wtw PurCon User manual

PurCon
Sample preparation
ba43107e10 11/2004 47
Operating manual

48
Accuracy when
going to press Theuseofadvancedtechnologyandthehighqualityofourinstruments aretheresultofcontinuousdevelopment.Thismayresultindifferences
between this operating manual and your instrument. Also, we cannot
guarantee that thereare absolutely noerrors in thismanual. Therefore,
we are sure you will understandthat we cannot accept any legal claims
resulting from the data, figures and descriptions.
Copyright ©Weilheim 2004, WTW GmbH
Reprinting - even as excerpts - is only allowed with the explicit written
authorization of WTW GmbH, Weilheim.
Printed in Germany.

PurCon Contents
49
1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
1.1 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
1.2 How it functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
2 Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
2.1 Authorized use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
2.2 General safety instructions . . . . . . . . . . . . . . . . . . . . . . . 55
2.3 Warning instructions and symbols . . . . . . . . . . . . . . . . . 57
3 Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
3.1 Installing the PurCon . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
3.2 Connecting the feed intake . . . . . . . . . . . . . . . . . . . . . . 61
3.3 Connecting the retentate nozzle . . . . . . . . . . . . . . . . . . 61
3.4 Connecting the outlet nozzle . . . . . . . . . . . . . . . . . . . . . 61
3.5 Installing the PurCon air outlet (option) . . . . . . . . . . . . . 62
3.6 Setting the manual valves . . . . . . . . . . . . . . . . . . . . . . . 63
3.7 Power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
3.8 Connecting the analyzer . . . . . . . . . . . . . . . . . . . . . . . . 64
3.9 Inserting the pump hoses . . . . . . . . . . . . . . . . . . . . . . . . 65
3.10 Starting sample preparation . . . . . . . . . . . . . . . . . . . . . . 66
4 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
5 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
5.1 Displacing the pump tubings . . . . . . . . . . . . . . . . . . . . . 70
5.2 Replacing the pump tubings . . . . . . . . . . . . . . . . . . . . . . 71
5.3 Cleaning the PurCon . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
5.3.1 Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
5.3.2 Sample preparation . . . . . . . . . . . . . . . . . . . . . . 72
5.4 Cleaning the air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
5.5 Replacing the fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
5.6 Taking out of operation . . . . . . . . . . . . . . . . . . . . . . . . . 81
6 What to do if ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
6.1 Replacing the filter plates . . . . . . . . . . . . . . . . . . . . . . . . 84
6.2 Replacing the tubes . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
7 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
8 Accessories and consumable materials . . . . . . . . . . . 91
9 Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

Contents PurCon
50

PurCon Introduction
51
1Introduction
1.1 General information
The PurCon sample preparation prepares the sample for the analysis
of component substances with analyzers. PurCon uses the most mod-
ern technologies that enable largely maintenance-free and long-term
operation.
Compared with traditional sample preparations, the amount of mainte-
nance of the PurCon is negligibly small.
Due to the low dwell time of the sample in the PurCon, the preparation
is carried out without any effect on existing component substances.
The sample preparation is carried out continuously. The permeate is
free from germs and total suspended solids so that analyzers can be
operated with very high reliability.
The maintenance costs of the analyzers are reduced considerably if
PurCon is used for the sample preparation.
Fig. 1 PurCon sample preparation
4
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PurCon
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Introduction PurCon
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1.2 How it functions
Fig. 2 Operating and functional elements
Feed The feed is connected by a hose to the feed nozzle (PurCon housing
base). The feed can be transported using an external pump or byusing
gravity to run it into the PurCon from a vessel placed higher than the
PurCon.
Housing The sample is prepared inside the PurCon housing.
1Mains switch 7Mains supply 115/230 VAC
2Selector switch of permeate
supply 8Fuse holder
3Permeate pump 9Locking
4Feed / inlet ball valve 10 Filler nozzle for cleaning
solution
5Outlet ball valve 11 Compressor lid
6Permeate nozzle 12 Anchoring lug

