Cerlic CBX User manual

2011-11-08 C81B5EN12
CBX
Cerlic CBX
Sludge Blanket Monitor

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CBX
Index
INDEX....................................................................................................................................................................2
GENERAL INFORMATION ................................................................................................................................................. 4
SECURITY INFORMATION................................................................................................................................................. 4
DESCRIPTION OF THE FUNCTION.................................................................................................................................... 4
WORKING PRINCIPLE ....................................................................................................................................................... 4
SENSOR BODY .................................................................................................................................................................... 4
INSTALLATION..................................................................................................................................................5
Unpacking............................................................................................................................................................................ 5
Damages............................................................................................................................................................................... 5
Packing.................................................................................................................................................................................. 5
Content.................................................................................................................................................................................. 5
Accessories........................................................................................................................................................................... 5
STARTING UP.....................................................................................................................................................6
Mechanical installation................................................................................................................................................. 6
Water connections........................................................................................................................................................... 6
Electrical connection...................................................................................................................................................... 6
Sludge rake guard limit switch, Trigger................................................................................................................ 6
USER INTERFACE .............................................................................................................................................................. 7
Configurations................................................................................................................................................................... 7
LED INDICATION .............................................................................................................................................................. 7
OPERATION........................................................................................................................................................8
CBX MODE......................................................................................................................................................................... 8
Rake interval ...................................................................................................................................................................... 8
EMERGENCY RETRACTION OF THE CABLE..................................................................................................................... 8
CONFIGURATION TERMS...............................................................................................................................9
Home position, A............................................................................................................................................................... 9
Blind zone, B ....................................................................................................................................................................... 9
Max depth, C ....................................................................................................................................................................... 9
Sludge level, D.................................................................................................................................................................... 9
Measured range, E ........................................................................................................................................................... 9
Raker, F................................................................................................................................................................................. 9
Fluff, G.................................................................................................................................................................................... 9
BB1/BB2 MENU FOR CBX...........................................................................................................................................10
Settings................................................................................................................................................................................10
CBX Setup...........................................................................................................................................................................11
Calibration.........................................................................................................................................................................11
Cleaning..............................................................................................................................................................................12
Scale / Alarm....................................................................................................................................................................12
System..................................................................................................................................................................................12
Timer....................................................................................................................................................................................13
INFORMATION DISPLAY .............................................................................................................................13
PROFILE............................................................................................................................................................ 14
CALIBRATION ..................................................................................................................................................................16
Calibration of sensor.....................................................................................................................................................16
DEITAILED INFORMATION OF CBX.........................................................................................................17
Main control board........................................................................................................................................................17
PICKUP BOARD ................................................................................................................................................................17
Axle board..........................................................................................................................................................................18
Sensor...................................................................................................................................................................................18
Cable drum assembly....................................................................................................................................................19

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CBX
Heater & fan......................................................................................................................................................................20
Flushing tube & valve ...................................................................................................................................................20
Connection terminal .....................................................................................................................................................20
APPENDIX 6 , OPTIONAL 4-20MA OUTPUT MODULE FOR BB1/BB2 ..........................................21
INTRODUCTION ...............................................................................................................................................................21
MODULE OVERVIEW.......................................................................................................................................................21
WIRE CONNECTIONS ......................................................................................................................................................23
GETTING STARTED WITH THE 4-20 MAMODULE.....................................................................................................23
TECHNICAL SPECIFICATION FOR 4-20MAMODULE..................................................................................................23
MAINTENANCE ...............................................................................................................................................24
MANUAL OPERATION OF CBX................................................................................................................... 24
Maintenance schedule..................................................................................................................................................24
Cable and sensor.............................................................................................................................................................24
TROUBLESHOOTING .......................................................................................................................................................25
ALARM..............................................................................................................................................................................25
APPENDIX 1, MOUNTING OF CBX SUPPORT STAND.......................................................................... 26
APPENDIX 2, MOUNTING OF FLUSH PIPE ............................................................................................. 27
APPENDIX 3, WIRING DIAGRAM......................................................................................................... 28
APPENDIX 4, SAFETY INSTRUCTIONS.................................................................................................... 29
CONTACT INFORMATION ...........................................................................................................................30
WARRANTY .....................................................................................................................................................30
SPECIFICATION, CBX .................................................................................................................................... 31
DIMENSIONS IN MM (“)............................................................................................................................32
APPENDIX 7, SERVICE FORM................................................................................................................33
APPEMNDIX 8, SETUP FORM .................................................................................................................... 34

