Endress+Hauser CAT820 User manual

Products Solutions Services
Operating Instructions
Liquiline System CAT820
Automatic sample conditioning system for
supplying process measuring devices with filtered
sample from sludge activation, secondary
clarification or surface water
BA01274C/07/EN/03.21
71530851
2021-07-31

Liquiline System CAT820 Table of contents
Endress+Hauser 3
Table of contents
1 About this document ........... 4
1.1 Warnings ........................... 4
1.2 Document function ................... 4
1.3 Symbols ............................ 4
2 Basic safety instructions ....... 6
2.1 Requirements for personnel ........... 6
2.2 Designated use ...................... 6
2.3 Workplace safety .................... 6
2.4 Operational safety ................... 6
2.5 Product safety ....................... 7
3 Product description ............. 8
4 Incoming acceptance and
product identification .......... 9
4.1 Incoming acceptance ................. 9
4.2 Product identification ................. 9
4.3 Scope of delivery .................... 10
5 Certificates and approvals .... 10
5.1  mark ........................... 10
5.2 EAC .............................. 10
6 Installation .................... 11
6.1 Installation conditions ............... 11
6.2 Mounting the sample preparation
system ............................ 14
6.3 Mounting the ceramic filter in the
process ............................ 19
6.4 Mounting the plate filter in the
process ............................ 24
6.5 Connecting external compressed air ....24
6.6 Post-installation check ............... 25
7 Electrical connection .......... 26
7.1 Version with Memosens technology ... 26
7.2 Time-controlled version .............. 27
7.3 Connecting cables and hoses .......... 27
7.4 Structure of the spiral hose ........... 29
8 Operation options ............. 30
8.1 Version with Memosens technology ... 30
8.2 Time-controlled version .............. 30
9 Commissioning ................ 31
9.1 Function check ..................... 31
10 Operation ...................... 32
10.1 Setup of version with Memosens
technology ......................... 32
10.2 Setup of version with time control ..... 32
11 Diagnostics and
troubleshooting ............... 34
12 Maintenance .................. 35
12.1 Maintenance schedule ............... 35
12.2 Maintenance tasks .................. 35
12.3 Replacing the pump hose and pump
head .............................. 37
12.4 Replacing the ceramic filter ........... 38
12.5 Replacing the plate filter ............. 38
13 Repair .......................... 39
13.1 Spare parts ........................ 39
13.2 Return ............................ 41
13.3 Disposal ........................... 41
14 Accessories .................... 42
14.1 Cleaner for hoses and filter CY820 ..... 42
15 Technical data ................. 43
15.1 Temperature inputs ................. 43
15.2 Power supply ....................... 43
15.3 Performance characteristics .......... 44
15.4 Environment ....................... 45
15.5 Process ............................ 45
15.6 Mechanical construction ............. 46
Index ................................. 49

About this document Liquiline System CAT820
4 Endress+Hauser
1 About this document
1.1 Warnings
Structure of information Meaning
LDANGER
Causes (/consequences)
If necessary, Consequences of non-
compliance (if applicable)
‣Corrective action
This symbol alerts you to a dangerous situation.
Failure to avoid the dangerous situation will result in a fatal or serious injury.
LWARNING
Causes (/consequences)
If necessary, Consequences of non-
compliance (if applicable)
‣Corrective action
This symbol alerts you to a dangerous situation.
Failure to avoid the dangerous situation can result in a fatal or serious injury.
LCAUTION
Causes (/consequences)
If necessary, Consequences of non-
compliance (if applicable)
‣Corrective action
This symbol alerts you to a dangerous situation.
Failure to avoid this situation can result in minor or more serious injuries.
NOTICE
Cause/situation
If necessary, Consequences of non-
compliance (if applicable)
‣Action/note
This symbol alerts you to situations which may result in damage to property.
1.2 Document function
These Operating Instructions contain all the information that is required in various phases of
the life cycle of the device: from product identification, incoming acceptance and storage, to
mounting, connection, operation and commissioning through to troubleshooting,
maintenance and disposal.
1.3 Symbols
Additional information, tips
Permitted or recommended
Not permitted or not recommended
Reference to device documentation
Reference to page
Reference to graphic
 Result of a step
1.3.1 Symbols on the device
Reference to device documentation

Liquiline System CAT820 About this document
Endress+Hauser 5
Do not dispose of products bearing this marking as unsorted municipal waste. Instead, return them to the
manufacturer for disposal under the applicable conditions.

