Endress+Hauser Stamolys CA71CODcr Operating Instructions Manual Download | Manualshive

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Safety instructions

Stamolys CA71CODcr

4

Hauser

1

Safety instructions

1.1

Designated use

The analyzer is a compact photometric analysis system.

In particular, CA71 is designated for:
• Monitoring sewage treatment plant outlets
• Monitoring the sewage treatment plant inlet
• Monitoring of industrial wastewater
• Monitoring the discharge of industrial wastewater

Any other use than the one described here compromises the safety of persons and the entire
measuring system and is not permitted.
The manufacturer is not liable for damage caused by improper or non-designated use.

1.2

Installation, commissioning and operation

Please note the following items:
• Installation, commissioning, operation and maintenance of the measuring system must only be

carried out by trained technical personnel.
Trained personnel must be authorized for the specified activities by the system operator.

• Electrical connection must only be carried out by a certified electrician.
• Technical personnel must have read and understood these Operating Instructions and must

adhere to them.

• Before commissioning the entire measuring point, check all the connections. Ensure that

electrical cables and hose connections are not damaged.

• Do not operate damaged products and secure them against unintentional commissioning.

Mark the damaged product as being defective.

• Measuring point faults may only be rectified by authorized and specially trained personnel.
• If faults can not be rectified, the products must be taken out of service and secured against

unintentional commissioning.

• Repairs not described in these Operating Instructions may only be carried out at the

manufacturer’s or by the service organization.

1.3

Operational safety

The analyzer has been designed and tested to the highest standards and left the factory in perfect
functioning order.
Relevant regulations and European standards have been met.

As the user, you are responsible for complying with the following safety conditions:
• Installation instructions
• Local prevailing standards and regulations.

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Summary of Contents for Stamolys CA71CODcr

Page 1: ...C 07 EN 14 12 71162867 Valid of Software version 01 03 06 Operating Instructions Stamolys CA71CODcr Photometric analytical system for determining the chemical oxygen demand following the DIN dichromate method ...

Page 2: ...r hose inlet from canister with 0 mg l O2 standard a0012419 Fig 1 Analyzer cabinet version without hoses 1 2 3 4 5 6 Reagent pump P2 inlet from canister Display and temperature indicator Serial interface RS 232 Reactor unit Valve V4 Cover broken open in the graphic 7 8 9 10 11 12 Rinse outputs wastewater chromate waste overflow Reagents standard Valve V3 Valve V2 Valve V1 Sample and sulfuric acid ...

Page 3: ...ation 22 5 3 Timers version with back flush pump only 28 5 4 Modbus RS485 optional 29 5 5 Calibration 30 6 Commissioning 31 6 1 Function check 31 6 2 Switch on 31 7 Maintenance 34 7 1 Maintenance schedule 34 7 2 Replacing reagents 34 7 3 Replacing pump hoses 36 7 4 Setting the hose cases 38 7 5 Replacing valve hoses 39 7 6 Cleaning 40 7 7 Placing out of service 41 8 Accessories 42 8 1 Collecting v...

Page 4: ...e carried out by a certified electrician Technical personnel must have read and understood these Operating Instructions and must adhere to them Before commissioning the entire measuring point check all the connections Ensure that electrical cables and hose connections are not damaged Do not operate damaged products and secure them against unintentional commissioning Mark the damaged product as bei...

Page 5: ...symbol alerts you to a dangerous situation Failure to avoid the situation can result in a fatal or serious injury CAUTION Cause consequences Consequences if safety message is not heeded Corrective action This symbol alerts you to a dangerous situation Failure to avoid this situation can result in minor or medium injury NOTICE Cause situation Consequences if safety message is not heeded Action note...

Page 6: ...prises an analyzer with mains plug 4 fastening clips a cleaning injector a tube of silicone grease a NORPREN hose length 2 5 m 8 2 ft ID 1 6 mm 1 16 inch a C FLEX hose length 2 5 m 8 2 ft ID 3 2 mm 1 8 inch a PVC hose length 2 5 m 8 2 ft ID 10 mm 0 39 inch two hose fittings of each size 1 6 mm x 1 6 mm 1 16 inch x 1 16 inch 3 2 mm x 1 6 mm 1 8 inch x 1 16 inch a hose fitting 3 2 mm x 1 6 mm 1 8 in...

Page 7: ...onized European standards It thus complies with the legal requirements of the EC directives The manufacturer confirms successful testing of the product by affixing the 4 symbol 2 3 2 Manufacturer certificate Quality certificate With the certificate the manufacturer confirms compliance with all technical regulations and the successful testing individually for your product ...

