Maintenance Instructions Testomat 808

Summary

Product Identification

• Product: Testomat® 808

Maintenance and Service Information

This document provides maintenance and service instructions for the Testomat® 808. It details procedures for cleaning, part replacement, firmware updates, and error correction.

Safety Information

• Read all operating and maintenance instructions carefully before performing any work.
• Observe all warning notices and safety guidelines.
• Adhere to safety data sheets when handling reagents, chemicals, and cleaning agents.
• Maintenance requires fundamental electrical and process engineering knowledge; it should be performed by a specialist.
• Warning notices are structured with a description of the danger, consequences of non-observance, and preventive measures.
  • DANGER: Immediate hazardous situation, likely to result in death or serious injury.
  • WARNING: Potentially hazardous situation, could result in death or serious injury.
  • CAUTION: Potentially hazardous situation, could result in minor/moderate injuries or property damage.
  • 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 at regular intervals (approx. every 3 months).
• Replace all seals in the measuring chamber and sight glasses after approximately 12 months. A seal and inspection glass set (Article no. 270351) is available.
• More frequent cleaning may be necessary if the water is from a well or has high iron content.
• Use a dry, lint-free cloth for cleaning.
• Wait at least 5 seconds between switching the instrument off and on again at the main switch.
• Only perform actions described in these instructions; deviations may affect warranty claims.
• For repairs, the instrument must be dismantled and returned with an error description, indicator type, and measured medium.
• Before returning for repair, remove the indicator bottle and ensure the measuring chamber is flushed and empty.
• Document errors using the provided checklist.

Cleaning Agents

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

Maintenance Work Intervals

Tools and Software

• Software: T808ServiceMonitor, FlashTool are available for download at www.heyl.de.
• Firmware: Latest firmware available for download at www.heyl.de.
• Hardware: Notebook, Null modem cable (Art. no. 31972), USB > Serial adapter (Art. no. 32286).
• Repair and service kits (Art. no. 270342, 270351) are available.

Carrying Out Maintenance

Cleaning the Measuring Chamber

1. Switch off the instrument and close the stop valve.
2. Disconnect the cable from the LED holder and loosen the pump hose.
3. Remove the indicator bottle if necessary.
4. Loosen screws fixing the solenoid valve.
5. Loosen the hose connection to the solenoid valve, pull the valve down, and place it aside.
6. Turn the angled hose connector upwards to prevent residual water escape.
7. Remove the outlet hose.
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 decalcification/rust removal agent (max. 5-10% solution) and flush thoroughly.

Cleaning Sight Glasses

• If stuck, carefully push out from the inside; do not use excessive force or sharp objects.
• Ensure tension-free mounting and tighten screws alternatingly.
• Use cleaning spirit for sticky films.

Installing and Operating the Measuring Chamber

• Switch the instrument off before installation.
• Install the measuring chamber in reverse order of removal.
• Connect the pump hose.
• Bleed the pipeline system before operation.

Cleaning the Housing

• Clean with a normal plastic cleaner; avoid other solvents.

Pump Head Maintenance

• Replacement Interval: Advised after approx. 2 years or when the E4 message "Maintenance message pump head" flashes.
• The effective runtime is counted; after 150 hours of operation (approx. 2 years or 54000 analyses), LED E4 flashes.
• Resetting Counter: Switch off, then switch on while holding key 4 (horn).
• Replacement Procedure:
  1. Switch off the instrument.
  2. Pull hoses off hose connectors.
  3. Loosen screws at the pump head and pull it off the motor shaft.
  4. Install the new pump head in reverse order, ensuring correct alignment (twist protection).
  5. Connect the long hose to the indicator bottle and the short hose for comparison.
  6. Press key 4 (horn) and hold while switching on to reset the counter.
  7. Bleed indicator pipes.

Bleeding Indicator Lines

1. Switch the instrument to standby mode.
2. Flush the pipeline system by activating key 2 (Flush).
3. Check all connections and seals for leaks.
4. Switch on the instrument and press key 3 (Standby) to activate standby mode.
5. Press and hold key 1 (Manual) for approx. 2 seconds to start the pump and bleed the lines.
6. Let the pump run until no air bubbles escape from the dosing needle, then press key 1 again to stop the pump.

Replacing the Gear Motor

• Requires a gear motor for dosing pump (Art. no. 100494).
• Disassembly:
  1. Switch off and disconnect power.
  2. Close water supply.
  3. Open cover and terminal box.
  4. Disconnect power supply plug (J4).
  5. Remove pump head (disconnect tubes, loosen screws).
  6. Loosen and remove motor block screws.
  7. Remove gear motor.
• Assembly: Reverse of disassembly, paying attention to the anti-twist guard on the motor shaft and pump head. Ensure correct alignment of flat surfaces. Do not overtighten pump head screws.

Changing from Testomat® BOB to Testomat® 808

• Use the water supply and discharge conversion kit (Article no. 37576).
• Switch off and disconnect power.
• Remove hose and unscrew inlet/discharge connections from the BOB unit.
• Mount the Testomat® 808 in the same position (dimensions are identical).
• Screw the reduction into the inlet connection.
• Connect water supply and discharge with a 6/4 x 1 opaque plastic hose (max. 5 m).
• Consider installing a manual shut-off valve.
• Flush the supply pipe before operation.

