Testomat 2000

Summary

Product identification

The Testomat 2000® is an online analysis unit for water, designed to automatically determine and monitor:

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

Intended use

The Testomat 2000® is intended for use in water treatment sectors such as osmosis plants, water softening, and drinking water applications. The feed water must be clear, colorless, and free of undissolved particles. The instrument's measurement parameters and range are determined by the selected indicator and user programming.

Performance specifications

• Menu-driven operation and programming with a plain text display.
• Measures residual hardness, total hardness, carbonate hardness, minus m-value, and p-value via indicator selection.
• Freely selectable hardness units: °dH, °f, ppm CaCO₃, mmol/l.
• High measuring accuracy due to a precise piston-dosing pump.
• Analysis initiation can be:
  • 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 for maintenance requests.
• Extended operating periods with a 500 ml indicator storage bottle.
• Optional interfaces:
  • 0/4-20 mA or 0/2-10 V.
  • RS 232 for a log printer.
  • SD Card data logger.

Indicators for Testomat 2000® instruments

Water hardness

Carbonate hardness, minus m-value, p-value

Display indications outside the measuring range are shown as "< [value]" for falling below and "> [value]" for exceeding.

Note: When TC indicators are used for carbonate hardness, the device does not monitor dosage. Ensure sufficient indicator is available and set the indicator level to 100% after exchanging a bottle.

Application instructions

• Wait at least 5 seconds between switching the instrument off and on at the main switch.
• Use Heyl Testomat 2000® indicators for reliable operation. Operate within a pH range of 4 – 10.5 when determining total hardness.
• Heavy metal ions (iron > 0.5 mg/l, copper > 0.1 mg/l, aluminum > 0.1 mg/l) in softened water may influence color reactions.
• Incorrect evaluations can occur if measuring water contains more than 20 mg/l CO₂ (carbonic acid).
• A visual inspection should be carried out regularly to check indicator expiry dates, hose connections, presence of air in dosing hoses, water connections, instrument soiling, and cleanliness of the measuring chamber and drain duct.
• Trouble-free operation requires regular maintenance as detailed in the "Maintenance manual of Testomat 2000®/Testomat ECO®".
• Refer to the "Error messages/Troubleshooting" section for problem resolution.

Caution: Do not open the measuring chamber holder; this can damage the device and void the warranty.

Installation

General

• Install the Testomat 2000® in a location protected from dripping or splash water, dust, and aggressive substances (e.g., in a switch cabinet or on a wall).
• Install vertically and without mechanical stress, on a vibration-free site.
• Ensure the water inlet hose is as short as possible (max. 5 m).
• Leave sufficient space on the left side for the door to open.

Operating Testomat 2000® in the pressure range of 0.3 to 1 bar

The instrument is factory set for 1 to 8 bar. To operate at 0.3 to 1 bar, remove the flow controller valve body.

Water inlet and outlet

• Water Pressure: 0.3 bar to 8 bar. Avoid strong pressure fluctuations.
• Water Temperature: 10 °C to 40 °C. For temperatures above 40 °C, a cooler is recommended.
• Water Inlet: Connect to the main water line directly after the water treatment plant. The connection should be laid vertically upwards. Install a manually operated shut-off valve. Use an opaque plastic hose (6/4 x 1, max. 5 m). Flush the inlet line before connection.
  • For operation at 0.3 to 1 bar or with a booster pump, remove the valve body from the controller and filter housing. The pump should have a feeding capacity of 25-35 liters/hour and be resistant to the medium.
• Water Outlet: Connect the outlet to a hose (internal diameter 12 mm) and lay it without backwater or siphoning effect to the drain, e.g., via an open funnel.

Connecting the power supply and devices

• Always disconnect power before installation.
• Use cables with sufficient cross-sections.
• Avoid installing connecting cables parallel to power cables or in close proximity to electromagnetic fields. Keep cables as short as possible and install them separately.
• Connect the instrument to the protective earth conductor (for 230/115 VAC).
• Protect the instrument against interference voltages using a mains filter.
• Shield the instrument against strong electromagnetic fields.

Mains voltage connection

• Connect to the specified mains voltage (refer to the rating plate).
• Connect power supply to terminals PE, N, L (for 115/230 VAC) or U, V (for 24 V).
• The terminal block connections are: PE (Protective earth conductor), N (Neutral conductor), L (Phase). For consumers, switched neutral (n) and switched phase (l) are available (max. 4 A).

Connecting plant components (Relay Outputs)

Relays 1 to 19 are available for connecting plant components. Switched mains voltage (l) and neutral conductor (n) can be supplied to common contacts for components requiring mains voltage.

Connecting inputs and outputs

• Do not connect external voltage to these connections.
• Ensure leads are securely held in terminals.

Commissioning

Handling of reagents/indicators

• Adhere to the respective safety data sheets.
• Only Heyl Testomat 2000® indicators are guaranteed for trouble-free operation.

Inserting the indicator bottle

1. Remove the cap from the indicator bottle.
2. Connect the hose connector of the intake hose to the insert for the screw cap.
3. Place the insert with the intake hose into the indicator bottle.
4. Screw the screw cap with the hole onto the indicator bottle.

