Testomat
®
808
Online Analysis Instrument
for Water Hardness
Operating Instructions
Content
Content
Content ................................................................................................. 2
Important safety information ............................................................. 4
Intended use ......................................................................................... 4
Qualification of the staff ........................................................................ 4
Warning notices in these instructions ................................................... 5
Notes and instructions to be observed ............................................ 5
General instructions .............................................................................. 5
Installation ............................................................................................. 6
Operation .............................................................................................. 6
Cleaning ................................................................................................ 6
De-installation ....................................................................................... 6
Disposal ................................................................................................ 6
Operating requirements ........................................................................ 7
Scope of delivery ................................................................................ 7
Performance specifications ............................................................... 8
Indicators for Testomat® 808 instruments ............................................. 8
Functions of the operating and display elements ........................... 9
Switching Testomat® 808 on/off ............................................................ 9
Front view Testomat® 808 ..................................................................... 9
Operating elements/Function keys ..................................................... 10
Display elements/LEDs ....................................................................... 11
Installation ......................................................................................... 12
Installing Testomat® 808 ..................................................................... 12
Operating Testomat® 808 in the pressure range 4 to 8 bar ................ 12
Connecting the water inlet and outlet ................................................. 13
Water inlet ........................................................................................... 13
Water outlet ......................................................................................... 14
Connecting the power supply and devices ......................................... 14
Plant example Testomat® 808 ............................................................. 15
Internal design Testomat® 808 ............................................................ 16
Rear of the controller board ................................................................ 16
Reset key S1 ....................................................................................... 16
Function key S6 .................................................................................. 16
Function key S7 .................................................................................. 16
Slide switch T1 .................................................................................... 17
Slide switch T2 .................................................................................... 17
Plug connector J1 ............................................................................... 17
Plug connector J2 ............................................................................... 17
Plug connector J3 ............................................................................... 17
Base circuit board Testomat® 808 ...................................................... 18
Plug connector J2 ............................................................................... 18
Plug connector J8 ............................................................................... 18
Current interface ................................................................................. 18
Inputs DEL. EXT. and STOP .............................................................. 19
Terminal block ..................................................................................... 19
Fuses .................................................................................................. 19
2
Content
Connecting the mains voltage............................................................. 20
Connecting the inputs and outputs ..................................................... 21
Description of the signal inputs ...................................................... 23
Interfaces ........................................................................................... 23
Current interface ................................................................................. 23
Serial interface RS232 ........................................................................ 24
Description of the relay outputs ...................................................... 24
Relay K3 – fault message ................................................................... 24
Relays K1 and K2 ............................................................................... 24
Switching functions of the relays K1 and K2 ....................................... 24
Commissioning ................................................................................. 26
Inserting the indicator bottle ................................................................ 26
Bleeding the indicator lines ................................................................. 26
Opening the water inlet ....................................................................... 26
Instrument settings and analysis .................................................... 27
Instrument settings .............................................................................. 27
Selecting the indicator type and bottle size ........................................ 28
Carrying out an analysis ..................................................................... 28
Analysis process ................................................................................. 29
Further basic functions and settings .............................................. 30
Internal flushing ................................................................................... 30
External flushing ................................................................................. 30
Flush process – internal/external in manual mode ............................. 30
Interval pause ..................................................................................... 31
72 h operation (operation without permanent supervision) ............... 32
Error messages/Troubleshooting ................................................... 32
Alarm/Error message/Relay K3 .......................................................... 32
Low water level ................................................................................... 35
Measuring fault analysis ..................................................................... 35
Further possible instrument errors ...................................................... 35
Maintenance ...................................................................................... 36
Service instructions ............................................................................. 37
Description of maintenance work ........................................................ 37
Replacing the indicator bottle.............................................................. 37
Cleaning the measuring chamber and the sight-glass windows ......... 38
Pump head maintenance message .................................................... 39
Testomat® 808 spare parts and accessories .................................. 41
Accessories - indicators ...................................................................... 42
Technical data ................................................................................... 43
EC conformity Declaration .................................................................. 44
Product overview Testomat 2000®-Instruments ............................ 45
3
Important safety information
Important safety information
Please read these operating instructions carefully and completely
prior to working with the instrument.
Ensure that these operating instructions are always available for all
users.
These operating instructions must always be passed on to the new
owner should Testomat® 808 change hands.
Always adhere to hazard warnings and safety information when
using reagents, chemicals and cleaning agents. Please adhere to
the respective safety data sheet! Download the safety data sheets
for the supplied reagents at http://www.heyl.de .
Intended use
Testomat® 808 has been designed for use in the field of water treatment (e.g. osmosis plants, electroplating, large boiler plants, laundries, canteen kitchens). The feed water must be clear, colourless
and free of undissolved particles. The instrument is a limit value
measuring instrument which automatically monitors the residual total
hardness (water hardness) in water.
Always adhere to the performance limits stated in the section enti-
tled “Technical data” on page 43.
Always observe the application areas/application limits of the indi-
cators and the requirements of the medium being measured.
To ensure correct and intended usage, always read and understand
these instructions, especially the section entitled “Important safety
information”, prior to use.
The instrument is not used as intended if
it is used in areas not specified in these instructions.
it is used in areas which do not correspond to the ones described
in these instructions.
Qualification of the staff
Assembly and commissioning require fundamental electrical and
process engineering 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, knowhow and experience as well as knowledge of relevant regulations can
assess assigned tasks, recognise potential hazards and ensure appropriate safety measures. A specialist should always adhere to the
relevant technical regulations.
4
Notes and instructions to be observed
WARNING
!
WARNING
!
NOTE
CAUTION
!
DANGER
!
SIGNAL WORD!
Warning notices in these instructions
The warning notices in these instructions warn the user about potential dangers to individuals and property resulting from incorrect handling 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 damage.
“NOTE” indicates important information. If this information is not observed, it may result in an undesirable result or state.
Notes and instructions to be observed
General instructions
Adhere to health and safety regulations, electrical equipment safe-
ty regulations, and environmental protection regulations valid in the
country of use and at the installation site.
Adhere to national and local regulations during installation and
commissioning.
Always protect the instrument against moisture and humidity. It
should never come into contact with condensation or splash water.
Do not carry out any changes or modifications at the instrument
which are not described in these instructions;
these instructions will negatively affect any warranty claims that
you make thereafter.
failure to adhere to
5
Notes and instructions to be observed
WARNING
!
NOTE
Installation
Always completely disconnect the relevant plant part before in-
stalling the instrument or connecting/disconnecting it to/from the
power supply. Secure the plant against reconnection.
Only connect the instrument to the mains voltage specified on the
rating plate.
Always observe technical data and ambient parameters.
Testomat® 808 requires an interference free and stable power
supply. If necessary, use a mains filter to protect Testomat
against interference voltages caused, e.g., by solenoid valves or
large motors. Never lay connecting cables parallel to power cables.
®
Operation
Ensure that the maximum electrical load capacity of the relay out-
puts is never exceeded.
