Maintenance Instructions Testomat 808

Summary

Product Identification

• Product Name: Testomat® 808

Maintenance and Service Information

This document provides maintenance and service instructions for the Testomat® 808.

Qualification of Staff

Maintenance work requires fundamental electrical and process engineering knowledge. It should be carried out by a specialist or under their supervision.

Warning Notices

• DANGER: Indicates an immediate hazardous situation resulting 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 may lead to an undesirable result or state if not observed.

Further Documents

Always observe the documentation of the plant manufacturer, as Testomat instruments are plant components.

General Instructions

• Regular maintenance and visual inspections are necessary for trouble-free operation and operational reliability.
• Clean the measuring chamber at regular intervals (approx. every 3 months). Seals and sight glasses should be replaced after approximately 12 months using the seal and inspection glass set (Article no. 270351).
• More frequent cleaning may be necessary for well water or water with 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.
• Do not perform actions not described in these instructions; failure to adhere may negatively affect warranty claims.

Important Before Carrying Out Repairs!

• Repairs require the instrument to be dismantled and returned with an error description.
• Inform the service provider of the indicator type and measured medium.
• Before returning for repair, remove the indicator bottle and ensure the measuring chamber is flushed and empty.
• Write down a description of the error (failure effect) before dismantling, using the provided checklist or downloading it from www.heyl.de.

Prior to Carrying Out Maintenance Work

• Perform a visual inspection: check door/cover closure, soiling, air in dosing hoses, leaks at pump hose connections, and indicator expiry date.
• 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 and observe safety regulations.

Overview of Maintenance Work

Maintenance intervals may vary based on water and pipeline quality.

Permissible Tools

• Suitable tools are required for tasks like firmware updates.
• Software (FlashTool, T808ServiceMonitor) and firmware updates are available for download at www.heyl.de.
• Tools can also be found in the repair and service kits for the Testomat 808 (Article no. 270342).

Carrying Out Maintenance

Cleaning the Measuring Chamber

1. Removing: Switch off the instrument, close the stop valve, disconnect the LED holder cable and loosen the pump hose. Remove the indicator bottle if needed. Loosen screws fixing the solenoid valve. Disconnect the hose from the solenoid valve. Turn the angled hose connector upwards. Press the locking ring of the top angled hose connector and remove the outlet hose. Turn this connector upwards to prevent water escape. Pull the measuring chamber off its retaining bolts. Turn the bottom angled hose connector downwards to drain residual water.
2. Cleaning: Clean with a suitable decalcification and rust removal agent (max. 5-10% solution). Rinse thoroughly afterwards.

Cleaning the Sight Glasses

• If sight glass windows are difficult to remove, carefully push them out from the inside after opening the cover. Do not use excessive force or sharp objects.
• Ensure tension-free mounting and tighten screws alternatingly.
• Use cleaning spirit for sticky films caused by hard water.

Installing and Operating the Measuring Chamber

1. Switch the instrument off before installing.
2. Install the measuring chamber in reverse order of removal.
3. Connect the pump hose.
4. Bleed the pipeline system before operating the instrument.

Cleaning the Housing

• Use a normal plastic cleaner. Avoid organic solvents.

Pump Head Maintenance Intervals

• Replace the pump head when the E4 indicator ("Maintenance message pump head") flashes.
• Replacement is advised after approximately 2 years due to potential performance decrease from wear.

Pump Head Maintenance Message

• The pump head runs for 150 hours, triggering the E4 maintenance message. This is approximately 2 years or 54,000 analyses (at 10 min intervals).
• To reset the counter: Switch off the instrument, then press and hold key 4 (horn) while switching it back on.

Replacing the Pump Head

1. Switch off the instrument.
2. Pull off hoses from hose connectors.
3. Loosen two screws at the pump head and pull it off the motor shaft.
4. Install the new pump head in reverse sequence. Connect the long hose to the indicator bottle and the short hose for comparison.
5. Press and hold key 4 (horn) while switching on to reset the operating time.
6. Bleed the indicator pipes.
7. Twist Protection: Ensure the locating lugs on the pump head engage with the housing holes. The long hose should point right.

Bleeding the Indicator Lines

• Check for leaks after maintenance.
• Switch instrument to standby mode.
• Flush the pipeline system with key 2 (Flush).
• Check all connections and seals for leaks.
• To fill intake and transport hoses: Switch on, press key 3 (standby). Press and hold key 1 (manual) for approx. 2 seconds to start the pump. Let it run until no bubbles escape the dosing needle. Press key 1 again for approx. 2 seconds to stop the pump.

Replacing the Motor Block

• Requires a gear motor for dosing pump (Art. no. 100494).

