Maintenance Instructions Testomat 808 SiO2

Summary

Product Identification

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

Safety Information

• Read operating and maintenance instructions carefully before performing maintenance.
• Observe all warning notices and safety tips for reagents, chemicals, and cleaning agents. Safety data sheets are available at http://www.heyl.de.
• Maintenance work requires fundamental electrical and process engineering knowledge. It should only be carried out by specialists or supervised individuals.
• Warning notices are categorized as DANGER (immediate, fatal/serious injury), WARNING (potential, fatal/serious injury), CAUTION (potential, minor injury/property damage), and NOTE (important information).

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 and inspection glasses after approx. 12 months using the seal and inspection glass set (Article no. 270351).
• More frequent cleaning may be needed for water from wells or with high iron content.
• Use a dry, lint-free cloth for cleaning.
• Wait at least 5 seconds when switching the instrument on and off again at the main switch.
• Do not perform actions not described in these instructions, as it may affect warranty claims.

Maintenance Work Intervals

Tools and Software

• Software (FlashTool, T808_SiO2_ServiceMonitor) and firmware updates are available for download at www.heyl.de.
• Repair and service kits for the Testomat® 808 SiO2 are available (Article no. 270343 and 270351).
• Required tools include a notebook, null modem cable (Art. no. 31972), and USB > Serial adapter (Art. no. 32286).

Carrying Out Maintenance

Cleaning the Measuring Chamber

1. Disconnect power, close water supply valve.
2. Disconnect LED holder cable, loosen pump hoses.
3. Remove reagent bottle for access.
4. Loosen solenoid valve screws, push valve down.
5. Remove outlet hose by pressing locking ring.
6. Turn angled hose connector upwards to prevent water escape.
7. Pull measuring chamber off retaining bolts.
8. Turn bottom angled hose connector downwards to drain.
9. Clean with a suitable decalcifying/rust-removing agent and rinse thoroughly.

Cleaning Sight Glasses

• If difficult to remove, 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 alternately.
• For stubborn films, use cleaning spirit.

Cleaning the Housing

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

Pump Head Maintenance

• Replacement Interval: Recommended after approx. 2 years or when the "Maintenance message pump head" (E4) flashes.
• Maintenance Message: The E4 indicator flashes after 150 hours of operation. To reset the counter, switch off the instrument, then press and hold key 4 (horn) while switching it on.
• Replacement Procedure:
  1. Disconnect power.
  2. Pull off hoses from hose connectors.
  3. Loosen screws at the pump head and pull them off the motor shaft.
  4. Install new pump heads in reverse order.
  5. Connect hoses correctly (A to A, B to B) and to the measuring chamber.
  6. Press and hold key 4 (horn) while switching on to reset the counter.
  7. Bleed the indicator pipes.
• Twist Protection: Ensure correct alignment of pump heads on the motor shaft using the twist protection features.

Bleeding the 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).
5. Press and hold key 1 (manual) for approximately 2 seconds to start the dosing pump.
6. Let the pump run until no bubbles escape the dosing needle.
7. Press key 1 (manual) again for approx. 2 seconds to switch off the pump.

Replacing the Motor Block

1. Disconnect power, close water supply.
2. Open cover and terminal box.
3. Pull off plug connections for pump power supply.
4. Remove pump head (loosen screws, pull off motor shaft).
5. Loosen and remove screws of the motor block.
6. Remove the gear motor.
7. Assemble the new gear motor in reverse order, observing anti-twist guards and tightening screws without excessive pressure.
8. Reconnect power supply plugs.
9. Open water supply and put device into operation.
10. Depressurize lines before further analyses.

Synchronizing a New Optics Board

• Required after replacing the optics board or LED holder.
• Start the ServiceMonitor software and the synchronisation program.
• Press button 2 (flushing).
• Adjust the screw on the potentiometer of the optics board until a value of 900 digits ±10 is displayed on the ServiceMonitor.
• Press button 2 (flushing) to end synchronization.
• Press button 4 (horn) to monitor synchronization (green LED above button 1 and yellow LED above button 2 should light up).
• A displayed value of approximately 55 digits indicates successful synchronization.
• If synchronization is not possible, use a factory-synchronized full set of optics board and LED holder (Article no. 40365).