Page 8: ...ction Also keep to the approved ambient conditions see Technical data If you have any questions please contact your supplier or your local sales center 3 2 Installation conditions 3 2 1 Design dimensions a0001355 Fig 2 GFR version NOTICE Sufficient space and backwater in the outflow hose Allow at least 400 mm 16 under the housing as space for the waste collecting tank On the left hand side of the ...

Page 9: ...ng only 4 Lay the drain pipe for the reaction products Where possible use solid pipes PE internal diameter 1 with 3 incline 5 Route the drain hoses through the device floor to the outside a0016672 Fig 3 Collecting vessel 1 Connection for level measurement 2 Ventilation 3 Sample supply to analyzer connection for hose with ID3 2mm 0 13 4 Connecting cable of electric agitator 5 Sample supply connecti...

Page 10: ...acid pump left rear position reagent pump right center position The direction of flow of the sample and reagent must be counterclockwise 10 Connect the sample supply For questions regarding sample conditioning and its automation please contact Service or the sales center responsible for your region 11 Connect the tubes from canisters containing reagents andstandards to the following nozzles a00124...

Page 11: ...r 2 Connect the hoses for sample intake sample supply to analyzer and sample overflow to the appropriate hose connections å 3 Connection of the level measurement unit and agitator ä 19 3 3 3 Back flush pump optional Install the back flush pump unit to the analyzer s side as shown in diagram Use the couplings shipped with the instrument a0017247 Fig 8 Installation of the back flush pump ...

Page 12: ...measuring system comprises a sample pump with backwash function an agitated collecting vessel a CA71CODcr analyzer a0013925 Fig 9 Complete measuring system 1 2 3 4 Backwash filter Compressor or compressed air Sampling pump or sample pressure line Sample outlet 5 6 7 8 Collecting vessel optional Overflow Analyzer Sample line to the analyzer a0016626 1 Fig 10 Complete measuring system 1 2 3 Pump wit...

Page 13: ...llation Endress Hauser 13 3 5 Post installation check After installation check that all connections are fitted tightly and are leakage resistant Ensure that the hoses cannot be removed without effort Check all hoses for damage ...

Page 14: ...d avoiding damage You have to fold out the frame of the analyzer to reach the terminal block After folding the frame into position check that all the tubes are properly secured and fit properly into the bottles as otherwise there is a risk of flooding or incorrect measurement Fold out the frame as follows 1 Release the two bottom Allen screws AF 6 by 3 4 rotations å 11 item 1 2 Unscrew the two upp...

Page 15: ...ssignment and colors Only use the terminal assignment of the sticker in the device å 13 to connect your analyzer a0012456 Fig 12 Example of the connection sticker a0017149 Fig 13 Analyzer from top open version resp folded out 1 Connection department sticker 2 Printed circuit board with terminal strip 3 Backside of the analyzer 4 Connection department sticker Modbus RS485 optional ...

Page 16: ...OM 28 NC 27 NO 26 Fault COM 19 NC 18 NO 17 Reserve unassigned terminals COM 22 NC 21 NO 20 Analog output 1 0 4 20 mA 36 35 Screen PE1 Sample conditioning remote control Input 57 0 V 53 Function Designation Terminal one channel Mains L 3 N 2 PE1 1 Alarm value 1 COM 25 NC 24 NO 23 Alarm value 2 COM 28 NC 27 NO 26 Fault COM 19 NC 18 NO 17 Reserve unassigned terminals COM 22 NC 21 NO 20 Analog output ...

Page 17: ... 2 1 Screening of the analog outputs The interference suppressor attenuates electromagnetic effects on control power and signal lines After the connection of the data transfer cables clip the interference suppressor in scope of delivery on the cable cores not on the outer insulation of the cable Place the cable screen out of the interference suppressor and connect it to PE brass screw with bolt to...

Page 18: ...s error message using operation menu Measurement end Displays Measurement finished 5 s Analog output l 1 channel 1 0 or 4 mA measuring range start 20 mA measuring range end Connection Terminal connection for condition fulfilled Terminal connection for condition not fulfilled Terminal connection for power off AV 1 A R 25 25 23 24 A R 25 25 24 23 25 24 AV 2 A R 28 28 26 27 A R 28 28 27 26 28 27 Faul...

Page 19: ...C in order to read out data D Data memory Measured values C Data memory Calibration factors S Setup parameter entry configuration F Frequency current 4 5 Connection of the sampling vessel 1 De energize the analyzer 2 Fold out the analyzer frame å 11 3 Guide the cable of the level measurement into the analyzer and connect the terminals as follows Black electric line BK to terminal no 58 Yellow elec...

