Endress+Hauser Liquiline System CAT860 User manual

Products Solutions Services
BA01278C/07/EN/01.14
71237653
Operating Instructions
Liquiline System CAT860
Automatic sample preparation system for supplying
process measurement devices with filtered sample
from primary clarification and sludge activation

Endress+Hauser
Liquiline System CAT860
Table of contents
1 Document information . . . . . . . 4
1.1 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.2 Symbols used . . . . . . . . . . . . . . . . . . . . . . . 4
2 Basic safety instructions . . . . . . 5
2.1 Requirements for personnel . . . . . . . . . . . 5
2.2 Designated use . . . . . . . . . . . . . . . . . . . . . . 5
2.3 Occupational safety . . . . . . . . . . . . . . . . . . 5
2.4 Operational safety . . . . . . . . . . . . . . . . . . . 5
2.5 Product safety . . . . . . . . . . . . . . . . . . . . . . 5
3 Device design . . . . . . . . . . . . . . . 6
4 Incoming acceptance and
product identification . . . . . . . . 7
4.1 Incoming acceptance . . . . . . . . . . . . . . . . . 7
4.2 Product identification . . . . . . . . . . . . . . . . 7
4.3 Scope of delivery . . . . . . . . . . . . . . . . . . . . 8
4.4 Certificates and approvals . . . . . . . . . . . . 8
5 Installation . . . . . . . . . . . . . . . . . 9
5.1 Installation conditions . . . . . . . . . . . . . . . 9
5.2 Manometer transportation lock . . . . . . 13
5.3 Mounting the filter in the process . . . . . 14
5.4 External compressed air connection . . . 20
5.5 Mounting the solenoid valve . . . . . . . . . 20
5.6 Post-installation check . . . . . . . . . . . . . . 21
6 Electrical connection . . . . . . . . 21
6.1 Cable and hose entries . . . . . . . . . . . . . . 22
6.2 Terminal connection . . . . . . . . . . . . . . . . 23
6.3 Wiring diagram . . . . . . . . . . . . . . . . . . . . 24
6.4 Structure of the spiral hose . . . . . . . . . . 25
7 Operation. . . . . . . . . . . . . . . . . . 26
8 Commissioning. . . . . . . . . . . . . 26
8.1 Function check . . . . . . . . . . . . . . . . . . . . . 26
8.2 Venting the diaphragm pump . . . . . . . . 26
9 Operation. . . . . . . . . . . . . . . . . . 27
10 Diagnostics and
troubleshooting . . . . . . . . . . . . 27
11 Maintenance . . . . . . . . . . . . . . . 28
11.1 Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
11.2 Replacing the pump hose and pump
head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
11.3 Replacing the filter . . . . . . . . . . . . . . . . . . 31
12 Repair. . . . . . . . . . . . . . . . . . . . . 32
12.1 Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . 32
12.2 Return . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
12.3 Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
13 Accessories . . . . . . . . . . . . . . . . 34
14 Technical data. . . . . . . . . . . . . . 35
14.1 Temperature inputs . . . . . . . . . . . . . . . . . 35
14.2 Power supply . . . . . . . . . . . . . . . . . . . . . . . 35
14.3 Performance characteristics . . . . . . . . . . 36
14.4 Environment . . . . . . . . . . . . . . . . . . . . . . . 36
14.5 Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
14.6 Mechanical construction . . . . . . . . . . . . . 38
Index. . . . . . . . . . . . . . . . . . . . . . 40

Document information Liquiline System CAT860
4Endress+Hauser
1 Document information
1.1 Warnings
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").
1.2 Symbols used
Safety message structure Meaning
DANGER
!
Causes (/consequences)
Possible consequences if
ignored
‣Corrective action
This symbol alerts you to a dangerous situation.
Failure to avoid the situation will result in fatal or serious
injury.
WARNING
!
Causes (/consequences)
Possible consequences if
ignored
‣Corrective action
This symbol alerts you to a dangerous situation.
Failure to avoid the situation can result in fatal or serious
injury.
CAUTION
!
Causes (/consequences)
Possible consequences if
ignored
‣Corrective action
This symbol alerts you to a dangerous situation.
Failure to avoid this situation can result in medium or minor
injury.
NOTICE
Cause/situation
Possible consequences if
ignored
‣Action/note
This symbol alerts you to situations that can cause damage to
equipment or property.
Additional information, tips
Permitted or recommended
Forbidden or not recommended

