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Summary of Contents for Heyl Testomat 808 Series
- Page 1 Maintenance and Service Instructions ® Testomat 808 series ® This manual applies to all devices of the Testomat 808 series, also ® ® Testomat 808 2019 and Testomat 808 SiO2 2019 devices.
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Page 2: Table Of Contents
Contents 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 ................ -
Page 3: Important Safety Information
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. -
Page 4: Further Documents
• 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. -
Page 5: Prior To Carrying Out Maintenance Work
General instructions 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? •... -
Page 6: Permissible Tools
Software and Firmware NOTE 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... -
Page 7: Carrying Out Maintenance
Carrying out maintenance 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. ... -
Page 8: Cleaning The Sight Glasses
Carrying out maintenance Cleaning the sight glasses Removal and installation of the sight glass windows ATTENTION 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. -
Page 9: Pump Head Maintenance Intervals
Carrying out maintenance Pump head maintenance intervals Replace the pump head: • When the E4 indicator, “Maintenance message pump head” flashes. Replacing the pump head NOTE 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. -
Page 10: Bleeding The Indicator Lines
Carrying out maintenance Twist protection NOTE 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. -
Page 11: Disassemble The Gear Motor
Carrying out maintenance 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. ... - Page 12 Carrying out maintenance Tighten the 2 or 3 screws of the pump head. Tighten screw without hard pressure! NOTE 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.
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Page 13: Changing From Testomat Bob To Testomat 808
Service programs ® ® Changing from Testomat BOB to Testomat ® 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). ... -
Page 14: Test And Adjustment Program
Service programs Service programs Test and adjustment program ® ® Using the Testomat 808 Monitor software (for Testomat 808 de- ® ® vices) or Testomat 808 SiO2 ServiceMonitor (for Testomat 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... -
Page 15: Functions Of Keys In The Test Program
Service programs 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 NOTE Operation via the serial interface is no longer possible from this point. - Page 16 Service programs 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 NOTE fourth key activation.
- Page 17 Service programs 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 NOTE point. A change to the serial interface is only possible after the first key activation.
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Page 18: Serial Interface Settings
Service programs ® 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. -
Page 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. - Page 20 Updating the firmware 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. ...
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Page 21: Error Correction
Error correction Error correction 1. Error E4 “Optics problem 1” To show errors: LED performance too low, too little light (or hardware fault) Proposed solution: Check whether the water is cloudy. Excess clouding can compro- mise the measurement. press keys simultaneously ... -
Page 22: Defective Pump Motor
Error correction secondary air. Check the suction lance. Make sure that no air bubbles are escaping from the dosing needle. ® Only for Testomat 808 devices: Check fuse F3 and replace it. If the fuse continues to trip, replace the pump motor. 4. -
Page 23: Spare Parts List Testomat ® 808
Spare parts list Testomat® 808 ® Spare parts list Testomat Spare parts – measuring Art. no. 31592 Fuse, soldered T1.0A chamber 31593 Fuse, soldered T0.8A 33777 Flat seal 24x2 31585 Fuse, soldered T0.315A 40170 Sight-glass window 30x3 31584 Fuse, soldered T0.2A 40176 Sight-glass window holder 31595... -
Page 24: Spare Parts List Testomat 808 Sio2
Spare parts list Testomat® 808 SiO2 ® Spare parts list Testomat 808 SiO2 Spare parts – measuring Art. no. 31592 Fuse, soldered T1.0A chamber 31593 Fuse, soldered T0.8A 33777 Flat seal 24x2 31585 Fuse, soldered T0.315A 40170 Sight-glass window 30x3 31584 Fuse, soldered T0.2A 40176... -
Page 25: Component Positions
Component positions Component positions ® For Testomat From device number 245352 without switch; before that 37400 Cable loom 37562 Pump head 40364 LED holder 40393 LED holder ® Testomat 2019 37579 Bottle insert for screw cap and push-fit suction tube 40364 Optical board 37734 Cable ducting 37570 Solenoid valve... -
Page 26: Measuring Chamber Testomat ® 808
BauteilepositionComponent positions ® Measuring chamber Testomat Measuring chamber (Article no 37615 (1-4bar) or 37616 (0,3-1bar)) Sight-glass window holder (Article no. 40176) Magnetic stirrer (Article no. 40050) Measuring chamber cover (Article no. 37534) Dosing needle (Article no. 37536) Screw M3x40 (Article no. 33253) Screw M3x12 (Article no. -
Page 27: For Testomat ® 808 Sio2
Component positions ® For Testomat 808 SiO2 37859 Double pump head 37570 Solenoid valve Inside 40365 LED holder 37734 Cable ducting 40365 Optical board 37735 Nut M16 x 1,5 40394 LED holder Testomat 40394 Optical board Testomat 808 SiO2 2019 808 SiO2 2019 37322 Controller board 37324 Base circuit board... -
Page 28: Measuring Chamber Testomat 808 Sio2
BauteilepositionComponent positions ® Measuring chamber Testomat 808 SiO2 Measuring chamber (Article no 37533 (1-4bar) Sight-glass window holder (Article no. 40176) Magnetic stirrer (Article no. 40050) Measuring chamber cover (Article no. 37679) Dosing needle (Article no. 37680) Screw M3x40 (Article no. 33253) Screw M3x12 (Article no. -
Page 29: Location Of Fuses
Component positions Location of fuses The following fuses can be found on the base circuit board. Designation Function Comment Art. no. Relay protection fuse 31582 Primary fuse 230 V / 0,1 A 31595 115 V / 0,2 A 31584 24 V / 1 A 31592 Secondary fuse 31592... - Page 30 BauteilepositionComponent positions ® ® Testomat 808 and Testomat 808 SiO2: new from serial number 245352:...
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Page 31: Testomat 808/808 Sio2 Checklist
Testomat® 808/808 SiO2 checklist ® Testomat 808/808 SiO2 checklist Dear customers and service technicians, This check list cannot replace your expertise or extensive experience in fault resolution. It is intended to support fast and sys- tematic error diagnosis and error documentation. This list does not claim to be complete. We are therefore always grateful for any advice and information you may be able to provide. - Page 32 Operation/Indicator ® The proper operation of Testomat instruments can only be assured where original Heyl Testomat indicators are used. These indicators permit an exact analytic measurement of the smallest quantities of substances. As for all reactive chemical substances, their effectiveness is also influenced by environmental conditions.
- Page 33 Testomat® 808/808 SiO2 checklist...
- Page 34 Gebrüder Heyl Analysentechnik GmbH & Co. KG Orleansstraße 75b D 31135 Hildesheim Serviceanleitung_808_GB_190820.docx www.heyl.de Scan the code and visit us on our website!
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