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Section 6

Maintenance

The manufacturer recommends taking out a service contract. This contract
extends the warranty to 5 years and ensures that all inspection and maintenance
work is performed by qualified personnel.

The maintenance to be performed by the user is then limited to regular visual
inspections, replacing consumables and cleaning, if necessary.

6.1 Maintenance work

The reliable and correct operation of this sample conditioning system can only be
ensured if the maintenance work is performed regularly as per the maintenance
calendar.

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Summary of Contents for Filtrax

Page 1: ...DOC023 52 03045 FILTRAX User Manual 02 2015 Edition 4 HACH LANGE GmbH 2003 2010 2012 2015 All rights reserved Printed in Germany ...

Page 2: ......

Page 3: ...ng tubes 20 3 4 Electrical connections 25 3 5 Connection to process instruments 27 Section 4 Commissioning 30 4 1 Placing instrument in operation 30 4 2 Taking instrument out of operation 32 4 2 1 Filter modules 32 4 2 2 Control unit 32 Section 5 Operation 34 5 1 Using the keypad 34 5 2 Menu overview 35 5 3 DEVICEDATA menu 36 5 4 SIGNALS menu 37 5 5 OP COUNTERS menu 38 5 6 SERVICE menu 39 Section ...

Page 4: ...2 Contents Section 8 Spare parts 51 Section 9 Warranty and liability 53 Section 10 Contact 55 ...

Page 5: ...Warning contact floating contact 230 V max 3 A Service interface RS 232 Cable length Suction tube 5 m heated Sample tube 2 m unheated Sample tube 10 m heated 20 m heated 30 m heated User maintenance approx 1h month Medium temperature 5 C to 40 C Ambient temperature 20 C to 40 C Enclosure rating IP 55 Fuses T 4A E 250V 2 T 7A E 250V 2 Mass Control unit approx 22 kg Module carrier with 5 m suction t...

Page 6: ...4 Technical data ...

Page 7: ...hazardous situation which if not avoided could result in death or serious injury CAUTION Indicates a potentially hazardous situation that may result in minor or moderate injury NOTICE Indicates a situation which if not avoided may cause damage to the instrument Information that requires special emphasis This is the safety alert symbol Obey all safety messages that follow this symbol to avoid poten...

Page 8: ...ide the control unit draw the sample alternately from the two filter modules using a common 5 m long heated suction tube to the control unit that is installed in close proximity to the sampling point From there the sample is pumped 2 m 10 m 20 m or 30 m depending on the sample tube connected to the process instruments A venting device 5 underneath the filter modules largely prevents the adhesion o...

Page 9: ...tificate 3 Sample tube 2 m 10 m 20 m 30 m 11 DOC273 xx 04006 Maintenance calendar 4 LZX677 Filter module 2 Included in accessory set LZX702 12 Mounting bracket for sample tube 13 Blanking plugs 2 sealing rings 2 14 HLS191 2 4 tube 6 m 15 Cleaning sponge 16 Clip 5 EYV017 Plastic bag for filter module 4 6 Cable gland M20 x 1 5 2 7 LZX702 Accessory set 8 LZX701 Tube adapter set ...

Page 10: ...ening 5 Air filter cover air outlet 6 Door lock 2 Connection for equipotential bonding 7 Green and red signal lamps 3 Air filter cover air inlet 8 Sample tube connection right or underneath on the right Blanking plugs and sealing ring for the unused opening 4 Cable gland for electrical connecting cable 2 1 Module carrier 4 Sample suction tube 3 2 mm OD 2 2 Suction tube 5 m 5 Connecting cable for t...

Page 11: ...ened the filter membranes must not be allowed to dry out again and are sealed in a plastic bag for protection 1 Sample tube 2 m 23 mm 0 91 inch not heated 4 Sample pressure tube 3 2 mm OD 2 Sample pressure tube 3 2 mm OD 5 Connecting cable for the tube heater 3 Sample tube 10 m 20 m 30 m 23 mm 0 91 inch heated NOTICE The surface of the membrane is very delicate ...

Page 12: ...10 General information Fig 2 6 Filter module ...

Page 13: ...s connect a surge arrester between the mains and the system Products intended by the manufacturer for outdoor use offer a higher level of protection against the penetration of liquids and dust If these products are connected to a mains outlet with a cable and plug rather than a permanently connected cable the plug and outlet are much more susceptible to liquid and dust penetration The operator mus...

Page 14: ...1 Module carrier 5 Process instrument 2 Bracket FILTRAX module carrier option 6 Sample tube 3 Suction tube 5 m 7 Bracket FILTRAX control unit option 4 Control unit aaaa aaaa aaaa aaaa aaaaaaa aaaaaaa aaaaaaa aaaaaaa aaaaaaa aaaaaaa aaaaaaa aaaaaaa ...

