Online Measurement and Automation Systems
We bring everything from instant monitoring to alarmed automation for the critical parameters in your water and process lines together in a single system. Hamilton process sensors, Walchem controllers, Pyxis optical sensors, Wenglor fluid sensors, and Heyl Testomat analyzers provide continuous measurement in boiler, cooling tower, bioprocess, wastewater, and pure water lines, connecting directly to PLC and automation systems.
Get a technical quote for Online Measurement and Automation Systems — describe your application; we’ll help you identify the right model and configuration together.
Request a QuoteAnalytical Solutions by Parameter
Select the parameter you want to monitor in your process line to see sensor, analyzer, and controller configurations.
pH
Walchem W100W/Intuition controllers and Hamilton EasyFerm/Polilyte process sensors for pH monitoring and dosing control.
Conductivity
Walchem contacting/toroidal sensors and Hamilton Conducell (incl. USP 645 compliant UPW) for conductivity measurement.
Dissolved Oxygen (DO)
Hamilton optical (VisiFerm/VisiWater) and amperometric (OxyFerm/Oxysens) sensors, Pyxis ST-772, and Hefer OD-3000C analyzer.
Free Chlorine
Walchem amperometric disinfection sensors, Pyxis combined optical chlorine sensor, and Hefer CL series analyzer.
Chlorine Dioxide (ClO₂)
ClO₂ residual monitoring with amperometric sensors; Testomat 2000 colorimetric measurement alternative.
Ozone (O₃)
Hefer O3-3000C potentiostatic analyzer for real-time ozone control in pure water tanks and disinfection lines.
Water Hardness
Heyl Neomeris Testomat series automatic titration analyzers (EVO, 2000, 808, LAB) with scale breakthrough alarm.
Carbonate Hardness / Alkalinity
Testomat ECO C and Titromat KH for p/m value acid capacity and boiler alkalinity titration.
Turbidity & TSS (NTU)
Pyxis LT-73X ultra-low turbidity and ST-730 inline optical probes; nephelometric 90° light scattering technology.
Fluoride (F⁻)
Hefer F-3000C online ISE analyzer for fluoride monitoring in drinking water and industrial wastewater discharge lines.
COD / UV254 / Spectrometry
Instant COD, BOD and TOC determination with the TriOS OPUS / LISA spectral immersion probe, without consuming chemical reagents.
Iron, Phosphate, Bromine, Polymer
Corrosion inhibitor and feedwater chemical tracking in cooling circuits with the Testomat 2000 photometric platform.
Silica (SiO₂)
Testomat 808 SiO₂ version; silica breakthrough alarm for steam boilers, turbine feedwater, and pure water deionization.
Viable & Total Cell Density
Hamilton InCyte capacitance (viable biomass) and Dencytee NIR optical (total cell) bioreactor sensors.
Pressure Sensors
Wenglor UniBar 1.4404 stainless steel electronic pressure sensors (-1…600 bar) and OLED display transmitters.
Temperature Sensors
Wenglor UniTemp 1.4404 stainless steel immersion sensors (0…140 °C; 0…200 °C variant) and weFlux² IO-Link temperature sensors (-50…200 °C).
Flow & Flow Rate Sensors
Wenglor weFlux² and UniFlow calorimetric stainless steel flow sensors; orientation-independent mounting and dry-run protection.
LPR Corrosion Rate Sensor
Pyxis CR series LPR sensors for simultaneous inline tracking of general corrosion (mpy) and pitting corrosion.
PTSA Fluorometer & Refractometer
Pyxis PTSA/fluorescein fluorometers for chemical dosing verification; RT-100 inline digital refractometer.
Cooling Tower Automation
Full integration of blowdown, biocide, inhibitor, and corrosion management with Walchem Intuition-9/6 and W100W controllers.
Boiler, Condensate & Steam Generator
Scale and corrosion prevention in boiler piping with high-temperature conductivity probes, automatic blowdown valves, and a hardness alarm.
Oil in Water & Hydrocarbon (PAH)
TriOS enviroFlu-HC UV fluorometer and Pyxis HM-900 handheld analyzer; oil leak monitoring in condensate recovery and cooling water.
