn the instrument on or off. The instrument fuse (2) protects the unit and outputs.

Operating System - Date, Time, Weekday Input

Settings are made via the "M" key to access the ">PROGRAM" menu, then navigating to ">DATE/TIME OF DAY" using the cursor block. Numbers are selected and confirmed using the cursor keys and "ENTER".

Password Protection and Basic Program

A four-digit password, which is the current time in reverse order, is required to access the basic program settings.

Entering Basic Program Data

• Indicator and Bottle Size: Select via ">PROGRAM VALUES => INDICATOR TYPE".
• Operating Mode: Choose from Time Controlled, Volume Interval, Dynamics, or External Analysis Start via ">PROGRAM VALUES => MODE OF OPERATION".
  • Time Control: Set interval pause (0-99 minutes) and flush times (internal/external).
  • Volume Control: Enter desired water quantity (1-9999 litres) and select water meter constant (litre/impulse).
  • Dynamics: Set plant capacity (m³), start percentage, start/end interval times, and reset conditions (Limit value 1, Limit value 2, or IN1).
  • External Start: Triggered via a contact at the start input.
• Displayed Unit: Select the unit (°dH, °f, ppm CaCO₃, mmol/l) via ">PROGRAM VALUES => DISPLAYED UNIT".

Further Basic Program Data

• Internal Flushing: Set flushing time (seconds) in ">PROGRAM VALUES => FLUSH TIMES/INTERVAL". Recommended for longer analysis intervals or sampling lines (> 3 m, 6 mm internal diameter). Requires approx. 0.5 litres for one minute of flushing.
• External Flushing: Configure external flush time (seconds) in ">PROGRAM VALUES => FLUSH TIMES/INTERVAL". Recommended for very short analysis intervals or long/large diameter supply lines to prevent sample mixing.

Maintenance

Regular maintenance is crucial for trouble-free operation. Refer to the "Maintenance" section and the "Maintenance manual of Testomat 2000®/Testomat ECO®" for detailed instructions.

Technical Data

See the official PDF for exact tabulated values.

Disclaimer

This summary is based on extracted text and may not include all figures, footnotes, or revisions. Contractual data must be confirmed against the specific OEM PDF revision used for the project.

Official datasheet (PDF)

Lenntech datasheet mirror