Immediately switch off Testomat® 808 and contact service staff if
malfunctioning occurs. The warranty will be void if you tamper with
or attempt to repair Testomat® 808. Repairs must be carried out by
authorised service staff.
Cleaning
Only use a dry, lint-free cloth for cleaning.
De-installation
Prior to de-installing a defective instrument, always write down a
description of the error (failure effect). It is only possible to repair a
defective instrument (irrespective of the warranty period) if it has
been de-installed and returned to us with a description of the error.
Use to the enclosed error log to describe the error and return it to
us together with the instrument. If the error log is no longer available, download it at www.heyl.de.
Disposal
Dispose of the instrument in accordance with national regulations.
6
Scope of delivery
NOTE
CAUTION
!
Operating requirements
In order for Testomat® 808 to operate reliably, use Heyl Tes-
tomat® indicators in the pH-range 4 – 10.5!
Only operate the instrument with the parameters specified under
“Technical data”.
With Testomat® instruments for water hardness monitoring, larger
quantities of heavy metal ions in the softened water might influence the colour reaction, especially iron above 0.5 mg/I, copper
above 0.1 mg/I and aluminium above 0.1 mg/l (brownish-red colour display).
If the measuring water contains more than 20 mg/I CO2 (carbonic
acid), incorrect evaluations cannot be excluded. In this case, use
an aerator (e.g. special Heyl accessories).
The concentration of influencing contents can be determined by
using our colorimetric TESTOVAL® test kit
Important! Excessive carbonate hardness and also the ex-
istence of disinfectants in the water can result in erroneous
evaluations.
Careful handling of the instrument increases both its operational
reliability and service life! Therefore, carry out a visual inspection
at regular intervals as described below:
- Has the use-by-date of the indicator expired?
- Are the hose connections of the dosing pump free of leaks?
- Is there any air inside the dosing hoses?
- Are all the water connections free of leaks?
- Are the doors of the instrument closed properly?
- Is the instrument heavily soiled?
- Are the measuring chamber and the drain duct/drain hose
clean?
Trouble-free operation is only possible when maintenance is car-
ried out on a regular basis! For more information, please refer to
the section entitled “Maintenance” on page 36.
If problems occur, please refer to the section entitled “Error mes-
sages/Troubleshooting” on page 32.
Scope of delivery
1x Testomat® 808
1x plastic bag containing a screw cap with a hole and an insert for the
screw cap of the indicator bottle
2x fuse
1x operating instructions
Special accessories (available separately): Filter inlet, candle filter as
well as pressure regulator
Required hose connections and supply lines for Testomat® 808 are
available from Heyl.
7
Performance specifications
Indicator
type
Monitoring
range
Limit value LEDs
(good/poor display)
Measuring result
(information on water quality)
300 – 330
Residual hardness
0.02 – 10 °dH
“GOOD” green
Residual hardness < indicator limit
value
“POOR” red
Residual hardness > indicator limit
value
Performance specifications
Testomat® 808 is used for the automatic monitoring of residual total
hardness (water hardness) in water. The limit value to be monitored
is determined by the indicator selection.
Limit values for residual hardness of 0.02 – 10.0 °dH* deter-
minable by indicator selection
Analysis start:
- Automatic interval mode
(interval pause can be set from 0 – 60 minutes)
- External control
- Manual start
Extended operating periods due to 500 ml indicator storage
bottle
RS232 interface for optional firmware update
Indicators for Testomat® 808 instruments
Indicators with various limit values are available for the application of
Testomat® 808 instruments according to operational requirements.
All indicator types are available in two bottle sizes (100 ml and
500 ml). Please refer to the section entitled “Testomat® 808 spare
parts and accessories” on page 41 for a detailed list of the individual
indicator types with the respective article numbers.
8
Functions of the operating and display elements
Functions of the operating and display elements
Operating statuses and measuring results are displayed at Testomat
808 via LEDs. The input keys for operating the instrument are positioned below the LEDs.
Switching Testomat® 808 on/off
(1) Power switch
Switch the instrument on/off using the green power switch (after
opening the housing cover on the front of the instrument).
(2) Instrument fuse (internal)
These fuses protect Testomat® 808 and the outputs against overloads and short circuits.
DPlease refer to the sections entitled “Fuses” on page 19 and
“Error messages/Troubleshooting” on page 32 for descriptions of
the fuses.
Front view Testomat® 808
®
9
Functions of the operating and display elements
Key 1
(manual)
Short key press: Starts an analysis (manual start),
the respective LED flashes.
Long key press: Switches the dosing pump for bleeding the pipes on/off. The LED illuminates while the
pump is running.
Key 2
(flushing)
Short key press*: Switches the internal flush valve
on/off, the respective LED flashes as long as the
valve is open.
Long key press*: Activates an external flush valve via
relay K1 (on/off). The LED above key 2 and LED K1
illuminate as long as the external valve is activated.
Key 3
(standby)
Short key press: Switches the standby function
on/off. The respective LED flashes if standby is active.
Long key press: The respective LED displays whether operation is possible for longer than 72 h (operation without supervision).
Key 4 (horn)
Short key press: Acknowledges current errors/alarms.
Long key press: Sets the indicator display from 0% to
100% (the LEDs 10% to 90% illuminate).
Note: It is not possible to enter any indicator level.
Operating elements/Function keys
All operating elements/function keys are assigned twice. The respective function is triggered by a short or long (min. 2 seconds) key
press.
* only in standby mode
10
Functions of the operating and display elements
The LED illuminates if the instrument is switched
on via the power switch on the front of the instrument and is operating.
Limit value LEDs (red/green) for displaying the
measuring result:
Limit value not achieved => green LED illuminates
Limit value exceeded => red LED illuminates
When a new measuring is running, the result of
the previous measurement flashes.
The LEDs K1 and K2 display the status of the
relays. They illuminate if the respective relay has
been switched (also see the section entitled
“Switching functions of the relays K1 and K2” on
page 24)!
10% – 90%: These LEDs display the calculated
filling level of the indicator bottle (also see the
section entitled “Measuring fault analysis” on page
35).
E4 – E1: These LEDs display current errors after
simultaneously pressing key 3 and key 4 for ap-
prox. 2 seconds (also see the section entitled
“Error messages/Troubleshooting” on page 32).
E4 flashes: The pump head has been in operation
for 150 hours and must be replaced (also see the
section entitled “Pump head maintenance mes-
sage” on page 39)
NOTE
red
green
Display elements/LEDs
All measuring results as well as activated functions are displayed at
Testomat® 808 via LEDs.
The LEDs above the function keys illuminate/flash when the respective function is activated.
11
Cancelling error messages/warning messages
Press key 4 to acknowledge the messages and,
if necessary, eliminate the cause of the fault.
Installation
NOTE
WARNING
!
Installation
Risks resulting from incorrect installation!
Install Testomat® 808 at a location where it is protected against
dripping or splash water, dust and aggressive substances – e.g. in
a control cabinet or on a suitable wall.