PurCon Introduction
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Retentate Any excess (retentate) is removed via a discharge nozzle.
Since no chemicals are added in the PurCon, any excess can be fed
back into the process.
Permeate The permeate pump transports the permeate to the analyzers via a
hose that is also supplied with the PurCon. It is connected to the per-
meate nozzle.
The quantity to be transported can be varied by a 4-step selection
switch and, thus, optimally adapted to requirements.
Cleaning After 6-9 months of operation, the sample preparation instrument must
be cleaned. Detergent is poured into the filler nozzle for this purpose.
The detergent is disposed of via the outlet nozzle. In sewage treatment
plants, the detergent can be disposedof in the sewage treatment plant.
However, in installations with measuring points for drinking or surface
water, it is imperative that the detergent is disposed of separately.
Inside the housing The actual sample preparation is located inside the housing. The air
supply required for operation is obtainedvia a compressor. 4 permeate
tracks areoperatedalternately viaa valve. The PurCon isconnectedto
the analyzer via a permeate nozzle.
Valve settings Two manual valves enable the feed flow to be shut off or the sample
preparation to be emptied.
Fig. 3 Valve setting for normal operation
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Introduction PurCon
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Fig. 4 Valve setting for emptying the sample preparation instrument
Fig. 5 Valve setting for cleaning the sample preparation instrument
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PurCon Safety instructions
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2 Safety instructions
This operating manual contains essential instructions that must be fol-
lowed during the commissioning, operation and maintenance of the
instrument.
Consequently, all responsible personnel must read this operating man-
ual carefully before working with the instrument. The operating manual
must always be kept available within the vicinity of the instrument.
2.1 Authorized use
Authorized use consists exclusively of the preparation of samples for
the analysis of component substances using analyzers. The technical
specifications given in chapter TECHNICAL DATA mustbe observed. Any
other use is considered to be unauthorized.
2.2 General safety instructions
This instrument is constructed and tested according to the legally
required safety regulations for electronic measuring instruments. It left
the factory in a safe and secure technical condition.
Function and
operational safety Thefailure-free functionandoperationalsafety oftheinstrumentis only guaranteed if the generally applicable safety measures and the special
safety instructions in this operating manual are followed during its use.
The smooth functioning and operational safety of the instrument can
only be guaranteed under the climatic conditions specified in the chap-
ter, TECHNICAL DATA.
If the instrument was transported from a cold environment to a warm
environment, the formation of condensate can impair the functioning of
the instrument. In this case, wait for the instrument to adjust to room
temperature before recommissioning.
Caution
Opening the instrument or adjustment, maintenance and repair work
must only be performed by personnel authorized by WTW.
EN 61010-1 The instrument complies with the requirements of EN 61010-1, protec-
tion class I.
For the type of protection, see the chapter, TECHNICAL DATA.
All work on the instrument beyond the activities described in this man-
ual, especially all installation activities, must only be performed by
trained and qualified personnel.
This also applies to changing the fuses of electronic parts.
Safe operation Ifsafeoperationis no longerpossible,theinstrumentmustbetakenout

Safety instructions PurCon
56
of operation and secured against inadvertent operation.
Safe operation is no longer possible if the instrument:
lhas been damaged in transport
lhas been stored under adverse conditions for a lengthy period of
time
lis visibly damaged
lno longer operates as described.
If you are in any doubt, you should contact the supplier of your instru-
ment.
Symbols used Warning
This symbol warns of dangerous electrical voltages.
Caution
indicates notes that you must read – for reasons of your own safety as
well as the safety of others and to protect your instrument from dam-
age.
Note
indicates notes that draw your attention to special features.

PurCon Safety instructions
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2.3 Warning instructions and symbols
Danger symbol according to the hazardous substance regulation that
means:
Causes severe corrosion.
Do not allow this substance to get into the hands of children. Wearsuit-
able protective gloves and goggles/face mask when working with this
substance.
If this substance gets into the eyes, rinse thoroughly with water and
consult a doctor.
Danger symbol according to the hazardous substance regulation that
means:
This symbol indicates a warning instruction.
It is applied to the relevant chemical containers and appears in the cor-
responding text passages of the operating manual. The instructions
that appear next to this label must be strictly followed.
Mandatory sign, Wear protective goggles.
This sign indicates that you must wear protective goggles.
This sign is used in this operating manual to mark activities that could
endanger health, especially the eyes.
Mandatory sign, Wear protective gloves.
This sign indicates that you must wear protective gloves.
This sign is used in this operating manual to mark activities that could
endanger health, especially the hands.
Mandatory sign, Wear protective clothing.
This sign indicates that you must wear a protective suit.
This sign is used in this operating manual to mark activities that could
endanger health.

