Maintenance Instructions Testomat 2000 & ECO

Summary

Product Identification

• Testomat 2000®
• Testomat ECO®

Important Safety Information

• Read operating and maintenance instructions carefully before performing maintenance.
• Observe all warning notices.
• Adhere to safety regulations when handling reagents, chemicals, and cleaning agents. Refer to the respective Safety Data Sheet, available at http://www.heyl.de.

Qualification of Staff

Maintenance requires fundamental electrical and process engineering knowledge. It should only be performed by or supervised by a specialist.

Warning Notices

• DANGER: Indicates an immediate hazardous situation that will result in death or serious injury if not avoided.
• WARNING: Indicates a potentially hazardous situation that could result in death or serious injury if not avoided.
• CAUTION: Indicates a potentially hazardous situation that could result in minor or moderate injuries or property damage if not avoided.
• NOTE: Indicates important information that, if not observed, may result in an undesirable outcome.

General Instructions

Regular maintenance and visual inspections are necessary for trouble-free operation. Many common errors can be fixed by the user.

Maintenance Intervals Overview

General Maintenance Notes

• Clean the measuring chamber approximately every 6 months. Consider replacing the measuring chamber holder seals and sight-glass windows.
• More frequent cleaning may be needed with high iron content water.
• Use only a dry, lint-free cloth.
• Confirm error messages like "Mf. soiling" or "Ff. optics" after maintenance.
• For Testomat 2000®, confirm maintenance after an instrument maintenance message in the SERVICE I menu.
• Wait at least 5 seconds before switching the instrument on and off again.
• For repairs, the instrument must 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, as it may affect warranty claims.

Testomat 2000® in Steam Boiler Plants with BOB Operation

According to TRD 604, Sheet 1 (new WÜ 100), Testomat 2000® requires regular maintenance and inspection every six months by the plant operator or an authorized provider.

Prior to Carrying Out Maintenance Work

• Perform a visual inspection:
  • Are instrument doors closed properly?
  • Is the instrument heavily soiled?
  • Is there air in the dosing hoses?
  • Are dosing pump hose connections leak-free?
  • Has the indicator's expiry date passed?
• 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

Refer to the tool kit T2000 (Art. no. 40138) for suitable tools.

Carrying Out Maintenance

Cleaning the Measuring Chamber and the Sight-Glass Windows

1. Switch off the instrument or press "STANDBY". Optionally, drain the measuring chamber via SERVICE > MANUAL OPERATION > Drain chamber.
2. Close the manually-operated valve of the supply line.
3. Unhook the toggle fastener, tilt and remove the measuring chamber.
4. Release and remove the sight-glass window holders and clean the windows.
5. Clean sight-glass windows with alcohol. For stubborn films, use the cleaning method described for the measuring chamber.
6. Clean the measuring chamber with a decalcifying and rust-removing agent. Rinse thoroughly.
7. Re-insert sight-glass windows with seals, ensuring correct fit.
8. Re-insert the measuring chamber and secure with the toggle fastener.

Cleaning the Receiver Optics

Clean soiled lenses of the receiver optics with a dry, lint-free cloth.

Cleaning the Filter Housing

1. Close the manually-operated valve of the supply line.
2. Depressurize lines 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. Clean 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 and reassemble. Replace seals if needed.
8. Insert the filter strainer with the cone facing downwards.
9. Re-attach hose connections.
10. After assembly, check for leaks.

Cleaning the Housing

Clean the instrument housing surface with alcohol. Avoid 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) from the measuring chamber holder (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, ensuring the plug is locked.

Re-adjusting the Measuring Chamber Holder (Overflow Detection)

Applies to instruments with serial numbers below 222.899. Instruments from serial number 222.899 and higher have a self-adjusting electronic circuit and do not require adjustment.

Required tool: Adjustment pin 2 mm (Art. no. 30990).

1. Switch off the instrument.
2. Press and hold the "DOWN" key, then switch on the instrument (calls "Adjust mode").
3. 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. Check overflow detection using the INPUT VALVE key: The "Analysis" LED must illuminate while water overflows. Press the key again to quit; the LED must extinguish once overflow finishes.
6. Return to normal operation by pressing the "LEFT" and "DOWN" keys simultaneously.

Replacing the EPROM (Software Update)

Required tool: Torx 8x60.

1. Switch off the instrument.
2. Loosen the six fastening screws (a) of the display circuit board.
3. Carefully remove the EPROM (b) from its socket, noting its orientation.
4. Insert the new EPROM.
5. Fasten the display circuit board.
6. Switch on the instrument.
7. Perform basic programming after replacement.

Opening the Factory Programming

After replacing the EPROM, reset to factory settings by switching on the instrument while simultaneously pressing the PROGRAM and i keys. Programmed settings will be lost.

