Heyl Testomat 808 Series Manual

1
Maintenance and
Service Instructions
This manual applies to all devices of the Testomat®808 series, also
Testomat®808 2019 and Testomat®808 SiO2 2019 devices.
Testomat® 808 series

Contents
2
Contents
Contents...............................................................................................2
Important safety information .............................................................3
Qualification of the staff ...................................................................3
Warning notices in these instructions..............................................3
Further documents...........................................................................4
General instructions...........................................................................4
Important before carrying out repairs! .............................................4
Prior to carrying out maintenance work ................................................5
Permissible tools..............................................................................6
Carrying out maintenance..................................................................7
Cleaning the measuring chamber.........................................................7
Removing the measuring chamber..................................................7
Cleaning the measuring chamber....................................................7
Cleaning the sight glasses...............................................................8
Installing and operating the measuring chamber.............................8
Cleaning the housing.......................................................................8
Pump head maintenance intervals .......................................................9
Pump head maintenance message ......................................................9
Replacing the pump head.....................................................................9
Bleeding the indicator lines.................................................................10
Disassemble the gear motor..........................................................11
Assemble the new gear motor.......................................................11
Changing from Testomat®BOB to Testomat®808.............................13
Service programs..............................................................................13
Test and adjustment program..............................................................14
Access to the Test and Adjustment program.................................14
Operating the T808 Monitor Program............................................14
Functions of keys in the test program............................................15
Serial interface settings: ................................................................18
Zeroing the first pump head operating hours counter.........................18
Updating the firmware......................................................................19
Error correction.................................................................................21
Defective pump motor....................................................................22
Spare parts list Testomat®808........................................................23
Spare parts list Testomat®808 SiO2...............................................24
Component positions.......................................................................25
For Testomat®808..............................................................................25
Measuring chamber Testomat®808 ...................................................26
For Testomat®808 SiO2.....................................................................27
Measuring chamber Testomat®808 SiO2 ..........................................28
Location of fuses.................................................................................29
Testomat®808/808 SiO2 checklist...................................................31

Important safety information
3
Important safety information
Please read the operating instructions and maintenance instruc-
tions carefully and completely prior to carrying out maintenance
work at Testomat instruments.
Observe the warning notices in these maintenance instructions
and the operating instructions of the respective instrument.
Always adhere to hazard warnings and safety tips when using
reagents, chemicals and cleaning agents. Please adhere to the re-
spective safety data sheet! Download the safety data sheets for
the supplied reagents at http://www.heyl.de.
Qualification of the staff
Maintenance work requires fundamental electrical and process engi-
neering knowledge as well as knowledge of the respective technical
terms. Assembly and commissioning should therefore only be carried
out by a specialist or by an authorised individual supervised by a
specialist.
A specialist is someone who due to his/her technical training, know-
how and experience as well as knowledge of relevant regulations can
assess assigned tasks, recognise potential hazards and ensure ap-
propriate safety measures. A specialist should always adhere to the
relevant technical regulations.
Warning notices in these instructions
The warning notices in these instructions warn the user about poten-
tial dangers to individuals and property resulting from incorrect han-
dling of the instrument. The warning notices are structured as follows:
Description of the type or source of danger
Description of the consequences resulting from non-observance
Preventive measures. Always adhere to these preventive
measures.
“DANGER” indicates an immediate hazardous situation which, if not
avoided, will result in death or serious injury.
“WARNING” indicates a potentially hazardous situation which, if not
avoided, could result in death or serious injury.
“CAUTION” indicates a potentially hazardous situation which, if not
avoided, could result in minor or moderate injuries or property dam-
age.
“NOTE” indicates important information. If this information is not ob-
served, it may result in an undesirable result or state.
WARNING
!
NOTE
CAUTION
!
DANGER
!
SIGNAL WORD