Information for trouble-free operation
Install Testomat® 808 vertically and without mechanical stress.
Install Testomat® 808 at a vibration-free site.
Installing Testomat® 808
Select an installation site where the water inlet hose can be kept as
short as possible (max. 5 m).
Drill the mounting holes as shown in the drawing below.
Use three screws to attach the instrument at a suitable position on
the wall.
12
Installation
Outlet
Inlet
NOTE
Operating Testomat® 808 in the pressure
range 4 to 8 bar
Prior to installation, please check whether a higher operating pressure (between 4 and 8 bar) is required. Use a pressure controller (art.
no. 37602) for ranges between 4 and 8 bar. Optimum operation of
Testomat® 808 is achieved with operating pressure of between 2 and
4 bar.
Information for trouble-free operation
The water pressure must be between 1 and 8 bar; a pressure re-
ducer should be used for the 4 to 8 bar range (special accessories). This pressure regulator must be set under flow pressure!
Avoid strong pressure fluctuations.
Connecting the water inlet and outlet
Information for trouble-free operation
Ensure there are no foreign particles bigger than 150 µm which
caused blocking. Use our candle filter (Art. No. 37583) at the front
end of the device if you have problems with blocking.
The measuring water temperature must be between 10°C and
40°C.
For water temperatures above 40°C, install the KCN type cooler in
the supply line of Testomat® 808.
Water inlet
The measuring water is taken from the main water line of the water
treatment plant and fed to the inlet connection of Testomat® 808. The
instrument is equipped with a plug connector for plastic hoses 6/4 x 1
(external diameter 6 mm/ internal diameter 4 mm, wall thickness 1
mm) as standard).
Install the connection for the branch line of Testomat® 808 directly
at the main water line directly after the water treatment plant.
Always lay the branch line connection vertically upwards in order to
prevent dirt particles from entering the instrument from the main
water line.
We recommend you to install a manually operated stop valve (see
figure “Plant example Testomat® 808” on page 15) in the branch
line to Testomat® 808.
Use an opaque plastic hose 6/4 x 1 (max. length 5 m) for the water
inlet .
Flush the supply line to remove any dirt particles.
13
Installation
CAUTION
!
WARNING
!
NOTE
NOTE
When using a cooler
The hot water can cause burns and damage wetted parts of
Testomat® 808.
Water outlet
The feed water flows through the measuring chamber to the drain via
the outlet hose.
Remove the red plug from the outlet connection.
Connect the outlet connection of Testomat® 808 to an outlet hose
(internal diameter 4 mm).
Feed the hose to an outlet.
Transportation plug!
The outlet is sealed with a plug to prevent leakage during transportation. Keep and store the plug for possible transportation at a later
date.
Connecting the power supply and devices
Risk of electric shocks during installation!
If the power supply is not disconnected prior to installation, it may
result in personal injuries, destruction of the product or damage to
plant parts.
Always disconnect the relevant plant parts before installing Tes-
tomat® 808.
Only use tested cables with sufficient cross-sections for the con-
nections.
Risk of damages caused by electromagnetic fields!
If Testomat® 808 or the connecting cables are installed parallel to
power cables or in close proximity to strong electromagnetic fields,
the instrument may be damaged or measurements incorrect.
Ensure that connecting cables are as short as possible.
Always install connecting cables and power cables separately.
Connect the instrument to the protective earth conductor (for
230/115 VAC).
Shield the instrument against strong electromagnetic fields.
14
Installation
Plant example Testomat® 808
15
Installation
S7
S6
Internal design Testomat® 808
Rear of the controller board
Keys 1 to 4 are located at the front of the board. Please refer to the
section entitled “Functions of the operating and display elements” on
page 9 for a detailed description of its operating system and the display elements.
The following function keys and slide switches as well as plug connectors are also provided:
Reset key S1
Use reset key S1 to execute a reset, i.e. to reset the firmware of
Testomat® 808 after an update.
Function key S6
Use function key S6 to set the interval pause between measure-
ments. Please refer to the section entitled “Interval pause” on page
31 for an overview of possible switching positions and interval pauses. (The standard setting is 3.)
Function key S7
Use function key S7 to set the switching behaviour of the relays
K1 and K2. Please refer to the section entitled “Switching functions of
the relays K1 and K2” on page 24 for an overview of possible switch-
ing positions. (The standard setting is 3.)
16
Installation
Indicator
Switch position
100 ml bottle
Left
500 ml bottle
Right
NOTE
Switch position right
(delivery status)
NOTE
Switch position left
(delivery status)
NOTE
!
Switch position
The respective switch position is read after evaluating a measuring
result and after a reset.
Slide switch T1
Switch position LEFT: If the slide switch is in the left position
and the instrument is switched on or the reset key pressed while the
instrument is switched on, the microcontroller executes the operating
program (firmware).
Switch position RIGHT: If the slide switch is in the right position
and the instrument is switched on or the reset key pressed while the
instrument is switched on, the instrument is set to a mode which enables a firmware update via the serial interface.
If your instrument requires a firmware update, Heyl will provide you
with further detailed information.
Switch position
The switch position is only read immediately after a reset.
Slide switch T2
Use the slide switch T2 to determine the size of the indicator bottle. The following indicator bottle sizes are possible:
Switch position
The status of the slide switch T2 is read after resetting the indicator
display to 100% and after a reset.
Plug connector J1
The plug connector J1 is a programming interface. It is not im-
portant for instrument operation.
Plug connector J2
The connection to the base circuit board is established via the plug
connector J2 using a ribbon cable.
Plug connector J3
The connection to the RS232 interface is established via the plug
connector J3 using a ribbon cable. Please refer to the section
entitled “Serial interface RS232” on page 24 for a detailed description.
17
Installation
Base circuit board Testomat® 808
The illustration above provides an overview of the design of the base
circuit board.
18
Plug connector J2
The connection to the controller board is established via the plug
connector J2 using a ribbon cable.
Plug connector J8
The power switch is connected at plug connector J8 .
Current interface
Please refer to the section entitled “Interfaces” on page 23 for a description of the current interface .
Installation
No.
Designation
Function
Comment
F1
Relay protection fuse
4 A
F2
Primary fuse
230 V / 0.1 A
115 V / 0.2 A
24 V / 1 A
F3
Secondary fuse
1 A
Inputs DEL. EXT. and STOP
Please refer to the section entitled “Description of the signal inputs”
on page 23 for a description of the inputs “Delete externally” and
“Stop” .
Terminal block
Please refer to the sections entitled “Connecting the mains voltage”
on page 20 and “Connecting the inputs and outputs” on page 21 for a
description of the terminal block .
Fuses
The following fuses can be found on the base circuit board.
Please refer to the section entitled “Testomat® 808 spare parts and
accessories” on page 41 for the article numbers when reordering fus-
es.
19
Installation
Terminal
description
Type
Function
Comment
PE
IN
Mains protective earth (4x)
Only with mains
115/230 V !
