Endress+Hauser Stamolys CA71CODcr User manual

BA458C/07/EN/06.10
71115573
Valid of:
Software version 01.00.04
Operating Instructions
Stamolys CA71CODcr
Photometric analytical system for determining the chemical
oxygen demand following the DIN dichromate method

Brief overview Stamolys CA71CODcr
2Endress+Hauser
Brief overview
Inlet to the sample pump:
•ValveV1
– Front hose: sample inlet
– Rear hose: inlet from valve V2 (0 mg/l O2standard or standard)
•ValveV2
– Front hose: inlet from canister with standard
– Rear hose: inlet from canister with 0 mg/l O2standard
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 pump P1

Stamolys CA71CODcr
Endress+Hauser 3
Table of contents
1 Safety instructions . . . . . . . . . . . . . . . . 4
1.1 Designated use . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.2 Installation, commissioning and operation . . . . . . . . 4
1.3 Operational safety . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.4 Return . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.5 Safety messages and their meaning . . . . . . . . . . . . . 5
2 Identification . . . . . . . . . . . . . . . . . . . . 6
2.1 Device designation . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.2 Scope of delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.3 Certificates and approvals . . . . . . . . . . . . . . . . . . . . 7
3 Installation . . . . . . . . . . . . . . . . . . . . . . 8
3.1 Incoming acceptance, transport, storage . . . . . . . . . . 8
3.2 Installation conditions . . . . . . . . . . . . . . . . . . . . . . . 8
3.3 Installation instructions . . . . . . . . . . . . . . . . . . . . . 10
3.4 Installation examples . . . . . . . . . . . . . . . . . . . . . . . 11
3.5 Post-installation check . . . . . . . . . . . . . . . . . . . . . . 12
4 Wiring . . . . . . . . . . . . . . . . . . . . . . . . 13
4.1 Electrical connection . . . . . . . . . . . . . . . . . . . . . . . 13
4.2 Signal connection . . . . . . . . . . . . . . . . . . . . . . . . . 15
4.3 Switching contacts . . . . . . . . . . . . . . . . . . . . . . . . 16
4.4 Serial interface . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4.5 Post-connection check . . . . . . . . . . . . . . . . . . . . . . 17
5 Operation . . . . . . . . . . . . . . . . . . . . . . 19
5.1 Display and operating elements . . . . . . . . . . . . . . . 19
5.2 Local operation . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
5.3 Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
6 Commissioning. . . . . . . . . . . . . . . . . . 27
6.1 Function check . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
6.2 Switch-on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
7 Maintenance. . . . . . . . . . . . . . . . . . . . 29
7.1 Maintenance schedule . . . . . . . . . . . . . . . . . . . . . . 29
7.2 Replacing reagents . . . . . . . . . . . . . . . . . . . . . . . . . 29
7.3 Replacing pump hoses . . . . . . . . . . . . . . . . . . . . . . 30
7.4 Replacing valve hoses . . . . . . . . . . . . . . . . . . . . . . 32
7.5 Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
7.6 Placing out of service . . . . . . . . . . . . . . . . . . . . . . . 33
8 Accessories. . . . . . . . . . . . . . . . . . . . . 34
8.1 Collecting vessel . . . . . . . . . . . . . . . . . . . . . . . . . . 34
8.2 Reagents, cleaner, standard solutions . . . . . . . . . . . 34
8.3 Maintenance kit . . . . . . . . . . . . . . . . . . . . . . . . . . 34
8.4 Additional accessories . . . . . . . . . . . . . . . . . . . . . . 34
9 Trouble-shooting . . . . . . . . . . . . . . . . . 35
9.1 Trouble-shooting instructions . . . . . . . . . . . . . . . . . 35
9.2 System error messages . . . . . . . . . . . . . . . . . . . . . . 35
9.3 Process errors without messages . . . . . . . . . . . . . . 36
9.4 Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
9.5 Software history . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
9.6 Return . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
9.7 Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
10 Technical data . . . . . . . . . . . . . . . . . . . 39
10.1 Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
10.2 Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
10.3 Power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
10.4 Performance characteristics . . . . . . . . . . . . . . . . . . 40
10.5 Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
10.6 Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
10.7 Mechanical construction . . . . . . . . . . . . . . . . . . . . 41
11 Appendix. . . . . . . . . . . . . . . . . . . . . . . 42
11.1 Operating matrix . . . . . . . . . . . . . . . . . . . . . . . . . . 42
11.2 Maintenance schedule . . . . . . . . . . . . . . . . . . . . . . 44
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Safety instructions Stamolys CA71CODcr
4Endress+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
• Estimating the oxygen demand in the aeration basin
• 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.
1.4 Return
If the analyzer has to be repaired, please return it cleaned to the responsible sales center.
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"!

