Endress+Hauser Liquiline System CA80AL User manual

Products Solutions Services
Operating Instructions
Liquiline System CA80AL
Colorimetric analyzer for aluminum
BA01585C/07/EN/03.20
71462496
2020-01-31
Valid as of version
01.07.00

Liquiline System CA80AL Table of contents
Endress+Hauser 3
Table of contents
1 About this document ................ 5
1.1 Warnings ............................ 5
1.2 Symbols .............................. 5
1.3 Symbols on the device ................... 5
1.4 Documentation ........................ 6
2 Basic safety instructions ............ 7
2.1 Requirements for the personnel ............ 7
2.2 Designated use ........................ 7
2.3 Workplace safety ....................... 7
2.4 Operational safety ...................... 7
2.5 Product safety ......................... 8
3 Product description ................. 9
3.1 Product design ......................... 9
3.2 Measuring system ...................... 9
3.3 Equipment architecture ................. 12
4 Incoming acceptance and product
identification ..................... 14
4.1 Incoming acceptance ................... 14
4.2 Product identification ................... 14
4.3 Scope of delivery ...................... 15
4.4 Certificates and approvals ............... 15
5 Installation ....................... 16
5.1 Installation conditions .................. 16
5.2 Mounting the analyzer on a wall .......... 18
5.3 Installing version with analyzer stand ....... 19
5.4 "Outdoor" version: mounting on a post ....... 21
5.5 Post-installation check .................. 24
6 Electrical connection .............. 25
6.1 Connection conditions .................. 25
6.2 Connecting the analyzer ................. 25
6.3 Connecting sample preparation ........... 29
6.4 Connecting the sensors and additional
modules ............................ 32
6.5 Hardware settings ..................... 39
6.6 Ensuring the degree of protection .......... 40
6.7 Post-connection check .................. 41
7 System integration ................ 42
7.1 Web server .......................... 42
7.2 Service interface ...................... 43
7.3 Fieldbuses ........................... 44
8 Operation options ................. 46
8.1 Structure and function of the operating
menu .............................. 46
8.2 Access to the operating menu via the local
display ............................. 46
9 Commissioning .................... 49
9.1 Preparatory steps ...................... 49
9.2 Function check ....................... 51
9.3 Switching on the measuring device ......... 52
9.4 Setting the operating language ............ 52
9.5 Configuring the measuring device .......... 52
10 Operation ......................... 54
10.1 Display ............................. 54
10.2 General settings ....................... 55
10.3 Analyzer ............................ 68
10.4 Sample preparation .................... 73
10.5 Current inputs ........................ 77
10.6 Binary inputs and outputs ............... 78
10.7 Signal outputs ........................ 86
10.8 Additional functions ................... 95
11 Diagnostics and troubleshooting .. 118
11.1 General troubleshooting ................ 118
11.2 Diagnostic information on local display ..... 119
11.3 Diagnostic information via web browser .... 119
11.4 Diagnostic information via fieldbus ........ 119
11.5 Adapting the diagnostic information ...... 120
11.6 Overview of diagnostic information ....... 122
11.7 Pending diagnostic messages ............ 129
11.8 Diagnostics list ...................... 129
11.9 Logbooks ........................... 130
11.10 System information ................... 135
11.11 Sensor information ................... 137
11.12 Simulation .......................... 137
11.13 Device test .......................... 138
11.14 Resetting ........................... 140
11.15 Operating time information ............. 140
11.16 Firmware history ..................... 141
12 Maintenance .................... 142
12.1 Maintenance schedule ................. 142
12.2 Cleaning ........................... 143
12.3 Replacing reagents, standard and cleaner ... 144
12.4 Carrying out zero point calibration ........ 145
12.5 Replacing the hoses ................... 146
12.6 Replacing filter mats .................. 146
12.7 Replacing dispensers .................. 147
12.8 Replacing the Liquid Manager ........... 148
12.9 Taking out of service .................. 149
13 Repair ........................... 151
13.1 Spare parts ......................... 151
13.2 Return ............................. 153

Table of contents Liquiline System CA80AL
4 Endress+Hauser
13.3 Disposal ........................... 154
14 Accessories ...................... 155
14.1 Sample preparation ................... 155
14.2 Installation accessories ................ 155
14.3 Consumables for CA80AL .............. 155
14.4 Maintenance kit CAV800 ............... 156
14.5 Cleaner CY820 (for hoses of sample
preparation system and of
sample collecting vessel) ............... 156
14.6 Upgrade kits CAZ800 .................. 156
14.7 Sensors ............................ 157
14.8 Additional functionality ................ 160
14.9 Measuring cable ..................... 161
14.10 Software ........................... 161
14.11 Other accessories ..................... 162
15 Technical data ................... 163
15.1 Input .............................. 163
15.2 Output ............................ 163
15.3 Current outputs, active ................. 164
15.4 Relay outputs ........................ 165
15.5 Protocol-specific data .................. 166
15.6 Power supply ........................ 167
15.7 Performance characteristics ............. 168
15.8 Environment ........................ 169
15.9 Process ............................ 170
15.10 Mechanical construction ............... 170
Index ................................. 172