Disassemble the Gear Motor

1. Switch off the device and disconnect power.
2. Close water supply.
3. Open cover and terminal box door.
4. Pull off power supply plug connections (from socket J4).
5. Remove pump head (pull off tubes, loosen screws).
6. Loosen and remove screws of the motor block.
7. Remove the gear motor.

Assemble the New Gear Motor

1. Assemble in reverse order.
2. Insert motor block and tighten screws.
3. Mount pump head onto the shaft, observing anti-twist guard (flat surfaces on shaft and pump head align them). Ensure pump head snaps into place.
4. Tighten pump head screws without excessive force to avoid damaging tapped bores.
5. Connect tubes.
6. Connect power supply plugs.
7. Close terminal box door and cover.
8. Open water supply.
9. Put the device into operation.
10. Depressurize lines before further analyses.

Changing from Testomat® BOB to Testomat® 808

• Use the water supply and discharge conversion kit (Article no. 37576).
• Switch off and disconnect power of the Testomat® BOB.
• Pull hose from outlet, unscrew inlet/discharge connections.
• Remove Testomat® BOB and install Testomat® 808 (dimensions are identical).
• Screw reduction into the inlet connection.
• Connect water supply and discharge using a 6/4 x 1 opaque plastic hose (max. 5 m).
• Install a manual shut-off valve in the secondary supply.
• Flush the supply pipe before operation.
• Refer to the Testomat® 808 operating instructions for operation.
• Prevent Soiling: Establish a vertical connection to prevent dirt particles from entering the instrument.

Service Programs

Test and Adjustment Program

• The Testomat® 808 Service Monitor software allows reading data and resetting meter readings.
• Requires a notebook connected via a null modem cable (or USB adapter Art. no. 32286) to the RS232 interface.

Access to the Test and Adjustment Program

• Hold key 1 (manual start) and switch on the instrument. Release key 1 when the POWER LED flashes.
• Alternatively: After switching on, hold reset key S1, then hold key 1 and release S1. Release key 1 when the POWER LED flashes.

Operating the T808 Service Monitor Program

1. Open "T808ServiceMonitor" on your notebook.
2. Select the correct COM port under "Serial Port".
3. Click "Read" to get status information in the "Info-Data" section.
4. Use "Reset Runtime Head" to reset the pump head operating hours counter.
5. Use "Reset Rejection Counter" to reset the total rejection counter.
6. The "Output Window" displays the ADC value or V level. Click "Clear" to delete it.

Functions of Keys in the Test Program

• Manual Start Key (Key 1): Short press activates manual start/bleed. Repeated presses cycle through functions and activate serial interface communication.
• Internal Flushing Key (Key 2): Short press activates flushing cycles. Repeated presses cycle through functions.
• Standby Key (Key 3): Short press checks the watchdog timer.
• Quit Alarm Key (Key 4): Initiates a two-step auto-adjustment process for clear water.

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 E4 maintenance indicator stops flashing.
• The first counter registers up to 150 hours. The second counter can be reset via PC ("WRH").

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. Unzip the self-extractor.
3. Connect the notebook to the Testomat® 808 using a null modem cable (or USB adapter Art. no. 32286).
4. Switch off the Testomat® 808.
5. Move slide switch T1 to the RIGHT position and press reset key S1.
6. Hold the Hand key down and switch on the Testomat® 808.
7. Double-click the "T808_Flash.bat" file.
8. Specify the correct COM port and press Enter.
9. Specify the firmware file name and press Enter.
10. An error message will appear for incorrect COM port or file name.

Error Correction

1. Error E4 “Visual problem 1” (Low LED performance)
   • Check for cloudy water, soiled measuring chamber/sight glass.
   • Replace sight glass if silicate content > 15 mg/l causes a white film.
   • Check for sensor/LED damage or incorrect installation of chamber/LED fitting.
   • Perform visual adjustment if necessary.
2. Error E3 “Visual problem 2” (High LED performance)
   • Ensure housing cover is closed (avoid ambient light like sunlight).
   • Check for sensor/LED damage.
   • Perform visual adjustment if necessary.
3. Error E2 “MST analysis”
   • Check indicator bottle status, ensure it matches bottle volume.
   • Use only approved Heyl Testomat® 808 indicators.
   • Verify the stirring bar is present and turning.
   • Check pump indicator supply.
   • Inspect the dosing needle for blockages or damaged O-ring. Ensure hoses do not draw air. Check suction lance and for air bubbles escaping the dosing needle.
   • Check fuse F3; if it trips repeatedly, replace the pump motor.
4. Error E1 “Lack of water”
   • Check water hoses for leaks and proper connection.
   • Ensure all shut-off valves are open.
   • Check for blockages from foreign particles.
   • Very dirty or turbid water can cause E1; check water quality and use a particulate filter if necessary.

