Testomat EVO TH

Summary

Product identification

The Testomat® EVO TH is an online analysis instrument designed for the automatic determination and monitoring of residual total hardness (water hardness) in water.

Intended use

This instrument is intended for the automatic determination and monitoring of residual total hardness in water. The measurement scope is determined by the selected indicator and user programming. It is crucial to comply with the output limits specified in the "Technical Data" section and to observe the application areas of the indicators and the requirements of the medium being measured.

Improper use includes operating the device outside its specified scope or under deviating conditions.

Qualification of personnel

Assembly and commissioning require basic electrical and process engineering expertise, as well as knowledge of specialist terms. These tasks must be performed by a specialist or a properly trained and supervised individual.

Warnings in this manual

Warnings are used to indicate risks of injury or property damage and are structured as follows:

• DANGER: Indicates a significant, direct, and unavoidable threat that will result in severe injury or death.
• WARNING: Indicates a possible danger that could result in severe injury or death if not avoided.
• CAUTION: Indicates a potentially dangerous situation that could result in minor to moderate injury or property damage if not avoided.
• NOTE: Highlights important information that may affect operational procedures if not heeded.

General Information

• National and local requirements, as well as accident prevention and conservation regulations, must be observed during assembly and commissioning.
• No modifications beyond the specified scope of use are permitted and will void the warranty.

Requirements for the installation site

• Indoor use only.
• Ambient temperature: 10 to 40°C.
• Altitude: Under 2000 m.
• Relative humidity: Maximum 80% at up to 31°C (linearly declining to 50% at 40°C).
• The device must be protected from moisture, splashed water, and condensate.
• Surge category: II.
• Soiling degree: II.

Requirements of cable for mains voltage and system components and installed lines

• Dielectric strength: 30 V to 260 V (according to the specification plate).
• Cable ducts: Clamping range of 4.5 mm – 10 mm (external diameter).
• Terminal strips: Core cross-sections of 0.08 mm² to 2.5 mm² for single-wire and fine-wire cores (with wire end ferrules without plastic collar). For fine-wire cores with plastic collar, up to 1.5 mm². AWG28 – AWG12 can also be used for single-wire cores.

Requirements for cable ducts

• Housing recesses are intended for M16 ducts.
• Duct openings should be smooth and rounded.
• Secure bending protection is required (five times the maximum cable diameter).
• Ducts must include strain relief that prevents slippage and cannot be disengaged without a tool.
• Material flammability rating must be V1 or better if using non-OEM ducts.

During assembly

• Always disconnect the system component from the power source before assembly or connection/disconnection.
• Connect the device only to the specified mains voltage.
• Observe technical data and environmental parameters.
• Mains voltage and relay output cables must be laid separately.
• Do not operate the device without partition walls or terminal area covers.
• Use a mains filter to shield against interference voltages.
• Never lay connecting cables parallel to mains cables.
• Take ESD safety measures when opening the casing.

During operation

• The device has no power switch; use an external power switch.
• Ensure the maximum electrical load capacity of switching outputs is not exceeded (total load must not reach 4A).
• In case of malfunctions, immediately switch off the device and inform service personnel. Never attempt self-repair.

During cleaning

• Use only a dry and lint-free cloth.
• Refer to the "Servicing and maintenance" section for detailed instructions.

Malfunctions/repairing a defective device

• Defective devices must be serviced by authorized personnel after dismantling and description of the error.
• Empty the measuring chamber, remove the indicator bottle and drain funnel before sending for repair.
• Note the error type (number, effect, log file) before dismantling.
• If a protective device triggers, resolve the cause before reactivating. Frequent triggering indicates an error.
• Pack the power pack individually in its original box for return.

During disposal

• Dispose of the device in accordance with national regulations.

Operating requirements

• Problem-free operation requires using only Heyl Testomat indicators within the pH range of 4 – 10.5. Using external indicators may void the warranty.
• Operate only within specified parameters.
• Heavy metal ions (Iron > 0.5 mg/l, Copper > 0.1 mg/l, Aluminum > 0.1 mg/l) can disturb the color reaction.
• More than 20 mg/l CO₂ may lead to erroneous evaluations; use an irrigator if necessary.
• Test water must be clean and bubble-free.
• Excessive carbonate hardness, disinfecting agents, or silicate may soil the measuring chamber, leading to erroneous evaluations.
• Regular visual inspection of the device is recommended (indicator expiry, hose connections, air in hoses, leaks, soiling, cleanliness of measuring chamber/drain).
• Problem-free operation is contingent on regular maintenance.