Extracting the indicator

1. Switch the instrument on and press the "STANDBY" key.
2. The pump automatically extracts indicator.
3. To ensure indicator is available for initial analyses, manually extract indicator by pressing the "manual" key several times until the intake and transport hoses are filled up to the measuring chamber. Always switch on the instrument at the main switch first.
4. Slightly tighten hose connectors if bubble formation occurs.

Opening the water inlet

1. Slowly open the manually operated shut-off valve to prevent the measuring chamber overflowing.
2. Ensure water-conducting parts are not leaky.
3. The measuring chamber should fill in 2 to 6 seconds. If water sprays from the measuring chamber tube, reduce the inlet water flow.

Functions of the operating and display elements

Switching Testomat 2000® on/off

• Use the main switch (1) to turn the instrument on or off.
• The instrument fuse (2) protects the Testomat 2000® and outputs against overloads and short circuits.

Display functions

• Limit value status displays (1, 2): Illuminate red if a limit value is reached or exceeded; illuminate green if the value falls below the limit.
• Text display (2 lines 2-4): Shows current analysis results, statuses, and programming data. Lines 2 and 3 display the measured value for measuring point 1 (M1) and 2 (M2). Values outside the measuring range are shown as "<" or ">". Line 4 displays set limit values LV1 and LV2.
• Alarm (3): Red indicator for malfunctions, error messages, or warning messages.
• Maintenance message (4): Yellow indicator for current maintenance requests.
• Status display (5): Six displays indicating the current instrument and analysis status.

To acknowledge error/warning messages, press the horn key.

Operating elements and function keys

• Programming keys (cursor block): Used for navigating menus, selecting functions, and entering data. Press "ENTER" to confirm selections or data input.
• Manual key (): Starts an analysis manually.
• STANDBY key (): Puts the instrument into standby mode (automatic analyses are stopped).
• Horn key (): Acknowledges error and warning messages.
• M key (): Opens the programming menu for settings. Pressing it again exits the programming mode.
• i key (): Calls up instrument information and settings.

Operating system

Date, time and weekday input

1. Press the "M" key to access the ">PROGRAM" menu.
2. Use the cursor block to select "Date/Time of day" and press "ENTER".
3. Select "DATE" and press "ENTER". Use cursor keys to enter the date and keys to move between fields. Press "ENTER" to confirm.
4. Select "TIME OF DAY" and press "ENTER". Use cursor keys to enter the time and keys to move between fields. Press "ENTER" to confirm.
5. Select "DAY OF WEEK" and press "ENTER". Use the cursor block to select the current weekday and press "ENTER".
6. Press the "M" key twice to exit programming.

Password protection and basic program

A four-digit password is required to enter data and settings in the basic program. The password is the current time in reverse order.

Entering basic program data

Selecting the indicator and the bottle size

1. In the ">BASIC PROGRAM" menu, navigate to "PROGRAM VALUES" > "INDICATOR TYPE" and press "ENTER".
2. Select the indicator bottle size (500 ml bottle is factory set) and press "ENTER". An asterisk (*) indicates the active selection.
3. Select the indicator type (TH2005 for Water hardness is factory set) and press "ENTER". An asterisk (*) indicates the active selection.

Selecting the operating mode

The "Mode of Operation" setting allows selection of the analysis controller type: Time control, Quantity control (via water meter), Dynamic analysis start, or External analysis start.

• Time Control: Select "TIME CONTROLLED" and enter the "INTERVAL PAUSE" (0-255 minutes), "INTERNAL FLUSH TIME" (seconds), and "EXTERNAL FLUSH TIME" (seconds). The analysis interval is the sum of these times plus the analysis duration.
• Volume Control: Select "VOLUME INTERVAL" and enter the programmed water quantity (1-9999 litres). The analysis is carried out once this quantity is measured. Time control has higher priority if the programmed interval time is reached.
• Water Meter Type: Select the water meter constant (litres/impulse). 100 litres/impulse is factory set. Options include 5, 2.5, 10, 100, 500, 1000 litres/impulse.
• Dynamics (Dynamic analysis start): Select "DYNAMICS". Enter the plant "CAPACITY" (m³), "Start at" percentage, "Start interval" (minutes), and "End interval" (minutes). Select the reset type (Limit value 1, Limit value 2, or IN1). The interval period automatically decreases as plant capacity decreases. The start interval resets when limit value 1 or 2 is exceeded or via a signal at input IN1.
• External Analysis Start: Occurs via a contact at the start input.

Selecting the display unit

The unit for displayed values can be programmed. Available units are °dH, °f, ppm CaCO₃, and mmol/l. "DISPLAY IN °dH" is factory set.

Entering further basic program data

Internal flushing

Ensures the analyzed sample represents the current value by flushing the sampling line. Recommended flushing time is greater than 60 seconds if the plant has been inactive or for long analysis intervals. Flushing starts by simultaneously opening the inlet and outlet valves. The analysis interval duration is directly dependent on the programmed flushing time.

---

Disclaimer: This extraction may miss figures, footnotes, or revisions. Contractual data must match the OEM PDF revision used on the project.

Official datasheet (PDF)

Lenntech datasheet mirror