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CBX
General information
It is of great importance to read all parts of this manual prior to startup of the
instrument. If the Blanket Monitor is not used and handled according to this manual,
then the life and functionality may be jeopardized, and all warranties will be voided.
Security information
This instrument should be used by qualified and authorized personnel only.
It is mandatory to follow all security and other routines that apply at site when
using the CBX.
Within EU it is prohibited to dispose of electric and electronic waste in regular
waste as these may contain harmful substances. All electric and electronic
waste must be sorted and left for recycling. Such products are labeled with an
X-marked waste bin. It is important that everyone cooperate in order to secure
a high level when it comes to recycling and help to save our environment. If such waste
is handled and recycled according to regulation (EC Directive 2002/96/EC) the
environment as well as people’s health may be jeopardized
Description of the function
CBX is an optical suspended solids meter designed to measure sludge and fluff blanket
depth in clarifiers, thickeners, etc. in water and wastewater plants, as well in other
facilities. It is possible to display measured values as text or as a graphic image of the
sludge profile.
Working principle
The sensor is sent down into the clarifier/thickener and measures the suspended solids
as it descends and sends the data via a communication cable to the BB2 control box. By
submersing the sensor into the liquid you are able to obtain reliable suspended solids
readings versus depth and avoid problems from foam and fluff layers in the
clarifier/thickener.
Sensor body
The sensor body contains optics and electronics that should not be exposed to
mechanical abuse or high temperatures. If the sensor body has mechanical damages,
water may penetrate into the sensor and destroy the electronics and optics. Please see
section Maintenance for more information.

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CBX
Installation
It is important that installation, maintenance and configuration only are done by
authorized personnel to avoid damages on the product. .
Unpacking
The unit has been tested and approved before delivery from factory. Please check to
confirm that no visible damages occurred during shipment. Make sure that all
equipment inside the cabinet is secure and that the sensor and cable can move freely.
Damages
If damages occurred during shipment, immediately contact your shipper as well as your
Cerlic representative within 2 days of receipt. The shipment may be returned only after
contact has been made with Cerlic.
Packing
The original packing is designed to protect the equipment and should be used for
storage or if the goods must be returned. If other packing material is used Cerlic is not
responsible for damages during transport.
Content
Please check that the content corresponds to your order and packing list.
Options
P/N
SS Handrail Mounting Bracket 10305893
BB2 Control Box 11905426
BB1 Control Box 11905885
Mounting plate for BB1/2 10305532
M12 Cable 1.5m (5’) 20805752
M12 Cable 10m (33’) 20805510
M12 Cable 30m (100’) 20850727
Sensor with 33’ cable 11305888
Flushing Valve 115V 11705516B
Motor 115V 21750924
Fan 115V 21750926
Door key 20305403
Accessories
Cerlic Sensor Cleaning Fluid (CSC) 10905944
CBX Jacket (for cold weather) 11205969

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CBX
Starting up
Connect the CBX to the BB1/BB2 and connect 110/1/60 power to both units. BB1/BB2
must have program version 3.1 or higher so it will automatically detect and connect to
the CBX.
Mechanical installation
Mechanical mounting is described in appendix 1 “Mounting of stand”. When CBX is
installed outdoors there is a risk of flush lines freezing at sub zero temperatures. This
will not damage the instrument but the automatic cleaning function will stop working. It
is also recommended to use a CBX Jacket (P/N 11205969) when there is a risk of
temperatures below 23ºF (-5ºC).
Water connections
On the bottom right hand side of the cabinet there is a ¼” npt male connection for
flexible flush hose. A description of the connection can be found in appendix 3
“Mounting of hose”. Outdoor installations must protect water pipe or hose from freezing
conditions or the water must be disconnected and emptied to avoid the hose or valve
from freezing. Under all circumstances flushing should be avoided when the outdoor
temperature is below 0 ºC (32ºF).
Electrical connection
In the bottom lower left corner of the cabinet there are the four (4) ½” npt female
electrical connections. Any wires required to go outside the cabinet can be found here.
Electrical connections must be installed by authorized personnel only. The connections
are terminated in the junction box inside the cabinet on the left side. Description is given
in appendix 3 “Electrical connections”.
Sludge rake guard limit switch, Trigger
All sampling modes are dependent of the connection of a rake guard limit switch which
is a N/O (normally open) contact. The digital input for the limit switch can be used in
several different ways for control of the CBX
NOTE! A limit switch must be used in all applications where a rake or other
moving equipment may come in contact with the sensor or cable. Cerlic Controls
AB does not assume any responsibility for damages caused by the absence or
malfunction of the rake guard limit switch.

