Heyl Testomat Modul TH Service Instructions Manual
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Heyl Testomat Modul TH Service Instructions Manual

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Service Instructions
®
Testomat
Modul TH
These operating instructions are the copyrighted property of Heyl Analysen-
technik GmbH & Co. KG.
It is intended for customer service and should only be used by authorised ser-
vice staff.
No part of this publication may be reproduced or transmitted in any form or by
any means to a third party, in particular to our competitors, without express
prior permission of Heyl Analysentechnik GmbH & Co. KG.

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Summary of Contents for Heyl Testomat Modul TH

  • Page 1 Service Instructions ® Testomat Modul TH These operating instructions are the copyrighted property of Heyl Analysen- technik GmbH & Co. KG. It is intended for customer service and should only be used by authorised ser- vice staff. No part of this publication may be reproduced or transmitted in any form or by any means to a third party, in particular to our competitors, without express prior permission of Heyl Analysentechnik GmbH &...

  • 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 Prior to carrying out maintenance work ..........6 Permissible tools ................... 6 Carrying out maintenance ..............

  • Page 3: Important Safety Information

    Important safety information 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. ...

  • Page 4: Further Documents

    General instructions 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! Fix errors by yourself.
  • Page 5 General instructions • Clean the measuring chamber at regular intervals (approx. every 6 months) and, if possible, replace the two seals of the measuring chamber holder and the sight-glass windows. • If the water has high iron content, cleaning might be necessary more often.

  • Page 6: Prior To Carrying Out Maintenance Work

    General instructions Prior to carrying out maintenance work Carry out a visual inspection of the instrument: • Is the cover of the unit (if present) always carefully closed? • Is the instrument heavily soiled? • Is there air inside the dosing hoses? •...

  • Page 7: Carrying Out Maintenance

    Carrying out maintenance Carrying out maintenance This service manual describes maintenance work that goes beyond the regular maintenance work described in the “Maintenance and repairs” chapter of the operating manual. see Operating manual Cleaning the measuring chamber and the viewing window Page 41 Cleaning the filter housing...

  • Page 8: Cleaning Of Clogged Solenoid Valves

    Carrying out maintenance Cleaning of clogged solenoid valves When the solenoid valve is clogged with impurities, the measuring chamber is not properly emptied. In this case, the solenoid valve can be carefully cleaned. For dismantling all Testomat devices, please proceed as follows: ...
  • Page 9 Carrying out maintenance  When microbial contamination or deposits are present, clean the  valve chamber and the parts of the valve with a small brush (e.g. from our cleaning brush set, Art. No. 32287).  Carry out assembly by following the steps for dismantling of the same in reverse.

  • Page 10: Additional Cleaning Instructions

    Carrying out maintenance Additional cleaning instructions Procedure in the event of corrosion: Temporarily place the tie rod in a metal cleaning solution (no longer than 5 minutes, depending on the concentration). Subsequently, neu- tralise with plenty of clear water. Under no circumstances must sandpaper be used! It is far better to use metal-free cleaning fleece, e.g.

  • Page 11: Repairing Or Replacing The Dosing Pump

    Carrying out maintenance Repairing or replacing the dosing pump Maintenance rate ® The dosing pump DOSIClip is a high-precision piston dosing pump, NOTE which makes up to 400 000 pump strokes per year depending on the settings (a measurement all 10 minutes x 4 pump strokes every day). To ensure proper operation for many years, we recommend sending in the pump for servicing every 2-3 years.

  • Page 12: Replacing The Dosing Pump Valves

    Carrying out maintenance Replacing the dosing pump valves In certain cases and with an obvious cause of malfunctioning, it is also possible to replace the pump valves. Please proceed as follows:  Remove the transparent cover.  Use a suitable screwdriver to remove the electronics from the housing (snap-on installation).

  • Page 13: Replacing The Backup Battery

    Carrying out maintenance Replacing the backup battery When the device is switched off the internal clock is powered by a lithium backup battery (CR2032 type), which is designed to have a service life of 10 years. After this period, it should be replaced for preventive reasons, and always ensuring a measured voltage <2.3V.