Page 20: ... the restriction that you measure the current values at the terminals of the analyser and not at the PLC SPL or data logger If these current values are correct please check your PLC SPL the data logger or the electrical cables Device status and specifications Note Is the analyser or cable externally undamaged Visual inspection Electrical connection Note Does the supply voltage correspond to the da...

Page 21: ...D measured value 2 LC display status 3 Serial interface RS 232 4 Operating keys and control LEDs 5 Display of the heating element 5 1 2 Timers for the back flush pump function The back flush pump of the sample preparation is controlled by two multi function timers The timers are already installed and wired up at the factory a0017248 Fig 16 Timers of the back flush pump ...

Page 22: ...value Measuring range undershot F select option adopt value forwards in the sub menu horizontal 1 1 By pressing the V or W and the F key simultaneously you can set the digit after the decimal point Retrieve error message J selection in the sub menu Cleaning interval is running Selection Display Info AUTO MEASURING Calibration measurement time controlled actions PARAMETER ENTRY Default settings for...

Page 23: ...gh the menu third last point In the event of a reset the date for the 1st calibration and the 1st flush is set to the following day Measuring unit mg l O2 The measuring unit selected depends on the type of photometer This setting also affects the scope of the measuring range no selection Calibrate slope yes no Manual calibration Use the K key to start measuring the standard solution to determine t...

Page 24: ...measuring range scope If the concentration measuring range 0 to x mg l O2 either 4 mA or 0 mA corresponds to 0 mg l The end of the measuring range is the same in both cases at 20 mA Alarm value AV 1 NO NC Changes only take effect after a reset power off on Setting as to whether the contact for alarm value 1 works as an NO or NC contact Alarm value AV 2 Setting as to whether the contact for alarm v...

Page 25: ...in to 1440 min 2 min Time between two measurements If the setting is 2 minutes the measurements take place without any pauses Time 1 calibration 01 01 96 00 00 to 31 12 95 23 59 Time of 1st calibration DD MM YY time hh mm After each change the instrument does not wait for the calibration interval If the calibration is to start immediately set the time in the past Analyzers are delivered pre calibr...

Page 26: ...rror which occurred previously no longer exists it is automatically cancelled 5 2 7 MAINTENANCE Menu item Display Info Empty reactor Starts a process of cooling draining and rinsing the reactor so you can perform maintenance work on the reactor assembly without any safety hazards Also empty the reactor before replacing the hoses to remove the acid from the pump hose Tank fill level read only Displ...

Page 27: ... Display Info Pumps and valves Virtual switching board Various valve and pump combinations can be selected The setting options are Valve 1 and Valve 5 P sample rinse water outlet or S standard chromate waste outlet Valve 2 S standard or 0 standard 0 mg l O2 Valve 3 P sample or H acid Valve 4 to empty the reactor c closed or o open Pump 1 sample or standard standard 0 mg l O2 and pump 2 reagents s ...

Page 28: ... is delivered from the factory However you might need to alter the settings if the process conditions change or a timer has to be replaced 5 3 1 Time range The correct time range for the switch on and switch off time is between 1 and 9999 seconds It is normally set at the factory and should not be changed To change the time ranges you first have to remove the timer Selection Display Info Measured ...

Page 29: ...OCK message on the display must disappear If you now simultaneously press the SET LOCK button and the second rocker switch from the right Pu c must appear on the display for approx 2 seconds If another message appears please simultaneously press the SET LOCK button and the rocker switch on the far right Then release both buttons Now press the rocker switch on the far right until Pu c appears on th...

Page 30: ...requency offset is displayed in Hertz 5 Use K to go to the Calibrate Slope item and press J to confirm Once the standard calibration has been performed the current calibration factor is displayed 6 Press H to return to the main menu AUTO MEASURING 7 Press F for the measuring mode Calibration example 2 Automatic calibration This consists of two offset measurements and a calibration of the K factor ...

Page 31: ...of measurement with a cold analyzer new hoses longer interruption of the measurement or variable measurement cycles the first measuring results will be errored The reaction is temperature dependent and if the temperature is too low the predefined reaction time is insufficient for a complete reaction For this reason never carry out calibration with a cold analyzer Wait for two or three measurements...

Page 32: ...This removes any residues of standard or 0 mg l O2 standard Then switch P1 off m Empty the reactor V1 P V4 o 7 With H you can return to the main menu The analyzer starts automatically triggered by a control signal or integrated timer with the Measurement procedures with your device parameters 1st measurement and the respective intervals control the procedure 6 2 1 Switching times setting version w...

