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Endress+Hauser Stamoclean CAT430, Руководство по эксплуатации

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Safety instructions

Stamoclean CAT430

4

Hauser

1

Safety instructions

1.1

Designated use

The CAT430 micro/ultra filtration system is designated to take samples for process measuring 
devices in sewage treatment plants.
The system transports clear samples directly from the clarification basin to the measuring device.

Any other use than the one described here compromises the safety of persons and the entire 
measuring system and is, therefore, 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. 
The technical 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 for 

correctness. 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 product is designed to meet state-of-the-art safety requirements, has been tested and left the 
factory in a condition in which it is safe to operate. Relevant regulations and European standards 
have been observed.

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

1.4

Return

If the device requires repair, please send it 

cleaned

 to the sales centre responsible. Please use the 

original packaging, if possible.

Please enclose the completed "Declaration of contamination" (copy the second last page of these 
Operating Instructions) with the packaging and the transportation documents.
No repair without completed "Declaration of contamination"!

Содержание Stamoclean CAT430

Страница 1: ...BA380C 07 en 02 07 51517603 Operating Instructions Stamoclean CAT430 Micro Ultra filtration system with diaphragm pump ...

Страница 2: ...th the operating elements and the various setting options In the Commissioning section you learn how to switch on CAT 430 and check the functioning Maintenance ä 25 ä 27 ä 36 For normal operation of the CAT430 it is absolutely essential to carry out maintenance tasks on a regular basis such as filter cleaning etc Individual parts are subject to normal wear and tear Here you can find out how to rep...

Страница 3: ...nection 16 4 2 Post connection check 18 5 Operation 19 5 1 Operation and commissioning 19 5 2 Display and operating elements 19 5 3 Local operation 20 6 Commissioning 22 6 1 Function check 22 6 2 Switch on 22 6 3 Checking the sampling quantity 23 6 4 Checking the sample transportation 23 6 5 Setting the collecting volume 23 7 Maintenance 25 7 1 Maintenance activities 25 7 2 Repairs 27 8 Accessorie...

Страница 4: ...correctness 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 unintenti...

Страница 5: ...to the instrument or to persons if ignored Caution This symbol alerts you to possible faults which could arise from incorrect operation They could cause damage to the instrument if ignored Note This symbol indicates important items of information È ä 1 This symbol indicates a cross reference to a defined page e g p 1 È å 2 This symbol indicates a cross reference to a defined figure e g fig 2 ...

Страница 6: ...50 m 160 ft hose 6 up to 100 m 330 ft with diaphragm pump and 20 m 65 ft hose 9 Special version acc to customers specification Heating at the discharge side A Without sample hose heater D With 8 m 26 ft sample hose heater F With 18 m 59 ft sample hose heater Y Special version acc to customers specification Power supply 0 230 V AC 1 115 V AC Heating at the suction side A with heating B without heat...

Страница 7: ...8 2 ft 1 PTFE hose roll 3 1 5 mm 0 12 0 06 inch length 2 5 m 8 2 ft 1 or 2 Filter plate s depending on ordered version 1 or no assembly depending on ordered version 1 Filtrate line with PE filtrate hose 4 2 mm 0 16 0 08 inch min length 20 m 66 ft depending on ordered version 1 Acceptance certificate 1 Allen key 4 mm 0 16 inch 1 Allen key 4 mm 0 16 inch with handle length 200 mm 7 9 inch 1 Fitting ...

Страница 8: ...ns please contact your supplier or your sales center responsible 3 2 Quick installation guide A complete measuring system comprises a CAT430 filter system a collecting vessel a CA71xx analyzer Optionally a sensor with flow assembly can also be integrated into the measuring system external only cannot be installed in the control box housing If an assembly with low dead volume and flow resistance is...

Страница 9: ...r elements Check that there is sufficient space between the filter unit and the rim of the basin This applies especially to filter units with numerous filter elements If there is not sufficient space a special holder must be used The flow rate at the point of installation must not be over 2 m s 6 6 ft s 3 3 1 Mounting the filter element holders Note Please order filter element holders separately S...