Liquiline System CA80AL About this document
Endress+Hauser 5
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 Symbols
Symbol Meaning
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 Symbols on the device
Symbol Meaning
Reference to device documentation
Caution: Hazardous voltage
Warning: Risk of injury from rotating cogwheels

About this document Liquiline System CA80AL
6 Endress+Hauser
1.4 Documentation
The following instructions complement these Operating Instructions and are available on
the product pages on the Internet:
• Brief Operating Instructions Liquiline SystemCA80AL, KA01236C
• Operating Instructions Memosens, BA01245C
• Software description for Memosens inputs
• Calibration of Memosens sensors
• Sensor-specific diagnostics and troubleshooting
• Guidelines for communication via fieldbus and web server
• PROFIBUS, SD01188C
• Modbus, SD01189C
• Web server, SD01190C
• EtherNet/IP, SD01293C
• Special documentation on reagents:
CY80AL

Liquiline System CA80AL Basic safety instructions
Endress+Hauser 7
2 Basic safety instructions
2.1 Requirements for the 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 CA80AL is a wet-chemical analyzer for the almost continuous
determination of the concentration of aluminum in liquid media.
The analyzer is designed for use in the following applications:
• Control of the precipitation of phosphates in wastewater treatment plants
• Monitoring of precipitants in drinking water and wastewater treatment plants
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.
During operation:
1. If faults cannot be rectified:
products must be taken out of service and protected against unintentional operation.
2. Keep the door closed when not carrying out service and maintenance work.

Basic safety instructions Liquiline System CA80AL
8 Endress+Hauser
LCAUTION
Activities while the analyzer is in operation
Risk of injury and infection from medium, reagents or cleaner!
‣Before you release any hoses, make sure that no actions, such as the pumping of
sample, are currently running or are due to start shortly.
‣Wear protective clothing, goggles and gloves or take other suitable measures to protect
yourself.
‣Wipe up any spilt reagent with a disposable tissue and rinse with clear water. Then dry
the cleaned areas with a cloth.
LCAUTION
Risk of injury from door stop mechanism
‣Always open the door fully to ensure the door stop engages properly.
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.
Devices connected to the analyzer must comply with the applicable safety standards.
2.5.2 IT security
We only provide a warranty if the device is installed and used as described in the
Operating Instructions. The device is equipped with security mechanisms to protect it
against any inadvertent changes to the device settings.
IT security measures in line with operators' security standards and designed to provide
additional protection for the device and device data transfer must be implemented by the
operators themselves.

Liquiline System CA80AL Product description
Endress+Hauser 9
3 Product description
3.1 Product design
4
5
6
1
2
3
A0028795
 1 Example of a Liquiline System CA80
1 Sample collecting vessel (optional)
2 Window
3 Air vent for cooling
4 Bottle tray for reagents, cleaner and standard
5 Photometer
6 Controller
3.2 Measuring system
A complete measuring system comprises:
• Analyzer Liquiline System CA80AL with the configuration ordered
• reagents cleaner and standard solution (to be ordered separately)
• Liquiline System CAT8x0 sample preparation (optional)
Microfiltration (Liquiline System CAT810)
• Function: pressure pipe sampling and filtration
• Sieve filter, 50 µm
• Control via CA80
Optional: time control via integrated timer
• Backflushing, with compressed air or water
• Panel version or integration into analyzer stand
• Application: drinking water, industrial wastewater
Membrane filtration (Liquiline System CAT820), ceramic filter version
• Function: sampling and filtration
• Ceramic membrane filter cartridge; pore size 0.1 µm
• Communication via Memosens protocol, control via CA80
• Backflushing with compressed air (version with Memosens technology)
• Easy installation with Flexdip CYH112 (TI00430C)
• Application: sludge activation, drinking water, industrial wastewater, surface water