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CBX
User interface
The BB1/BB2 will show the CBX as a standard “X” sensor on the display and it will show
both sludge and fluff level in text on the display.
Configurations
The figure below shows the different terms used for distances that are involved in the
configuring of the CBX.
To set the basic parameters like, Max depth, Blind zone and scale do the following.
Lower the sensor head to 1’ (0.3m) below the liquid surface (see calibration section for
instructions), note the distance on the BB1/BB2. This is the length of cable to the blind
zone (B) . Continue to feed the sensor down until the sensor is just touching the bottom.
You can see this by watching the cable, when the sensor is all the way down the cable
will go slack. Feed sensor back up until you have about 2” (5 cm) of clearance between
the bottom of clarifier and sensor. Note the distance on the BB1/BB2, this is the Max
Depth (C). Exit the Manual UP/DOWN mode and scroll down to “CBX setup” and enter
the “blind zone (B)” “Max depth (C)” and “Measuring scale (E)” do not forget to set Rake
height (F) if you have a botton rake or if you want to compensate for a slope. Calculate
Measuring range by subtracting Blind zone from Max depth (C-B=E). Measuring range is
the max depth for sludge and fluff that correspond to 20mA on channel 1 (blanket) and 2
(Fluff).
LED indication
Red
Yellow
Green
Status
CBX Start Up, Light Test
Standby, waiting for next sample cycle
Configuration or Setup Mode
Sampling
Configuration or Setup error, check parameters
Mechanical or Electrical Problem
Cold Temp, less then 36ºF inside the unit.
Shut down the CBX to alleviate cold weather damage
Fig 1

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CBX
Operation
All configurations are done via BB1/BB2 that is connected to the CBX. All settings shall
be done and saved (done by exiting the menu) before a new sampling is preformed.
Depth and concentration is shown on the BB1/BB2 on-line during a sampling cycle.
CBX Mode
There is two different modes the CBX can be set to, Setup and Trig.
Trig is the normal working mode. In this mode the CBX will take a sample on every
external trig from the rake limit switch.
Setup, the CBX must be set to this mode before changing calibration parameters or
using “MANUAL UP/DOWN” button.
Rake interval
The rake limit switch starts a measuring cycle. When the rake is passing the rake limit
switch the CBX will execute a sampling cycle. It is possible to configure the number of
pulses from the rake switch that is needs for a measuring cycle to start. This parameter
is called “trig int”. It can be used for delaying the time between the samples, normally
you will take a sample every 30 - 45 minute.
Emergency retraction of the cable
If the CBX for some reason does not retract the cable, then it is possible to do manually.
But always try to switch off the main power to the CBX for 10 seconds and then back on
line again. The CBX will always start with retracting the cable to “home position” after a
power loss. If the cable still does not retract use the emergency motor control switch
that is located on the box for the terminal block inside the CBX. The switch can be
located on top of the terminal box or under the lid. As a safety feature, you must press
and hold the door switch in during manual operation.
NOTE!
As a safety you must press and hold the door switch in during manual operation.

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CBX
Configuration terms
Home position, A
The sensor will always return to this position.
Blind zone, B
Sludge or foam detected in this zone during lowering of the sensor is not registered.
Unwanted interference is prevented by setting this zone to be 1’ (0.3m) below the
normal liquid surface. Sensor does not start to measure until it reaches this distance.
Max depth, C
This is the maximum distance from the home position. The sensor will stop at this depth
if no sludge is detected. The sensor might stop and return at a shorter distance if a rake
guard offset is entered (F).
Sludge level, D
The sludge level distance from bottom found when the preset sludge concentration is
reached.
Measured range, E
The output signal will vary from 4-20 mA within this range.
Raker, F
This denotes the safe height from the bottom (Max depth) to a point where the sensor
always must stop and then turn back to home position to alleviate hitting the bottom
rake.
Fluff, G
The fluff layer or depth found when the present fluff concentration is reached.
Fig 2

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CBX
BB1/BB2 menu for CBX
This section describes the menus used in BB1/BB2 to set up the CBX for
operation. ! Important, you need to exit the Settings menu to save the
parameters or changes!
Settings
Tag
Name of the sensor (10 characters) shown on the main
display.
I-Time[s]
Integration time or dampening - can be set up to 999
seconds. This is integration in BB1/BB2. The value
coming from CBX is normally also an average.
Manual
up/down
Enables the BB1/BB2 to control the sensor in the CBX to
go UP and DOWN. In this mode the depth and
concentration are displayed in the BB1/BB2 . Must
change “MODE” to “TRIG” to activate.
Depth Unit
Unit used for distances in CBX settings in
m, cm, inches or feet & inches.
Cons units
Unit for measure in
”%”, ”ppm”, ”g/l”, or ”mg/l”
Analog
Set the analog output channels for sludge blanket depth
(distance D in fig 4) as primary and (optional) second
analog for fluff (distance G in fig 4) if used.. 1, 2, 3, 4, 1&2,
3&4, all or none. Standard is all
Second
This shows the height of the fluff layer from the bottom
Blanket
Concentration
Set the consistency that will define the blanket. This can
be done by entering a blanket concentration.
Fluff Cons
(optional)
Set the concentration that will define the fluff layer. This
can be done by entering a fluff concentration.
CBX setup
Sub Program for initial CBX set-up
Mains
freq
The frequency of the power, i.e. 50HZ in Europe and
60Hz in the USA.
Trig
Number of trig closures before lowering the sensor