Endress+Hauser asp-station d 2 User manual

Nothing beats know-how
Endress Hauser
Multi-function
water sampler
asp-station d 2
Installation and operating instructions
BA 034R/09/en/04.97
Part No. 50051362

Complete delivery●Check: That the delivery note and delivery contents correspond!
Check the package and contents for external damage.
Transport insuranceShould there be any visible damage you should immediately inform both the
transport agency as well as your supplier. If this is not done any later claims
cannot be handled under the guarantee.
Please take note of the following characters:
Hint: Hints for better installation.
Attention: Ignoring this note can lead to damage of the
device or faulty operation.
Danger: Ignoring this warning can lead to personal injury.
Should the "asp-station d 2" be in storage for more than 6 months please
take note of the storage details in chapter
"Maintenance, general".
Please enter details here:
Unit number: _____________________
Software version: _____________________
Door key number: _____________________
.... Always give these details when reordering or on any queries.
asp-station d 2 Please note:
1

Dimensional drawing,
complete unit
Dimensional drawing, complete unit with all options
(above).
A = Roof (option)
B = Suction hose (accessories)
C = Sampler
asp - station d 2
D = Power cable
E = Base (option, also available as a completely
enclosed base, eg. for mounting external pumps
or electrode armatures))
Note: All dimensions shown are for the "standard housing".
For "wide housing" dimensions see technical data.
Sampler asp-station a (left):
1 = Controller
liqui-box d 2
2 = Distribution tray (tap and tray)
3 = Bottle tray with bottles and lids
4 = Terminal box (behind cover plate)
5 = Refrigeration unit (inside lower part of housing)
Extra: Flow through armature if needed is fitted
in the lower right part of the sampler.
1
5
4
3
2
E+H Wetzer Printed in W. Germany (INT)
Modifications reserved
Dimensional drawing, complete unit asp-station d 2
2

PageContents
1Please note: 1- Complete delivery 1- Transport insurance 1- Enter unit information
2asp-station d 2 2- Dimension drawing, complete construction
3
Contents
5General notes 5- Safety
6Mechanical installation 6- General 6
- Installation 6
- Hose connection / installation 7
- Sampling point recommendations 8
- Foundation recommendations
9Electrical installation 9- Power supply 9
- Terminal box 10- Terminal connections 10
- Outputs 10
- Inputs 10
- Control input 11- Connection examples 11
- Input 11
- Output 12- What happens on power up ? 12
- Power failures 12
- Switching on and off (ON/OFF push buttons)
13Sampling principle
14For first installation
16Setting up sample volume 16- Setting up steps (1 to 8)
19Maintenance 19- General 19- Repairs
asp-station d 2 Contents
3

Page
Operating and display components 20
- General 20
- Operating components 21
- Setting up principle 21
- Short form instructions 22
- Programme selection and information 24
- Base settings 26
- Programmes: Creating and changeover 28
- Start/stop operation 30
- Service level 32
- Operator settings 34
Changing analogue input 36
Sample distribution conversion 37
- Changing number of containers/bottles 37
Problems and solutions 38
- Fault messages 38
- Spare parts 39
Technical data 40
Contents asp-station d 2
4

SafetyThis unit is constructed and tested according to EN 61010-1 /
VDE 0411 Part 1 and left our works in perfect and safe condition. In order to
maintain this condition and operate safely the user must take note of the
following safety information and warnings contained in these instructions.
First check that the power supply to be used corresponds with that on the
unit legend plate.
This unit is supplied with a loose power cable including plug and socket
arrangement and is therefore classified to protection class I.
The power supply plug must only be connected to a socket with an earth
protection connection. This protection must be continued when using
extension leads. Any breakage of the earth conductor within or outside the
unit or loosening the earth connections can make the unit potentially
dangerous. Intentional disconnection or an open circuit of this earth
connection is not permissible.
There are no components in the unit that can be repaired by the user. All
repairs must be made by trained service personnel.
Removing covers or components, except where this can be done by hand,
must only be carried out by skilled personnel.
If it is assumed that the unit cannot be safely operated it must be
immediately taken out of operation and secured against unintentional use.
It can be assumed that the unit cannot be safely operated,
- if the unit is visibly damaged
- if the unit no longer operates
- if the unit has been in storage under adverse conditions for a longer
period of time
- after long transport under adverse conditions.
The manufacturer does not accept liability for any damage that has been
made due to the unit not having been used in accordance with these safety
instructions.
asp-station d 2 General notes
5