Service Programs

Test and Adjustment Program

• Access via Testomat® 808 Service Monitor software connected via RS232 (null modem cable or USB adapter).
• Access:
  • Press and hold key 1 (manual start) while switching on the instrument (POWER LED flashes), then release key 1.
  • Alternatively, after switching on, hold reset key S1, then hold key 1 and release S1 (POWER LED flashes), then release key 1.
• T808 Service Monitor Program:
  • Select the correct COM port.
  • "Read" button retrieves status information.
  • "Reset Runtime Head" resets the pump head operating hours counter.
  • "Reset Rejection Counter" resets the rejection counter.
  • Output Window displays ADC value or V level.
  • "Clear" button clears the Output Window.

Functions of Keys in Test Program

• Manual Start Key (Key 1): Various functions depending on the number of activations, including calling up serial interface options, reading inputs ("Delete Ext.", "Stop"), and controlling relays/pumps.
• Internal Flushing Key (Key 2): Controls measurements (LEDs 1 & 2), displays ADC values, and flashes the POWER LED after four activations.
• Standby Key (Key 3): Checks watchdog timer; initiates a reset after 12 seconds.
• Quit Alarm Key (Key 4): Performs auto-adjustment in two steps:
  1. Measures using LED 1 (yellow), adjusts amplifier gain. Success stored, LED 2 (Flush) lights. Failure, LED 1 flashes.
  2. Measures using LED 2 (red), adjusts current. Success stored, LED 4 (Alarm) lights. Failure, LED 3 (Standby) lights.
  • Upon successful completion, all key LEDs light, pump operating time presets to 7 seconds, and the program returns to the main loop.

Serial Interface Settings

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

Zeroing the First Pump Head Operating Hours Counter

• Press and hold the horn key (key 4) and switch the instrument on.
• The counter resets to 0, and the maintenance indicator (LED E4) stops flashing.
• The first counter registers up to 150 hours. The second counter can be reset via PC.

Updating the Firmware

1. Download "T808_FlashTool_SelfExtractor.exe" and the latest firmware from www.heyl.de. Save both to the same folder on your notebook.
2. Connect the notebook to the Testomat® 808 using a null modem cable (or USB adapter).
3. Switch off the Testomat® 808.
4. Move slide switch T1 to the RIGHT position and press reset key S1.
5. Hold the Hand key down and switch on the Testomat® 808.
6. Double-click "T808_Flash.bat".
7. Specify the correct COM port and press Enter.
8. Specify the firmware file name and press Enter. Error messages appear for incorrect entries.

Error Correction

• E4 "Visual problem 1": Low LED performance/light.
  • Check for cloudy water, soiled measuring chamber/sight glass.
  • Replace sight glass if silicate content is high (>15 mg/l).
  • Check sensor/LED for damage, lack of water, or incorrect installation.
  • Perform visual adjustment if necessary.
• E3 "Visual problem 2": High LED performance/too much light.
  • Ensure housing cover is closed (avoid direct sunlight).
  • Check sensor/LED for damage.
  • Perform visual adjustment if necessary.
• E2 "MST analysis":
  • Check indicator bottle level and if it matches display.
  • Use only approved indicators for Testomat® 808.
  • Check for presence and rotation of the stirring bar.
  • Check pump and indicator supply.
  • Check dosing needle for blockage or O-ring damage; ensure hoses do not draw air.
  • Check and replace fuse F3 if necessary; if it trips repeatedly, replace the pump motor.
• E1 "Lack of water":
  • Check water hoses for leaks and proper connection.
  • Ensure all shut-off valves are open.
  • Check for blockages or foreign particles.
  • Very dirty or turbid water can cause E1; use a particulate filter.

Clear Value Balancing Failure

• The system stops after 15 failures to prevent endless testing.
• A red limit value LED will flash.

Spare Parts List

Comprehensive lists of spare parts for the measuring chamber, instrument, bottle connection, and accessories are provided, including article numbers. Notable items include:

• Measuring chamber (1-4 bar or 0.3-1 bar)
• Pump head
• Gear motor for dosing pump
• Fuses (various ratings)
• Seals and sight-glass windows
• Service Sets

Component Positions

Diagrams and lists indicate the location of various internal components, including circuit boards, solenoid valve, pump head, LED holder, and bottle insert.

Measuring Chamber Components

A detailed breakdown of measuring chamber parts with article numbers is provided:

• Measuring chamber
• Sight-glass window holder
• Magnetic stirrer
• Measuring chamber cover
• Dosing needle
• Various screws and O-rings
• Hose adapters and plug-in connectors

Location of Fuses

The location and designation of fuses on the base circuit board are detailed for different serial number ranges.

• F1/F2: Relay protection fuse (4 A)
• F3: Primary fuse (0.1 A for 230V, 0.2 A for 115V, 1 A for 24V)
• F4: Secondary fuse (1 A)
• F5: Relay protection pump head (0.315 A)

Testomat® 808 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 (mains voltage, water flow, cleanliness, leaks, indicator shelf life, bottle size, water pressure, outlet back pressure, outlet hose clarity, fresh water supply, hose venting).
• Manual analysis checks (indicator pump supply, mixing).
• Programming data / operating conditions (continuous mains power supply).

General User Instructions (from Checklist)

• Basic Design: Designed for permanent water monitoring with assumed daily measurements. Longer intervals require attention to flushing times/volumes.
• Switching Off: Use "Standby" or "Stop" functions. Disconnecting from mains can lead to soiling and malfunctions. If off for several days, refill with water and ensure pump is operated manually to clear air from hoses.
• Initial Start-up: Flush pipelines before connecting the instrument. Use a fine filter; clean/replace regularly.
• Operation/Indicator: Use original Heyl Testomat® indicators. Shelf life depends on storage conditions; replace upon expiry.
• Water Inlet: Maintain specified pressure limits. Insufficient flow can lead to errors.
• Water Outlet: Ensure a discharge 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