Clear Value Balancing Failure

• The instrument stops after 15 failures if clear value balancing is unsuccessful due to water cloudiness. A red limit value LED will flash.

Spare Parts List

Measuring Chamber Parts

Instrument Parts

Bottle Connection/Suction Device

Special Accessories

Bottle Connection: Testomat® 808 is delivered with a bottle connection for a 500 ml bottle. A connection for a 100 ml bottle can be ordered separately.

Component Positions

Inside

• 32375 Optical board
• 37322 Controller board
• 37324 Base circuit board
• 37570 Solenoid valve
• 40190/40191 Cable gland
• 37579 Bottle insert for screw cap and push-fit suction tube
• 37578 Pump head
• 37568 LED holder
• 40200 Cable loom

Measuring Chamber Components

1. Measuring chamber (Art. no. 37615 or 37616)
2. Sight-glass window holder (Art. no. 40176)
3. Magnetic stirrer (Art. no. 40050)
4. Measuring chamber cover (Art. no. 37534)
5. Dosing needle (Art. no. 37536)
6. Screw M3x40 (Art. no. 33253)
7. Screw M3x12 (Art. no. 33246)
8. Flat seal 24x2 (Art. no. 33777)
9. Sight-glass window 30x3 (Art. no. 40170)
10. Hose adapter (Art. no. 37538)
11. Angled plug-in connector (Art. no. 40157)
12. O-ring 3.8x1.78 (Art. no. 33797)
13. O-ring 4.5x1.5 (Art. no. 11264)
14. O-ring 1.78x1.78 (Art. no. 11245)

Location of Fuses

Fuses are located on the base circuit board.

Note: Fuse locations differ based on serial number (pre- and post- 244325 / 245352).

Testomat® 808 Checklist

This checklist supports systematic error diagnosis and documentation.

Block 1 / Plant and Instrument Data

• Testomat® 808
• Instrument type
• Instrument number
• Indicator type
• Software status

Block 2 / Error Message and Error History

• Indicate displayed error messages (by pressing keys "3" and "4" simultaneously).
• Note if LED above key 4 is flashing or lit.
• Indicate if other LEDs are lit.

Block 3 / Visual Inspection and Functional Test

• Verify correct mains voltage supply.
• Check for water flow from discharge hose during analysis.
• Confirm measuring chamber and sight glasses are clean.
• Ensure measuring chamber and water hoses are watertight.
• Check indicator for remaining shelf life and note expiry date.
• Verify correct bottle size setting (100 ml / 500 ml).
• Ensure water pressure is within prescribed limits.
• Confirm outlet is installed free of back pressure.
• Check if the outlet hose is clear.
• Ensure fresh measuring water reaches the chamber within the 10-second flushing time.
• Confirm hoses are vented (manual pump operation/analysis).
• Manual Analysis:
  • Verify indicator pump supplies a dose when analysis is triggered.
  • Check if indicator is properly mixed in the measuring chamber (magnetic stirrer).
• Programming Data / Operating Conditions:
  • Ensure the instrument is constantly supplied with mains power, except during maintenance (use "Standby" or "Input stop" keys).

Refer to "Error messages / Troubleshooting" in the operating instructions for further details. If all questions in Block 3 are answered "Yes", the instrument functions are considered operational. It is recommended to perform all checklist tests during each service and when faults occur.

General User Instructions for Testomat® 808

Basic Design

• Designed for permanent water monitoring with daily measurements.
• Longer intervals between analyses require appropriate flushing times and volumes to prevent measuring residual/mixed water or exceeding indicator expiry dates.
• Water requirement per analysis is 80-150 ml.

Switching Off the Instruments / Stopping Measurements

• Use the "Standby" (instrument) or "Stop" (external) functions for interruptions.
• Disconnecting from mains can cause the measuring chamber to fill with water, leading to soiling and potential malfunctions upon restart.
• If switched off for several days, ensure chambers are filled with water only and restart as per initial commissioning, including bleeding the pump manually.

Initial Start-up of New Plants

• Flush pipelines thoroughly before connecting the instrument.
• Consider fitting a fine filter to the water supply hose, and clean/replace it regularly to prevent clogs that could cause malfunctions or affect solenoid valve function.

Operation/Indicator

• Use only original Heyl Testomat® indicators for precise measurements.
• Indicator effectiveness is influenced by environmental conditions. Shelf life data assumes room temperature and exclusion of direct light.
• Replace indicator upon expiry to guarantee reliable function.

Water Inlet

• Adhere to the water inlet pressure limits on the rating plate.
• Insufficient water flow (e.g., due to a soiled filter) prevents proper measurement and can lead to repeated measurements and error messages.

Water Outlet

• Ensure a discharge free of back pressure during assembly.

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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