General Remove the external protection film as soon as possible as this can stick
due to sun rays.The water sampler must be installed so that it stands higher
than the sampling point. It can be installed outside and mounted on a
concrete foundation or solid level ground. The unit can be levelled by using
the four levelling screws fitted in the bottom of the sampler. All components
are mounted in a lockable, thermostatically controlled stainless steel cabinet.
The cabinet must be installed in an area where an additional heating effect
from external sources (eg. radiators, etc.) is avoided. In order to ventilate the
built in refrigeration system the sampler, when mounting next to a wall, must
be fitted with the 50mm long spacers supplied in the accessory pack.
Do not install the sampler close to large magnetic fields (eg. motors,
transformers, large contactors, etc). Do not install the sampler in areas
where it can be subject to high mechanical vibration. Avoid shocks when
transporting the sampler.
Hose connection / installation The suction hose must be installed so that it always rises from the sampling
point to the hose connection on the sampler !
Syphons must be avoided between the sampling point and sampler !
Wrong Right
The sampler must not be connected to a pressurised system !
For sample lift less than 2 m we recommend using a 15 mm suction hose.
Both 13 mm and 15 mm connections are delivered.
The minimum conductivity of the sample liquid must not be less than 30
microsiemens !
●The 13 mm internal ∅hose must be of a spirally reinforced type.
●The hose can be connected to the connector on the top left hand side of
the cabinet.
●Maximum height difference: 6m from sampling point to sampler.
●Maximum hose length: 30m
Mechnanical installation asp-station d 2
6

Sampling point
recommendations
The suction hose must always be submerged in liquid at the sampling point.
Suitable measures for this are:
Weight the end of the hose using a short length of V2A tubing or fixing the
hose to the channel (tank) wall using a hose saddle or the submersion
armature (can be ordered as an accessory).
Submersion armature: PVC. is pivoted to move in all directions. Order No. 50038168
A suction filter can be used in applications
where large solids particles are not required
in the sample.
A= Filter
B= Connector
C= Jubilee clip
Filter order No. 50038327
Recommendation:
Never submerge the hose against
the flow direction !
If possible sample with the flow.
Sampler with flow through
armature
Flow rate min.200l/h max.1500l/h
Vacuum sampling from A
Inlet B3/4"
Outlet C11/4"
Attention: It must be guaranteed
that liquid flow at the outlet C is
free to atmosphere. Should the
system come under pressure the
water head at A will rise and can
lead to flooding the sampler.
We accept no liability for damage caused by ignoring this information !
asp-station d 2 Mechanical installation
7

Foundation recommendation
(For standard units)
A = Fixing dimensions (There are four 10 mm dia holes in the base of the cabinet)
B = Defrost water drain.
C = Possible cable entries.
Foundation recommendation on
option
For special version (wide housing) eg. 24 x
2.5 l bottle distribution
Mechnanical installation asp-station d 2
8

Power supplyThe sampler is delivered with a 3core mains cable (length approx. 1.4m)
connected to a 2 pin plug with earth contact.
This cable is fed through the sampler left side panel and is already
connected to the mains terminals (KL1/1, KL/2 and PE) in the terminal box.
Terminal boxOpen the cabinet door.
The terminal box is situated behind the hinged blanking plate (2) at the base
of the sampler.
Remove the mains plug from the power supply (the system must be
without power).
Push both snap locks (1) inwards and hinge the blanking plate (2)
downwards. The terminal box (3) can now be seen.
Undo screws (4) and remove the terminal box lid.
There is a terminal connection diagram stuck to the inside of the lid.
The terminal box contains all in/output terminals, TTY interface for direct
connection to the
Primo-Bit sample protocol printer, internally connected
cables to the functional module, alarm and sample sequence end relay
outputs (for retransmission), heating and cooling relays (internal) as well as
the mains fuse SI1 (6,3AT).
asp-station d 2 Electrical intallation
9

For skilled personnel only:
On site cable connections must only be made through the PG glands.
Only connect the terminals mentioned in the following text.
Terminal connections Auxiliary voltage 0 Volt (common ground) KL 9/1
Auxiliary voltage +8...+18,5 Volt (max. 200 mA) KL 9/2
Outputs Alarms and signals are retransmitted using the three relay outputs. These
outputs can be individually allocated in setting up addresses 150 to 152.
... potential free Outputs 1 and 2 are constructed as separate potential free changeover
contacts and have the following configuration: 1 is connected to 3 in alarm
condition and power failure. 1 connected to 2 in all other conditions ( valid
for outputs KL6/1/2/3 and output KL7/1/2/3.
... mains powered Output 3 switches mains voltage (from KL1/1 to KL5/1). The switch fail-safe
function is dependent on the settings “standard” or “inverse” in address 152.
Standard: Power on, active (alarm condition) = Contact closed
Power on, not active (no alarm) = Contact open
Power off = Contact open
Inverse: Power on, active (alarm condition) = Contact open
Power on, not active (no alarm) = Contact closed
Power off = Contact open
KL5/2 is permanently connected with KL1/2 potential
Application example:
Standard: Annunciator (230V I max. 1 A) for alarm connected between
KL5/1 and KL5/2, gives an audible signal on alarm condition.
Inverse: Lamp (230V I max. 1 A) connected between KL5/1 and KL5/2,
illuminates on fault and power failure.
When using programme LCA 100 A this output switches the external pump.
Address 152 cannot be selected.
Inputs
Flow impulse inputs 1 Impulse input (KL9, terminal 3 via optocoupler)
Max.25Hz (+7 to +27 Volt).
For connecting an external quantity measuring system
Analogue flow input 1 analogue input (current or voltage)
KL8 terminal 4 for negative connection KL8 terminal 5 for positive
connection. For connecting an external quantity measuring system
External stop 1 Stop input (KL9, terminal 4 via optocoupler).
A voltage between +7 to +27 Volt on the input stops all sampler functions.
0 Volt (or open circuit) to +3 Volt initiates normal operation.
Electrical inatallation asp-station d 2
10