Product description Liquiline System CA80AL
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Membrane filtration (Liquiline System CAT860)
• Function: sampling and filtration
• Ceramic membrane filter cartridge; pore size 0.1 µm
• Communication via Memosens protocol, control via CA80
• Automatic backflush function with cleaning solution and compressed air
• Easy installation with Flexdip CYH112 (TI00430C)
• Application: wastewater treatment plant inlet
1
2
3
4
A0028796
 2 Measuring system with Liquiline System, self-priming
1 Liquiline System CA80AL
2 Photometer
3 Dosing dispenser
4 Particle-free sample
1
2
3
4
5
6
7
A0028792
 3 Measuring system with Liquiline System
CAT810
1 Overflow
2 Liquiline System CA80
3 Sample collecting vessel overflow
4 Sample
5 Pressurized sample
6 Filter unit
7 Liquiline System CAT810
1
2
3
4
5
6
7
8
9
A0028793
 4 Measuring system with Liquiline System
CAT810 and cleaning valve
1 Overflow
2 Liquiline System CA80
3 Sample collecting vessel overflow
4 Sample
5 Cleaning valve
6 Pressurized sample
7 Filter unit
8 Purge connection (compressed air or water)
9 Liquiline System CAT810

Liquiline System CA80AL Product description
Endress+Hauser 11
12
4
5
3
6
7
A0028789
 5 Measuring system with Liquiline System
CAT820
1 Pump
2 Liquiline System CA80
3 Sample collecting vessel
4 Sample collecting vessel overflow
5 Sample
6 Filter (ceramic)
7 Medium
123
4
5
6
7
8
910
A0028788
 6 Measuring system with Liquiline System
CAT860
1 Pump
2 Valve
3 Liquiline System CA80
4 Sample
5 Valve
6 Compressed air
7 Liquiline System CAT860
8 Cleaning solution
9 Medium
10 Filter (ceramic)
12
3
4
5
6
A0028790
 7 Measuring system with 2 Liquiline Systems CAT820
1 Pump
2 Liquiline System CA80
3 Sample
4 Valve
5 Medium
6 Filter (ceramic)

Product description Liquiline System CA80AL
12 Endress+Hauser
1234
5
6
7
8
9
A0028787
 8 Measuring system with Liquiline System CA80, Liquiline System CAT820 and second analyzer
1 Backflushing with compressed air (optional) 6 Second analyzer
2 Valve (optional) 7 Sample to second analyzer
3 Pump 8 Filter (ceramic)
4 Liquiline System CA80 9 Medium
5 Sample
3.3 Equipment architecture
3.3.1 Slot and port assignment
Slot
1
2
Ports
BASE-E
1
2
1
2
A0040673
 9 Slot and port assignment
A0040672
 10 Slot and port assignment
A0040671
 11 Slots and ports on the
display
* Analyzer measured value
(parameter-specific)
• Inputs are assigned to measuring channels in the ascending order of the slots and ports.
In the example above:
"CH1: 1:1 pH glass" means:
Channel 1 (CH1) is slot 1 (basic module) : Port 1 (input 1), pH glass sensor
• Outputs and relays are named according to their function, e.g. "current output", and are
displayed in ascending order with the slot and port numbers
• Display shows SP1: analyzer measuring channel 1 with sampling point SP1 (measured
value display is parameter-specific; is not illustrated in the example)

Liquiline System CA80AL Product description
Endress+Hauser 13
3.3.2 Terminal diagram
The unique terminal name is derived from:
Slot no. : Port no. : Terminal
Example, NO contact of a relay
Device with 4 inputs for digital sensors, 4 current outputs and 4 relays
• Base module BASE2-E (contains 2 sensor inputs, 2 current outputs)
• 2DS module (2 sensor inputs)
• 2AO module (2 current outputs)
• 4R module (4 relays)
1 2 34
43 42 41
Relay 1
Relay 2
Relay 3
Relay 4
Slot
Slot 4 Port 1 Pin 41
BASE2-E 2DS 4R 2AO
43 42 41 43 42 41
43 42 41
43 42 41
A0039621
 12 Creating a terminal diagram using the example of the NO contact (terminal 41) of a relay

Incoming acceptance and product identification Liquiline System CA80AL
14 Endress+Hauser
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.
NOTICE
Incorrect transportation can damage the analyzer
‣Always use a lifting truck or a fork-lift to transport the analyzer.
4.2 Product identification
4.2.1 Nameplate
Nameplates can be found:
• On the inside of the door on the bottom right, or on the front in the bottom right-hand
corner
• On the packaging (adhesive label, portrait format)
The nameplate provides you with the following information on your device:
• Manufacturer identification
• Order code
• Extended order code
• Serial number
• Firmware version
• Ambient and process conditions
• Input and output values
• Measuring range
• Activation codes
• Safety information and warnings
• Approvals as per order version
‣Compare the information on the nameplate with the order.
4.2.2 Identifying the product
Product page
www.endress.com/ca80al