Страница 10: ...llowing steps outside the basin resp the open channel 1 Feed the filtrate hose å 6 pos 3 of the filtrate line pos 1 through the T piece at the PVC retaining slide pos 5 2 Screw the filtrate line in tight with the PVC hose gland of the T piece 3 Fasten the stainless steel chain at the retaining slide by directing it through the heaxagon nut pos 8 4 Remove the PVC screw caps pos 4 and place them so ...

Страница 11: ...ve the press board 2 Cut the upper end of the bag open and take the filter element out 3 Remove the protective nonwoven from the filter plate 4 Screw the supplied threaded elbow joint into the threaded hole on the reverse side of the filter element Carefully tighten the threaded elbow joint with the open end wrench so that the O ring on the threaded elbow joint seals cleanly to the PVC carrier pla...

Страница 12: ...ide of the control box For this the clips must be fixed to the upper holes 2 Rail mounting Screw the clips on the highest horizontally running rail pipe right by the filter station For the box to hang straight the supplied rubber buffer must be attached to the reverse side of the box For this drill a hole with a 4 mm 0 16 inch diameter in the middle of the box position on which a lower horizontal ...

Страница 13: ...can insert them comfortably into the Y fitting plug in connectors pos 10 Sample line to the measuring devices The sample line to the measuring devices consists of a spiral jacket hose a thin filtrate hose and depending on scope of order an electric band heater In the spiral jacket hose are PTFE hose 1 5 3 mm 0 06 0 12 inch standard PE hose 2 4 mm 0 08 0 16 inch reserve Caution Lay hose lines such ...

Страница 14: ...ection please read the chapter Wiring 9 Cut the filtrate hose to the right length 10 Insert the hose into the fitting on the pressure side top of the pump 11 Now lay the sample line from the control box to the measuring devices Where possible use available cable ducts or empty underground pipes With the corresponding order the filtrate hose is protected by the electric band heater over the entire ...

Страница 15: ...rwise the thermal switch reacts to the temperature of the heater instead of the ambient temperature and therefore switches off the heater 3 4 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 ...

Страница 16: ...2 Disconnect the 4 pole connection between cover and terminal PCB pos 3 and secure the cover 3 Guide the power cable through the Pg cable gland into the pump box Pull the cable through the right hand cable duct into the connection box 4 Shorten the cable accordingly and connect the wires to terminals 15 20 and 24 5 Pull both wires for the supply lead of the 24 V hose heater through the left hand c...

Страница 17: ...c band heater discharge side of the pump Housing heater T1 1 T terminal Assignment T1 Assignment T1 Assignment 1 24 V to hose heater 10 Phase L housing heater 19 not connected 2 24 V from thermal switch 11 Phase L to control 6 20 Phase L mains supply 3 not connected 12 Phase L to control 2 21 not connected 4 not connected 13 Zero conductor as required 22 not connected 5 24 V to thermal switch 14 E...

Страница 18: ...es the specifications on nameplate 230 V AC 115 V AC The mounted cables slack and not twisted Factory set cable routing split properly power cable weak current cable All the cable entries installed tightened and sealed All cable entries mounted downwards or sideways cable loops downwards water drains off ...

Страница 19: ... operating elements Main switch Timer The timer is a time relay of Trumeter 7955 X type When CAT430 is delivered the timer is ready to use installed and connected Please refer to the following figure for information only a0007162 Fig 15 Cover of connection box 1 2 3 Heating Power on Control Suction hose evacuating pump runs at continuous operation a0007161 Fig 16 Trumeter 7955 X 1 2 5 6 3 4 termin...

Страница 20: ...n 5 3 3 Timer setting During operation of the CAT 430 the Trumeter 7955 X display shows the respective operating status On pumping Off pause and the remaining time until switching over to the next operating status During programming the current settings for pumping and pause are displayed This is how to program the time relay 1 Hold down the PROG key until the countdown 3 2 1 0 is completed and RC...

Страница 21: ...igure the LEU message appears in the display The time controller is activated as soon as voltage is supplied to the relay 11 Keep pressing RESET until the relay icon appears in the display again The programming procedure is completed 12 Now switch the middle switch controller on the connection box off and on again The controller starts 020 SEC RC ...