Copper and Nickel Plating Systems
Precise concentration tracking in electroless plating baths with Walchem Intuition-6 Copper/Nickel (WCU6/WNI6) photometric controllers.
Analyzer or sensor? Which one do you need
The sensor measures, the controller decides. The sensor reads the value in the process; the controller compares this value against the setpoint, generates an alarm, and drives the dosing pump or valve. What the market commonly calls an "analyzer" is often exactly this: sensor + controller. If you're looking for a "pH analyzer," what you actually need is a pH sensor paired with a suitable controller — we supply both together, matched to each other.
Choosing a controller doesn't limit your sensor choice: thanks to their universal sensor input and analog input, the Intuition-6 and Intuition-9 work with practically the full range of sensors on the market. The table below shows our recommended sensor–controller pairing for each parameter.
Recommended Sensor and Controller Pairings
| Measured Parameter | Recommended Sensor | Recommended Controller |
|---|---|---|
| pH / ORP | Hamilton EasyFerm Plus, Polilyte Plus, ChemoTrode · Walchem WEL/WDS | Intuition-6 · W100W · W600 |
| Conductivity | Hamilton Conducell · Walchem contacting and toroidal | Intuition-6 · W100W · W600 |
| Dissolved oxygen | Hamilton VisiFerm DO · Pyxis ST-772 · Hefer PME | Intuition-6 · Intuition-9 · Hefer OD-3000C |
| Dissolved carbon dioxide | Hamilton CO₂NTROL | Intuition-6 · Intuition-9 |
| Chlorine · chlorine dioxide · ozone | Hefer PME potentiostatic · Walchem amperometric | Intuition-6 · Intuition-9 (with 2030 transmitter) · Hefer 3000-C series |
| Water hardness | Hefer WHA-2000 ISE electrode | Intuition-6 · Intuition-9 · Hefer WHA-3000-C · Testomat (ready-made analyzer) |
| Turbidity | Hefer TU-311 / TU-341 (loop-powered) | Intuition-6 · Intuition-9 · Hefer TSS-3000C |
| Cell density · Brix | Hamilton InCyte · Dencytee · Pyxis RT-100 (Brix) | Intuition-6 · Intuition-9 |
| COD · SAC254 · nitrate | TriOS OPUS · LISA-254 · NICO | Intuition-6 · Intuition-9 · TriBox |
You don’t need a separate analyzer for every parameter
Hefer sensors connect in two ways:
(a) Ready-made analyzer — PME electrode + its own controller: CL-3000-C (chlorine), CLO-3000-C (chlorine dioxide), O-3000-C (ozone), WHA-3000-C (hardness), OD-3000C (oxygen). One parameter, one box.
(b) Transmitter to a single hub — PME electrode + 2030 series transmitter (PH-2030 (pH), MV-2030 (ORP), C-2030 (conductivity), CL-2030 (chlorine / dissolved ozone)) generates a 4-20 mA signal; this signal connects to an analog input card fitted to the Intuition-6 or Intuition-9.
In other words, instead of four separate analyzers for four parameters, you get four transmitters and a single controller.
How many parameters will you measure?
- W100W — entry level, wall-mounted: conductivity and pH.
- Intuition-6 — 6 relay outputs, universal sensor input; expandable with analog, Modbus, and combination cards.
- Intuition-9 — 24 sensor inputs, 12 relays, color touchscreen; the same card architecture.
- W600 — network-connected; conductivity, pH, ORP, and disinfectant.
Card architecture: the Intuition-6 and Intuition-9 are modular — sensor input, analog (4-20 mA), Modbus, and combination cards are selected according to the application. This is why the controller can practically work with the full range of sensors on the market: any missing connection type is simply added with a card.
The W900 has been discontinued; the Intuition-9 replaced it.
If you want a ready-made analyzer in a single box
Hefer CL / CLO-3000-C / O-3000-C / WHA · Testomat EVO TH, LAB, 808, ECO · TITROMAT carbonate + total hardness · Heyl Neomeris · TriOS EGC Water Analyzer.
Product Families by Brand
Process instrumentation portfolio of the globally leading brands represented by Mikron Proses.
Walchem Multi-Parameter Controllers & Sensors
Intuition-9, Intuition-6, W600, and W100 controllers, WDS differential pH, toroidal conductivity, amperometric disinfection sensors, and the Walchem Fluent® IoT cloud platform.