Page 33: ...ontacts of the level measurement 3 Set twice that measured time as the new value for t1 4 Set any value from 1 to 3 minutes for the pause interval t2 at the timer on the right Set the value for the back flush period timer on the left Backflush 1 Set the time t1 to any value from 1 to 3 minutes 2 Calculate the time t2 from the values set before t2 Backflush t1 Forward t2 Forward t1 Backflush 3 Set ...

Page 34: ... safety data sheets when handling reagents or cleaning solutions Wear protective clothing gloves and goggles Wear protective clothing gloves and goggles Never add water to reagents Reagents containing acids may splash and heat may build up If you store the reagents correctly in the dark not over 20 C they will be stable for minimum 12 weeks from the date of manufacture batch number When this perio...

Page 35: ...m the canisters and wipe them with a clean and dry paper towel Wear protective gloves when doing this 2 In the Service menu first switch valve V1 to S and valve 4 to s This ensures that the liquids required in the subsequent steps can flow out of the reactor 3 Switch on the reagent pump for about 5 seconds for the hoses to be drained 4 Switch valve V3 to H and the sample and acid pump P1 to g for ...

Page 36: ...n If the hose elasticity becomes too low and the pump rate is no longer reproducible it is necessary to replace the hoses Removing the old hoses 1 Remove the reagent hoses from the reagent canisters in order to prevent contamination of the reagents 2 Flush the old hoses with water first and then with air to empty them see SERVICE 3 Remove the hoses from the nipples of the valve block 4 Release the...

Page 37: ... 3 First pull the hose downwards at both ends and then push the guide on the hose into that of the nipple on the hose box Make sure it is seated correctly 4 First place the hose box into the upper retainer item 2 of the pump and then press the box into the lower retainer item 3 5 Reconnect the reagent hoses to the canisters and the valve block 6 After installation refill the hoses with sample stan...

Page 38: ...icone grease 3 Attach the safety cover again and fix it by the screws 1 to 3 4 Energize the back flush pump 7 4 Setting the hose cases The analyzer is supplied with preset hose cases You must only reset these cases if you discover that little or no medium is pumped after a hose has been replaced 1 Place a beaker with distilled into the device and place the hoses for sample and reagent R2 into the ...

Page 39: ...pty them see SERVICE 2 Remove the hoses from the valves a You can disconnect the front hoses directly because the valves are open when de energised b To remove the back hoses press the black button on the valve and disconnect the hoses 3 Grease the new hoses with silicone grease before inserting them 4 Install the new valve hoses in the reverse sequence of operations Ensure that the hoses are conn...

Page 40: ...mat is at the backside of the analyzer center top 1 Remove the cover to replace the filter mat 2 To clean the filter mat you have various options a Wash the filter mat in water approx 40 C with a mild detergent if necessary b Alternatively you can beat or vacuum the mat or blow it with compressed air c In case of greasy substances Wash the filter mat in benzine trichlorethylene or warm water with ...

Page 41: ...on for 3 min see Service section in Operation chapter 4 Empty the reactor by switching the valves to passage for chromate containing waste V1 S V4 a Close aagin the valve V1 P V4 z 5 Switch successively a V1 P V2 S V3 H and pump P1 on for 1 min b V1 S V2 S V3 P and pump P1 on for 1 min c V1 S V2 O V3 P and pump P1 on for 1 min d V1 P V2 S V3 P and pump P1 on for 1 min 6 Remove the hoses from the w...

Page 42: ...he safety data sheets of the reagents Reagent set for CA71COD A Order no CAY440 V10AAE 250 ml 8 45 fl oz dichromate solution 4 x 1 l 34 fl oz H2SO4 Dichromate decontamination reagent Order no CAY440 V20AAE 250 ml 8 45 fl oz dichromate solution 2 x 2 5 l 85 fl oz H2SO4 Dichromate decontamination reagent Reagent set for CA71COD B Order no CAY441 V10AAE 250 ml 8 45 fl oz dichromate solution 4 x 1 l 3...

Page 43: ... 6 mm 1 16 a NORPRENE hose ID 1 6 mm 1 16 3 hose fittings 1 6 x 1 6 mm 1 16 x 1 16 2 reduction fittings PP 4 glands with nozzle PTFE 2 hose cases a hose extension tool a tube of silicone grease 2 g a cleaning injector 20 ml Order no 71102950 8 4 Additional accessories Interference suppressor for control power and signal lines order no 51512800 Silicon grease tube 35 g order no 71017654 ...