N (U)
L (V)
IN
Mains, N=neutral (U=24 V)
Mains, L=live (V=24 V)
Mains input 50-60 Hz
24 V / 115 V / 230 V
n
l
OUT
Neutral, switched (3x)
Live, switched (3x)
Mains for consumers,
max. 4 A
Connecting the mains voltage
Only connect the instrument to the specified mains voltage. Refer to
the rating plate for the appropriate mains voltage. Connect the cables
as follows:
Open the housing cover and subsequently loosen the two fas-
tening screws at the top and bottom of the door to the interior of
Testomat® 808. The door can now be opened and the terminal box
accessed.
Feed the cable through one of the cable glands underneath the
housing into the terminal box.
Feed the cable through one of the cable glands underneath the
housing into the terminal box.
Subsequently pull back the cable until the bush has been turned
over (2).
Connect the power supply to the terminals PE, N, L.
To do so, insert the conductors into the round cable input at the
terminal block. Ensure that the strands are held securely in the
terminals.
To loosen the connection, insert a screwdriver into the square
opening without force in order to open the terminal. Once the terminal has been opened, remove the conductor.
20
Installation
Terminal
description
Type
Function
Comment
RELAY 3
OUT
Fault message output – changeover contact
Volt-free relay output*
RELAY 2
OUT
Control for external application
Volt-free relay output*
RELAY 1
OUT
Control for external flush valve
Volt-free relay output*
EXT. DEL.
IN
Acknowledgment message input –
normally open
Volt-free input
STOP
IN
Flow controller/Switch input –
normally open
Volt-free input
CAUTION
!
Connecting the inputs and outputs
Connecting the inputs
Do not connect external voltage to these connections!
Testomat® 808 has the following connections for control and monitoring functions.
Ensure that the strands are held securely in the terminals.
Use the two fastening screws to close the door once installation
has been completed.
21
Installation
* Please refer to the section entitled “Technical data” on page 43 for
the maximum contact load of the relays.
Please refer to the section entitled “Description of the signal inputs”
on page 23 or “Description of the relay outputs” on page 24 for a
detailed description.
22
Description of the signal inputs
CAUTION
!
EXT. LÖSCH.
terminals
STOPP
terminals
NOTE
Description of the signal inputs
Connecting the signal inputs
Only connect the signal inputs “Delete externally” and “Stop” to
volt-free contacts!
The connection of external voltages would damage the instrument!
DEL. EXT. (EXT. LÖSCH.) of relay K3
The input “Delete externally” is used for the external dele-
tion/acknowledgment of current errors/alarms. It reacts the same as
key 4 (horn) after a short press, i.e. all fault messages can also be
acknowledged via a remote control (normally open).
STOP
The input “Stop” is the input for an external flow controller or switch
(volt-free, normally open). It reacts the same as key 3 (standby) after
a short press. The LED above key 3 flashes and the instrument no
longer executes analyses. However, an analysis currently in progress
will be completed.
Priority of input STOP
The external stop function has priority over key 3 (standby)!
If the standby function (key 3) has been activated and subsequent-
ly deactivated during an analysis pause, the interval pause time is
reset. However, if the standby function is terminated via the “Stop”
input, the analysis starts immediately.
Interfaces
Current interface
The results of the analyses or statuses can be registered via the output of the current interface (I-OUT (+) / I-IN (-)). The following defined
values for status and error messages are output for this:
5 mA = Pause
8 mA = Good measurement
11 mA = Poor measurement
14 mA = Low water level
17 mA = Low indicator level (< 10%)
20 mA = Indicator is empty or
optical fault or no or
insufficient indicator in the measuring chamber
23
Description of the relay outputs
NOTE
Function key S7
NOTE
NOTE
Current interface load
The current interface is galvanically decoupled. A maximum load of
500 Ohms should not be exceeded!
For faults and when using very long cables (approx. 20 m), a
screened cable should be used if possible.
Serial interface RS232
The serial interface RS232 is located at the front of Testomat® 808
(after opening the housing cover). Use a ribbon cable with a 9-pole
Sub-D connector to connect the plug J3 on the controller board to
RS232. Use this RS232 interface to connect a computer/notebook to
the controller board of Testomat® 808 via a null modem cable and
update the instrument’s firmware.
Description of the relay outputs
All relay outputs are neutral contacts. This ensures that all connection
options are available. The switching of mains voltage and external
voltage, and the direct switching of inputs, e.g. a process controller,
can thus be realised. Please refer to the chapter entitled “Technical
data” on page 43 for the maximum load of the relays.
Relay K3 – fault message
Relay K3 is designed as a change-over contact and used for fault
messages indicating low water level, low indicator level, power failure
and measuring faults.
After several consecutive faulty measurements the relay K3 deactivates and an error message is issued via the current interface.
Relays K1 and K2
Two volt-free relay contacts are available to signal that a limit value
has been exceeded. Set the function of the relays via the switch position of function key S7.
Switching functions of the relays K1 and K2
24
Switch position
The respective switch position is read after evaluating a measuring
result and after a reset.
The following switch positions are possible:
Description of the relay outputs
Switch
position
Relay K2
(message poor analysis)
Relay K1
(external flush)
Comment
for relay K2
0
Normally open – closes in
case of 1 poor analysis,
remains closed until the next
good analysis
Normally open – closes after a
poor analysis for 1 minute
Continuous contact can be deleted
via key 4 (horn) or “Delete external-
ly”. Measures continue despite mes-
sage via the relay K3.
1
Normally open – closes in
case of 1 poor analysis,
remains closed until the next
good analysis
Normally open – closes after a
poor analysis for 3 minutes
Continuous contact can be deleted
via key 4 (horn) or “Delete external-
ly”. Measures continue despite mes-
sage via the relay K3.
2
Normally open – closes after
2 poor analyses, remains
closed until the next good
analysis
Normally open – closes after
the first poor analysis for 1
minute and after the second
poor analysis for 2 minutes
Continuous contact can be deleted
via key 4 (horn) or “Delete external-
ly”. The instrument skips the interval
pause after the first poor analysis.
Measures continue despite mes-sage
via the relay K3.
3*
Normally open – closes after
3 poor analyses, remains
closed until the next good
analysis
Normally open – closes after
the first poor analysis for 1
minute, after the second poor
analysis for 2 minutes and
after the third poor analysis for
3 minutes
Continuous contact can be deleted
via key 4 (horn) or “Delete external-
ly”. The instrument skips the interval
pause after the first and second poor
analysis. Measures continue despite
mes-sage via the relay K3.
4
Normally open – closes in
case of 1 poor analysis and
remains closed.
Opens again once the alarm
has been deleted
Instrument goes into standby. Continuous contact can be deleted via
key 4 (horn) or “Delete externally”.
5
Normally open – closes after
2 poor analyses and remains closed.
