Testomat 808 Operating Instructions Manual Download

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Technical data

EC conformity Declaration

Summary of Contents for 808

Page 1: ...1 Testomat 808 Online Analysis Instrument for Water Hardness Operating Instructions ...

Page 2: ...mat 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 Fu...

Page 3: ... 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 Se...

Page 4: ...re 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 i...

Page 5: ...uation 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 Notes and instructions to be ob served General instructions Adhere to health and safety regulations electrical equipment safe ty regulations and environmental protection regulations valid...

Page 6: ...pacity 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 dow...

Page 7: ...ment 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 h...

Page 8: ...ace 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 Indicator type Monitoring range Limit value LEDs good poor display Measuring result information on water quality 300 330 Residual hard ness 0 02 10 dH GOOD green Residual hardness indicator ...

Page 9: ... 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 over loads and short circuits DPlease refer to the sections entitled Fuses on page 19 and Error messages Troubleshooting on page 32 for desc...

Page 10: ...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 ac tive Long key press The respective LED displays wheth er operation...

Page 11: ...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 pres...

Page 12: ...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 positi...

Page 13: ...oblems 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 ex...

Page 14: ...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 install...

Page 15: ...Installation 15 Plant example Testomat 808 ...

Page 16: ...1 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 paus es The standard setting is 3 Function key S7 Use function key S7 to set the switching behav...

Page 17: ...tion 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 bot tle The following indicator bottle sizes are possible Indicator Switch position 100 ml bottle Left 500 ml bottle Right Switch position The status of the slide switch T2 is read after resetting the indicator display to 100 and after a reset Plug connecto...

Page 18: ...ircuit board 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 de scription of the current interface ...

Page 19: ...e 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 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 Please refer to the section entitled Testomat 808 spare parts and accessories on page 4...

Page 20: ...rneath 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...

Page 21: ...two fastening screws to close the door once installation has been completed Terminal description Type Function Comment RELAY 3 OUT Fault message output change over 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...

Page 22: ...ection 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 ...

Page 23: ...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 analy...

Page 24: ...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 a...

Page 25: ...rm has been deleted Instrument goes into standby Con tinuous contact can be deleted via key 4 horn or Delete externally 5 Normally open closes after 2 poor analyses and re mains closed Opens again once the alarm has been deleted Normally open closes after the first poor analysis for 1 minute Instrument goes into standby Con tinuous contact can be deleted via key 4 horn or Delete externally The ins...

Page 26: ...cator 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 ...

Page 27: ...ease 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 elemen...

Page 28: ...le Right 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 st...

Page 29: ...set interval pause 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...

Page 30: ... 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...

Page 31: ... est 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 Position Interval pause 0 0 min 1 5 min 2 10 min 3 15 min 4 20 min...

Page 32: ... not possible The LED above key 3 standby illuminates for 4 seconds The LED above key 3 standby flashes quickly for 4 seconds 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 b...

Page 33: ...cator Illuminates Indicator filling level is between 0 and 10 All other errors Error messages are output via the current interface The following status error messages are possible 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 i...

Page 34: ...e housing cover The environment is too bright sunlight thus negatively influencing the measure ment 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 indi...

Page 35: ...nal 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 be...

Page 36: ... 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 cham...

Page 37: ...ator 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 bot...

Page 38: ...f 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...

Page 39: ... 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 decalci...

Page 40: ...or 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 mainte nance message for the pum...

Page 41: ...ard 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 ...

Page 42: ...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 re sidual hardness 140006 141006 310 1 dH 18ppm CaCO3 1 8 f re sidual hardness 140007 141007 320 2 dH 36ppm CaCO3 3 6...

Page 43: ... 17 20 mA for displaying status and error mes sages 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 10 5 to 4 x 10 5 Pa use measuring chamber with art no 37616 1 4 bar 1 x 10 5 to 4 x 10 5 Pa depending on design a pressure reducer special accessories should be used from 4...

Page 44: ...Technical data 44 EC conformity Declaration ...

Page 45: ...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 o...

Page 46: ...46 Gebrüder Heyl Analysentechnik GmbH Co KG Orleansstraße 75b D 31135 Hildesheim www heyl de Testomat_808_GB_131024 doc Scan the code and visit us on our website ...

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