Page 15: ...accept no liability if the instrument is installed incorrectly Plan how to lay cables and tubes and their path in advance Lay the tubes data cables and power cables without any bends and so they do not pose a tripping risk NOTICE For information on installation with optional accessories refer to the relevant installation instructions NOTICE The filter module should only be unpacked directly before...

Page 16: ...14 Installation Fig 3 9 Module carrier and filter module ...

Page 17: ...rol unit bracket components 1 HRO304 supporting pipe 1 8 m Included in hardware LZX416 6 Cheese head bolt M8 x 16 4 7 Blanking plug 8 Plug 2 Setscrew M8 x 10 2 in LZX416 3 LZY827 base 4 HHH277 bracket 2 5 EHK063 pipe clamp 2 6 7 8 ...

Page 18: ...th control unit bracket LZX676 Fig 3 11 Installation of control unit bracket aaaa aaaa 1 Rear of control unit 6 Bracket 2 2 Supporting pipe 1 8 m 7 Nut M8 2 3 Base 8 Pipe clamp 2 4 Setscrew M8 x 10 2 9 Cheese head bolt M8 x 16 2 washer 2 5 Anchor 4 ...

Page 19: ... 12 Installation on a wall hole diagram Procedure 1 Make the two upper holes 2 Use wall plugs and screws from the accessory set 3 Fit instrument 4 Mark third hole at the bottom and make hole 5 Fit instrument At least 300 mm ...

Page 20: ...h slot on side for LZY714 99 43050 6 LZY804 fastening lug Included in retaining clamp LZY449 2 Clamp half 1 3 Cheese head bolt M5 x 20 3 4 Clamp half with thread 1 Included in hardware LZX416 7 Cheese head bolt M8 x 40 8 Blanking plug 9 Plug 5 LZY827 base Included in hardware LZX417 10 Flat seal Included in hardware LZY362 11 Cheese head bolt M5 x 12 6 5 6 7 8 9 10 11 ...

Page 21: ...Fastening lug 2 Anchor 4 8 Cheese head bolt M8 x 40 3 Blanking plug 9 Cheese head bolt M3 x 10 6 4 Plug 10 Flat seal 5 Mounting pipe 2 0 m for LZY714 99 43020 or mounting pipe 2 0 m with slot on side for LZY714 99 43050 11 Module carrier 6 Retaining clamp aa aa aa aa ...

Page 22: ...Installation 3 3 Connecting tubes Fig 3 15 Preparation of suction tube connection 1 Protective tube transport protection 4 Cable gland M20 x 1 5 2 Shrink tube 5 Suction tube 3 Metal sleeve 6 Blanking plug ...

Page 23: ...Installation 21 Fig 3 16 Preparation of sample tube connection 1 Protective tube transport protection 4 Cable gland M20 x 1 5 2 Shrink tube 5 Suction tube 3 Metal sleeve 6 Blanking plug ...

Page 24: ...ut of suction tube 1 Suction tube 4 Air tubes 2 Pipe heater connecting cable 5 Clip 3 Sample suction tubes NOTICE The tubes must be laid with the aid of the clips such that they cannot chaff due to the vibration from the compressor ...

Page 25: ... 1 is pushed through the flowmeter from below and fastened to the 90 fitting 3 The fixing screw 2 is then tightened lightly Fig 3 18 Laying sample tube 1 Sample pressure tube 4 Pipe heater connecting cable 2 Fixing screw 5 Sample tube 3 90 fitting ...

Page 26: ... are laid correctly The filter modules may be damaged if sample is pumped back via the sample suction tubes 1 2 1 Sample suction tube filter module A or B 4 Pump cartridges 2 Sample suction tube filter module A or B 5 Metering tube 3 Connecting tube 6 Sample pressure tube ...

Page 27: ...from the mains it must be made sure that the correct power plug is pulled e g labeling of the sockets This is recommended for long term disuse and can prevent potential dangers in the event of a fault Therefore make sure that the sockets to which the device is connected are easy to reach by each user at all times NOTICE On removal of the power plug fixed installation of mains supply lead a suitabl...

Page 28: ...A E T7A E IEC UL NOTICE Route the signal lines 21 22 23 24 separated from the power cable Terminal no Connection 1 N 230 V AC 50 60 Hz option 115 V AC 2 L 230 V AC 50 60 Hz option 115 V AC 7 N sample tube heater 8 N suction tube heater 9 L sample tube heater 10 L suction tube heater 18 Earth for screening signal wires 19 Earth for suction tube heater 20 Earth for sample tube heater 21 22 Floating ...