Control input1 control input (KL8/ terminal 7 via optocoupler).
Presettable as programme change or event input.
... for programme change
Condition: Address 270 is set to "ext. signal".
A voltage of +7 to +27 Volt stops the actual programme (Adr.010) and
changes to the target programme (as preset in address 271).
0V (or open circuit) to +3 Volt returns system to the initial programme.
... as event input
Each positive signal edge initiates an immediate sample cycle. The condition
for this is that the selected active programme (as preset in address 010) is
set to "Event", (Setting up for programmes 1 to 6 is done in addresses 210,
220, 230, up to 260).
Interface (TTY Primo-Bit )To record sampling sequences and preset parameters.
Connect KL8/ terminal 8 (TXD) to pin 24 on the
Primo-Bit .
Connect KL8/ terminal 12 (+UTTY) to pin 17 on the
Primo-Bit .
Set up addresses 160 to 169.
Do not connect any terminals (KL...) not mentioned in these
instructions !
Connection sticker inside
terminal box lid
Attention! Details without brackets are valid for both “A2 and D2
controllers”. Details within brackets are additionally valid for the
“D2 controller”. Whether an “A2” or D2” controller is installed can be seen
on the controller legend plate.
Connection examplesAlternatives: In example "Impulse input for flow input"
a: Using external aux. voltage b: Using internal aux. voltage
eg. for potential free contacts
b
a
KL9
KL9
asp-station d 2 Electrical intallation
11

Output Outputs 1 and 2 (KL6/KL7) are individual potential free changeover contacts
and can be directly connected to either DC or AC sources.
Output 3 (KL5/1 - KL5/2) is connected to mains power and is therefore
dangerous.
What happens on power up ?
Power failures a) The unit runs a self check (start up). Display shows ”OFF” and whether it
is in a heating or refrigeration phase.
b) Short term power failures (<24 hrs) during automatic operation
No samples are taken, the inputs are not interrogated, however, the
internal clock continues to run during power failure.
On return of power the unit initiates a self check, any bottle changes
required are caught up. The sampler now continues to operate as
normally. If the power failure occurred during a sample cycle the water in
the dosing glass is then released into a bottle.
c) Long term power failures (>24 hrs) during automatic operation:
No samples are taken, the inputs are not interrogated, however, the
internal clock continues to run during power failure.
On return of power the unit initiates a self check, any bottle changes
required are not caught up. The sampler now continues to operate as
normally.
d) Long term power failures (500 hrs) have the following effect:
Internal buffer accumulator is discharged. An error message is displayed
(for message acknowledgement please see chapter “Problems and
solutions”).
Reset operational data again. The unit must then be connected to mains
power for at least 1 week (accumulator recharge). The sampler will
operate normally during this time.
On/off switching using the ON
and OFF push buttons Switch off (operate OFF): This aborts the automatic cycle. Display shows "OFF". The unit should not be switched off during a sample cycle, always
wait until the unit has completed the cycle. The sampler is switched off but
still connected to the mains supply therefore heating and refrigeration
continue to operate.
Switch on (operate ON): Display shows "ON". The unit can be restarted
(from first bottle) by operating the “AUT” button.
Electrical inatallation asp-station d 2
12

Vacuum principle
+
=
=VP
D
-
3The sample is now dosed to the
preset volume (VP). This is
dependent on the dosing tube
position (D). Excess liquid flows
back to the sampling point due
to a syphonic effect.
2A fresh sample is then sucked
into the dosing chamber until
the conductivity level switch is
activated (sensors in the dosing
chamber flange)
4The hose clamp is released and
the sample flows into the
composite container or bottles if
operating using sample
distribution.
1The dosing system is
pneumatically sealed at the
beginning of each sample cycle.
The diaphragm pump then
blows the suction hose free of
obstructions via the dosing
chamber
asp-station d 2 Sampling principle
13

