Maintenance Instructions Testomat 2000 & ECO

Summary

Product identification

• Testomat 2000®
• Testomat ECO®

Maintenance Information

This document provides maintenance instructions for the Testomat 2000® and Testomat ECO® instruments.

Important safety information

• Read the operating and maintenance instructions carefully before performing any work.
• Observe all warning notices.
• Adhere to safety regulations when handling reagents, chemicals, and cleaning agents, and consult the respective Safety Data Sheets.
• Maintenance work requires fundamental electrical and process engineering knowledge and should only be performed by qualified specialists.

Warning notice structure

• DANGER: Immediate hazardous situation resulting in death or serious injury if not avoided.
• WARNING: Potentially hazardous situation that could result in death or serious injury if not avoided.
• CAUTION: Potentially hazardous situation that could result in minor or moderate injuries or property damage if not avoided.
• NOTE: Important information that, if not observed, may lead to an undesirable result or state.

General instructions

• Regular maintenance and visual inspections are necessary for trouble-free operation and increased reliability.
• Many common errors can be resolved by the user, with troubleshooting hints provided in this manual.
• Maintenance intervals may vary depending on water and pipeline quality.

Maintenance work overview

• Clean the measuring chamber approximately every 6 months and consider replacing seals and sight-glass windows.
• High iron content in water may require more frequent cleaning.
• Use only a dry, lint-free cloth for cleaning.
• Confirm error messages like "Mf. soiling" or "Ff. optics" before maintenance.
• For Testomat 2000®, confirm instrument maintenance messages in the SERVICE I menu.
• Wait at least 5 seconds after switching off before switching back on.
• Repairs require the instrument to be dismantled and returned with an error description, indicator type, and measured medium. Ensure the measuring chamber is flushed and empty before returning.
• Do not perform actions not described in these instructions to avoid negatively impacting warranty claims.

Testomat 2000® in steam boiler plants with BOB operation

• In accordance with TRD 604, Sheet 1, Testomat 2000® requires regular maintenance and inspection every six months by the plant operator or an authorized service provider.

Prior to carrying out maintenance work

• Visual inspection:
  • Are instrument doors closed properly?
  • Is the instrument heavily soiled?
  • Is there air in the dosing hoses?
  • Are hose connections leak-free?
  • Has the indicator's use-by date expired?
• Ensure sight-glass windows are clean before inserting a new indicator bottle.

Cleaning agents

• Never use organic solvents on the measuring chamber or plastic parts.
• Use an acidic cleaning agent.
• Observe safety regulations when handling cleaning agents.

Permissible tools

• Use suitable tools. A tool kit (T2000, Art. no. 40138) is available.

Carrying out maintenance

Cleaning the measuring chamber and the sight-glass windows

1. Switch off the instrument or press "STANDBY". If necessary, drain the chamber via SERVICE I > MANUAL OPERATION > Drain chamber.
2. Close the manual supply valve.
3. Unhook the toggle fastener, tilt and remove the measuring chamber.
4. Release and remove sight-glass window holders and clean the windows.
5. Clean windows with alcohol. For hard-to-remove film (from prolonged use with hard water), clean as described for the measuring chamber.
6. Clean the measuring chamber with a decalcifying/rust-removing agent. Flush thoroughly afterward.
7. Re-insert sight-glass windows with flat seals, securing with holders.
8. Re-insert the measuring chamber and secure with the toggle fastener.

Cleaning the receiver optics

• Clean soiled lenses (left of the measuring chamber holder) with a dry, lint-free cloth.

Cleaning the filter housing

1. Close the manual supply valve.
2. Depressurize via SERVICE > MANUAL OPERATION > Flush chamber.
3. Switch off the instrument and loosen hose connections at the filter housing.
4. Unscrew the inlet connection (size 22 spanner).
5. Remove, clean, and reassemble the seal, spring, and filter.
6. Remove the retaining pin, extract the flow controller, and remove the valve body.
7. Clean the filter housing with water or alcohol. Reassemble.
8. Replace seals if necessary.
9. Insert the filter strainer with the cone facing downwards.
10. Re-attach hose connections.