General instructions
4
Further documents
Testomat instruments are plant components. Therefore, always ob-
serve the documentation of the plant manufacturer.
General instructions
Regular maintenance is necessary to ensure trouble-free operation of
the Testomat instrument. Regular visual inspections also increase
operational reliability. Also refer to the notes in the operating instruc-
tions!
•Clean the measuring chamber at regular intervals (approx. every 3
months). All seals in the measuring chamber should be replaced
after approx. 12 months. The inspection glasses must also be
replaced at the same time. For maintenance, use our seal and in-
spection glass set (Article no. 270351).
•If the water is from a well or has high iron content, cleaning might
be necessary more often.
•Only use a dry, lint-free cloth for cleaning (also refer to the chapter,
Cleaning the measuring chamber on page7).
•Wait at least 5 seconds before switching the instrument on and
then off again at the main switch.
•Do not carry out any actions at the instrument which are not de-
scribed in these instructions; failure to adhere to the instructions
will negatively affect the warranty claims that you make thereafter.
Important before carrying out repairs!
•The repair of a defective instrument –irrespective of the warranty
period - is only possible after the instrument has been dismantled
and returned to us with a description of the error.
•Furthermore, please inform us of the indicator type being used and
the measured medium.
•Before you return the instrument for repair work, remove the bottle
and ensure that the measuring chamber has been flushed out and
is empty.
•Prior to dismantling, always write down a description of the error
(failure effect). For this purpose, use our checklist which you will
find on page 31 or download it from the download area at
www.heyl.de.

General instructions
5
Prior to carrying out maintenance work
Carry out a visual inspection of the instrument:
•Are the instrument door and the cover closed properly?
•Is the instrument heavily soiled?
•Is there air inside the dosing hoses?
•Are the hose connections of the dosing pump free of leaks?
•Has the use-by date of the indicator expired?
Always make sure that the sight-glass windows are clean before in-
serting a new indicator bottle.
Cleaning agents
Never use organic solvents to clean the measuring chamber or
other plastic parts!
Use an acidic cleaning agent for cleaning.
Please observe the safety regulations when handling cleaning
agents!
Overview of maintenance work to be executed
The maintenance intervals may vary depending on the water and
pipeline quality.
Maintenance work
Quarterly
Semi-
annually
Triquarterly
Annually
Page
Cleaning sight-glass
windows
X
8
Cleaning measuring
chamber / Measuring
chamber holder
X
7
Cleaning the waste
water line
X
Electrical and hydrau-
lic connections
X
Renewing the seals
(33777) and
sight-glass windows
(40170)
X
7
If used: Cleaning
candle filter (37583)
X
Replace pump head
(37578)
When pump head maintenance message flashes
9
Replace motor block
(100494)
When pump head maintenance message flashes
11
CAUTION
!

General instructions
6
Permissible tools
Always use suitable tools for the described tasks. Refer to the table
below for an overview of suitable tools for updating the firmware.
Software and Firmware
The software FlashTool for updating the firmware and the soft-
ware T808Monitor or T808_SiO2_ServiceMonitor is available for
free download on our website at www.heyl.de.
New firmware for Testomat®808 or Testomat®808 SiO2 can be
found on our website at www.heyl.de
All tools listed above (not including the notebook) can also be
found in our repair and service kits for the Testomat®808 (article
no. 270342) or for the Testomat®808 SiO2 (article no. 270343).
Type
Application
Art. no.
Software
T808Monitor
or
T808_SiO2_S
erviceMonitor
Service program, e.g. to read and reset
the meter readings
Down-
load
Software
FlashTool
Program for installing the new firmware
Down-
load
New firmware
The latest firmware for Testomat®808
or Testomat®808 SiO2
Down-
load
Notebook
For transferring the firmware
-
Null modem
cable
For connecting the PC and Testomat
808
31972
Adapter
USB > Serial
An adapter for the null modem cable, for
when the notebook has no available
serial interface.
32286
NOTE