Opens again once the alarm
has been deleted
Normally open – closes after
the first poor analysis for 1
minute
Instrument goes into standby. Continuous contact can be deleted via
key 4 (horn) or “Delete externally”.
The instrument skips the interval
pause after the first poor analysis.
6
Normally open – closes after
3 poor analyses and remains closed.
Opens again once the alarm
has been deleted
Normally open – closes after
the first poor analysis for 1
minute and after the second
poor analysis for 2 minutes
Instrument goes into standby. Continuous contact can be deleted via
key 4 (horn) or “Delete externally”.
The instrument skips the interval
pause after the first and second poor
analysis.
7
Normally open – closes in
case of 1 poor analysis,
remains closed until the next
good analysis
Normally open – closes for
90 s before the analysis
Continuous contact can be deleted
via key 4 (horn) or “Delete externally”
Measures continue despite mes-sage
via the relay K3.
8
Normally open – closes after
the 2 poor analyses for 1
minute
Normally open – closes after
the first poor analysis for 1
minute and after the second
poor analysis for 2 minutes
The instrument skips the interval
pause after the first poor analysis.
Measures continue despite mes-sage
via the relay K3.
9
Normally open – closes after
the 3 poor analyses for 1
minute
Normally open – closes after
the first poor analysis for 1
minute, after the second poor
analysis for 2 minutes and
after the third poor analysis for
3 minutes
The instrument skips the interval
pause after the first and second poor
analysis. Measures continue despite
mes-sage via the relay K3.
Updated: July 2013
25
* Delivery status
Commissioning
CAUTION
!
Commissioning
Handling reagents/indicators
Please adhere to the respective safety data sheet!
Trouble-free operation of Testomat® 808 is only guaranteed when
using Heyl Testomat® indicators!
Inserting the indicator bottle
Open the housing cover to access the housing.
Remove the cap from the indicator bottle.
The supplied plastic bag contains the blue screw cap with a hole
and the respective insert for the indicator bottle.
Caution! There are two inserts. One is for the 100 ml indicator bottle and the other one is for the 500 ml indicator bottle. The length
of the suction tube indicates which insert is for which bottle. Select
the insert that matches your indicator bottle. When inserted, the
suction tube should almost reach the bottom of the indicator bottle.
Place the insert into the indicator bottle.
Screw the blue screw cap with hole hand-tight onto the indica-
tor bottle.
Place the indicator bottle next to the water inlet in the housing.
Push the intake hose hand-tight onto the hose connector of the
insert.
Bleeding the indicator lines
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.
Opening the water inlet
Slowly open the manual stop valve in the water line to open the
water inlet.
26
Instrument settings and analysis
NOTE
NOTE
NOTE
Instrument settings and analysis
Please read the following information before carrying out the required
settings at the instrument.
Instrument settings
The required instrument settings for executing analyses, e.g. measuring interval pause, indicator bottle size and behaviour of relays K1
and K2, are carried out on the controller board using the function
keys and slide switches. Please refer to the section “Internal design
Testomat® 808” on page 16 for a detailed description.
Double assignment of the function keys
The four function keys at Testomat® 808 for instrument operation
basically have two functions.
A short or long key press (at least 2 seconds) is required for opera-
tion.
A short key press activates the top functional level (displayed in black
on the key). A long key press is required to activate the bottom key
function (displayed in white). Please refer to the section entitled
“Operating elements/Function keys” on page 10 for a description of
the individual functions.
Displaying operating statuses and measuring results
Only LEDs are used to display operating statuses and measuring
results at Testomat® 808.
Depending on the status or measuring result, the LEDs can either
flash or illuminate continuously (see the section entitled “Display
elements/LEDs” on page 11).
Limit value display
Testomat® 808 is a pure limit value measuring instrument
which uses two limit value LEDs to display the measuring
result.
The green LED illuminates when the limit value specified by the
selected indictor is not achieved during the analysis.
The red LED illuminates if the limit value is exceeded.
If a new measurement is running after completion of another
measurement, the result of the previous measurement flashes in the
display. The respective LED displaying the result of the previous
measurement illuminates continuously during the interval pause.
Both LEDs are switched off if an error occurred during the previous measurement.
27
Instrument settings and analysis
Indicator
Switch position
100 ml bottle
Left
500 ml bottle
Right
NOTE
NOTE
!
NOTE
NOTE
Selecting the indicator type and bottle size
Specifying the measuring/monitoring range of Testomat® 808
The measuring/monitoring range of Testomat® 808 is specified by
the selected indicator type only.
Please refer to the section entitled “Testomat® 808 spare parts and
accessories” on page 41 for a list of available indicators.
All listed indicator types are available in two bottle sizes. To specify
the size of the indicator bottle, move slide switch T2 on the rear of the
controller board to the respective switch position (see the section
entitled “Internal design Testomat® 808” on page 16):
Switch position
The status of slide switch T2 is read after resetting the indicator
display to 100% and after a reset.
Set indicator quantity to 100%
After selecting the bottle size and inserting the bottle, press key 4
(horn) to set the display for the indicator quantity to 100%.
Carrying out an analysis
After switching it on, the instrument commences automatic interval
mode. The first analysis starts after 15 seconds. The following analyses start automatically according to the set interval pause.
Duration of the interval pause
The duration of the interval pause between two measurements can
be set between 0 and 60 minutes, also see the section entitled
“Interval pause” on page 31.
Attention! After a poor analysis, the interval pause is ignored in
some switching positions of function key S6 (2/3/5/6/8 and 9) and
another analysis is carried out immediately.
28
Instrument settings and analysis
Operating
mode
Function/Process
Standby
The instrument is switched on and in standby.
Short press key 3 (standby) to switch standby
on/off.
Note: During an interval pause, the instrument
immediately switches to standby; a started analysis is always completed.
Manual
Precondition: The instrument is in standby or in an
interval pause.
Short press key 1 (manual) to switch on manual
mode.
An analysis is started immediately, irrespective of
the set interval pause.
Automatic interval mode can be interrupted via standby and analyses
started manually.
Analysis process
The analysis takes approx. 2 minutes. The water analysis process for
determining the residual total hardness is as follows:
Analysis start
The solenoid valve for water inlet opens
The measuring chamber is flushed
The solenoid valve closes after the flush time
The optical transmitter is switched on to measure possible
turbidity in the water
The measurement continues until the turbidity clears (the wa-
ter has been fully outgassed)
The measurement starts when the measured value is con-
stant
The dosing pump and stirring bar are activated
The current measured value is read
The colour change in the measuring chamber is evaluated
If necessary, switch relay, result is displayed
The measuring chamber is flushed
Analysis end
29
Further basic functions and settings
Pressure
Max. water quantity
per analysis
1 bar
80 ml
2 bar
120 ml
3 bar
160 ml
NOTE
Further basic functions and settings
Internal flushing
To ensure that the analysed sample represents the current value, the
sampling line must be sufficiently flushed.
Duration of the internal flush time
The duration of the internal flush time is preset (10 s before and
The quantity of flush water for internal flushing depends on the pressure:
after a measurement) and cannot be influenced by the operator.
