Endress+Hauser Liquiline System CAT860 User manual

Products Solutions Services
Operating Instructions
Liquiline System CAT860
Automatic sample conditioning system for
supplying process measuring devices with filtered
sample from sludge activation, secondary
clarification or surface water
BA01278C/07/EN/02.16
71335038

Liquiline System CAT860 Table of contents
Endress+Hauser 3
Table of contents
1 Document information ......... 4
1.1 Document function ................... 4
1.2 Warnings ........................... 4
1.3 Symbols used ........................ 4
2 Basic safety instructions ....... 6
2.1 Requirements for personnel ........... 6
2.2 Designated use ...................... 6
2.3 Occupational safety .................. 6
2.4 Operational safety ................... 6
2.5 Product safety ....................... 7
3 Product description ............. 7
4 Incoming acceptance and
product identification .......... 9
4.1 Incoming acceptance ................. 9
4.2 Product identification ................. 9
4.3 Scope of delivery .................... 10
4.4 Certificates and approvals ............ 10
5 Installation .................... 11
5.1 Installation conditions ............... 11
5.2 Manometer transportation lock ....... 15
5.3 Mounting the filter in the process ..... 15
5.4 External compressed air connection .... 20
5.5 Connecting CAT860 sample
preparation system to analyzer CA80 .. 21
5.6 Post-installation check ............... 22
6 Electrical connection .......... 22
6.1 Connecting cables and hoses .......... 23
6.2 Terminal connection ................ 24
6.3 Structure of the spiral hose ........... 25
7 Operation ...................... 26
8 Commissioning ................ 26
8.1 Function check ..................... 26
8.2 Ventilating vacuum pump ............ 26
9 Operation ...................... 27
10 Diagnostics and
troubleshooting ............... 27
11 Maintenance .................. 27
11.1 Cleaning ........................... 28
11.2 Replacing pump hose and pump head .. 29
11.3 Replace filter ....................... 30
12 Repairs ......................... 30
12.1 Spare parts ........................ 31
12.2 Return ............................ 32
12.3 Disposal ........................... 32
13 Accessories .................... 32
14 Technical data ................. 33
Index ................................. 38

Document information Liquiline System CAT860
4 Endress+Hauser
1 Document information
1.1 Document function
1.1.1 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.
1.2 Warnings
Structure of information Meaning
LDANGER
Causes (/consequences)
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)
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)
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
Consequences of non-compliance (if
applicable)
‣Action/note
This symbol alerts you to situations which may result in damage to property.
1.3 Symbols used
1.3.1 Symbols
Symbol Meaning
Additional information, tips
Permitted or recommended
Not permitted or not recommended
Reference to device documentation
Reference to page

Liquiline System CAT860 Document information
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Symbol Meaning
Reference to graphic
 Result of a step
1.3.2 Symbols at the device
Symbol Meaning
Reference to device documentation

Basic safety instructions Liquiline System CAT860
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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.
• Measuring point faults may be repaired only by authorized and specially trained personnel.
Repairs not described in the Operating Instructions provided may only be carried out
directly by the manufacturer or by the service organization.
2.2 Designated use
The Liquiline System CAT860 sample preparation system is designed to automatically supply
process measuring devices with filtered sample from preclarification and sludge activation
(see Technical data).
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 Occupational safety
As the user, you are responsible for complying with the following safety conditions:
• Installation guidelines
• Local standards and regulations
• Regulations for explosion protection
2.4 Operational safety
1. Before commissioning the entire measuring point, verify that all connections are
correct. Ensure that electrical cables and hose connections are undamaged.
2. Do not operate damaged products, and safeguard them to ensure that they are not
operated inadvertently. Label the damaged product as defective.
3. If faults cannot be rectified:
Take the products out of operation and safeguard them to ensure that they are not
operated inadvertently.

Liquiline System CAT860 Product description
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2.5 Product safety
2.5.1 State of the art
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
European standards have been observed.
3 Product description
• Liquiline System CAT860 sample preparation system
• Local operation with soft keys and status LEDs
• Filter unit with filter and holder in the configuration ordered
• Automatic cleaning function with compressed air (external compressed air supply
necessary)
• Peristaltic pump for pumping the sample
• Vacuum pump for the automatic backflush function with cleaning solution
• Housing heating (optional)
• Sample hose, filter to pump in the configuration ordered, optionally heated
• Sample hose, pump to analyzer in the configuration ordered, optionally heated
• Cleaner (must be ordered separately)

Product description Liquiline System CAT860
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1 2 3
5
4
6
7
A0030136
 1
1
2
3
4
5
6
7
Soft keys
Peristaltic pump
Pressure gauge
Pressure-reducing valve for compressed air
Housing heating (optional)
Cleaner
Vacuum pump