Installing the Interface Cards SK910, UK910, RS910 (Testomat 2000® only)

1. Switch off the instrument.
2. Open the upper housing cover.
3. Insert the plug-in circuit board into the left-hand slot with the component side on the left (contact no. 1 at the top).
4. Switch on Testomat 2000®.
5. In the menu, under "BASIC PROGRAM > PROGRAM VALUES > INTERFACES," select the appropriate type for your card (e.g., "type 0-20mA" for SK910/UK910, "type RS232" for RS910).

Position and Function of the Fuses

Testomat 2000® Fuses

Testomat ECO® Fuses

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

Repairing or Replacing the Dosing Pump

The DOSIClip® dosing pump is a high-precision component. Servicing every 2-3 years is recommended. Calibration on-site is not possible; exchange and factory servicing are recommended for defective pumps.

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 indicator in a container.
5. Push the pump housing lock downwards and remove the housing.
6. Place the replacement pump on the DIN rail and push the housing down until it locks.
7. Reconnect cables (observe color sequence).
8. Reconnect hose connections (note suction and pressure sides).

Special Function “Adjust Mode”

This mode is used for adjusting overflow detection and testing optical amplification.

Calling Adjust Mode

Press and hold the "DOWN" key and switch on the instrument.

Returning to Measuring Mode

Press the "DOWN" and "LEFT" keys simultaneously.

Testing of the Overflow Detection

1. Press the "M" key to open the input valve IN.
2. The "ANALYSIS" LED must illuminate when water flows through the overflow borehole. If not, adjust overflow detection.
3. Press the "i" key to open the output valve OUT.

Checking the Automatic Adjustment

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

Possible reasons for not achieving target values:

• Turbid water
• Air bubbles in 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

Water consumption comprises:

• Analysis-relevant volume: 18.1 ml per analysis.
• Measuring water adjustment: 150 – 200 ml per analysis.
• Internal flushing: 0.5 L (500 ml) per minute.
• Flushing after analysis: approx. 50 ml.

Flushing is achieved by opening inlet and outlet valves simultaneously. Measuring water adjustment and internal flushing volumes vary with input water pressure. With a 10-second internal flushing time, water consumption is 83 ml. For connections longer than 3 m and a 6 mm internal hose diameter, a minimum 10-second internal flushing time is required.

Example Calculation (Default Setting):

• Inlet pressure 2 bar: 200 ml measuring water adjustment + 18.1 ml analysis volume = 218.1 ml per analysis.
• With 10 sec internal flushing: 83 ml + 218.1 ml = 301.1 ml total waste water per analysis.

Indicator Consumption

Testomat uses automatic titration, dosing indicator drop-by-drop until color change. Higher water hardness and analysis frequency increase indicator consumption.

Example Calculation (Indicator TH 2005):

At 0.1 °dH hardness, three strokes may be dosed. A 500 ml bottle can last for 16,667 strokes (5,555 analyses). At an analysis every 30 minutes, the bottle lasts approximately 2,777 hours, resulting in an annual consumption of ~3.15 bottles. This is an approximate value.

Indicator TH2025, TH2100, TH2250 (500 ml bottle)

Annual Requirement (8760 hours/year):

Indicator TH2005 (500 ml bottle)

Annual Requirement (8760 hours/year):

(All information without guarantee)

Manual Measured Value Check

This check can be performed by diluting a standard solution on-site and introducing it into the measuring chamber.

Creating a Standard Solution

Dilute a 1000 ppm solution on-site to achieve the desired value in the upper third of the measuring range.

Manual Supply of the Standard Solution

1. Stop the water supply to the instrument.
2. Remove the right-hand plug from the measuring chamber.
3. Start the measurement via the START key.
4. Manually fill the measuring chamber with the standard solution via the opened borehole until it overflows.
5. Allow the solution to drain (flushing).
6. Once the output valve closes, refill the measuring chamber until it overflows. The filling level will then adjust to the intended sample volume.
7. The measured value will be displayed after the analysis is complete.

Troubleshooting

Error message MST analysis

Occurs when water is too "light" after the second dosing.

Possible Causes and Remedies:

1. Indicator expiry date exceeded: Use a new indicator. If not a Gebr. Heyl indicator, replace with a recommended one.
2. Stirring bar not rotating:
   • Stirring bar is stuck due to soiling: Clean the measuring chamber.
   • Measuring chamber holder is leaky, damaging electronics: Replace holder.
   • Flexible cable plug is loose: Re-insert plug properly.
   • Stirring bar magnet is weak: Replace 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. Contact customer service or replace the pump.
   • Check pump dosing. Contact customer service or replace the pump.
4. Air trapped in indicator hose:
   • Bleed hoses by repeatedly pressing the "Manual" button on the dosing pump.
   • Ensure all indicator hoses are correctly fitted.
   • Replace the bottle insert for a screw cap with a suction tube (Art. no. 40135) if the error recurs.
   • Ensure suction and pressure hoses are not kinked; replace if necessary (Suction hose Art. no. 40011, Pressure hose Art. no. 40016).
5. Insufficient water pressure: Water level remains too high after closing the inlet valve.
   • Water level should be approx. 32 mm above the lower edge of the measuring chamber.
   • Ensure water pressure is between 0.3 - 1 bar (without valve body) and 1 - 8 bar (with valve body).
   • Ensure all dummy plugs are in place and fitted correctly to prevent air leaks.
6. Blocked drain pipe:
   • Ensure the water outlet is not blocked and clean if necessary.
7. Soiled measuring chamber:
   • All channels and sight-glass windows must be free of indicator residue or contamination. Use ethyl alcohol or a plastic cleaner.
   • Clean the receiver optics.
8. Measuring water contains bubbles or is milky:
   • Ensure no air bubbles and less than 20 mg/l CO₂ in the measuring water. This may be due to incorrect softener regeneration or residual salt. Contact customer service or use aerator R (Art. no. 130010).
9. Iron, copper, and aluminum ions impair measurement:
   • Caused by old iron pipes, new copper pipes, or well water changes. Monitor measuring water composition. Use colorimetric 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 ingress and siphoning issues.
    • Replace old or missing closing plugs with new ones (Maintenance lab Art. No. 270335).
    • Check the inlet solenoid valve for correct opening/closing.
    • Ensure correct indicator and water quantity.

Switching on the Real-Time Clock (Testomat 2000® only)

If the integrated clock fails, restart it: Switch off the instrument, press and hold the "ENTER" key, then switch the instrument on again.

Low water level

Remedy:

• Check inlet water (filter strainer) for foreign particles and clean if necessary.
• If the IN lamp is lit but no inlet water is present, check the inlet water connection.
• Inlet pressure may be too low (< 1 bar). Remove the pressure valve body.
• Typically, 400 ml/min must flow through the measuring chamber for flushing and filling.
• Check the inlet solenoid valve, F6 fuse, and plug contact at the inlet valve.
• Check overflow detection function.

Error message FST optics (Testomat 2000®)

Remedy:

• The plug-in circuit board driver/receiver SE-T2000 (Art. no. 40091) may be defective; replace it.
• The optical component or receiver may be defective; replace the measuring chamber holder.
• Cold water (<8°C) with warm, humid ambient temperatures (>28-30°C) can cause condensation on sight-glass windows.

Error message MST turbid

Remedy:

• Check if the supplied measuring water is very turbid or soiled.
• Check and clean sight-glass windows if soiled.
• Consider installing an inlet filter (Art. no. 11217).
• Cold water (<8°C) with warm, humid ambient temperatures (>28-30°C) can lead to condensation on sight-glass windows.

Error message Ff outlet to drain

Water remains in the measuring chamber though the "OUT" LED is illuminated.

Remedy:

• Check if the outlet valve is soiled or the connector is oxidized. If the error persists, replace the valve.

Error due to defective hardware

1. Dosing pump runs permanently: Check the broadband cable at the main and front board for looseness or defects.
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. Check for permanent voltage on the valve, which indicates a software or hardware error. Perform a reset. If the error persists, replace the valve.

Readjusting the Current Interface

If a signal of less than 20mA is output at the current interface, contact customer service.

Spare Parts Lists

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

Spare Parts for 2-3 Years of Operation:

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

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

Diagrams illustrating component locations are provided.

Testomat 2000® Component Positions

(Figures omitted for text-based output)

Content of the Gasket Set T2000 (Art. no.: 40124)

Check List Testomat 2000®

This checklist supports fault diagnosis and documentation.

Block 1 / Plant and instrument data

• Plant type
• Instrument type (Testomat 2000® / Testomat® ECO)
• Instrument no.
• Indicator type
• Software status
• Pump no.

Block 2 / Error message and error history

• Does the instrument's error history display any messages? (See operating instructions)
• Does an error message appear on the display? (See operating instructions: "Error messages / Troubleshooting")

Block 3 / Visual inspection and functional test

• Is the instrument connected to the correct mains voltage?
• Does a message appear on the display?
• Does the instrument display a plausible measured value?
• Are the measuring chamber and sight-glass windows clean?
• Are the measuring chamber and water-carrying hoses leak-free?
• Is the indicator's expiry date still valid?
• Has the correct indicator type been programmed?
• Is the water pressure within the specified range (400 ml/min)?
• Does the drain hose prevent backwater risk (no "syphoning effect")?
• Is the drain hose free of blockages?
• Does the set flushing time/quantity ensure only fresh water is measured?
• Are the hoses at the dosing pump free from air bubbles?

Carrying Out a (Manual) Analysis:

• Does the water column rise evenly up to the overflow borehole when filling the measuring chamber (5 mm below the upper edge)?
• Does the indicator pump dose correctly when starting an analysis?
• Have the indicator and water been mixed properly in the measuring chamber after dosing?

Programming Data / Operating Conditions

• Have the limit values been set correctly?
• Is the Testomat instrument always supplied with mains voltage (except during maintenance/emergencies)?

Refer to the operating instructions for further information on error messages and troubleshooting. Functional tests and service instructions can be found in the maintenance manual.

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

Official datasheet (PDF)

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