Page 44: ...filter Wrong optical cell Incorrect photometer Check the setting in the CONFIGURATION menu Photometer Sample collector empty No sample Establish sample transfer Level measurement defective Check level measurement at the sample collector Spillage error Leak at canisters or hoses Replace defective components and clean and dry the analyzer or those components affected by the leak No measuring signal ...

Page 45: ...e a counter sample at the analyzer inlet and check the concentration in the laboratory If there is no deviation to the analyzer measured values replace the ultrafiltration modules or reversible flow filters more frequently System blocked or contaminated Flush with 12 5 bleaching lye monthly maintenance Dosing Replace pump hoses Cell dirty First clean with 2 ammonium hydroxide solution and then rin...

Page 46: ...ssible cause Tests and or corrective measures a0012420 A B C D E F Sample input Standard and reagent canister tray Collecting vessel Outlet air Compressed air supply Composite container for chromate waste G P S H2O H2SO4 K2Cr2O7 Wastewater Sample Standard solution canister 100 or 2500 mg l O2 Standard 0 mg l O2 canister Sulfuric acid canister R1 Dichromate solution canister R2 Item Spare part Orde...

Page 47: ...e item 240 1 C Flex hose ID 1 6 mm item 230 1 Norprene A hose ID 1 6 mm item 232 1 pack of hose connectors item 260 261 262 264 1 tube of silicone grease 1 cleaning injector 71102950 220 222 Kit CA71COD hose set 1 PTFE hose ID 1 6 mm item 221 1 PTFE hose ID 4 0 mm item 222 1 PFA hose ID 0 8 mm item 220 71103284 250 263 Kit CA71COD hose connectors item 250 251 253 254 262 263 71103286 F Kit CA71COD...

Page 48: ...ns sample residue and acid Reagent waste must be disposed of correctly Your local sales office will be happy to assist in the correct disposal of reagent waste Observe local regulations The device contains electronic components and must therefore be disposed of in accordance with regulations on the disposal of electronic waste Please observe local regulations ...

Page 49: ...odbus RS485 optional Signal on alarm Contacts 2 limit contacts per channel 1 system alarm contact Load max 300 Load capacity 230 V AC max 2 A Serial interface RS232 C Modbus RS485 optional Data logger 1024 data pairs with date time and measured value 100 data pairs with date time and measured value for calibration factor determination diagnostic tool Signal coding EIA TIA 485 Data transmission rat...

Page 50: ...asuring interval tmes 150 min factory setting shorter digestion times can be set Sample requirement 54 ml 1 82 fl oz per measurement Reagent requirement 250 ml 8 45 fl oz of dichromate solution 4 l 1 06 US gal of H2SO4 for 60 days with a digestion time of 2 h Calibration interval 0 to 720 h Maintenance interval 1 week typical Servicing requirement 15 minutes per week typical Protocol RTU Function ...

Page 51: ...y possible with protective devices customer supplied Ingress protection IP 43 10 7 Process Sample temperature 5 to 40 C 40 to 100 F Sample flow rate min 5 ml 0 17 fl oz per min Consistency of the sample aqueous and homogenized Sample inlet Unpressurized 10 8 Mechanical construction Design dimensions see chapter Installation Weight approx 32 kg 71 lbs Material Housing Front windows Endless hose Pum...

Page 52: ...Appendix Stamolys CA71CODcr 52 Endress Hauser 11 Appendix 11 1 Operating matrix a0012416 en ...

Page 53: ...Stamolys CA71CODcr Appendix Endress Hauser 53 a0012417 en ...

Page 54: ...rocess errors 45 System errors 44 F Filter mat 40 Frequency offset 24 G Grenzwerte 24 H Hose case 38 Housing fan 40 I Icons 5 Incoming acceptance 8 Input 49 Installation 4 8 13 51 Safety instructions 4 Installation examples 12 Interference suppressor 17 L LANGUAGE 26 M Main menu 22 MAINTENANCE 26 Maintenance 34 Schedule 34 Maintenance kit 43 Measuring unit 23 Mechanical construction 51 Menu Auto M...

Page 55: ...terface 18 SERVICE 27 Signal connection 17 Software history 47 Spare parts 46 Standard solution 42 Storage 8 Switching contacts 18 Switch on 31 Symbols 5 T Technical data 49 Environment 51 Input 49 Installation 51 Mechanical construction 51 Output 49 Performance characteristics 50 Power supply 50 Process 51 Terminal assignment 15 Timer settings 32 Timers 28 Timers of the back flush pump 28 Transpo...

Page 56: ...BA00458C 07 EN 14 12 FM9 ...

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