Stamolys CA71CODcr Safety instructions
Endress+Hauser 5
1.5 Safety messages and their meaning
1.5.1 Generals
The structure, signal words and safety colors of the signs comply with the specifications of
ANSI Z535.6 ("Product safety information in product manuals, instructions and other collateral
materials").
1.5.2 Special messages
Safety message structure Meaning
DANGER
!
Cause (/consequences)
Consequences if safety message
is not heeded
►Corrective action
This symbol alerts you to a dangerous situation.
Failure to avoid the situation will result in a fatal or serious
injury.
WARNING
!
Cause (/consequences)
Consequences if safety message
is not heeded
►Corrective action
This 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
This symbol alerts you to situations that can result in damage to
property and equipment.
Wear protective clothing
Wear a laboratory coat, protective gloves and protective goggles when working on the analyzer and
when handling chemicals.
Please observe the information on the safety data sheets with regard to the dangers posed by the
chemicals used.

Identification Stamolys CA71CODcr
6Endress+Hauser
2 Identification
2.1 Device designation
2.1.1 Nameplate
Compare the (extended) order code on the nameplate (on the analyzer) to the product structure and
your order.
You can read the following information from the nameplate:
•Ordercode
• Extended order code (=order code from the product structure)
• Serial number
•Measuringrange
• Outputs and communication
• Power supply
• Ingress protection
• Environment conditions
2.1.2 Order code and device version
To find out the version of your device, enter the order code indicated on the nameplate in the
search screen at the following address: www.products.endress.com/order-ident
2.2 Scope of delivery
The scope of delivery comprises:
• an analyzer with mains plug
• a cleaning injector
• 4 fastening clips
• a tube of silicone grease
• a Norprene 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 C-flex hose, length 2.5 m (8.2 ft), ID 6.4 mm (1/4 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)
• two T-hose fittings of each size:
– 1.6 mm x 1.6 mm x 1.6 mm (1/16 inch x 1/16 inch x 1/16 inch)
– 3.2 mm x 3.2 mm x 3.2 mm (1/8 inch x 1/8 inch x 1/8 inch)
• a hose fitting 3.2 mm x 1.6 mm (1/8 inch x 1/16 inch) for Tygon hose
• an interference suppressor for the current output
• 4 edge covers
• protective cloves
• protective glasses
•alabcoat
• a hose 4/6 mm (0.16/0.24 inch), PTFE, length 4.5 m (14.7 ft)
• a 5 l (1,32 US gal.) container for chromate containing waste
• a cover for the container, with hose connector
• a quality certificate
• Operating Instructions (English).

Stamolys CA71CODcr Identification
Endress+Hauser 7
2.3 Certificates and approvals
2.3.1 4approval
Declaration of conformity
The product meets the requirements of the harmonized European standards. It thus complies with
the legal requirements of the EC directives.
The manufacturer confirms successful testing of the product by affixing the 4symbol.
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.

Installation Stamolys CA71CODcr
8Endress+Hauser
3 Installation
3.1 Incoming acceptance, transport, storage
• Make sure the packaging is undamaged!
Inform the supplier about any damage to the packaging.
Keep the damaged packaging until the matter has been settled.
• Make sure the contents are undamaged!
Inform the supplier about damage to the contents. Keep the damaged products until the matter
has been settled.
• Check that the order is complete and agrees with your shipping documents.
• The packaging material used to store or to transport the product must provide shock protection
and humidity protection. The original packaging offers the best protection. 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 device, observe a lateral distance of at least 120 mm (4.7") for
mounting the collecting vessel.
►The outflow hose should not form a siphon.
60 (2.36)
100(3.94)
140 (5.51)
160 (6.30)
250 (9.84)
125(4.92)
165 (6.50)
Ø21(0.83)
Ø26/1.02
Ø21
(0.83)
119(4.69)
78(3.07)
47(1.85)
648 (25.5)
360 (14.2)
436 (17.2)
243 (9.57)
200 (7.87)
120
(4.72)
326 (12.8)
330 (13.0)
110
(4.33)
Ø27(1.06)
Ø 16 (0.63)
Ø 27 (1.06)
120(4.72)
555 (21.8)
465 (18.3)
500 (19.7)
7-11/
0.28 - 0.43
(M 6)
Ø 26(1.02)
mm (inch)
38 (1.5)