  • Page 14: Replacing The Fuse

    Carrying out maintenance Replacing the fuse ® This fuse protects the Testomat Modul TH device or outputs against overload and short circuit. The main fuse F1 (1 A MT) for outputs and equipment is located on the motherboard (behind the controller board).

  • Page 15: Troubleshooting

    There is insufficient dye in the indicator. Use a new indicator.  When using an indicator that is not from Gebr. Heyl, replace it with the one recommended by us. 2. The stirring bar in the measuring chamber holder fails to rotate, resulting in an insufficiently mixed indicator.
  • Page 16 Troubleshooting 4. Air is trapped in the indicator hose. Remedy:  Bleed the dosing hoses by pressing the “Manual” button on the dosing pump several times.  Make sure that all the indicator hoses are fitted correctly. If not, air may enter the hoses! ...

  • Page 17: Error Message "38 Water Low

    Troubleshooting 9. Iron (< 0.5 mg/l), copper and aluminium ions (<0.1 mg/l) may impair the measurement. Remedy:  This is probably caused by old iron pipes, new copper pipes or changes to the well water. Pay attention to the composition of the measuring water.

  • Page 18: Error Message "„33 Fault Optics Led1" And „27 Fault Optics Led2

    Troubleshooting Error message “„33 Fault optics LED1” and „27 Fault optics LED2” Remedy  There is an error at the optical component. The receiver is defec- tive. Replace the measuring chamber holder.  Cold water (<8°C) combined with a warm and humid ambient tem- perature (>28-30°C) can lead to the formation of water drops on the sight-glass windows.

  • Page 19: Spare Parts For Testomat Modul Th

    Spare parts for Testomat® Modul TH ® Spare parts for Testomat Modul TH Art. no. Pressure controller Caution! 40125 Controller / Filter receiver, complete Should you send your Tes- 40120 Controller / Filter receiver ® tomat Modul TH in for 40129 Controller plug T2000, complete maintenance, please make...

  • Page 20: Component Positions

    Component positions Component positions Motherboard 37896 (behind) Controller board 37805 Dosing pump 270470 Cable loom 2V 40060 Cable loom 2P 40062 Measuring chamber 40022 Sight glass window with seal 40173 Sight glass holder Valve block 40056 40176 Measuring cham- ber holder 40392 Screw cap with insert 37644 Plug-in connector...
  • Page 21 Component positions Controller/filter receiver Item Name Article number Quantity Controller plug 40129 Flow controller valve body, 11225 Angled plug-in connector 40157 Locking pin 11270 Controller / filter receiver 40120 Flat seal 24x2 33777 Inlet filter 11217 Spring for inlet filter 11218 ...
  • Page 22 Component positions Drainage and piping Item Name Article number Quantity Reducing connector 10-6 40152 Plug-in angular connector 40154 Pipe 10x98 40240 Pipe 6x115 40142 Plug-in connector 40150 G1/8“ - 6 Plug-in connector 40156 G3/8“ – 10 T connector 10 40112 Pipe 10x45 35863 Drain funnel...
  • Page 23 Component positions Measuring chamber complete (40022) Item Name Article number Quantity Measuring chamber hous- 37810 Flat seal 24x2 33777 Sight-glass window 30x3 40170 Sight-glass holder, 40176 Bolt M3x40 33253 Plug for measuring cham- 11210 Angled plug-in connector 40320 Tube, PVC, 3,0/1,5, 35852 200mm Latch fastener...

  • Page 24: Checklist Testomat Modul

    ® Checklist Testomat Modul TH Dear customers and service technicians, The following checklist is no substitute for your expertise and experience applied to the process of troubleshooting. It should assist you and facilitate swifter and more systematic detection and logging of errors. No claim of completeness may be inferred from this list. We are grateful to receive supplementary feedback at any time.
  • Page 26 Gebrüder Heyl Analysentechnik GmbH & Co. KG Orleansstraße 75b D 31135 Hildesheim Serviceanleitung_T-Modul_TH_EN_210706.docx www.heylanalysis.de Scan the code and visit us on our website!

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