General The sampler is constructed for practical operation and can be applied
virtually everywhere.
In addition to the versatile setting up the operator also has the possibility to
preset six individual programmes. These can be accessed at any time.
These programmes save time when changing from one application to
another and can be done by unskilled personnel.
Presetting: The sampler leaves the factory preset with basic data. After switching on
and operating the “AUT” push button it automatically operates using
programme 1. This programme is preset to operate as time proportional
sampling with a sample taken every 15 minutes and time proportional
sample distribution with a bottle/container change every 2 hours. The
sampling sequence is automatically stopped after the last bottle has been
filled.
Restart by operating the “AUT” push button (do not forget to remove and
empty or replace the filled bottles/containers).
Over fill security: Setting up addresses 110 and 111 are very important. These are used for
setting up the automatic bottle/container overfill security.
Addr. 110 = Set up dosing volume (Dosing tube position in the dosing
chamber) in ml (factory setting 200ml).
Addr. 111 = Set up bottle/container volume (factory setting 0,6l).
Always reset the dosing and bottle/container volume values on initial
installation and when either of these criteria are changed (diferent dosing
volume).
Programmes: There are 6 individual programmes available. Programmes can be selected
in address 010 without the use of a security code.
For programme 2functions see setting up addresses 220 to 225
For programme 3functions see setting up addresses 230 to 235
For programme 4functions see setting up addresses 240 to 245
and so on up to 6programmes
The programme parameters can be easily changed by the user.
Automatic programme change (eg. Q-T or Q-q) can also be defined in
addresses 270 to 276.
Time synchronisation Sampling and bottle/container change can be synchronised to a particular
time. Setting up addresses 126, 127 and 128 are used for this purpose.
These settings are only valid at the start of a programme using time
proportional sample distribution.
Addr Description Works setting
126 Synchronisation mode: Time for automatic start
(Aut push button) or preset time (addr. 127)
operate as synchronisation time base
AUT push
button
127 Synchronisation time for sample cycle and
bottle/container change 00:00
128 Switch on/off fixed time base of bottles/containers off
For first installation asp-station d 2
14

Time synchronisation example:"asp-station d 2" with 12 bottles and 2 hour filling time per bottle.
On synchronisation time of 00:00 (addr. 127) and switched on bottle
synchronisation (addr. 128) each bottle is allocated a fixed filling time
independently from the time of the automatic sequence start
Bottle Fill time
1 0 to 2 Uhr
2 2 to 4 Uhr
3 4 to 6 Uhr
If bottle synchronisation is set to "OFF" in address 128 the automatic
sequence starts with bottle 1. Bottle change takes place at the preset time
(addr. 127). This is only valid if the actual programme runs with time
proportional distribution.
In order to become familiar with the uses of this multi function programme it
is recommended that the user should work through each individual setting
up level and address.
It is also recommended that new settings be noted in the empty charts
(“Operator settings”).
asp-station d 2 For first installation
15

Varying sample volume Follow the next steps.
1. Open cabinet door
2. Switch unit off Operate the - OFF- (4) push button at the "liqui-box d 2".
Dosing system:
➀= Elbow ➁= Dosing tube
➂= Dosing chamber ➃= Piping clamp
3. Remove air hose
1
2
3
4
Setting up sample volume asp-station d 2
16

4. Remove dosing systemLift clamp from pipe elbow.
Pull dosing system forwards and
remove from controller.
5. Remove flangeRelease the bayonet fitting by turning
the lower part of the flange as shown.
Remove the flange from the dosing
chamber.
6. Set sample volumeSet the dosing tube to the required
sample volume by pushing it in or out.
Take note of the engraved quantities
on the tube. (The further the tube is
pulled out of its retainer the smaller
the sample volume)
(Only move the dosing tube. NEVER
loosen the nut and NEVER move the
upper elbow.)
300
350
400
450
500
asp-station d 2 Setting up sample volume
17

7. Replace dosing system ➀ = Nipple
➁ = Suction pipe elbow
➂ = Hose clamp
➃ = Contacts
➄ = Spring contacts
➅= Fixing clamp
➆ = Silicon hose
●Push silicon hose ➆into the hose clamp ➂.
●Push suction pipe elbow ➁onto the nipple ➀. (Make sure that the
spring contacts and flange contacts are made).
●Push fixing bracket ➅downwards.
"The contacts ➃and contact springs ➄must be made
(otherwise faults can occur).
We cannot be held responsible for damage caused by not complying with
these instructions !
8. Replace air hose
Setting up sample volume asp-station d 2
18