Stamolys CA71CODcr Installation
Endress+Hauser 9
3.2.2 Connecting the sample line
Adjusting the level measurement
Adjust the conductive level measurement due to the number of connected analysers.
1. In dependence of the application, mount the right adjusting pin or no adjusting pin (→å5
and →å6, position 2).
2. To receive an optimum sample volume, pull the marked pipe (position 3) downwards due to
your application (1, 2 or 3 analysers).
a0001363
Abb. 3: Collecting vessel at analyzer (optional)
1 Ventilation
2 Sample inlet from sampling
3 Collecting vessel
4 Electrical connections
5 Analyzer sample inlet
a0001346
Abb. 4: Collecting vessel dimensions
* variable, freely adjustable dimensions
6 Sampling for analyzer
7 Sample overflow
8 Analyzer outlet
Collecting vessel (at analyzer, with or without level measurement)
Connection hose ID 3.2 mm (1/8 inch)
Customer collecting vessel
Connection hose ID 1.6 mm (1/16 inch)
Max. distance from collecting vessel to analyzer 1 m (3.3 ft)
Max. height difference from collecting vessel to analyzer 0.5 m (1.6 ft)
*
*
*
130 (5.12)
17 (0.67)
10 (0.39)
145 (5.71)
79 (3.11)
120 (4.72)
140 (5.51)
115 (4.53) Ø 34/25 (1.34/0.98)
3 x Ø 28/20 (1.1/0.79)
4 x Ø 6.6 (0.26)
27 (1.06) 60 (2.36)
4 x Ø 5.5/10.4 (0.22/0.41)
Ø56(2.2)
Ø 50H7 (1.97H0.28)
M20x1.5
Ø 24 (0.94)
70 (2.76)
100 (3.9)
80(3.15)
mm (inch)
48(1.89)
42(1.65)
70(2.76)
60(2.36)

Installation Stamolys CA71CODcr
10 Endress+Hauser
3.3 Installation instructions
To install the analyzer at the intended location, proceed as follows:
1. Mount the analyzer and secure it to a vibration-free wall using screws (Ø6 mm / 0.24"). The
fastening clips on the housing make sure that the necessary distance to the wall is observed for
ventilation purposes.
For the installation dimensions, please see the previous chapter.
2. Using a spirit level, check that the cabinet is hanging straight. Only in this way can any air
bubbles present escape from the cell.
3. Fit the edge covers (with GFR housing 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.
6. Connect the drain hoses to the connections marked for chromate waste, rinse waste and
emergency overflow.
7. Route the drain hose for dichromate waste into the cover of the canister and make sure the
drain hose for the rinse water and that for emergency overflow end in the drain pipe previously
laid. The drain hose for emergency overflow must be open to air. Avoid siphon formation at all
times!
8. Insert the valve hoses accordingly. These were partly removed from the valves for
transportation. This prevents the hoses from sticking or pressure being applied to a point in the
hose over an extended period.
a0001367
Fig. 5: One analyser
1 M 3x12 (0.47")
2 M 3x35 (1.38")
3Mark1
a0001366
Fig. 6: Two analysers
1 M 3x12 (0.47")
2 M 3x20 (0.79")
3Mark2
a0001365
Fig. 7: Three analysers
1 M 3x12 (0.47")
3Mark3
a0012421
Fig. 8: Valves and valve hoses
1
2
3
4
5
6
7
8
9
10
11
Sample
Standard (100 or 2500 mg/l O2)
0 mg/l O2standard
Sulfuric acid R1
Dichromate solution R2
From sample/acid pump P1
Inlet to sample/acid pump P1
From reagent pump P2
Inlet, reagent pump P2
Inlet, reagent to reactor
Inlet, sample/acid to reactor
1
2
3
1
2
3
1
3