Basic safety instructions Liquiline System CAT820
6 Endress+Hauser
2 Basic safety instructions
2.1 Requirements for personnel
• Installation, commissioning, operation and maintenance of the measuring system may be
carried out only by specially trained technical personnel.
• The technical personnel must be authorized by the plant operator to carry out the specified
activities.
• The electrical connection may be performed only by an electrical technician.
• The technical personnel must have read and understood these Operating Instructions and
must follow the instructions contained therein.
• Faults at the measuring point may only be rectified by authorized and specially trained
personnel.
Repairs not described in the Operating Instructions provided must be carried out only
directly at the manufacturer's site or by the service organization.
2.2 Designated use
The Liquiline System CAT820 sample preparation system is designed to automatically supply
process measuring devices with filtered sample from sludge activation, secondary clarification
or surface water.
Use of the device for any purpose other than that described, poses a threat to the safety of
people and of the entire measuring system and is therefore not permitted. The manufacturer
is not liable for damage caused by improper or non-designated use.
2.3 Workplace safety
As the user, you are responsible for complying with the following safety conditions:
• Installation guidelines
• Local standards and regulations
Electromagnetic compatibility
• The product has been tested for electromagnetic compatibility in accordance with the
applicable international standards for industrial applications.
• The electromagnetic compatibility indicated applies only to a product that has been
connected in accordance with these Operating Instructions.
2.4 Operational safety
Before commissioning the entire measuring point:
1. Verify that all connections are correct.
2. Ensure that electrical cables and hose connections are undamaged.
3. Do not operate damaged products, and protect them against unintentional operation.
4. Label damaged products as defective.

Liquiline System CAT820 Basic safety instructions
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During operation:
‣If faults cannot be rectified:
products must be taken out of service and protected against unintentional operation.
2.5 Product safety
2.5.1 State-of-the-art technology
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. The relevant regulations and
international standards have been observed.

Product description Liquiline System CAT820
8 Endress+Hauser
3 Product description
A complete sampling unit comprises:
• Liquiline System CAT820 sample preparation system
• Controller with soft keys and status LEDs
• Peristaltic pump
• Filter unit with filter and assembly in the configuration ordered
• Flexdip CYH112 holder for mounting (must be ordered separately)
• Compressed air cleaning (optional) for longer filter maintenance intervals
• Sample hose, filter to pump in the configuration ordered
• Sample hose, pump to analyzer in the configuration ordered
• Cleaner (must be ordered separately)
1
2
3
4
5
6
A0046022
 1 CAT820 open
1 Carrier board
2 Cleaning valve (optional, identifiable by the additional hose fittings)
3 Peristaltic pump
4 Protective cover
5 Soft keys
6 Status LEDs

Liquiline System CAT820 Incoming acceptance and product identification
Endress+Hauser 9
4 Incoming acceptance and product identification
4.1 Incoming acceptance
1. Verify that the packaging is undamaged.
 Notify the supplier of any damage to the packaging.
Keep the damaged packaging until the issue has been resolved.
2. Verify that the contents are undamaged.
 Notify the supplier of any damage to the delivery contents.
Keep the damaged goods until the issue has been resolved.
3. Check that the delivery is complete and nothing is missing.
 Compare the shipping documents with your order.
4. Pack the product for storage and transportation in such a way that it is protected
against impact and moisture.
 The original packaging offers the best protection.
Make sure to comply with the permitted ambient conditions.
If you have any questions, please contact your supplier or your local Sales Center.
4.2 Product identification
4.2.1 Nameplate
The nameplate provides you with the following information on your device:
• Manufacturer identification
• Order code
• Serial number
• Power supply
• Degree of protection
• Ambient and process conditions
‣Compare the information on the nameplate with the order.
4.2.2 Product identification
Product page
www.endress.com/cat820
Interpreting the order code
The order code and serial number of your product can be found in the following locations:
• On the nameplate
• In the delivery papers
Obtaining information on the product
1. Go to www.endress.com.
2. Call up the site search (magnifying glass).

Certificates and approvals Liquiline System CAT820
10 Endress+Hauser
3. Enter a valid serial number.
4. Search.
 The product structure is displayed in a popup window.
5. Click on the product image in the popup window.
 A new window (Device Viewer) opens. All of the information relating to your
device is displayed in this window as well as the product documentation.
4.3 Scope of delivery
The scope of delivery comprises:
• 1 Liquiline System CAT820 in the version ordered
• 1 copy of the Operating Instructions (in the desired language on selection of the order
option)
• Optional accessories
‣If you have any queries:
Please contact your supplier or local sales center.
5 Certificates and approvals
5.1  mark
The product meets the requirements of the harmonized European standards. As such, it
complies with the legal specifications of the EU directives. The manufacturer confirms
successful testing of the product by affixing to it the  mark.
5.2 EAC
The product has been certified according to guidelines TP TC 004/2011 and TP TC 020/2011
which apply in the European Economic Area (EEA). The EAC conformity mark is affixed to the
product.

Liquiline System CAT820 Installation
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6 Installation
6.1 Installation conditions
6.1.1 Dimensions
162 (6.38)
Ø4 (0.16)
Ø9 (0.35)
199 (7.38) 128 (5.04)
237 (9.33)
194 (7.64)
A0029547
 2 Liquiline System CAT820. Engineering unit: mm (in)

Installation Liquiline System CAT820
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340 (13.39)
A0032007
 3 Ceramic filter. Engineering unit: mm (in)
400 (15.75)
350 (13.78)
350 (13.78)
450 (17.72)
! 34x2 (1.34x2)
10 (0.4)
A0045979
 4 Plate filter. Engineering unit: mm (in)

Liquiline System CAT820 Installation
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6.1.2 Mounting plate
80 (3.15)
190 (7.48)
3 (0.12)
4 x 6.5 (0.26)
170 (6.69)
125 (4.92)
A0029938
 5 Mounting plate. Engineering unit: mm (in)
6.1.3 Weather protection cover (optional)
NOTICE
Effect of climatic conditions (rain, snow, direct sunlight etc.)
Malfunctions through to complete failure of the sample preparation system
‣Always use the weather protection cover (accessory) when installing the device outdoors.