Carrying out maintenance
7
Carrying out maintenance
Cleaning the measuring chamber
You must remove the measuring chamber for cleaning. Proceed as
follows:
Removing the measuring chamber
Switch off the instrument.
Close the stop valve in the branch line to Testomat® 808.
Prior to removing the measuring chamber, disconnect the cable
from the LED holder and loosen the pump hose at the hose
connector of the measuring chamber.
You can also remove the indicator bottle to facilitate access.
Loosen the two screws fixing the solenoid valve to the rear
panel.
Loosen the connection between hose and solenoid valve by push-
ing the locking ring downwards. Pull the valve downwards and
place it on the shelf.
Turn the angled hose connector upwards.
Press the locking ring of the top angled hose connector up-
wards and remove the outlet hose.
Turn this angled hose connector upwards to ensure that any
residual water cannot escape from the measuring chamber.
Now simply pull the measuring chamber off the retaining bolts
towards the front.
To drain the measuring chamber, turn the bottom angled hose
connector downwards and let the residual water drain off.
Cleaning the measuring chamber
Clean the measuring chamber with a cleaning agent suitable for de-
calcification and rust removal (max. 5 –10% solution). Flush the
measuring chamber thoroughly after cleaning.

Push locking
ring upwards






Carrying out maintenance
8
Cleaning the sight glasses
Removal and installation of the sight glass windows
If the sight glass windows cannot be removed from the measurement
chamber, open the measurement chamber cover and then carefully
push them out from the inside. Do not apply excessive force and do
not use sharp objects that may damage the sight glass windows.
Ensure tension-free mounting of the sight glass windows. Tighten the
screws equally alternating both sides. Otherwise, the sight glass win-
dows may break.
If the instrument has been used to measure hard water for a longer
period of time, a hard-to-remove film may have formed on the sight-
glass windows. Use isopropanol to remove this sticky film.
Caution! Only clean the PMMA window with water.
Measuring chamber with double glazing
Tighten the screws (6) with a torque of 3.5 Ncm.
Installing and operating the measuring chamber
Switch the instrument off before installing the measuring chamber.
Install the measuring chamber again. To do so, carry out the
removal steps in reverse sequence.
Connect the pump hose to the hose connector of the measuring
chamber.
When all assembly work has been completed, the pipeline system
must be bled before the instrument can be operated again (see
Bleeding the indicator lines).
Cleaning the housing
The surface of the instrument housing is untreated. For this reason
avoid soiling it with indicators, oil or grease. However, should the
instrument housing become soiled, clean the surface with a normal
plastic cleaner (never use other solvents).
ATTENTION
!
2 Flat seal
3 Window 1.6 mm
4 Seal D30
5 Window holder
6 Screw 40 mm

Carrying out maintenance
9
Pump head maintenance intervals
Replace the pump head:
•When the E4 indicator, “Maintenance message pump head”
flashes.
Replacing the pump head
We advise replacing the pump head after approx. 2 years because
the pump head’s performance can decrease due to wear.
Pump head maintenance message
The effective runtime of the pump head is counted during operation.
After 150 hours of operation, the LED E4 flashes with the mainte-
nance message for the pump head. This runtime for the pump will be
reached during normal operation (analysis interval every 10 min.)
after approx. 2 years or 54000 analyses.
Switch off the instrument to acknowledge the message.
Press and hold key 4 (horn) when switching on the instrument.
The operating time of the pump head is then reset to 0.
Replacing the pump head
Please note that there may be different pump heads with or without
adapter plates in the devices. The manual describes the basic con-
version, which is comparable for all devices.
To replace the pump head, proceed as follows:
Switch the instrument off.
Pull the hoses off both hose connectors .
Loosen the 2 or 3 screws at the pump head .
Pull off the pump head together with the screws from the motor
shaft.
If the pump is mounted with an adapter plate and shaft extension,
remove both.
To install the new pump head, carry out the steps in reverse se-
quence.
Connect the long tube with the indicator bottle and the short tube
with the measuring chamber.
Press key 4 (horn) and keep it pressed while switching on.
Bleed the indicator pipes before carrying out further analyses.
NOTE