After assembly:

• Ensure connections are leak-free. Leaking water can damage components.
• Leak check: Switch to "STANDBY", manually fill chamber (SERVICE > MANUAL OPERATION > Fill chamber), manually dose indicator, check connections/seals, drain chamber.

Cleaning the housing

• The housing surface is untreated; avoid soiling from indicators, oil, or grease.
• Clean soiled surfaces with alcohol (never use other solvents).

Removing and installing the measuring chamber holder

• Required tool: Torx 10x80.

1. Stop water supply and drain the measuring chamber.
2. Switch off the instrument.
3. Remove the measuring chamber.
4. Remove the stirring bar.
5. Loosen the pressure hose (1).
6. Loosen the four fastening screws of the measuring chamber holder (2).
7. Loosen the valve block (3) (two screws).
8. Disconnect the flexible cable plug (4) from the base circuit board.
9. Remove the measuring chamber holder from the front after removing the drain pipe (5).
10. Install the new holder in reverse order. Ensure the plug is locked.

Re-adjusting the measuring chamber holder (Overflow detection)

• Instruments from serial number 222.899 and higher have self-adjusting electronics; no manual adjustment is required or possible.
• For instruments with serial numbers below 222.899, if re-adjustment is needed (error "low water level" despite filling):
  1. Switch off the instrument.
  2. Press and hold the "DOWN" key, then switch on the instrument (activates "Adjust mode").
  3. Use an adjustment pin to turn the potentiometer on the base of the measuring chamber holder (A) clockwise until the "Analysis" LED illuminates.
  4. Turn the potentiometer counter-clockwise by approximately 1/8 turn.
  5. Test overflow detection: Press key for input valve. "Analysis" LED must illuminate when water overflows. Press key again to quit; LED must extinguish after overflow stops.
  6. Return to normal operation by pressing "LEFT" and "DOWN" keys simultaneously.

Checking water recognition

• Use the key to check water recognition for instruments with self-adjusting electronics.

Replacing the EPROM (software update)

• Required tool: Torx 8x60.
• CAUTION: Avoid static charges.
  1. Switch off the instrument.
  2. Loosen the six screws (a) of the display circuit board.
  3. Carefully remove the EPROM (b) from its socket (note orientation).
  4. Insert the new EPROM.
  5. Fasten the display circuit board.
  6. Switch on the instrument.

Opening the factory programming

• After replacing the EPROM, perform basic programming.
• Switch on the instrument while simultaneously pressing the and keys. This resets programmed settings to factory defaults.

Installing the interface cards SK910, UK910, RS910 (only Testomat 2000®)

• CAUTION: Avoid static charges.
  1. Switch off the instrument.
  2. Open the upper housing cover.
  3. Insert the plug-in circuit board into the left slot with the component side on the left (contact #1 at the top).
  4. Switch on the Testomat 2000®.
  5. In the menu: BASIC PROGRAM > PROGRAM VALUES > INTERFACES, select the appropriate type:
     • "type 0-20mA" or "type 4-20mA" for SK910/UK910.
     • "type RS232" for RS910.

Position and function of the fuses

Testomat 2000®

Testomat ECO®

• Fuse F9 triggers in case of overload or short circuiting at the relay outputs if power for external consumers is supplied from terminals "l" to "n".

Repairing or replacing the dosing pump

• Maintenance rate: The DOSIClip® dosing pump makes up to 400,000 strokes per year. It is recommended to service the pump every 2-3 years.
• Calibration: On-site calibration is not possible. Exchange defective pumps and send them to the factory for servicing.
• Replacement procedure:
  1. Switch off the instrument.
  2. Loosen the five cables at the terminal connections.
  3. Loosen hose connections at the indicator bottle and measuring chamber holder.
  4. Collect the indicator in a container.
  5. Push down the pump housing lock with a screwdriver and remove the housing.
  6. Place the replacement pump on the DIN rail and push the housing down until the lock engages.
  7. Reconnect cables (observe color sequence).
  8. Reconnect hose connections (note suction and pressure sides).