Page 29: ...ample pressure tube inside the sample tube to the process instruments connected The bracket enables the sample tube to be fastened to a wall at a distance of approx 200 mm from the process instrument Fig 3 21 Mounting bracket 1 Sample pressure tube 3 Cable gland M20 x 1 5 2 Bracket 4 Sample tube ...

Page 30: ...Large fitting All the adapters necessary to the direct connection of the sample pressure tube to the sample feed openings on the process instruments are supplied in the tube adapter set LZX701 supplied If several instruments are supplied from one FILTRAX the sample must be provided from the first instrument to the next using the 2 4 tube to ensure a short time delay ...

Page 31: ...Installation 29 ...

Page 32: ... carrier 3 Fit the two thicker sample tubes and the two thinner air tubes to tube fittings of appropriate size as per the figure 4 Plug into the mains and set instrument parameters sec 5 Software menu system NOTICE The sample pressure tube must never be clamped such that it is blocked off the pressure build up would either result in damage to the tubes or the tube connections would spring off NOTI...

Page 33: ...Commissioning 31 Fig 4 23 Inserting filter modules ...

Page 34: ...n installation outdoors the control unit should always be in operation so that the temperature control can provide protection against overheating or freezing When the instrument is taken out of operation the SERVICE menu is opened or the control unit removed Prior to dismantling open the SERVICE menu and remove suction and sample tube Select PREPUMP command and leave the internal tubes to empty Th...

Page 35: ...Commissioning 33 ...

Page 36: ...display during operation To reach the menu level of the program one of the four function keys F1 F4 3 must be pressed for 3 seconds The significance of the keys on the menus appears sensibly abbreviated in the second line on the display softkey function Cancel Change the setting Back to the previous command Continue to the next command Fig 5 25 Display 1 Current sample volume approx ml h 3 Functio...

Page 37: ...rnal data in case of service MODUL A MODUL B TEMPERATURE control unit AMPL MEAS Z MEAS MEAS F SERVICE For maintenance and function tests INTERVAL EXTRACTION PREPUMP FILTERCLEANING OP COUNTERS display and reset TEST OF FUNCT SIGNALS DEVICEDATA STATUS output of detailed error messages and acknowledgement OP COUNTERS display only CLEANED MODUL A MODUL B PUMPTUBES PUMPCASSETTES PUMPWHEELS AIRFILTER CO...

Page 38: ...ation of the tube heaters HEAT START only for HEATER TIMER JAN to DEC Default setting OCT Activation of the heater at the start of the month selected HEAT STOP only for HEATER TIMER JAN to DEC Default setting MRZ March Deactivation of the heater at the end of the month selected WARNING 200 800 ml h in 10 ml steps Warning relay contact set when the sample volume drops below the amount set FAULT 100...

Page 39: ...the display of the data on operation MENU Command Description SIGNALS MODUL A Parameter for the flow rate in module A single measurement approximately corresponds to a sample volume in ml h MODUL B Parameter for the flow rate in module B single measurement approximately corresponds to a sample volume in ml h TEMPERATURE housing Temperature in the control unit in C or F AMPL Photometer gain MEAS Z ...

Page 40: ...ILTERCLEANING MODUL A Operating time for filter module A in days MODUL B Operating time for filter module B in days P TUBES IN Remaining operating time for both pump tubes in days 91 0 negative number P CARTR IN Remaining operating time for both pump cartridges in days 365 0 negative number P ROLL IN Remaining operating time for pump rollers in days 365 0 negative number AIR F C IN Remaining opera...

Page 41: ...OP COUNTERS TEST OF FUNCT are explained in detail in section 6 Maintenance and section 7 Faults causes rectification They are not required for normal operation MENU Command Setting Description SERVICE INTERVAL 30 300 s default setting 60 s Changeover interval for sample pumping between module A and B EXTRACTION 50 130 default setting 100 900 ml h this sample volume is produced on correct installat...

Page 42: ... and forward every 3 s stop housing fan on off hous heater on off heater tubes on off warning on off malfunction on off sensor a volume measurement a sensor b volume measurement b airvalve a op cl airvalve b op cl signallamps on off green red simultaneously Every component listed can be operated and tested individually SIGNALS Open SIGNALS menu DEVICEDATA Open DEVICEDATA menu STATUS Detailed fault...

Page 43: ...Operation 41 ...

Page 44: ...ance work is performed by qualified personnel The maintenance to be performed by the user is then limited to regular visual inspections replacing consumables and cleaning if necessary 6 1 Maintenance work The reliable and correct operation of this sample conditioning system can only be ensured if the maintenance work is performed regularly as per the maintenance calendar ...

Page 45: ...re supplied or included in the set of annual consumables NOTICE The sample pressure tube must never be clamped such that it is blocked off the pressure build up would either result in damage to the tubes or the tube connections would spring off ...