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4 Incoming acceptance and product identification
4.1 Incoming acceptance
1. Verify that the packaging is undamaged.
 Notify your supplier of any damage to the packaging.
Keep the damaged packaging until the matter has been settled.
2. Verify that the contents are undamaged.
 Notify your supplier of any damage to the delivery contents.
Keep the damaged products until the matter has been settled.
3. Check the delivery for completeness.
 Check it against the delivery papers and 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.
The permitted ambient conditions must be observed (see "Technical data").
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 connection
• Degree of protection
• Ambient and process conditions
‣Compare the data on the nameplate with your order.
4.2.2 Product identification
Product page
www.endress.com/cat860
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 the product page for your product on the Internet.

Incoming acceptance and product identification Liquiline System CAT860
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2. At the bottom of the page, select the "Online Tools" link followed by "Check your device
features".
 An additional window opens.
3. Enter the order code from the nameplate into the search field, and then select "Show
details".
 You will receive information on each feature (selected option) of the order code.
4.3 Scope of delivery
The scope of delivery comprises:
• 1 Liquiline System CAT860 in the version ordered
• 1 copy of the Operating Instructions (in the desired language on selection of the order
option)
• 1 CD-ROM with Operating Instructions in all available languages
• Optional accessories
If you have any questions, please contact your supplier or your 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 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.

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5 Installation
LCAUTION
Incorrect transportation or installation can cause injury and damage the device
‣Always use a lifting truck or a fork-lift to transport the sample preparation system. Two
people are needed for the installation.
‣Lift the device by the recessed grips.
‣Check that the sample preparation system is fully hooked into the wall holder unit at the
top and bottom and secure it to the upper wall holder unit using the securing screw.
5.1 Installation conditions
5.1.1 Dimensions
530 (20.87)463 (18.23)
793 (31.22)
A0028820
 2 Liquiline System CAT860, dimensions in mm (in)
340 (13.39)
A0032007
 3 Filter, dimensions in mm (in)

Installation Liquiline System CAT860
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5.1.2 Retainer
Mounting materials for securing the device to the wall (screws, wall plugs) are not
included in the delivery and must be provided by the client.
750 (29.53)
120 (4.72)
Ø 11 (0.43)
Ø 10.7 (0.42)
A0028810
 4 Holder unit dimensions. Engineering unit
mm (inch)
 5 Securing the holder unit on the housing

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5.1.3 Spacing required for mounting the wall holder units
≥330(12.99)
≥100 (3.94)
A0028811
 6 Minimum spacing required for mounting.
Engineering unit mm (inch).
≤116 °
A0028814
 7 Maximum opening angle

Installation Liquiline System CAT860
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5.1.4 Hooking the sample preparation system into the wall holder unit
1.
2.
A0028812
 8 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.
5.1.5 Installation site
Note the following when erecting the device:
• Make sure that the wall has sufficient load-bearing capacity and is fully perpendicular.
• Mount the device on a level surface (with additional base).
• Protect the device against additional heating (e.g. from heaters).
• Protect the device against mechanical vibrations.
• Protect the device against corrosive gases, e.g. hydrogen sulfide (H2S).
• Make sure that the fluid can drain freely without any siphoning effects.
• Make sure air can circulate freely on the front of the housing.

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5.2 Manometer transportation lock
NOTICE
The manometer transportation lock is not open
Damage to the manometer or device
‣Open the transportation lock of the manometer before commissioning
A0030139
‣Release the four screws with a
3 mm Allen key.
A0030140
‣Fold out the cover towards the
front.
A0030141
‣Open the transportation lock by
moving the bar from "CLOSE" to
"OPEN".
5.3 Mounting the filter in the process
Select the installation location in such a way that a suitable distance from the fixed
installations is maintained, and the filter cannot be damaged even when moved (moving
medium).
For fixed installation, the retaining point must be selected in such a way that the proper
operation and maintenance of the assembly is guaranteed. The immersion tube must project
at least 100 mm (3.94") above the retaining point (see figure).
The filter may only be installed with an assembly.