Installation Liquiline System CAT820
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320 (12.6)
270 (10.6)
300 (11.8)
80 (3.15)
170 (6.69)
170 (6.69)
80 (3.15)
8 x Ø 7 (0.28)
A0029939
 6 Weather protection cover. Engineering unit: mm (in)
6.2 Mounting the sample preparation system
The sample preparation system can be installed in 3 ways:
• on a pipe
• on a post
• on a railing (round or square, clamping range 20 to 61 mm (0.79 to 2.40 in)
The post mounting kit (optional) is required for mounting the device on a pipe, post or
railing.

Liquiline System CAT820 Installation
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6.2.1 Mounting the sample preparation system on a post
1 2 34
56
7
8
A0029941
 7
1 Weather protection cover (optional) 5 Spring washers, nuts (post mounting kit)
2 Post mounting plate (post mounting kit) 6 Pipe or railing (circular/square)
3 Spring washers, nuts (post mounting kit) 7 Mounting plate
4 Pipe clamps (post mounting kit) 8 Threaded rods (post mounting kit)
A0029949
 8 Post mounting
1.
2.
A0029950
 9 Attach the device and click it into place

Installation Liquiline System CAT820
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6.2.2 Mounting the sample preparation system on a railing
1 2 34
56
7
8
9
A0032012
 10
1 Weather protection cover (optional) 5 Spring washers, nuts (post mounting kit)
2 Post mounting plate (post mounting kit) 6 Pipe or railing (circular/square)
3 Spring washers, nuts (post mounting kit) 7 Mounting plate
4 Pipe clamps (post mounting kit) 8 Threaded rods (post mounting kit)
A0029952
 11 Rail mounting
1.
2.
A0029953
 12 Attach the device and click it into place

Liquiline System CAT820 Installation
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6.2.3 Mounting the sample preparation system on a wall
Mount the sample preparation system in such a way that the wall support surface is the size
of the rear housing panel at least.
≥ 340
(13,4)
≥ 150 (5,91)
A0029957
 13 Installation clearance.
Engineering unit: mm
(in)
1
3
4
2
A0029958
 14 Wall mounting
1.
2.
A0029959
 15 Attach the device and
click it into place
1 Wall
2 Drill holes
3 Mounting plate
4 Screws Ø 6 mm (0.24 in)(not
included in scope of supply) 1)
1) The size of the drill holes depends on the wall plugs used. The wall plugs and screws must be provided by the
customer.
6.2.4 Securing the temperature sensor (version with heated housing or heated
hoses)
The sample preparation system has a temperature sensor for measuring the ambient
temperature. By measuring the ambient temperature, the device controls the heating of the
housing and hoses. At time of delivery, the temperature sensor is located in the housing of the
sample preparation system.

Installation Liquiline System CAT820
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Proceed as follows to secure the temperature sensor outdoors:
1. Release the 4 screws on the housing of the sample preparation system.

A0029977
 16 Releasing 4 screws on housing
2. Guide the cable of the temperature sensor through the cable entry and out of the
housing. The total cable length is 1 m (3.28 ft).

1
A0031726
1 Cable entry to guide the temperature sensor cable out
3. Secure the temperature sensor outside.
6.2.5 Disassembling (for conversion, cleaning)
NOTICE
The device can be damaged if dropped
‣When pushing the housing out of the holder, secure the housing to prevent it from falling.
If possible, ask a second person to help you.

Liquiline System CAT820 Installation
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1.
2.
A0029961
 17 Disassembling
1 Hold down the latch
2 Push up the housing to remove it from the
holder
3.
A0029962
 18 Disassembling
3 Remove the device from the front
6.3 Mounting the ceramic filter in the process
Select the installation location so that a suitable distance from fixed installations is
maintained, and the ceramic filter cannot be damaged even when the medium is moving.
For fixed installation, select the retaining point so that the proper operation and maintenance
of the assembly is guaranteed. The immersion tube must protrude by at least
100 mm (3.94 in) over the retaining point (→  19,  20).
The ceramic filter may only be installed with an assembly. Use Endress+Hauser
assemblies to install the ceramic filter correctly.

Installation Liquiline System CAT820
20 Endress+Hauser
min. 100
(3.94)
A0029963
 19 Retaining point (shown without splash protection cap)
6.3.1 Mounting as a fixed installation with immersion tube
The cross clamp is mounted in such a way that one closed side faces the center of the
basin while the other closed side faces upwards.
Mount the immersion tube as follows:
1
2
3
4
A0029965
 20
1
2
3
4
Immersion tube
Cross clamp, closed side facing center of basin
Cross clamp, closed side facing upwards
Holder transverse pipe