Страница 22: ...e the timer and the CAT430 starts operation with the cycles configured at the factory initial start up or with your individual settings The lower flip switch is used to set the pump to evacuate when the timer is switched on continuous operation of the pump Note To start the entire system immediately the Power switch and the Control switch must be activated If you are starting the machine in frosty...

Страница 23: ...the time that the sample requires from switching on the pump until arriving in the collecting vessel at the measuring devices This time is the minimum delay time that passes between taking the sample and measurement Change the delay time by increasing the fluid quantity or extending the operating time of the pump Note At the same cycle duration the delay time drops by a third when the operating ti...

Страница 24: ... desired volume is reached 3 Tighten the Pg hose gland again and check that it is leakage resistant Note If you use CAT430 for preparing samples for analyzers of the CA71 series please use the collecting vessel of the analyzer with or without level monitoring If a nitrate sensor with flow assembly is installed in the filtrate line you have to install the collecting vessel after the nitrate sensor ...

Страница 25: ...ilter elements At measuring points with a high grease and protein content however it can be necessary to treat the membranes from time to time with a mixture of 200 ml 6 8 fl oz 30 H2O2 1 l 34 fl oz water and 30 ml 1 flo oz concentrated HCl Warning Highly corrosive Be sure to wear protective gloves and protective goggles when handling hydrochloric acid HCl and hydrogen peroxide H2O2 1 Wash the fil...

Страница 26: ...he filtrate line from the filter elements 4 Close the vent screw again 5 Switch Evacuate off 7 1 4 Replacing filtrate hoses In the course of a few months a coating builds up in the transparent PVC filtrate hoses in the control box despite ultra filtration It is not worth cleaning them Replace the hoses as described below 1 Switch the controller off 2 Pull all transparent hoses out of the black PP ...

Страница 27: ...be carried out on damaged CAT430 components are described below Warning Work on electrical components must only be carried out by authorised and trained technical personnel Before beginning work switch the factory fitted fuses for the complete machine off 7 2 1 Replacing a filter element The filter element membranes have a service life of approx 2 years depending on operating conditions After this...

Страница 28: ...roperly 7 2 3 Replacing the timer It is assumed that the timer is defective if despite mains voltage being present and the middle switch on the connection box being switched on the display is blank or the relay for the pump does not switch on as intended in the cycle Warning Before replacing the timer be sure to switch the factory fitted fuses for the entire machine off 1 Loosen all wires from the...

Страница 29: ...alve seats 6 Pressure connection 1 Screw the valve out of the pump head 2 Remove the O ring å 20 item 4 from the pump head with a small screwdriver 3 Press the valve inserts item 2 out of the valve by guiding a suitable tool e g an Allen key through the opening of the pressure connection item 1 4 Use the screwdriver to remove the valve seats item 5 In doing so let the valve balls item 3 fall onto ...

Страница 30: ...on item 5 4 Use the screwdriver to remove the valve seats item 3 In doing so let the valve balls item 2 fall onto a piece of paper so they can be found easily again 5 Clean all parts thoroughly with water 6 Replace damaged parts see Spare parts 7 Drop the valve balls into the valve seats and press on the valve inserts 8 Press the valve inserts with the small hole in the direction of flow arrow int...

Страница 31: ... head 7 Lift the diaphragm item 7 at the edges so you can hold it with your thumb and index finger 8 Turn the diaphragm counter clockwise to remove it from the drive axle 9 Remove the head disk item 3 and check the safety diaphragm item 4 for damage Replace it if necessary 10 Only push the new safety diaphragm so far onto the drive axle until it is in level contact with the pump housing item 5 11 ...

Страница 32: ...mp 1 Insert an Allen screw with washer into the lower slot at the base of the pump pump head left 2 With one hand insert the Allen key 200 mm into the screw and bring the pump into position in the control box 3 Turn the screw with the Allen key and at the same time move the pump slightly to and fro until the screw engages the threaded hole in the carrier plate 4 Align the pump in such a way that t...

Страница 33: ...1511353 with vertical retaining slide for basin 1 80 m 5 9 ft order no 51511354 with horizontal retaining slide for open channel 1 50 m 4 9 ft order no 51511373 with horizontal retaining slide for open channel 1 80 m 5 9 ft order no 51511374 a0007158 Fig 23 Holder for open channel side view a0007157 Fig 24 Holder for basin side view 100 3 94 525 20 7 75 2 95 150 5 91 200 7 87 100 3 94 1500 1800 59...