External flushing
If a very long (approx. 3 – 10 metres) sampling line or a line with a
large diameter is used, install an external flush valve upstream of
Testomat® 808. Connect the external flush valve to the "Relay 1"
outlet.
Flush process – internal/external in manual mode
Proceed as follows to additionally flush the instrument:
At first switch the instrument into standby mode for flushing. Short
press key 3 (standby) to achieve this.
If a measurement is running, wait until the measurement has been
completed.
Internal flush process:
Short press key 2 (Flush) to open the internal flush valve.
The valve opens and the measuring chamber is flushed.
The LED above key 2 (Flush) flashes as long as the internal flush
valve is activated.
Short press key 2 (Flush) again to terminate the flush process.
30
Further basic functions and settings
Position
Interval pause
0
0 min.
1
5 min.
2
10 min.
3*
15 min.
4
20 min.
5
25 min.
6
30 min.
7
40 min.
8
50 min.
9
60 min.
NOTE
NOTE
External flush process:
Long press (approx. 2 seconds) key 2 (Flush) to activate the exter-
nal flush valve.
The external valve is activated via relay K1 and the line is flushed.
Long key press (approx. 2 seconds) key 2 (Flush) again to termi-
nate the external flush process.
The LED above key 2 (Flush) and LED K1 illuminate as long as the
external flush valve is activated.
Interval pause
If the analysis is started via a timer, the interval between two analyses (plus flush time) is determined by the interval pause. The shortest interval can be 0 minutes. In this case, analyses are carried out
continuously. The longest interval is 60 minutes.
Set the desired measuring interval pause via function key S6 on the
controller board (see the section entitled “Rear of the controller
board” on page 16). The following switching positions and interval
pauses are possible:
* Delivery status
Switch position
The current switch position is read after evaluating a measuring
result and after a reset.
Resetting the interval pause time
However, if the standby function has been activated and subse-
quently deactivated during an analysis pause, the interval pause
time is reset.
31
Error messages/Troubleshooting
72 h operation possible
72 h operation not possible
The LED above key 3 (standby)
illuminates for 4 seconds.
The LED above key 3 (standby)
flashes quickly for 4 seconds.
NOTE
72 h operation
(operation without permanent supervision)
If the instrument should run for a longer period of time without supervision (e.g. at the weekend), use this function to check whether sufficient indicator is available for a continuous measurement.
On the basis of the still available indicator, the set indicator pause
and indicator quantity consumed per measurement, the instrument
calculates whether the residual indicator quantity is sufficient for the
next 72 operating hours.
Press key 3 (standby) for approx. 2 seconds to check whether 72 h
operation is possible.
Error messages/Troubleshooting
Alarm/Error message/Relay K3
Testomat® 808 uses LEDs which either illuminate continuously or
flash to display alarm/error messages.
Error messages
All status/error messages are lost after a power failure!
Current error messages can be confirmed by pressing key 4 (horn)
briefly or via input DELETE EXT. (page 22).
We recommend you to carry out a manual analysis after an error
message to determine whether the error has been eliminated or
not. Further steps as described below.
If several consecutive faulty measurements have occurred, the
LED “POWER” lights and the LED above key 4 (horn) is blinking.
In this case press the reset key S1 or switch off/on the instrument
to acknowledge the alarm.
32
Error messages/Troubleshooting
LED
Cause
Flashes
Calculation shows that the indicator filling level is
zero
No or insufficient indicator in the measuring
chamber after dosing
Optical fault
The instrument is operated outside of the specifi-
cation (e.g. low temperature or with expired indicator)
Illuminates
Indicator filling level is between >0 and 10%
All other errors
Pause
5 mA
Good measurement
8 mA
Poor measurement
11 mA
Low water level
14 mA
Low indicator level < 10%
(acknowledgeable by pressing key 4)
17 mA
Indicator is empty (not acknowledgeable) or
optical fault or
no or insufficient indicator in the measuring
chamber or
the instrument is operated outside of the specification (e.g. low temperature or with expired indi-
cator)
20 mA
Activate the red alarm LED above key 4 (horn) as follows:
Error messages are output via the current interface. The following
status/error messages are possible:
33
Error messages/Troubleshooting
LED
Cause
Remedy
E4
Insufficient LED power, insufficient light (or hardware error)
Check whether the water is turbid. Strong turbidity can
negatively influence the measurement.
Check whether the measuring chamber/sight glass is
soiled.
The sensor or LED might be damaged.
Check whether the water level is too low.
Check whether the measuring chamber and the LED
fitting have been installed correctly. These elements
can loosen during transport. The measurement is no
longer being carried out correctly.
If necessary, carry out a visual adjustment as de-
scribed in the maintenance instructions for the Testomat® 808.
E3
Excessive LED power, excessive light (or hardware
error)
Close the housing cover. The environment is too bright
(sunlight), thus negatively influencing the measurement.
The sensor or LED might be damaged.
If necessary, carry out a visual adjustment as described
in the maintenance instructions for the Testomat® 808.
E2
Measuring fault analysis
Check whether the indicator bottle is empty.
Does the indicator display match the indicator quantity
in the bottle?
Check the indicator. Only use indicators which we
have approved for use in the Testomat® 808. Indicators
for other Testomat instruments produce erroneous
measurements or the error, “MST analysis”.
Check whether the stirring bar is present and turns.
Check whether the pump supplies indicator.
Check whether the dosing needle is blocked or its O-
ring is damaged. Make sure that the suction and pressure hoses do not draw secondary air. Check the suction lance. Make sure that no air bubbles are escaping
from the dosing needle.
E1
Low water level
Make sure the water lines are not leaky.
Are the water lines connected properly?
Are all stop valves in the inlet open?
Ensure there are no foreign particles which caused
blocking.
The individual errors can be displayed via the LEDs E1 to E4.
To do so, simultaneously press key 3 (standby) and key 4 (horn)
for approx. 2 seconds.
The following errors are displayed for 4 seconds:
34
Error messages/Troubleshooting
Error
Possible causes
Remedies
Instrument not functioning,
even though it is switched
on
Fuses F1, F2 or F3 defective
Power switch defective
Ribbon cable to controller board
or
base circuit board is loose
Error at controller board or base
circuit board
Replace fuses
Replace power switch
Reconnect ribbon cable
Replace controller or base cir-
cuit board
NOTE
Low water level
The LED above key 4 (horn) illuminates if the water level is low. The
low water level is also registered via relay K3. Contacts M and Ö are
connected for this purpose.
Press key 4 (horn) or close the contacts of the “Delete externally”
input to confirm the alarm.
After confirmation, the LED extinguishes via key 4 and relay K3 is
reactivated (contacts M and S are connected).
The alarm is also deleted without it being acknowledged once the low
water level has been eliminated after the following analysis.