screw long short

Carrying out maintenance
10
Twist protection
Pay attention to the twist protection on the motor shaft and the
pump head! The locating lugs on the pump head should engage
with the holes provided in the housing so that the long end of the
hose points towards the right.
If you have replaced an old (white) pump head with a new (blue)
pump head:
Do an update to firmware 45-015 or higher.
Bleeding the indicator lines
During maintenance, note the following:
Water leaks from seals can result in damage to instrument compo-
nents!
Please check the instrument for leaks before carrying out the first
analysis:
To this effect switch the instrument to standby mode.
Flush the pipeline system by a short activation of key 2 (Flush).
Check all connections and seals for leaks.
To ensure that indicator is available for the initial analyses, the intake
hose and the transport hose must be filled with indicator from the
pump up to the measuring chamber.
Switch on the instrument and press key 3 (standby) . The standby
function is switched on or off via a short key press. The LED above
the key flashes if the function is active.
Press key 1 (manual) for longer (approx. 2 seconds) to bleed the
lines. The dosing pump starts to run.
Let the pump run until no more bubbles escape from the dosing
needle. Then press key 1 (manual) again for approx. 2 seconds to
switch off the pump.
During operation, the pump automatically extracts the indicator.
CAUTION
!
NOTE

Carrying out maintenance
11
Replacing the motor block
To replace the gear motor you need a gear motor for dosing pump of
Testomat®808 (Art. no. 100494).
Disassemble the gear motor
For disassembling, please proceed as follows:
Switch off the device and disconnect it from the power supply.
Close the water supply from the supply line to the Testomat®808.
Open the cover.
Open the door of the terminal box.
Pull off the plug connections for the power supply of the Tes-
tomat®808 (from socket J4 pump on motherboard).
Now remove the pump head. Begin with pulling off the tubes from
the dosing needle and the indicator bottle.
Loosen the 2 or 3 fastening screws of the pump head.
Pull off the pump head together with the screws from the motor
shaft.
If the pump is mounted with an adapter plate and shaft extension,
remove both.
Loosen and remove the 2 screws of the motor block.
Remove the gear motor.
Assemble the new gear motor
Assemble the new gear motor in reverse order.
Insert the motor block and tighten the 2 fastening screws .
If present: Insert adapter plate and shaft extension onto the shaft.
Mount the pump head onto the shaft. Observe the anti-twist guard.
Anti-twist guard
Please observe the anti-twist guard on the motor shaft and the pump
head during installation! The drill hole and the shaft each have a flat
surface and only fit together in one position. Carefully turn the pump
head into the correct position until the snap-in noses snap into the
provided drill holes in the housing.

NOTE

screw long short

Carrying out maintenance
12
Tighten the 2 or 3 screws of the pump head.
Tighten screw without hard pressure!
Make sure that you don’t exercise too much pressure on the tapped
bores. It is possible that the tapped bores will be pushed out of the
housing under hard pressure.
Connect the long tube with the indicator bottle and the short tube
with the measuring chamber.
Plug on the plug connections for the power supply of the Tes-
tomat®808 (from socket J4 pump on motherboard).
Close the door of the terminal box.
Close the cover.
Open the water supply to the Testomat®808.
Put the device into operation again.
Depressurise the lines before performing any further analyses.

NOTE

Service programs
13
Changing from Testomat®BOB to Testomat®
808
If you wish to replace a Testomat®BOB instrument with a new Tes-
tomat®808 instrument, please use our water supply and discharge
conversion kit (Article no. 37576).
Switch the Testomat®BOB off and disconnect its power supply.
Pull the hose from the outlet of the Testomat BOB®.
Unscrew the inlet and discharge connection .
Remove the Testomat®BOB from the wall or control cabinet.
Install the Testomat®808 in the space now vacated. The new
instrument will fit into the same position as the Testomat®808 and
Testomat®BOB dimensions are identical.
Screw the reduction into the inlet connection.
Connect the water supply and discharge of the Testomat®808
with a 6/4 x 1 opaque plastic hose (max. length 5 m).
You are advised to install a manual shut-off valve in the secondary
supply to the Testomat®808.
Flush the supply pipe to remove dirt particles before operating.
To operate the Testomat® 808, proceed as described in the oper-
ating instructions for the Testomat® 808.
Prevent soiling
It is essential to establish a vertical connection in order to prevent
dirt particles from being carried from the main water supply into
the instrument.