Страница 34: ...apters needed per filter plate order no 51511355 Transportation box for filter elements for secure transportation resp storage of 1 or 2 filter plates 500 x 400 x 50 mm 19 7 x 15 8 x 1 97 inch oder no 51512477 a0007159 Fig 25 Dimensions a0007378 Fig 26 Transportation box 3 0 12 20 0 79 24 0 94 50 1 97 Ø40 1 57 G1 G1 3 0 12 ...

Страница 35: ...fixing screws or replace diaphragm Air in suction hose or pump head Clean filter elements and vent pump No filtrate or too little Switch controller off Disconnect the hose from the pressure side of the pump top and connect the supplied hose piece Switch on controller Does filtrate come Measure the amount with a measuring beaker No filtrate or too little Check the vacuum pressure at the pressure ga...

Страница 36: ...he checks mentioned above are o k and still no housing heating Micro thermostat defective repair required Failure in sample line heater to the measuring devices Problems with the sample line heater to the measuring devices are evident when the sample is not transported on from the control box to the measuring devices and all other causes mentioned above have been ruled out Check that the entire pa...

Страница 37: ...ard and transfo without cover 51514294 6 Diaphragm pump 100 to 230 V AC complete 71003245 6a Head valve for diaphragm pump 71038839 6b Foot valve for diaphragm pump 71038846 not in figure Pump diaphragm 71038847 Safety diaphragm for pump 71038848 7 Collecting vessel 51509238 8 Filtrate line with electric band heater length 4 5 m 15 ft 51509234 9 Thermal switch 51509232 10 Securing nut for filter e...

Страница 38: ...s 15 Filter element holder with horizontal retaining slide for open channel length 1 50 m 4 9 ft length 1 80 m 5 9 ft 51511373 51511374 not in figure Retaining rope PA 8 mm 0 31 inch 51509227 Plug connector set Y piece T piece Screw in connector Dummy plug 51514276 Set of plug connectors for 4 filter elements Screw in T connector 2 screw in connectors 51514279 Transportation and storage box for fi...

Страница 39: ...vided by the customer 10 2 Performance characteristics Filtrate volume approx 450 ml h 0 12 gal hr per filter element Sample transportation dis tance max 100 m 330 ft Life cycle approx 1 to 2 years Cleaning interval Chemical resistance pH 1 to 13 10 3 Environment Ambient temperature 25 to 50 C 10 to 120 F Humidity 0 to 95 no splash water Ingress protection IP 54 10 4 Process Sample temperature 5 t...

Страница 40: ... pump 15 kg 33 lbs Housing CAT430 A1A A4A 16 kg 35 lbs Filter element 1 kg 2 2 lbs Filter element holder 18 kg 40 lbs Control box housing and housing CAT430 A1A A4A Glass fibre reinforced polyester self quenching acc to ASTM D 635 resp UL 94 VO Filter element PVC carrier plate PES or PAN membrane1 1 PES polyether sulfone PAN polyacryl nitrile Filter element holders Stainless steel 1 4301 AISI 304 ...

Страница 41: ...lement holders 33 Filtrate volume 39 Foot valve 30 Fuses 28 H Head valve 29 Humidity 39 I Icons 5 Incoming acceptance 8 Ingress protection 39 Installation 4 8 9 L Life cycle 39 M Maintenance 25 Materials 40 Mechanical construction 40 N Nameplate 6 O Operation 4 19 Operational safety 4 Ordering information 6 P Performance characteristics 39 Power supply 39 Process 39 Product structure 6 Pump Changi...

Страница 42: ...Stamoclean CAT430 42 Endress Hauser U Use 4 V Valves Foot valve 30 Head valve 29 W Weight 40 ...

Страница 43: ...____________________________________________ ______________________________________________________________________________________________________________ We hereby certify that this declaration is filled out truthfully and completely to the best of our knowledge We further certify that the returned parts have been carefully cleaned To the best of our knowledge they are free of any residues in da...

Страница 44: ...www endress com worldwide BA380C 07 en 02 07 Printed in Germany FM SGML 6 0 DT 51517603 ...

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