Maintenance Instructions Testomat 808 SiO2

Summary

Product Identification

• Product Name: Testomat® 808 SiO2
• Document Title: Maintenance and Service Instructions

Important Safety Information

• Read operating and maintenance instructions thoroughly before performing work.
• Observe all warning notices.
• Adhere to safety regulations when using reagents, chemicals, and cleaning agents, and consult the respective safety data sheets.

Qualification of Staff

Maintenance requires fundamental electrical, process engineering knowledge, and familiarity with technical terms. Assembly and commissioning should only be performed by specialists or under specialist supervision.

Warning Notices

• DANGER: Immediate hazardous situation, results in death or serious injury if not avoided.
• WARNING: Potentially hazardous situation, could result in death or serious injury if not avoided.
• CAUTION: Potentially hazardous situation, could result in minor or moderate injuries or property damage if not avoided.
• NOTE: Important information; failure to observe may lead to undesirable results.

General Instructions

• Regular maintenance and visual inspections are necessary for trouble-free operation.
• Clean the measuring chamber approximately every 3 months; replace seals and sight glasses annually. Use the seal and inspection glass set (Article no. 270351).
• More frequent cleaning may be necessary for water from wells or with high iron content.
• Use only dry, lint-free cloths for cleaning.
• Wait at least 5 seconds between switching the instrument off and on again at the main switch.
• Do not perform actions not described in these instructions, as it may affect warranty claims.
• 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.
• Before dismantling, document the error using the provided checklist or download it from www.heyl.de.

Maintenance Work Intervals

Tools and Software

• Software: T808_SiO2_ServiceMonitor and FlashTool are available for download at www.heyl.de.
• Firmware: Latest firmware can be found at www.heyl.de.
• Hardware: Null modem cable (Art. no. 31972), USB to Serial adapter (Art. no. 32286). Repair and service kits are also available (Art. no. 270343).

Carrying Out Maintenance

Cleaning the Measuring Chamber

1. Disconnect from power supply.
2. Close the stop valve in the branch line.
3. Disconnect cable from LED holder and loosen pump hoses.
4. Remove reagent bottle for access.
5. Loosen screws fixing the solenoid valve.
6. Turn angled hose connector upwards, press locking ring, and remove the outlet hose.
7. Turn angled hose connector upwards to prevent water escape.
8. Pull the measuring chamber off the retaining bolts.
9. Turn the bottom angled hose connector downwards to drain residual water.
10. Clean with a suitable acidic cleaning agent for decalcification and rust removal. Flush thoroughly.
11. Reinstall by reversing the removal steps.
12. Bleed the indicator lines after assembly.

Cleaning Sight Glasses

• If removal is difficult, open the measurement chamber cover and carefully push them out from the inside.
• Do not use excessive force or sharp objects.
• Ensure tension-free mounting and tighten screws equally.
• For hard-to-remove films, use cleaning spirit.

Cleaning the Housing

• Clean the untreated housing surface with a normal plastic cleaner.
• Avoid using other solvents.

Pump Head Maintenance

• Interval: Replace when the E4 message "Maintenance message pump head" flashes.
• Recommendation: Replace approximately every 2 years due to potential wear.
• Maintenance Message Trigger: After 150 hours of operation.
• Resetting Maintenance Message: Switch off the instrument, then press and hold key 4 (horn) while switching on.
• Replacement Procedure:
  1. Disconnect from power.
  2. Pull hoses off connectors.
  3. Loosen screws and pull pump heads off the motor shaft.
  4. Install new pump heads in reverse order.
  5. Connect hoses correctly (A to bottle A, B to bottle B).
  6. Connect short tubes to the measuring chamber.
  7. Press and hold key 4 (horn) while switching on to reset the counter.
  8. Bleed indicator pipes.
  • Note: Pay attention to the twist protection on the motor shaft and pump heads.

Bleeding the Indicator Lines

• Check for water leaks from seals.
• Switch instrument to standby mode.
• Flush the pipeline system using key 2 (Flush).
• Check all connections and seals for leaks.
• To fill the lines:
  1. Switch on the instrument and press key 3 (standby).
  2. Press and hold key 1 (manual) for approx. 2 seconds to run the dosing pump until no bubbles escape from the dosing needle.
  3. Press key 1 (manual) again for approx. 2 seconds to stop the pump.

Replacing the Gear Motor

• Requires a gear motor for the dosing pump (Art. no. 100494).
• Disassembly: Disconnect power, close water supply, open cover and terminal box, disconnect power plug to pump, remove pump head, loosen motor block screws, remove gear motor.
• Assembly: Reverse the disassembly steps. Ensure correct alignment with the anti-twist guard. Connect hoses and power plug. Open water supply and put the device back into operation. Depressurize lines before further analyses.