Delivery includes

• 1 Testomat® EVO TH
• 1 plastic bag with screw cap and insert
• 1 package with drain funnel, 2 screws, and power supply
• 1 User manual

Service description

The Testomat® EVO TH offers:

• Menu-driven operation via a backlit graphic LCD.
• Measurement of overall hardness based on selected indicator.
• Free selection of hardness units (°dH, °f, ppm CaCO₃, or mmol/l).
• Precise measurement with a piston-dosing pump.
• 500 ml indicator storage bottle for extended operation.
• Analysis triggers: Automatic interval, contact water meter, or external signal.
• Two independent limit values with adjustable switching functions.
• SD card logging for measurement data, notifications, and alarms.
• Import/Export of settings.
• Error history for 20 notifications.
• Firmware update via SD card.
• Built-in self-test.
• Optional wireless data retrieval with WLAN SD card.
• Integration features: Fault signal output, 0/4-20 mA current loop, RS232 serial interface.

Available indicators for Testomat® EVO TH devices

Note: Using Heyl indicators is recommended to ensure accurate measurement and prevent device damage.

Assembly

• Assemble the device in a location shielded from water drips, splashes, dust, and aggressive substances.
• Assemble vertically and without mechanical stresses or vibrations.
• Minimize water inlet hose length (max. 5 m).
• Ensure sufficient room on the left side for door opening.
• Drill mounting holes as per sketches and secure with three screws.

Use of the Testomat® EVO TH within a pressure range of 0.3 to 1 bar

For operation between 0.3 to 1 bar, the flow governor core must be removed. This involves removing a locking pin, pulling out a controller plug, removing the core, and re-inserting the plug and pin. A MepuClip booster pump can be used for pressures under 0.3 bar or when sucking from a tank.

Connecting the water intake and discharge

• Water Temperature: Water exceeding 40°C can cause burns and damage. A cooler must be installed if temperatures exceed 40°C.
• Water Pressure: Must be between 0.3 to 8 bar. For operation between 0.3 to 1 bar, remove the controller core. A booster pump (25-35 liters/hour, medium-resistant) is recommended for pressures under 0.3 bar. Use a pressure reducer for pressures exceeding 8 bar. Avoid significant pressure fluctuations.
• Measurement Water Temperature: Must be between 10 and 40°C.
• Intake Lines: Recommend short lines (under 3m). Longer lines (>3m) require purge periods >60s. For lines >5-10m, consider external flushing via AUX input.
• Water Intake:
  • Connect the linking piece directly to the sampling pipe, vertically upwards.
  • Assemble a manual stop valve in the intake.
  • Use opaque plastic pressure hose 6/4 x 1 (max. 5 m).
  • Purge the intake to remove dirt particles.
• Water Drain:
  • Use the supplied funnel and a drain hose (internal diameter 12 mm/14 mm).
  • Lay the hose free of back pressure and without a siphon effect.

Connect mains and devices

• Safety: Disconnect all power before assembly. Use only verified cables with sufficient line cross-section.
• Disconnecting Device: The unit requires an external appliance switch or circuit breaker (IEC 608947-1 and IEC 60947-3) for power disconnection, located within reach and clearly marked. A three-pin plug can also be used.
• Electromagnetic Fields: Avoid laying connecting cables parallel to mains cables or near strong electromagnetic fields. Keep cables short, lay them separately, and use a mains filter if necessary. Connect the device with the protective conductor (for 230/100-240 VAC).

Terminal designations for mains connection:

• Mass/PE: Mains protective conductor (for 230 V and 100 – 240V).
• N (U): Grid Neutral conductor (U=24V). Power input 50-60 Hz.
• L (V): Grid Phase (V=24V). Power input 50-60 Hz.
• n: Neutral conductor, secured with 4A (for consumers, max. 4 A).
• l: Phase, secured with 4A (for consumers, max. 4 A).