Service Programs

Test and Adjustment Program (ServiceMonitor)

• Connect the Testomat® 808 SiO2 to a notebook via a null modem cable (RS232 interface) or USB adapter.
• Access: Keep key 1 (manual start) pressed while switching on the power supply, then release key 1. Alternatively, press the Reset button briefly after switching on while holding key 1.
• Operating the Program: Open "T808 SiO2 ServiceMonitor", select the COM port, and click "Read" for status information. Use "Reset Runtime Head" to reset the pump head operating hours counter.

Functions of Keys in Test Program

• Manual Start Key (Key 1): Various functions depend on the number of key activations, including setting inputs, controlling relays, pump operation, and interface settings.
• Internal Flushing Key (Key 2): Used for flushing, back to the test program, and displaying ADC values.
• Standby Key (Key 3): Checks watchdog timer and initiates a reset.
• Quit Alarm Key (Key 4): Performs auto-adjustment for clear water measurements.

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 on the instrument. The counter is reset to zero, and the maintenance indicator (LED E4) stops flashing. The counter registers up to 150 hours.

Updating the Firmware

1. Download "T808_FlashTool_SelfExtractor.exe" and the latest firmware update from www.heyl.de. Save both to the same folder on your notebook.
2. Connect the notebook to the Testomat® 808 SiO2 using a null modem cable or USB adapter.
3. Disconnect the Testomat® 808 SiO2 from the power supply.
4. Move slide switch T1 on the controller board to the RIGHT position.
5. Press and hold the Manual button (key 1) and switch on the power supply.
6. Double-click the "T808_Flash.bat" file.
7. Specify the COM port and confirm by pressing Enter.
8. Specify the firmware update file name and confirm by pressing Enter. Error messages will appear for incorrect entries.

Error Correction

• Error E4 “Visual problem 1”: Low LED performance. Check water clarity, soiling of measuring chamber/sight glass, potential sensor/LED damage, lack of water, or incorrect installation. Perform visual adjustment if necessary. Replace sight glass if silicate content is > 15 mg/l.
• Error E3 “Visual problem 2”: High LED performance. Check for ambient light (sunlight), potential sensor/LED damage. Perform visual adjustment if necessary.
• Error E2 “MST analysis”: Check indicator bottle (empty, correct volume/type), indicator quality, stirring bar presence/rotation, pump indicator supply, dosing needle (blockage, O-ring damage), and suction/pressure hoses for air. Check and potentially replace fuse F3. If the fuse continues to trip, replace the pump motor.
• Error E1 “Lack of water”: Check water hoses for leaks and proper connection, open shut-off valves, and ensure no blockages from foreign particles.

Defective Pump Motor

• Fuse F4 on the main board protects the pump motor. If this fuse blows, exchange the pump motor and F4 fuse.
• The pump motor can stop without blowing the fuse. If the motor no longer turns when the 'manual' button is pressed, it needs replacement.

Spare Parts List

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

• Measuring chamber (various pressure ranges)
• Sight-glass window (Art. no. 40170)
• Pump head (Art. no. 37578)
• Gear motor for dosing pump (Art. no. 100494)
• Optical board (Art. no. 40367)
• LED holder (Art. no. 40366)
• Full set with optics board and LED holder (factory synchronized, Art. no. 40365)
• Fuses (various ratings, e.g., T1.0A, T0.8A, T0.315A)

Component Positions

Diagrams and lists indicate the location of internal components, including the optical board, controller board, base circuit board, solenoid valve, LED holder, and measuring chamber components.

Location of Fuses

Fuses are located on the base circuit board:

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

Testomat® 808 SiO2 Checklist

This checklist supports systematic error diagnosis and documentation. It covers:

• 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 conditions, dosing pump, indicator mixing).
• Programming data and operating conditions.

General User Instructions

• The instrument is designed for daily monitoring with several measurements per day. Long intervals may require attention to flushing times and volumes.
• Interruptions to measurements should be done using "Standby" or "Stop" functions, not by disconnecting from the mains, to prevent soiling.
• For new plants, flush pipelines thoroughly, and consider a fine filter.
• Use only original Heyl Testomat® indicators. Adhere to shelf-life dates and storage conditions (room temperature, exclude direct light).
• Ensure water inlet pressure limits are met. Insufficient flow can lead to errors.
• Ensure the water outlet 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