Open Walchem Catalog →Hamilton Arc® Process Sensors & Laboratory
Memosens / Arc digital pH (EasyFerm), optical DO (VisiFerm), USP 645 conductivity (Conducell), cell density (InCyte), and precision laboratory electrodes.
Open Hamilton Catalog →Testomat® Online Water Hardness & Titration
Automatic DIN 38409 hardness and alkalinity titrators for continuous operation, with the Testomat EVO, Testomat 2000, Testomat 808, Testomat LAB, and Titromat series.
Open Testomat Catalog →Wenglor weFlux² 1.4404 Stainless Steel Fluid Sensors
Calorimetric flow and temperature sensors (weFlux² / UniFlow), UniBar stainless pressure, and UniTemp temperature transmitters (OLED display & IO-Link 1.1).
Open Wenglor Catalog →Hefer Potentiostatic Sensors & Controllers
PME chlorine, ozone, and chlorine dioxide sensors; CL-3000-C, O-3000-C, and CLO-3000-C controllers, the WHA-3000-C / WHA-2000 ISE hardness system, and the 2030 transmitter series.
Browse Hefer Products →Measurement & Automation Comparison Matrices
Determine whether your process line needs continuous inline control or portable handheld field analysis, and identify the most suitable controller model.
Inline Process Sensors (Pyxis ST / Hamilton / Walchem) vs Portable Handheld Devices (Pyxis SP Series)
| Criterion | Inline Process Sensors (ST-500, ST-772, Arc®, WDS) | Portable Handheld Analyzers (SP-910, SP-710B, SP-200) |
|---|---|---|
| Measurement Frequency | Continuous, Uninterrupted Measurement (1 reading per second, instant response) | Spot / Periodic Testing (Manual measurement as needed) |
| Control & Dosing Integration | Fully Automatic: drives dosing pumps and blowdown valves directly via 4–20 mA and Modbus RS-485. | Manual Reporting: generates and archives PDF/CSV reports via the uPyxis® mobile app. |
| Installation & Piping Requirements | Fixed installation via a pipeline tee fitting, bypass flow cell, or immersion housing. | Zero Installation: carried in a case, battery-powered, taken to any point in the field. |
| Sampling Requirement | No sampling required; measures directly inside the flowing pressurized line. | Measured in the field from a sample bottle (SP-910: 25 mL bottle; the colorimetric method's set reaction time, or a direct reading for PTSA/fluorescein/turbidity). |
| Primary Use Case | Process automation, limit-exceedance alarms, and continuous prevention of chemical waste and scaling. | Field audits, cross-calibration verification of inline sensors, and incoming chemical shipment acceptance testing. |
Comparison of Walchem Multi-Parameter Water Treatment Controllers
| Model | Sensor Inputs | Relay & Analog Outputs | Communication & IoT | Recommended Application |
|---|---|---|---|---|
| Intuition-9 (Flagship) | 4 I/O slots: up to 8 direct sensor inputs (pH, conductivity, DO, disinfection, etc.) and up to 24 analog (4-20 mA) inputs (model-dependent) | 12 relay outputs + 8 isolated 4-20 mA outputs | Ethernet, Wi-Fi, Modbus TCP/IP, BACnet, Walchem Fluent® | Large-scale industrial cooling towers, boiler rooms, and multi-point disinfection facilities. |
| Intuition-6 (Mid-range) | 0–2 sensor inputs + 0–2 analog (4-20 mA) inputs (model-dependent) | 6 relay outputs + 2 isolated 4-20 mA outputs | Ethernet (optional BACnet, Modbus TCP/IP), Walchem Fluent® | Mid-sized cooling towers (WCT), steam boilers (WBL), and dual-parameter pH/ORP processes. |
| W600 Series | Up to 4 sensor / analog inputs with 2 input cards | 6 relay outputs | Ethernet, Modbus TCP/IP, USB data logging | Single- or dual-line water conditioning, wastewater neutralization, and corrosion monitoring. |
| W100 Series (Compact) | 1 direct sensor input (pH, ORP, or conductivity) | 3 relay outputs + 1 x 4-20 mA output | Compact LCD display, simple menu | Small cooling towers, single boiler blowdown control, neutralization tanks, and OEM panels. |
Heyl Testomat® & Neomeris Online Water Hardness and Alkalinity Instruments
| Model | Measurement Parameter & Range | Measurement Principle | Outputs & Data | Application |