Special function “Adjust mode”

Checking dosing

• During hardness measurement, the yellow value should be at least 50 below the limit value after each dosing stroke (except the first). Each stroke typically reduces the value by 80-100 digits.
• Manually activate the dosing pump once.
• In "Adjust mode", display the yellow value under "G:####".
• The stirrer must be switched on during this check.
• Checks are only possible with indicator type TH.

Adjust mode

• Used for adjusting overflow detection and testing optical amplification settings. Amplification is set in normal measuring mode; this test is for checking and error detection.
• Call adjust mode: Press and hold the "DOWN" (1) key and switch on the instrument.
• Back to measuring mode: Press "DOWN" (1) and "LEFT" (9) keys simultaneously.

Testing of the overflow detection

1. Press the "M" (3) key to open the input valve (IN LED illuminates on Testomat 2000®).
2. The "ANALYSIS" (7) LED must illuminate as water flows through the overflow borehole. (Adjust overflow detection if not).
3. Press the "i" (4) key to open the output valve (OUT LED illuminates on Testomat 2000®).

Checking the automatic adjustment

1. Fill the measuring chamber with water until overflow occurs.
2. Switch to "Adjust mode".
3. Press the "ENTER" (2) key to switch on transmit diodes and stirring mechanism.
4. Press the "UP" (5) key to start automatic adjustment.
5. Manually activate the dosing pump.
6. Read yellow (Y:) and red (R:) values. Both should be 900 ± 20.

Possible reasons for values not being achieved:

• Turbid water.
• Air bubbles in the water.
• Incorrect measuring chamber filling.
• Soiled or cracked sight-glass windows.
• Soiled receiver optics.
• Loose flexible cable plug connector.
• Leaky measuring chamber holder damaging electronics.
• Defective electronic component on plug-in circuit board T2000-SE.

Water consumption

• Analysis-relevant volume: 18.1 ml per analysis.
• Measuring water adjustment: 150–200 ml per analysis (variable, depends on input pressure).
• Internal flushing: 0.5 L (500 ml) per minute (variable, depends on input pressure). With a 10-second flush time, consumption is 83 ml.
• Flushing after analysis: approx. 50 ml.
• Flushing is done by simultaneously opening inlet and outlet valves.
• Default setting example: Inlet pressure 2 bar = 200 ml measuring water adjustment + 18.1 ml analysis volume = 218.1 ml/analysis. With 10 sec internal flushing: 83 ml + 218.1 ml = 301.1 ml/analysis.
• For connections longer than 3m and 6mm internal diameter, a minimum internal flushing time of 10 seconds is required.

Indicator consumption

• Testomat uses automatic titration, dosing indicator drop-by-drop until color change.
• Indicator consumption depends on water hardness and analysis frequency.
• Example calculation for TH 2005 at 0.1 °dH with 3 strokes: 500 ml indicator lasts for 16,667 strokes (5,555 analyses). At 30-minute intervals, a bottle lasts approx. 2,777 hours, resulting in ~3.15 bottles annually. This is an approximate value.

Indicator TH2025, TH2100, TH2250

See the official PDF for exact tabulated values.

Indicator TH2005

See the official PDF for exact tabulated values.

Manual measured value check

• Usually performed via laboratory analysis. Can be done on-site by direct input of a standard solution.

Creating a standard solution

• Create on-site for rapid application.
• Dilute a solution (e.g., 1000 ppm) to achieve the desired value in the upper third of the measuring range.

Manual supply of the standard solution

1. Stop water supply.
2. Remove the right plug from the measuring chamber.
3. Start measurement via the key.
4. Testomat 2000® starts an analysis cycle. If flushing is programmed, wait for the "OUT" LED to extinguish before filling.
5. Fill the measuring chamber with standard solution until it overflows (IN LED extinguishes). Solution is then drained.
6. After the "OUT" LED extinguishes, refill with standard solution until it overflows. The filling level will drop to the intended sample volume.
7. The measured value is displayed after the analysis finishes.