Measuring fault analysis
The red alarm LED above key 4 (horn) illuminates if the calculated
indicator quantity is between >0 and 10%. This message is only
output once and can be acknowledged by short pressing key 4
(horn) at the instrument or a contact via “Delete externally”.
Both the red alarm LED and the standby LED (via key 3) flash
when the calculated indicator quantity is zero. The external inputs
“Stop” and “Delete externally” are ignored. You now have to re-
place the indicator bottle (see the section entitled “Replacing the
indicator bottle” on page 37).
The LED above key 4 (horn) flashes and the instrument goes into
standby mode if the measuring fault is due to lack of indicator.
Damaged or bent lines can cause this error. The indicator bottle
may also be empty if the indicator level has been set incorrectly.
35
Further possible instrument errors
Response of a protective circuit
After a protective circuit (fuse) has been tripped, attempt to eliminate
the cause of malfunctioning (e.g. replace a defective valve) before
reactivating the protective circuit. Frequent tripping is always due to
an error which, in certain circumstances, may also cause damage to
the instrument.
Maintenance
Component
Replacement interval
Pump head
if LED E4 flashes with “pump head mainte-
nance”
Check the system every 2 years with the pump
head maintenance set and change the head in
case of failure of calibration
NOTE
CAUTION
!
Scan the code to
download the latest
service manuals!
Malfunctioning/Repairing a defective instrument
The repair of a defective instrument – irrespective of the warranty
period - is only possible when the instrument is dismantled and returned to us with a description of the error. Please also inform us
about the currently used indicator.
Before you return the instrument for repair work, remove the bottle
and ensure that the measuring chamber has been flushed out and
is empty.
Insert a transportation plug into the outlet pipe to prevent leakage.
Use to the enclosed error log to describe the error and return it to
us together with the instrument. If the error log is no longer availa-
ble, download it at www.heyl.de.
Maintenance
Required maintenance measures
Regular maintenance is necessary to ensure trouble-free opera-
tion of the instrument (every six to twelve months)!
At least carry out the maintenance work described in the following
section on a regular basis when
the instrument displays the following error messages:
“Insufficient/Excessive light”, “Low water level” or “Low indicator
level”
the last maintenance was carried out no more than six months
ago.
Cleaning measures
Never use organic solvents to clean the measuring chamber or
other plastic parts! Use, e.g., cleaning spirit.
Always observe the safety regulations when handling cleaning
agents!
As a result of continuous operation, a coloured film may form on
the sight-glass windows. Use cleaning spirit to remove this sticky
film.
Replace the following components at the respective interval:
36
Maintenance
3 months
Semi-annually
Annually
Measuring
chamber for
cleanliness
and tightness
(see page 37)
check
check
check
NOTE
Service instructions
The surface of the instrument has not been treated. Therefore, avoid
any soiling caused by indicators, oil or grease. However, if the housing becomes soiled, please clean the surface with a commercial plastics cleaner (never use other solvents).
Description of maintenance work
Carry out the maintenance work described below on a regular basis.
Bleeding the lines
Bleed the lines after each mechanical step to ensure trouble-free
operation of the instrument. To achieve this, proceed as described
in the section entitled “Replacing the indicator bottle” on page 37!
Replacing the indicator bottle
If Testomat® 808 displays the error message “Low indicator level”,
replace the indicator bottle (refer to the section entitled “Error mes-
sages/Troubleshooting” on page 32) for information about error mes-
sages). Proceed as follows:
Put the instrument into standby mode. If a measuring process is
currently running, wait until it has been completed.
Proceed as follows to remove the empty indicator bottle: discon-
nect the intake hose from the hose connector at the top of the indi-
cator bottle and remove the empty bottle.
Insert the new indicator bottle as described in the section entitled
“Inserting the indicator bottle” on page 26.
Bleed the lines after inserting a new indicator bottle. To achieve
this, press key 1 (manual) for approx. 2 seconds. 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.
37
Maintenance
NOTE
CAUTION
!
Correct bottle size
Make sure that the correct indicator bottle size is set via slide
switch T2 (see the section entitled “Slide switch T2” on page 17)!
After bleeding the lines, press key 4 (horn) for approx. 2 seconds
to reset the internal analysis counter to 100%.
Resetting the analysis counter
Testomat® 808 automatically calculates the number of analyses depending on the set bottle size.
The instrument cannot measure the actual filling level of the indicator
bottle!
Only reset the analysis counter to 100% after inserting a new indi-
cator bottle!
Cleaning the measuring chamber and the sightglass windows
Switch off the instrument.
Close the stop valve in the branch line to Testomat® 808.
Prior to disassembling 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. Press down the top locking ring of the solenoid valve to al-
low the valve to be pushed down onto the support.
Turn the angled hose connector upwards. Press the locking
ring of the top angled hose connector upwards 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.
Disassemble the measuring chamber as follows for cleaning:
Loosen the 4 screws (7) of the measuring chamber cover (4) and
remove the cover and the flat seal (8).
Remove the dosing needle (5) from the measuring chamber.
Loosen 1 screw (6) on each side to remove the sight-glass window
holders (2) at the sides of the measuring chamber.
38
Maintenance
1 Measuring chamber (Article no 37615 (1-4bar)
or 37616 (0,3-1bar))
2 Sight-glass window holder (Article no. 40176)
3 Magnetic stirrer (Article no. 40050)
4 Measuring chamber cover (Article no. 37534)
5 Dosing needle (Article no. 37536)
6 Screw M3x40 (Article no. 33253)
7 Screw M3x12 (Article no. 33246)
8 Flat seal 24x2 (Article no. 33777)
9 Sight-glass window 30x3 (Article no. 40170)
10 Hose adapter (Article no. 37538)
11 Angled plug in connector (Article no. 40157)
12 O-ring 3.8x1.78 (Article no. 33797)
13 O-ring 4.5x1.5 (Article no. 11264)
14 O-ring 1.78x1.78 (Article no. 11245)
Push locking
ring upwards
Remove the sight-glass windows (9) and the respective flat seals
(8).
Use cleaning spirit to clean the film off the sight-glass windows. 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. In this case, clean the sight-glass windows
and the measuring chamber as described below.
Clean the measuring chamber with a cleaning agent suitable for
decalcification and rust removal (max. 5 – 10% solution). Flush the
measuring chamber thoroughly after cleaning.
Once the measuring chamber has been fully cleaned, it can be
reinstalled. Reassemble in reverse order to disassembly.
Once all assembly work has been completed, bleed the lines be-
fore restarting the instrument (see the section entitled “Inserting
the indicator bottle” on page 26).
39
Maintenance
NOTE
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 maintenance message for the pump head. This runtime for the pump will be
reached during normal operation (analysis interval every 10 minutes)
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
We recommend you to replace the pump head when the maintenance message for the pump head is displayed.
40
Testomat® 808 spare parts and accessories
Art. no.