Synchronizing a New Optics Board

• Required after replacing the optics board or LED holder.
• Procedure: Start ServiceMonitor, start synchronization program, press button 2 (flushing), adjust potentiometer on optics board until 900 digits ±10 is displayed, press button 2 to end, monitor with button 4. A value of approximately 55 digits indicates successful synchronization.
• Alternative: Use a factory-synchronized full set of optics board and LED holder (Art. no. 40365).

Service Programs

Test and Adjustment Program

• The Testomat® 808 SiO2 ServiceMonitor software allows data reading and meter resetting.
• Requires a notebook connected via null modem cable to the RS232 interface.
• Access:
  • Keep key 1 (manual start) pressed while switching on power. Release key 1 when POWER LED flashes.
  • Alternatively, keep key 1 pressed after switching on and briefly press the Reset button. Release key 1 when POWER LED flashes.
• Operating T808 Monitor Program: Open software, select COM port, click Read for info, use Reset Runtime Head to reset pump head counter, view values in Output Window. Click Clear to delete.

Functions of Keys in Test Program

• Key 1 (Manual Start/Bleed): Initiates manual start, bleeding, and various test program sequences depending on the number of presses.
• Key 2 (Flush internal/external): Initiates internal/external flushing, displays ADC value.
• Key 3 (Standby/BOB): Checks watchdog timer, initiates reset, switches standby mode on/off.
• Key 4 (Quit Alarm): Performs auto-adjustment (requires clear water).

Serial Interface Settings

• 9600 baud
• 8 bit
• 1 stop bit
• No parity

Updating the Firmware

1. Download "T808_FlashTool_SelfExtractor.exe" and latest firmware from www.heyl.de.
2. Save both files to the same folder on your notebook.
3. Connect notebook to Testomat® 808 SiO2 using a null modem cable or USB adapter.
4. Disconnect Testomat® 808 SiO2 from power.
5. Move slide switch T1 on the controller board to the RIGHT position.
6. Keep the Manual button pressed and switch on the power supply.
7. Double click "T808_Flash.bat" on the notebook.
8. Specify the COM port and confirm with Enter.
9. Specify the firmware file name and confirm with Enter.

Error Correction

• Error E4 (“Visual problem 1”): Low LED performance. Check water cloudiness, soiling, sensor/LED damage, water supply, and correct installation. Perform visual adjustment if necessary. Replace glass sight glass if silicate content > 15 mg/l causes white film.
• Error E3 (“Visual problem 2”): High LED performance. Check for bright surroundings (sunlight), sensor/LED damage. Perform visual adjustment if necessary.
• Error E2 (“MST analysis”): Check indicator bottle, indicator display vs. volume, approved indicator usage, stirring bar function, pump indicator supply, dosing needle (blockage, O-ring), suction and pressure hoses for air. Check and replace fuse F3 if necessary.
• Error E1 (“Lack of water”): Check water hoses for leaks and correct connections, ensure shut-off valves are open, check for blockages.

Defective Pump Motor

• Fuse F4 on the main board protects the pump motor. If it blows, the LED next to F4 is off. Exchange the pump motor and fuse F4.
• The pump motor can also stop without a short circuit, not tripping F4. If the indicator level is low or measurement is disrupted, check the pump motor by pressing the 'manual' button for 2 seconds. Replace if it no longer turns.

Spare Parts List

A comprehensive list of spare parts for the measuring chamber, instrument, bottle connections, and accessories is provided, including article numbers. Key items include:

• Seals and Sight-glass windows
• Measuring chambers (different pressure ranges)
• Optical board, controller board, base circuit board
• LED holder, Solenoid valve, Pump head
• Fuses (various ratings)
• Gear motor for dosing pump (Art. no. 100494)
• Repair and Service Kit (Art. no. 270343)
• Service Set (Art. no. 270351)

Component Positions

Diagrams showing the location of internal components and measuring chamber parts are included.

Location of Fuses

Fuses F1-F5 are located on the base circuit board with their designations and current ratings.

Testomat® 808 SiO2 Checklist

A checklist is provided for systematic error diagnosis and documentation, covering:

• Plant and instrument data
• Error messages and history
• Visual inspection and functional tests
• Programming data / Operating conditions

General User Instructions for Testomat® 808 SiO2

• Basic Design: Designed for permanent water monitoring with daily measurements. Longer intervals require attention to flushing times.
• Switching Off: Use "Standby" or "Stop" functions. Disconnecting from mains can lead to soiling. If off for days, fill chambers with water and restart as for initial commissioning, bleeding pump manually.
• Initial Start-up: Flush pipelines thoroughly. Consider a fine filter for the water supply hose.
• Operation/Indicator: Use only original Heyl Testomat® indicators. Observe shelf life and expiry dates.
• Water Inlet: Comply with pressure limits. Insufficient flow impacts measurement accuracy.
• Water Outlet: Ensure discharge is free of back pressure.

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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