Troubleshooting

Error message MST analysis

• Occurs when water is too "light" after the second dosing.
  1. Indicator expiry date exceeded: Indicator has insufficient dye. Use a new indicator. If not a Gebr. Heyl indicator, switch to a recommended one.
  2. Stirring bar fails to rotate:
     • Stirring bar stuck due to soiling. Clean the measuring chamber.
     • Leaky measuring chamber holder damaged the circuit board. Change the holder.
     • Loose flexible cable plug. Insert properly.
     • Weak magnet in stirring bar. Change stirring bar.
     • Insert a stirring bar if missing.
     • Check flexible printed circuit board plug contact. Replace holder if necessary.
  3. Insufficient indicator dosing:
     • Check dosing pump (see "Checking the dosing pump"). Contact customer service or replace the pump.
     • Check pump dosing (see "Checking dosing"). Contact customer service or replace the pump.
  4. Air trapped in indicator hose:
     • Bleed hoses by pressing the "Manual" button on the dosing pump multiple times.
     • Ensure all indicator hoses are fitted correctly to prevent air entry.
     • If error recurs, replace the bottle insert for a screw cap with a suction tube (art. no. 40135).
     • Check suction and pressure hoses for kinks or trapping. Replace if necessary (suction hose art. no. 40011, pressure hose art. no. 40016).
  5. Insufficient water pressure: Water supplied, but level too high after inlet valve closes.
     • Water level should be approx. 32 mm above the lower edge of the transparent measuring chamber block.
     • Water pressure should be within 0.3 - 1 bar (without valve body) and 1 - 8 bar (with valve body).
     • Ensure all dummy plugs are correctly fitted to prevent air leaks.
  6. Blocked drain pipe: Water may collect.
     • Ensure water outlet is not blocked. Clean if necessary.
  7. Soiled measuring chamber: Indicator residue or contamination in channels or sight-glass windows.
     • Remove dirt with ethyl alcohol or a plastic cleaner.
     • Clean receiver optics.
  8. Measuring water not bubble-free or milky:
     • Ensure no air bubbles and CO₂ content is not > 20 mg/l. Incorrect softening plant regeneration or residual salt can cause this. Contact customer service or use aerator R (art. no. 130010).
  9. Impairment by ions: Iron (< 0.5 mg/l), copper (<0.1 mg/l), and aluminum (<0.1 mg/l) ions.
     • Likely caused by old iron pipes, new copper pipes, or well water changes. Check measuring water composition. Use test kits for iron (art. no. 410547) and copper (art. no. 410562) for checks.
  10. Fuse failure for measuring amplification: Check and replace F6 fuse if necessary.
  11. Measuring chamber not correctly filled:
      • Check if closing plugs in the measuring chamber fit tightly, especially the rear plug, to prevent air suction and siphoning issues. Replace old/missing plugs (Maintenance lab Art. No. 270335).
      • Check the inlet solenoid valve. Incorrect opening/closing (due to foreign particles/wear) causes incorrect water levels.
      • Indicator and water quantity must be correct.

Switching on the real-time clock (only Testomat 2000®)

• If the integrated clock fails (e.g., due to EMC faults), restart it:
  1. Switch off the instrument.
  2. Press and hold the "ENTER" key.
  3. Switch on the instrument again.

Low water level

• Remedy:
  • Check inlet water (filter strainer) for foreign particles. Clean strainer if necessary.
  • Check inlet water connection if the IN lamp is lit but no water is supplied.
  • Inlet pressure too low (< 1 bar). Remove pressure valve body (see "Cleaning the controller/filter housing").
  • Approximately 400 ml/min should flow through the measuring chamber for flushing and filling.
  • Inlet solenoid valve defective. Check F6 fuse and plug contact at the inlet valve.
  • Overflow detection not reacting. Check overflow detection (see "Special function Adjust mode").