Liquiline System CA80AL Incoming acceptance and product identification
Endress+Hauser 15
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).
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.
4.2.3 Manufacturer address
Endress+Hauser Conducta GmbH+Co. KG
Dieselstraße 24
D-70839 Gerlingen
4.3 Scope of delivery
The scope of delivery comprises:
• 1 analyzer in the version ordered with optional hardware
• 1 print version of Brief Operating Instructions in the language ordered
• 1 Maintenance Manual
• Optional accessories
‣If you have any queries:
Please contact your supplier or local sales center.
4.4 Certificates and approvals
4.4.1  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.
4.4.2 cCSAus
The product meets the requirements as per "CLASS 2252 06 - Process Control Equipment"
and "CLASS 2252 86 - Process Control Equipment". It is tested to Canada and USA
standards: CAN/CSA-C22.2 No. 61010-1-12 UL Std. No. 61010-1 (3rd Edition).

Installation Liquiline System CA80AL
16 Endress+Hauser
5 Installation
LCAUTION
Incorrect transportation can cause injury and damage the device
‣Always use a lifting truck or a fork-lift to transport the analyzer. Two people are
needed for the installation.
‣Lift the device by the recessed grips.
5.1 Installation conditions
The device can be installed in the following ways:
• As an independent table-top device
• Mounted on a wall
• Mounted on a base
• Mounted on a stand
5.1.1 Dimensions
530 (20.87)463 (18.23)
793 (31.22)
A0028820
 13 Liquiline System CA80 closed version, dimensions in mm (in)
417 (16.42)
793 (31.22)
530 (20.87)
A0030419
 14 Liquiline System CA80 open version, dimensions in mm (in)

Liquiline System CA80AL Installation
Endress+Hauser 17
930 (36.61)
654 (25.74)
1723 (67.83)
A0028821
 15 Liquiline System CA80 with base, dimensions in mm (in)
1800 (70.9)
8 (0.31)
A0041592
 16 Post (accessory) for "Outdoor" version, dimensions in mm (inch)
5.1.2 Mounting location
Note the following when erecting the device:
‣If mounting on a wall, make sure that the wall has sufficient load-bearing capacity and
is fully perpendicular.
‣If mounting on a base, erect the device on a level surface.
‣Protect the device against additional heating (e.g. from a heating system).
‣Protect the device against mechanical vibrations.
‣Protect the device against corrosive gases, e.g. hydrogen sulfide (H2S) .
‣Make sure to pay attention to the maximum height difference and the maximum
distance from the sampling point.

Installation Liquiline System CA80AL
18 Endress+Hauser
‣Ensure that the unit can drain freely, without any siphoning effects.
‣Make sure air can circulate freely at the front of the housing.
‣Open analyzers (i.e. analyzers that are supplied without a door) may only be erected in
closed areas or in a protective cabinet or similar facility.
5.1.3 Spacing requirements when mounting
Spacing required for installing analyzer
≥330(12.99)
≥100 (3.94)
A0036774
 17 Minimum spacing required for mounting. Engineering unit
mm (in).
≤116 °
A0036775
 18 Maximum opening angle
Spacing required for installing wall-mount version
750 (29.53)
120 (4.72)
Ø 11 (0.43)
Ø 10.7 (0.42)
A0036779
 19 Holder unit dimensions. Engineering unit mm (in)
5.2 Mounting the analyzer on a wall
LCAUTION
Incorrect installation can cause injury and damage the device
‣If mounting on a wall, check that the analyzer is fully hooked into the wall holder unit
at the top and bottom, and secure the analyzer to the upper wall holder unit using the
securing screw.

Liquiline System CA80AL Installation
Endress+Hauser 19
The mounting materials required to secure the device to the wall are not supplied.
‣Provide the mounting materials to secure the device to the wall (screws, wall plugs)
onsite.
 20 Securing the holder unit on the housing
1.
2.
A0036781
 21 Hooking into the wall holder unit
1. Hook the analyzer into the wall holder unit.
2. Secure the two top parts of the wall holder unit with the screw supplied.
5.3 Installing version with analyzer stand
LCAUTION
Incorrect installation can cause injury and damage the device
‣If using the version with analyzer stand, make sure that the analyzer stand is secured
to the floor.

Installation Liquiline System CA80AL
20 Endress+Hauser
624 (24.57)
417 (16.42)
530 (20.87)
297 (11.70)
A
AA
A
A0036783
 22 Foundation plan
A Fasteners (4 x M10)
--- Dimensions of Liquiline System CA80
A0036785
 23 Securing the base
1. Screw the base to the ground.
2. With 2 people, lift the analyzer and fit it on the base. Use the recessed grips.
3. Secure the base to the analyzer using the 6 screws supplied.