Testomat 808 Manuel utilisateur

Testomat® 808

Online Analysis Instrument

for Water Hardness

Operating Instructions

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

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

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 treat-

ment (e.g. osmosis plants, electroplating, large boiler plants, laun-

dries, 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 respec-

tive technical terms. Assembly and commissioning should therefore

only be carried out by a specialist or by an authorised individual su-

pervised by a specialist.

A specialist is someone who due to his/her technical training, know-

how and experience as well as knowledge of relevant regulations can

assess assigned tasks, recognise potential hazards and ensure ap-

propriate safety measures. A specialist should always adhere to the

relevant technical regulations.

Notes and instructions to be observed

Warning notices in these instructions

The warning notices in these instructions warn the user about poten-

tial dangers to individuals and property resulting from incorrect han-

dling of the instrument. The warning notices are structured as follows:

Description of the type or source of danger

Description of the consequences resulting from non-observance

Preventive measures. Always adhere to these preventive

measures.

“DANGER” indicates an immediate hazardous situation which, if not

avoided, will result in death or serious injury.

“WARNING” indicates a potentially hazardous situation which, if not

avoided, could result in death or serious injury.

“CAUTION” indicates a potentially hazardous situation which, if not

avoided, could result in minor or moderate injuries or property dam-

age.

“NOTE” indicates important information. If this information is not ob-

served, it may result in an undesirable result or state.

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 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;

failure to adhere to

these instructions will negatively affect any warranty claims that

you make thereafter

WARNING

NOTE

CAUTION

DANGER

SIGNAL WORD!

Notes and instructions to be observed

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 availa-

ble, download it at www.heyl.de.

Disposal

Dispose of the instrument in accordance with national regulations.

WARNING

NOTE

Scope of delivery

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 influ-

ence 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 col-

our 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.

NOTE

CAUTION

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.

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 limit

value

“POOR” red

Residual hardness > indicator limit

value

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.

Functions of the operating and display elements

Functions of the operating and dis-

play elements

Operating statuses and measuring results are displayed at Testomat®

808 via LEDs. The input keys for operating the instrument are posi-

tioned 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 over-

loads 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

Functions of the operating and display elements

Operating elements/Function keys

All operating elements/function keys are assigned twice. The respec-

tive function is triggered by a short or long (min. 2 seconds) key

press.

Key 1

(manual)

Short key press: Starts an analysis (manual start),

the respective LED flashes.

Long key press: Switches the dosing pump for bleed-

ing 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 ac-

tive.

Long key press: The respective LED displays wheth-

er operation is possible for longer than 72 h (opera-

tion without supervision).

Key 4 (horn)

Short key press: Acknowledges current er-

rors/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.

* only in standby mode

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