Error message FST optics (Testomat 2000®)

• Remedy:
  • Plug-in circuit board driver/receiver SE-T2000 (art. no. 40091) is defective. Replace it.
  • Optical component error; receiver is defective. Replace the measuring chamber holder.
  • Cold water (<8°C) with warm, humid ambient temperature (>28-30°C) can cause condensation on sight-glass windows.

Error message MST turbid

• Remedy:
  • Check if measuring water is very turbid or soiled.
  • Check and clean sight-glass windows if soiled.
  • Install a filter (art. no. 11217) in the inlet if necessary.
  • Cold water (<8°C) with warm, humid ambient temperature (>28-30°C) can cause condensation on sight-glass windows.

Error message Ff outlet to drain

• Water remains in the measuring chamber despite the "OUT" LED illuminating.
• Remedy:
  • Check if the outlet valve is soiled or if the connector is oxidized. Replace the valve if the error persists.

Error due to defective hardware

1. Dosing pump runs permanently:
   • Check if the broadband cable at the main and front board is loose or defective.
2. Inlet valve allows water to flow through:
   • Check if the inlet valve is soiled.
3. Outlet valve allows water to flow through:
   • Check if the outlet valve is soiled. Is there permanent voltage on the valve (software or hardware error)?
   • Perform a reset (see operating instructions). If the error persists, replace the valve.

Readjusting the current interface

• A signal of less than 20mA is output.
• Remedy: Contact your customer service representative.

Spare parts lists

• Articles marked with * are for Testomat 2000® only.
• Articles marked with ** are for Testomat 2000 ECO® only.
• Unmarked components are compatible with both instruments.

See the official PDF for the complete list of spare parts.

Spare parts requirement for 2 - 3 years of operation

• Sight-glass window 30 x 3 with seal (40173): 2x
• Inlet filter (11217): 1x
• Gasket set T2000 (40124): 1x
• Fuse T0,315A (31585)
• Fuse T1,0A (31592)

Accessories

• Retrofit kit for water inlet (040123)
• Maintenance lab T2000/ECO (270337)
• Tool kit T2000/ECO (040138)
• Interface card (0/4-20 mA) SK 910 (270305)
• Interface card (0/2-10 V) UK 910 (270315)
• Interface card (RS232) RS910 (270310)

Component positions

See the official PDF for detailed diagrams of component positions for Testomat 2000®.

Content of the gasket set T2000 (Art. no.: 40124)

Check List Testomat 2000®

This checklist supports fault diagnosis and documentation but does not replace expertise.

Block 1 / Plant and instrument data

• Plant type
• Instrument type
• Instrument no.
• Indicator type
• Software status
• Pump no.

Block 2 / Error message and error history

• Status of instrument's error history display.
• Presence of current error messages on the display (e.g., "Mf. analysis", "Low water level").

Block 3 / Visual inspection and functional test

• Connection to mains voltage specified on rating plate.
• Message appearing on display.
• Plausibility of displayed measured value (possible manual measurement value).
• Cleanliness of measuring chamber and sight-glass windows.
• Leak-free status of measuring chamber and water-carrying hoses.
• Indicator expiry date validity.
• Correct indicator type programmed.
• Water pressure within specified range (400 ml/min).
• Drain hose preventing backwater (no "syphoning effect").
• Drain hose free of blockages.
• Set flushing time/quantity ensuring only fresh water is measured.
• Absence of air bubbles in dosing pump hoses.

Carrying out a (manual) analysis:

• Water column rising evenly to overflow borehole when filling measuring chamber (5 mm below upper edge). (Check water pressure, flow controller if not).
• Indicator pump dosing correctly when analysis starts (LED on pump illuminates).
• Proper mixing of indicator and water in measuring chamber after dosing (check magnetic stirrer).

Programming data / Operating conditions

• Limit values set correctly (within measuring range/plant performance limits).
• Instrument supplied with mains voltage at all times, except during maintenance/emergencies (temporary shutdown only via "Standby" key or "Stop" input).

Further functional tests and service instructions can be found in the maintenance manual (e.g., overflow detection and amplification setting).

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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