Outlet
Inlet
NOTE

Service programs
14
Service programs
Test and adjustment program
Using the Testomat®808 Monitor software (for Testomat®808 de-
vices) or Testomat®808 SiO2 ServiceMonitor (for Testomat®808
SiO2 devices), you are able to read data and to reset the meter read-
ings (information on downloading the software can be found on page
6).
To do this, the software must be saved on a notebook that is con-
nected to the Testomat®808 with a null modem cable via the RS232
interface. If the notebook doesn't have a serial interface, then please
use a USB 2 > serial adapter (Article no. 32286).
Access to the Test and Adjustment program
Press and hold key 1 (manual start) and switch the instrument on.
The POWER LED flashes.
Release key 1.
Operating the T808 Monitor Program
Open the "T808Monitor" or "T808 SiO2 ServiceMonitor" program
on your notebook by double clicking.
Under Serial Port, select the COM port to which the Testomat®
808 is connected.
Click Read to receive status information about the device in the
"Info-Data" section.
With Reset Runtime Head, you can set the counter of the pump
head operating hours meter to 0.
In the Output Window field, either the ADC value (for testing of
the yellowness index) or the value of the V level (for the clear wa-
ter comparison) will be displayed (see the description of the key
functions on pages 15-17).
To delete the Output Window field, click Clear.

Service programs
15
Functions of keys in the test program
Manual start key (first key from the left, short press of the key):
Calling up the serial interface
Operation via the serial interface is no longer possible from this
point. A change to the serial interface is only possible after the
sixth key activation.
Number of key activa-
tions
Function
first key activation
=> The LED above key no. 1 (Manual
start/Bleed) is lit.
The input, “Delete Ext.” is read in:
when contact is established, the LED
above key 4 (Alarm) is lit.
The input, “Stop” is read in: when con-
tact is established, the LED above key
3 is lit (Standby/72h).
second key activation
=> Only K1 on, LED above key 1
(Manual start/Bleed) on, LED K1 on.
third key activation
=> Only K2 on, LED above key 1
(Manual start/Bleed) on, LED K2 on.
fourth key activation
=> Only K3 on, LEDs above key 1
(Manual start/Bleed) and key 4 (Alarm)
on.
fifth key activation
=> All display LEDs are lit in succes-
sion and then simultaneously. The
input valve opens, all relays operate,
the rotating field operates, the measur-
ing LEDs are switched on, the pump is
operating and 20mA are supplied at the
power interface.
sixth key activation
=> Everything is switched off and the
power interface supplies 5 mA. The
POWER LED and the threshold LED
“Measurement good” flash.
NOTE

Service programs
16
Internal flushing key (second key from the left, short press of the
key):
Calling up the serial interface
Operation via the serial interface is no longer possible from this
point. A change to the serial interface is only possible after the
fourth key activation.
for Testomat®808 devices:
Number of key activa-
tions
Function
first key activation
=> Measurement LED1 (yellow) on,
LED above key 2 (Flush inter-
nal/external) on, LED above key 3
(Standby/72h) on.
second key activation
=> Measurement LED 2 (red) on, LED
above key 2 (Flush internal/external) on
and LED above key 4 (Alarm) on.
third key activation
=> The message, “ADC value BPW21:”
with attached measurement value is
displayed. The measurement value
must change according to the entry of
light to the BPW21 (reduction in light =>
reduction in ADC value). The LED
above key 2 (Flush internal/external) is
lit.
fourth key activation
=> The POWER LED flashes.
for Testomat®808 SiO2 devices:
Number of key activa-
tions
Function
first key activation
=> Measurement LED1 (blue) on, LED
above key 2 (Flush internal/external) on,
LED above key 3 (Pause/BOB) on.
second key activation
Back to test program
=> The message, “ADC value BPW20:”
with attached measurement value is
displayed. The measurement value
changes by adjusting the potentiometer
on the optics board. Target value ≈ 900
NOTE