Connect system components

• Remove blanking plugs from cable ductings, push cables through, and tighten the union nut for strain relief.
• Connect system components to relay outputs 1 to 4.
• For components requiring mains power, connect external switched mains voltage (l) to the root contact of the respective relay.
• Connect the neutral conductor to terminal (n) and the protective conductor to PE.
• Warning: If applying external voltages to relay contacts, affix a warning sticker to the device.

Relay Output Terminal Designations:

• LV1 (limit value) OUT: Root c, NO (closing contact), NC (break contact). Floating relay output, max. 240 VAC, 4 A.
• LV2 (limit value) OUT: Root c, NO (closing contact), NC (break contact). Floating relay output, max. 240 VAC, 4 A.
• AUX (auxiliaries) OUT: Function output – root c, NO (closing contact), NC (break contact). Floating relay output, max. 240 VAC, 4 A.
• Alarm OUT: Fault signal output – root c, NO (closing contact), NC (break contact). Floating relay output, max. 240 VAC, 4 A.

Connect inputs and outputs

• Follow cable ducting procedures as above.
• Do not expose connections to external voltage. Ensure cores are securely in place; incorrect connections will damage the device.

Input/Output Terminal Designations:

• 13, 14 (Out +/-): Current loop 0/4 - 20 mA (galvanically isolated).
• 15, 16 (Ext. Ack.): External reset/acknowledgment input for error and alarms (break/closing contact programmable, only isolated).
• 17, 18 (WM): Water meter intake (common ground for inputs, only isolated break/closing contact or observe meter technical data).
• 19, 20 (Stop): External disruption of analysis (common ground for inputs, only isolated break/closing contacts).

RS232 interface terminal assignment

• 2 (RXD): Data reception.
• 3 (TXD): Output of measured values/alarms.
• 5 (GND): Ground.

Connect indicator bottle

• Use only Heyl Testomat 2000® indicators for flawless operation and to maintain warranty.
• Insert Indicator Bottle: Open lower housing door, remove bottle cap, assemble screw cap with hole and insert. Screw hose connector into insert, plug into bottle, and screw cap onto bottle.
• Open Water Intake: Open lower housing lid, slowly open manual stop valve. Configure flow regulator to fill the measuring chamber within two to six seconds.
• Automatic Venting: After switching on, indicator lines are automatically vented and the chamber purged until indicator is detected. This process cannot be interrupted. Acknowledge "voltage failure" error after completion.

Device settings and data input

Functions of the control and display elements

• Display: Shows operating modes, measurement values, states, and programming data. Current measurement value on the right, configured limit values (LV1, LV2) on the left. Displays "<" for exceeding measurement range (e.g., < 0.05 °dH) and ">" for exceeding (e.g., > 10.0 °dH).
• Limit Value Indicators (red/green): Indicate if limit values are exceeded (red) or within range (green).
• LEDs:
  • In (green): Inlet valve open.
  • Analysis message (yellow): Analysis in progress.
  • Out (green): Outlet valve open.
  • Dosing (yellow): Dosing pump active.
  • BOB operation (green): BOB operation active.
  • Pause (green, flashing): Pause mode activated.
  • Service (yellow): Maintenance period elapsed.
  • Alarm (red): Functional error, error message, or warning message.
• Error/Warning Messages: Shown in rotation with the standard display. Eliminate cause and acknowledge with the "Horn" button.

Control and function keys

• Manual Button (): Starts manual analysis.
• PAUSE Button (): Puts the device into standby mode (no automatic analysis).
• Horn Button (): Acknowledges error and warning messages.
• M Button (): Accesses the programming menu for settings.
• i Button (): Accesses device information and settings.

Operating system

Symbols in the menu indicate function key availability:

• M / I: Indicates current menu (basic program/service or information).
•  / : Indicates additional selection options above or below.
•  / : Allows viewing settings with cursor keys (e.g., error list).
• +: Indicates an additional submenu.

Inputting date and time

Accessed via the "M" button, then selecting "Service" > "Time Date". Values are confirmed with "OK". If no input is made for 30 seconds, the device reverts to previous values.

Selection of functions (Example: "Select mode of operation")

Accessed via the "M" button, then selecting "Basic program" > "Mode of operation". Options include "Time controlled", "Volume interval", or "Volume and 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