Page 46: ...ol unit 6 1 2 Every 3 months All maintenance work must be performed in the SERVICE menu Replacement of consumables and cleaning Replacement of the metering tubes Replacement of control unit air filter depending on condition only air inlet Menu based cleaning this cleaning interval can vary depending on the conditions Fig 6 26 Consumables after 3 months Fig 6 27 Metering tube replacement ...

Page 47: ...ervice contract by customer service after 12 months Replacement of the metering tubes together with the connecting tubes Replacement of the pump cartridges and pump rollers Replacement of compressor air filter after 24 months Replacement of compressor Fig 6 28 ...

Page 48: ...with ok REM MOD CARRIER 3 Pull off the air and sample tubes connected to the module carrier carefully pull out the filter modules and acknowledge with ok REMOVE MODUL NOTICE As far as possible do not touch the delicate membranes and never allow the membranes to dry out if necessary store the filter modules in the plastic bags supplied 4 Carefully clean the filter modules using 5 chlorine bleach so...

Page 49: ...dules into the cleaning container Lay tubes as per diagram CLEAN MODUL 5 Carefully fill the cleaning container with 5 chlorine bleach sodium hypochloride WAR NI NG Observe the safety precautions when handling the cleaning solution and wear appropriate safety clothing The chlorine bleach must not come into contact with reagents containing acids chlorine gas will be formed 6 Soaking time 10 minutes ...

Page 50: ...48 Maintenance 9 Open the SERVICE menu and then the PREPUMP function SERVICE PREPUMP 600 s count down to 0 10 10 15 minutes later place all instruments back in operation ...

Page 51: ...olution and wear appropriate safety clothing The chlorine bleach must not come into contact with reagents containing acids chlorine gas will be formed 4 Pull off the sample tubes connected to the module carrier and acknowledge with ok Lay tubes as per diagram 5 Activate the cleaning of the sample pipes using the PREPUMP function counter counts down from 600 s the date for the operating time counte...

Page 52: ...as expired Replace pump rollers and reset operating time counter PUMPCASSETTE The operating time counter for the pump cartridges P CARTR has expired Replace pump cartridges and reset operating time counter COMPRESSOR The operating time counter for the compressor COMP has expired Replace compressor and reset operating time counter FAULT CAUSE RECTIFICATION PUMPTUBES The operating time counter for t...

Page 53: ...in the housing is 1 C the instrument is warming up Wait until the heater has raised the temperature in the housing to 1 C the warm up phase then takes a further 30 min Keep door closed FAULT SAMPLE The amount of sample from a module is below the threshold set under FAULT Check all tubes and pumps if necessary clean filter modules and sample pipe FAULT DEVICE Serious electronic fault bus fault Norm...

Page 54: ...ssor 115 V LZX025 Compressor 230 V LZX024 Module carrier complete with 5 m suction tube 230 V LZX670 Module carrier complete with 5 m suction tube 115 V LZX669 Sample connecting tube external 6m 2 4 mm black HLS191 Pump cartridge LZP777 Pump rollers 2 channel 5 pieces LZX019 Valve 2 2 way LZV205 Accessories Tank edge fastening module carrier LZY714 99 43020 Tank edge fastening module carrier mount...

Page 55: ...52 ...

Page 56: ...st 7 days after the identification of the fault If the customer fails to notify the supplier the product is considered approved despite the defect Further liability for any direct or indirect damages is not accepted If instrument specific maintenance and servicing work defined by the supplier is to be performed within the warranty period by the customer maintenance or by the supplier servicing and...

Page 57: ...54 Warranty and liability ...

Page 58: ...5 41 61 20 info hach lange be www hach lange be DR LANGE NEDERLAND B V Laan van Westroijen 2a NL 4003 AZ Tiel Tel 31 0 344 63 11 30 Fax 31 0 344 63 11 50 info hach lange nl www hach lange nl HACH LANGE APS Åkandevej 21 DK 2700 Brønshøj Tel 45 36 77 29 11 Fax 45 36 77 49 11 info hach lange dk www hach lange dk HACH LANGE AB Vinthundsvägen 159A SE 128 62 Sköndal Tel 46 0 8 7 98 05 00 Fax 46 0 8 7 98...

Page 59: ...era bb HR 42 000 Varaždin Tel 385 0 42 305 086 Fax 385 0 42 305 087 info hach lange hr www hach lange hr HACH LANGE MAROC SARLAU Villa 14 Rue 2 Casa Plaisance Quartier Racine Extension MA Casablanca 20000 Tél 212 0 522 97 95 75 Fax 212 0 522 36 89 34 info maroc hach lange com www hach lange ma HACH LANGE OOO Finlyandsky prospekt 4A Business Zentrum Petrovsky fort R 803 RU 194044 Sankt Petersburg T...

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