Service programs
17
Standby key (third key from the left, short press of the key):
Calling up the serial interface
Operation via the serial interface is no longer possible from this
point. A change to the serial interface is only possible after the first
key activation.
Number of key activa-
tions
Function
first key activation
=> Checking the watchdog timer: the
LED above key 4 (Alarm) and the
POWER LED flash. A reset is initiated
after 12 seconds and the instrument
starts in normal operating mode (the
POWER LED is lit).
Quit Alarm key (fourth key from the left, short press of the key):
Auto-adjustment
Prerequisite: clear water in the measurement chamber.
for Testomat®808 devices:
In the first step, measurement is carried out using the measurement
LED 1 (yellow). The measurement amplifier gain is adjusted by
means of an electronic potentiometer. The LED above key 1 (Manual
start / Bleed) is lit.
If the adjustment is successful, the potentiometer setting will be
stored permanently. The LED above key 2 (Flush internal/external) is
also lit.
If the comparison fails, the LEDs above key 1 (Manual start/Bleed)
and key 3 (Standby/72h) flashes.
In the second step, measurement is carried out using the measure-
ment LED 2 (red). The current through the measurement LED is set
using an electronic potentiometer. The LED above key 3
(Standby/72h) is lit. If the comparison is successful, the potentiometer
setting will be stored permanently. The LED above key 4 (Alarm) is
also lit.
If the adjustment fails, the LED above key 3 (Standby/72h) is lit.
When the adjustment has been completed successfully, all key LEDs
are lit and the pump operating time is preset to 7 seconds.
The program is now once again in the main loop of the test program
and the POWER LED flashes.
NOTE

Service programs
18
for Testomat®808 SiO2 devices:
A measurement is carried out using the measurement LED 1 (blue).
The measurement amplifier gain is adjusted by means of an electron-
ic potentiometer. The LED above key 1 (Manual start / Bleed) is lit.
If the adjustment is successful, the potentiometer setting will be
stored permanently. The LED above key 2 (Flush internal/external) is
also lit.
If the comparison fails the LED above key 1 (Manual start/Bleed)
flashes.
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 and switch the instrument on.
The first pump head operating hours counter is set to zero and the
maintenance indicator (LED E4) no longer flashes.
The first pump head operating hours counter registers up to a maxi-
mum of 150 hrs.
Only for Testomat®808 devices:
The second pump head operating hours counter registers until the
variables overflow (a theoretical value of over 1 million hours) and is
reset via "WRH" by means of a PC (see chapter, “Test and Adjust-
ment program”).
Testomat®808 SiO2 devices:
There is only one pump head operating hours counter for the double
pump head.

Updating the firmware
19
Updating the firmware
We recommend you to update the firmware installed on your device
at regular intervals. Proceed as follows:
Download the T808_FlashTool software and the latest firmware
from the download page of our home-page www.heyl.de and save
both on your notebook.
Unzip the file on your notebook.
Ensure that the firmware and T808_FlashTool have been saved in
the same folder in the notebook.
Using the null modem cable, connect the serial interface of your
notebook to the serial interface of the Testomat®808 device. If the
notebook doesn't have a serial interface, then please use a USB >
serial adapter (Article no. 32286).
Press the PAUSE key to switch the Testomat®808 into standby.
Move slide switch T1 at the controller board to switch position
RIGHT.
Press the reset button S1 .
All LED lamps are inactive in this state.



Updating the firmware
20
Double click on the "T808_Flash.bat" file. The following screen will
be displayed:
Specify the COM-Port that is being used to connect the Testomat®
808 to the notebook.
Confirm the entry by pressing Enter.
Specify the file name for the firmware update. All available files will
be displayed under "Available firmware files:". If there are no files
displayed, download the current firmware from our homepage and
save it in the same folder where the "T808_Flash.bat" file is saved.
Confirm the entry by pressing Enter.
If you have entered an incorrect COM-Port or an incorrect file
name for the firmware update then you will receive an error mes-
sage informing you of this.
When the firmware update is complete, slide the slide switch T1
to the left.
Press the reset button S1 .
The device is back to normal operation.