Installation Liquiline System CAT860
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min. 100
(3.94)
A0029963
 9 Retaining point (shown without splash protection cap)
5.3.1 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
 10
1
2
3
4
Immersion tube
Cross clamp, closed side facing center of basin
Cross clamp, closed side facing upwards
Holder transverse pipe

Liquiline System CAT860 Installation
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1. Adjust the clamps on the cross clamp.
2. Slide the cross clamp over the immersion tube. Make sure that the closed side of the
cross clamp is at the top.
3. Mount the multifunctional clamp ring (funnel-shaped side facing upwards) on the
immersion tube above the cross clamp. The multifunctional clamp ring acts as an anti-
slip lock.
4. Attach the cross clamp, along with the immersion tube, to the transverse pipe. Make
sure that the closed side of the cross clamp faces the basin.
5. Align the assembly and the holder.
6. Tighten the clamp screws finger-tight (finger-tight corresponds to 13 Nm (9.6 lbf ft)).
Mount the filter as follows:
1. Screw the immersion tube connection (straight, 90˚) onto the immersion tube.
2. Where applicable, screw the quick release fastener onto the immersion tube connection
(optional).
3. Remove the thread adapter nut from the hose. The thread adapter nut is not required
when installing with an immersion tube.
4. Guide the "filter to pump" hose with the connection for sample preparation through the
splash protection cap from below.
5. Guide the "filter to pump" hose with the connection for the filter through the immersion
tube from above.
6. If you are using a quick release fastener, insert the inner sleeve into the quick release
fastener (see "Quick release fastener" section).
7. Connect the 4 mm, blue polytetrafluoro-ethylene sample hose to the filter (replacement
hose PTFE, 4 mm, black).
8. Screw the filter onto the immersion tube connection or onto the quick release fastener if
one is used.
Screw the pipes together finger-tight (without any gaps). The threads are lubricated and
provided with an O-ring.
5.3.2 Mounting on a chain retainer
Prerequisite:
• The immersion tube is fitted with a filter.
• The transverse pipe is fitted with a chain.

Installation Liquiline System CAT860
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1234
x
A0029966
 11 Mounting the chain retainer
1 Mount the multi-functional clamping ring.
2 Guide the bracket into the chain.
3 Hook the bracket into the multi-functional clamping ring.
4 Fit the splash protection cap.
x 60 to 80 mm (2.35 to 3.15")
1. Immersion tube made of PVC:
If necessary, insert the stainless steel pipe supplied with the CYA112 assembly as a
weight into the PVC immersion tube.
2. Mount the weight onto the filter cap.
3. Screw the multifunctional clamp ring onto the immersion tube.
4. Guide the bracket into the lowest link in the chain.
5. Attach the bracket to the multifunctional clamp ring.
6. Guide the "filter to pump" hose through the splash protection cap from below (do not
bend).
7. Fit the Teflon hose onto the filter connection.
8. Secure the chain on the holder with the triangular carabiner.

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5.3.3 Mounting with float
Mount the filter as follows:
1. Screw the thread adapter nut onto the plastic insert of the float.
2. Connect the 4 mm, blue polytetrafluoro-ethylene sample hose to the filter.
3. Screw the filter adapter into the plastic insert of the float.
4. Guide the metal bracket through the lowest link in the chain.
5. Secure the metal bracket to the bores provided for this purpose.
6. Fix the "filter to pump" hose to the transverse pipe of the CYH112 holder using hook and
loop Velcro fasteners.
Make sure that the filter is vertical and medium flows over it fully.
5.3.4 Quick release fastener
1234
1.
2.
A0029974
 12 Quick release fastener
1 Bore hole - makes it easier to screw the adapter on tightly
2 Adapter
3 Thread adapter nut
4 Inner sleeve
Install the quick release fastener as follows:
1. Screw the adapter (item 2) into the immersion tube connection bracket.
2. Insert the Allen key or a similar tool through the bores (item 1) to secure the adapter.
3. Slide the thread adapter nut (item 3) over the adapter until the thread adapter nut
engages with a click.
4. Guide the inner sleeve (item 4) through the thread adapter nut into the adapter as far
as it will go.
5. Guide the hose for "filter to pump" through the immersion tube first of all and then
through the quick release fastener.

Installation Liquiline System CAT860
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6. Connect the sample hose (polytetrafluoro-ethylene, 4 mm, blue) to the filter.
7. Screw the filter into the quick release fastener as far as it will go. In doing so, turn the
thread adapter nut, not the filter.
5.4 External compressed air connection
LCAUTION
If not connected properly, this can result in injury and damage to the device
‣Connect a pressure-reducing valve upstream if the air pressure is likely to rise to more than
5 bar (73 psi) (even with short pressure surges).
4
1
2
3
4
123
5
7
8
9
10 6
6
A0032018
1 Control unit
2 Pump
3 Liquiline System CA80
4 Sample
5 PTFE hose, black/blue CAC800
6 PTFE hose, white, OD 6mm, ID 4mm
7 Medium
8 Filter (ceramic)
9 Compressed air
10 Cleaner