|---|---|---|---|---|
| Testomat 2000® | Total Hardness: 0.05 – 25.0 °dH Carbonate Hardness: 0.5 – 20.0 °dH | Automatic Colorimetric Titration (DIN 38409) | 2 limit relays; optional 4–20 mA (SK910) and RS-232 (RS910) cards | Reverse osmosis (RO) pretreatment, steam boiler feedwater, and commercial water softening systems. |
| Testomat EVO® | Total Hardness: 0.05 – 25.0 °dH (depending on indicator type) | Precision Titration with Piston Dosing Pump | Graphic LCD, SD card logging, RS232, 0/4–20 mA, 2 limit relays | Industry 4.0-ready modern power plants, pharmaceutical facilities, and SCADA-integrated processes. |
| Titromat® | Carbonate Hardness (KH): 0.7 – 53.6 mmol/L (reagent-dependent) Total Hardness (TH) and residual m-value (M1/M2) | Automatic Two-Reagent Titration | 2 limit contacts, 0/4–20 mA output | Boiler water corrosion control, cooling water acid conditioning, and decarbonization plants. |
| Testomat 808® | Total Hardness: 0.02 – 5.0 °dH | Compact Indicator-Based Limit Control | Relay alarm contact + 4-20 mA | Safety interlock ahead of boilers and reverse osmosis; instantly detects resin exhaustion. |
Frequently Asked Questions About Online Measurement and Instrumentation
A technical guide to sensor selection, fouling compensation, Memosens digital technology, and automatic controller architectures.
How is the PTSA fluorometer (Pyxis ST-500) unaffected by turbidity and suspended solids in tower water?
The Pyxis ST-500 and ST-500SS probes use a proprietary multi-channel optical design. The device simultaneously measures fluorescence emission and turbidity scatter, mathematically compensating for background color and sediment interference. According to the manufacturer, measurement performance is maintained up to 100 NTU turbidity and/or 5 ppm iron, providing a stable tracer reading across the 0–300 ppb PTSA range.
Which process parameters can be managed simultaneously with the Walchem Intuition-9 controller?
With up to 8 direct sensor inputs and up to 24 analog inputs, the Intuition-9 controller manages pH, ORP, contacting/toroidal conductivity, dissolved oxygen (DO), free/total chlorine, corrosion rate (LPR) and flow parameters from a single screen. Blowdown valves, biocide pumps, and antiscalant dosing are closed-loop controlled through its 12 relay outputs.
What are the key differences between the Heyl Testomat 2000 and Testomat EVO?
The Testomat 2000 is a well-established, industry-standard water hardness titrator with 2 limit relays and optional 4-20 mA / RS232 cards. The Testomat EVO is the successor to the Testomat ECO, offering precision titration with a piston dosing pump, a graphic LCD, SD card data logging, and an RS232 serial interface; its 0.05–25 °dH range is selected according to indicator type.
What advantages do Hamilton Arc® / Memosens digital sensors have over conventional analog electrodes?
Hamilton Arc® sensors carry the microprocessor inside the sensor body, converting the measured analog millivolt signal directly into digital data at the sensor head. They are completely unaffected by moisture, cable length, or electromagnetic interference (motor/frequency inverter noise). Because the sensor also stores its calibration data in memory, it can be pre-calibrated in the laboratory and then installed on-site as a plug-and-play unit.
Does the Hefer WHA-3000-C ion-selective (ISE) hardness system consume reagents?
No. The Hefer WHA-3000-C and WHA-2000 ISE electrode system operates on a completely reagent-free (no chemical consumption) potentiometric ion-selective principle. It measures Ca²⁺ and Mg²⁺ ions in as little as 30 seconds without consuming any titration reagent or indicator.
Let’s Select the Right Measurement Instrument for Your Process Together
Share your sample temperature, line pressure, conductivity range, and communication protocol requirements; drawing on 25+ years of field experience, we’ll design the right sensor and controller combination for you.