Liquiline System CAT860 Basic safety instructions
Endress+Hauser 5
2 Basic safety instructions
2.1 Requirements for personnel
‣Installation, commissioning, operation and maintenance of the measuring system must only
be carried out by specially 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.
‣Measuring point faults may only be rectified by authorized and specially trained personnel.
Repairs not described in the enclosed Operating Instructions may only be carried out by the
manufacturer directly or by the Service Organization.
2.2 Designated use
The Liquiline System CAT860 sample preparation system is designed to automatically supply
process measuring systems with filtered samples from secondary clarification and sludge
activation (see Technical Data).
If the device is used for any purpose other than that described, this poses a threat to the safety
of people and the entire measuring system and is therefore not permitted.
The manufacturer is not liable for damage resulting from improper or non-designated use.
2.3 Occupational safety
As the user, you are responsible for complying with the following safety conditions:
• Installation instructions
• Local prevailing standards and regulations.
2.4 Operational safety
‣Before commissioning the entire measuring point, check all the connections. Make sure that
electric cables and hose connections are not damaged.
‣Do not operate damaged products and secure them against unintentional commissioning.
Label the damaged product as defective.
‣If faults can not be rectified, the products must be taken out of service and secured against
unintentional commissioning.
2.5 Product safety
The product has been designed and tested to meet state-of-the-art safety requirements, and left
the factory in a condition in which it is safe to operate.
The relevant regulations and European standards have been complied with.

Device design Liquiline System CAT860
6Endress+Hauser
3Devicedesign
A complete sample preparation system consists of:
• Liquiline System CAT860 sample conditioning
• 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)
a0023147
1
2
3
4
5
6
7
Soft keys
Peristaltic pump
Manometer
Pressure-reducing valve for compressed air
Housing heating (optional)
Cleaner
Vacuum pump

Liquiline System CAT860 Incoming acceptance and product identification
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4 Incoming acceptance and product identification
4.1 Incoming acceptance
1. Make sure the packaging is not damaged.
Notify your supplier of any damage to the packaging.
Keep the damaged packaging until the matter has been settled.
2. Make sure the contents are not damaged.
Notify your supplier of any damage to the contents of the delivery.
Keep the damaged goods until the matter has been settled.
3. Check that the delivery is complete and nothing is missing.
Compare it with the delivery documents and your order.
4. Pack the product in such a way as to protect it reliably against impact and moisture for
storage and transportation.
The original packaging materials provide optimum protection.
The permitted ambient conditions must be observed (see technical data).
If you have any queries, please contact your supplier or your sales center.
4.2 Product identification
4.2.1 Nameplate
The nameplate provides you with the following information on your device:
• Manufacturer's details
• Order code (device version)
• Serial number
• Power supply
• Degree of protection
• (Permitted) ambient conditions
Compare the data on the nameplate with your order.
4.2.2 Identifying the product
The order code and serial number of your device can be found in the following locations:
• On the nameplate
• In the delivery papers

Incoming acceptance and product identification Liquiline System CAT860
8Endress+Hauser
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)
•1CD
• Optional accessories
4.4 Certificates and approvals
Declaration of Conformity
The product meets the requirements of the harmonized European standards.
It therefore complies with the statutory requirements of the EC directives.
The manufacturer confirms successful testing of the product by affixing the 4symbol.