Spare parts – measuring chamber
33777
Flat seal 24x2
40170
Sight-glass window 30x3
40176
Sight-glass window holder
33253
Screw M3x40, A2, DIN 965
33246
Screw M3x12
37615
Measuring chamber Testomat 808, complete
(1 – 4 bar)
37616
Measuring chamber Testomat 808, complete
(0.3 – 1 bar)
37534
Measuring chamber cover
37621
Dosing needle
40050
Magnetic stirrer, processed
40157
Angled plug-in connector G1/8“-6
33797
O-ring 2.8x1.78
11264
O-ring 4.5x1.5
11245
O-ring 1.78x1.78
Art. no.
Spare parts - instrument
32375
Optical board Testomat 808, complete
37322
Controller board Testomat 808, complete
37324
Base circuit board Testomat 808, complete
37568
LED holder Testomat 808, complete
37570
Solenoid valve Testomat 808
37578
Pump head Testomat 808
31592
Fuse, soldered T1.0A
31593
Fuse, soldered T0.8A
31584
Fuse, soldered T0.2A
31595
Fuse, soldered T0.1A
31666
Fuse GS-T, 5x20, T A4
40190
Cable gland 5-7, grey
40191
Cable gland 7-10, grey
40200
Cable loom compl. with power switch and cover
Art. no.
Bottle connection/Suction device
37579
Bottle insert for screw cap and push-fit suction
tube, 500 ml bottle
37580
Bottle insert for screw cap and push-fit suction
tube, 100 ml bottle
37538
Hose adapter Testomat 808
Caution!
Should you send your
Testomat 808 in for
maintenance, please
make sure that the
measuring chamber
has been emptied.
Testomat® 808 spare parts and accessories
41
Testomat® 808 spare parts and accessories
Art. no.
Special accessories
37583
Candle filter Testomat 808 complete
37584
Filter insert
37593
Plug D = 6
37576
Conversion set for water inlet and water outlet
from Testomat BOB to Testomat 808
37602
Pressure regulator, complete for Testomat
270342
Maintenance case Testomat 808*
270351
Service set Testomat 808*
Indica-
tor type
Colour change at a limit value of
Art. no.
100 ml
bottle
Art. no.
500 ml
bottle
300
0.02°dH = 0.4ppm CaCO3 = 0.04°f
residual hardness
140001
141001
300 S
0.05°dH = 0.9ppm CaCO3 = 0.09°f
residual hardness
140002
141002
301
0.1°dH = 1.8ppm CaCO3 = 0.18°f
residual hardness
140003
141003
302
0.2°dH = 3.6ppm CaCO3 = 0.36°f
residual hardness
140004
141004
303
0.3°dH = 5.4ppm CaCO3 = 0.54°f
residual hardness
140005
141005
305
0.5°dH = 9ppm CaCO3 = 0.9°f residual hardness
140006
141006
310
1°dH = 18ppm CaCO3 = 1.8°f residual hardness
140007
141007
320
2°dH = 36ppm CaCO3 = 3.6°f residual hardness
140008
141008
330
3°dH = 54ppm CaCO3 = 5.4°f residual hardness
140009
141009
NOTE
* Available from December 2013
Accessories - indicators
42
Please refer to our delivery programme for an up-to-date overview of
available accessories at www.heyl.de .
Bottle connection
Testomat® 808 is delivered with a bottle connection for a 500 ml bottle. Please order a bottle connection for a 100 ml bottle upon request.
Technical data
Power supply:
(24 / 115)* 230V, 50 – 60 Hz
Instrument protection 230 – 240 V: T0.1 A
Instrument protection: 115 V: T0.2 A
Instrument protection: 24 V: T0.8 A
Mains protection for
consumers:
max. 4 A (n , l)
Power consumption:
max. 16 VA, without external load
Protection class:
I
Degree of protection:
IP 54
Conformity:
EN 61000-6-2, EN 61000-6-4,
EN 61010-1
Ambient temperature:
10 - 40°C
Measuring range:
See the section entitled "Performance specifications"
Current interface:
Output of defined values (5, 8, 11, 14, 17,
20 mA) for displaying status and error messages, max. load 500 Ohms
Contact load
Relay
230V / 4A AC ohm resistive load
Dimensions:
W x H x D = 364 x 314 x 138 mm
Weight:
4,350 g
Mains water supply
Operating pressure:
0.3 – 1 bar / 0,3 x 105 to 4 x 105 Pa (use
measuring chamber with art. no. 37616!)
1 - 4 bar / 1 x 105 to 4 x 105 Pa depending
on design
(a pressure reducer (special accessories)
should be used from 4 to 8 bar range)
Water inlet:
Opaque hose with 6 mm external diameter/4 mm internal diameter
Water outlet:
Opaque hose with 6 mm external diameter/4 mm internal diameter
Water temperature:
10 to 40°C
Technical data
43
We reserve the right to make technical changes without notice in
the interest of constantly improving our products!
Technical data
EC conformity Declaration
44
Product overview Testomat 2000®-Instruments
Model/Type
Measuring Parameter
Measuring
Range
Applications/Functions
Testomat 2000®
• Water hardness
• Carbonate hard-
ness
• p-value
• minus-m-valuet
0.05-25 °dH
0,5-20 °dH
1-15 mmol/l
0.05-0.5 mmol/l
• Universal for water treatment
plants
• allowed for boiler houses
Testomat 2000® Antox
as
Testomat 2000®
as
Testomat 2000®
• dosing a reducing agent
Testomat 2000® CAL
as
Testomat 2000®
as
Testomat 2000®
• Automatic calibration function
Testomat 2000® CLF
• Free Chlorine
0-2.5 mg/l
• DPD-method for swimming
pool and drinking water control
Testomat 2000® CLT
• Total Chlorine
0-2.5 mg/l
• DPD-method for swimming
pool and drinking water control
Testomat 2000® CrVI
• Chromate
• Chrome-VI
0-2.0 mg/l
0-1.0 mg/l
• process control of waste water
in galvanic industry
Testomat 2000® Duo
as
Testomat 2000®
as
Testomat 2000®
• Controlling of two measuring
points
Testomat 2000
®
Fe
• Iron-II and Iron-III
0-1.0 mg/l
• De-Ironing plants
Testomat 2000
®
SO3
• Sulphite
0-20 mg/l
• Controll oft he Oxygen-binding
by Sulphite in boiler feed water
Testomat 2000
®
self clean
as
Testomat 2000®
as
Testomat 2000®
• Automatic cleaning oft he
measuring chamber
Testomat 2000 THCL®
• Total Chlorine
• Water hardness
0-2.5 mg/l
0.25-2.5 °dH
• DPD-method for swimming
pool and drinking water control
• combination system for hardness and chlorine
Testomat 2000
®
V
• Water hardness
• Carbonate
hardness
1.0-25.0 °dH
1.0-20.0 °dH
• blending water
Product overview Testomat 2000®Instruments
45
Gebrüder Heyl
Analysentechnik GmbH & Co. KG
Orleansstraße 75b
D 31135 Hildesheim
www.heyl.de
Testomat_808_GB_131024.doc
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