Liquiline System CAT860 Installation
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5Installation
CAUTION
!
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.
‣Ensure that the sample preparation system is properly hooked into the wall holder unit at
the top and bottom and fix it in place on the upper wall holder unit with the securing screw.
5.1 Installation conditions
5.1.1 Dimensions
a0022855
Fig. 1: Liquiline System CAT860 dimensions. Engineering unit mm (in).
530 (20.87)
417 (16.42)
793 (31.22)

Installation Liquiline System CAT860
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5.1.2 Holder unit
Mounting materials for securing the unit on the wall (screws, wall plugs) are not included
in the delivery and must be provided by the client.
a0021955
Fig. 2: Holder unit dimensions. Engineering unit mm (in).
a0021967
Fig. 3: Securing the holder unit on the housing

Liquiline System CAT860 Installation
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5.1.3 Spacing required for mounting the wall holder units
a0021961
Fig. 4: Minimum spacing required for mounting.
Engineering unit mm (in).
a0021997
Fig. 5: Maximum opening angle
≥330(12.99)
≥100 (3.94)

Installation Liquiline System CAT860
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5.1.4 Hooking the sample preparation system into the wall holder unit
a0021982
Fig. 6: Hooking into the wall holder unit
1. Hook the analyzer into the wall holder unit.
2. Secure the two upper parts of the wall holder unit with the screw supplied.

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5.1.5 Mounting location
When installing the device, observe the following:
• Make sure that the wall has sufficient load-bearing capacity.
• Protect the device against additional heating (e.g. from heaters).
• Protect the device against mechanical vibrations.
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
a0023290 a0023291 a0023292
Release the four screws with a 3 mm Allen
key.
Fold out the cover towards the front. Open the transportation lock by
moving the bar from "CLOSE" to
"OPEN".

Installation Liquiline System CAT860
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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.
a0023262
Fig. 7: Retaining point (shown without splash protection cap)

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5.3.1 Mounting as 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. 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)).
a0011292
Fig. 8: Mounting the cross clamp
1
2
3
4
Immersion tube
Cross clamp, closed side facing center of basin
Cross clamp, closed side facing upwards
Holder transverse pipe
1
2
3
4

Installation Liquiline System CAT860
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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.

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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
a0023260
Fig. 9: Mounting the chain retainer
1 Mount the multi-functional clamp ring
2 Guide the bracket into the chain
3 Hook the bracket into the multi-functional clamp ring
4 Fit the splash protection cap
x 60 to 80 mm (2.35 to 3.15")
1. Insert the weights into the immersion tube.
2. Screw the multifunctional clamp ring onto the immersion tube.
3. Guide the bracket into the lowest link in the chain.
4. Attach the bracket to the multifunctional clamp ring.
5. Guide the "filter to pump" hose through the splash protection cap from below (do not bend).
6. Fit the Teflon hose onto the filter connection.
7. Secure the chain on the holder with the triangular carabiner.

Installation Liquiline System CAT860
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5.3.3 Mounting with a 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.

Liquiline System CAT860 Installation
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5.3.4 Quick release fastener
a0022633
Fig. 10: Mounting the chain retainer
1 Bore - makes it possible to screw the adapter tight
2Adapter
3 Thread adapter nut
4Innersleeve
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.
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.
12 3
2.
1.
4

Installation Liquiline System CAT860
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5.4 External compressed air connection
CAUTION
!
If not connected properly, this can result in injury and damage to the device
‣Set a pressure of max. 5 bar (73 psi) at the pressure-reducing valve.
a0023277
Fig. 11: Connecting external compressed air
1 Hose, pump to analyzer
2 Hose, filter to pump
3 Hose, compressed air / cleaner
Prerequisites:
• Compressed air of 2 to 5 bar (29 to 73 psi)
• The compressed air must be filtered (40 μm) and free from water and oil
• No continuous air consumption
• Minimum nominal diameter for air ducts: 4mm (0.16 ")
1. Connect the compressed air line to the connection provided on the bottom of the housing.
2. Run the valve's rinsing air connection at an air pressure of 2 to 5 bar (29 to 73 psi).
Connect the pressure to the pressure-reducing valve.
5.5 Mounting the solenoid valve
The scope of delivery of the Liquiline System CAT860 includes a solenoid valve and a liquid
detector for mounting in the Liquiline System CA80. For further information on mounting
the valve in the analyzer, please refer to the enclosed kit instructions.