Safety instructions PurCon
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PurCon Commissioning
59
3 Commissioning
Scope of delivery lPurCon sample preparation instrument
lOperating manual
Caution
The PurCon must be assembled by trained personnel only.
The key that is supplied must be kept safe and must only be used
by qualified electricians.
Fig. 6 Dimensions (specification in mm)
Safety datasheets The current safety datasheets for all chemicals and solutions used can
be found on the Internet under www.WTW.com.
XXXXXXX
3,15AT(115VAC)
1,6AT(230VAC)
Fuse Power
Permeat
PurCon
4
3
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12
PurCon
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30
25
290 575
735
D=8,4 mm

Commissioning PurCon
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3.1 Installing the PurCon
Caution
Ensure that the screws are strong enough.
If the instrument is attached to a wall, ensure that the wall is strong
enough to withstand the weight of the PurCon (see chapter, TECHNICAL
DATA).
Caution
Ensure that the PurCon is installed in the immediate vicinity of the ana-
lyzers to avoid dead times as the result of lengthy permeate feed
routes.
Caution
The mounting stand must be fixed to the floor. It is not allowed to use
the mounting stand without screwing itto the floor. Use the screws that
are supplied.
Fig. 7 PurCon with mounting stand
1Fetch 4 suitable screws (Ø8 mm) for installing the instrument.
2 Use the four screws to attach the anchoring lugs to a stable
wall or the PurCon mounting stand (accessory).
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PurCon Commissioning
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3.2 Connecting the feed intake
Connect the feed transport to the feed nozzle of the PurCon using a
3/4“hose (ID 19 mm).
Caution
When setting up the quantity to be transported by the feed transport,
follow the chapter TECHNICAL DATA of this operating manual. We rec-
ommend to usethe PurCon PB Bypass system in order to precisely set
up the quantity to be transported by the feed transport.
3.3 Connecting the retentate nozzle
Caution
Always use a seal when using a discharge pipe. Ensure that the seal is
seated correctly.
If a hose is used, always use hose clips and tighten them.
3.4 Connecting the outlet nozzle
The outlet nozzle is used to empty the sample preparation instrument.
During cleaning, detergent is released.
Always ensure the suitable disposal of detergent.
Caution
Detergent must not get into drinkingwater or surface water. Dispose of
the detergent as described in the safety datasheets.
1Fetch a suitable 50 mm discharge pipe.
2 Attach the discharge pipe to the retentate nozzle of the Pur-
Con.
The discharge must be pressure-free.
The PurCon does not cause any impairment of the feed.

Commissioning PurCon
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3.5 Installing the PurCon air outlet (option)
We recommend to install the PurCon air outlet if the drain pipe is not
entirely pressure-free. By using the air outlet, no overpressure can
develop in the system which prevents the retentate from running off.
The PurCon air outlet is mounted on the filler nozzle instead of the cap.
Fig. 8 PurCon air outlet
Installation
PurCon
3Disable the feed transport.
4 Switch off the power switch of the PurCon.
5Unscrew the cap of the filler nozzle on the top of the housing.
6 Put the PurCon air outlet on the filler nozzle as shown in Fig. 8
and screw it tight by hand.
7To avoid obnoxious odors, plug a suitable DN 30 tube on the
tube nozzle and lead the other end of the tube into the open or
into a discharge.

PurCon Commissioning
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3.6 Setting the manual valves
The valves in the housing of the PurCon enable various operating
modes.
Caution
Ensure that the setting is correct when commissioning the instrument
(see Fig. 9).
Fig. 9 Feed inlet open, outlet shut
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Commissioning PurCon
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3.7 Power supply
Warning
Have the loading capacity of the mains socket checked by a qualified
electricianbeforeconnectingtheinstrument.Themainssocketmustbe
earthed. Do not use an extension line.
Warning
The data on the nameplate (specified line voltage) of the PurCon must
match that of the mains socket.
See the chapter, TECHNICAL DATA, for the connecting data.
Fig. 10 Mains socket of the PurCon (top of the housing)
3.8 Connecting the analyzer
Caution
The permeate hose from the PurCon to the first analyzer should not
exceed a length of 2 m.
1Fetch the power cable that was supplied.
2 Use the power cable to connect the PurCon to an easily
accessible mains socket.
1Fetch the permeate hose that was supplied.
2 Connecttheanalyzertothepermeatenozzleonthefrontofthe
instrument.
1
23
N
PE
L

PurCon Commissioning
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3.9 Inserting the pump hoses
Proceed as follows:
Fig. 11 Inserting the pump hoses
1Takethepumpcassetteoutoftheholderbypressingtheclamp
strap.
2 Fix the pump hoses supplied between the first and second
stopper in the pump cassette.
3Replace the pump cassette inthe holder and snapin the clamp
strap.
4 Fix the pump cassette on the gripping lever.
5Repeat this procedure for all 4 permeate hoses.

Commissioning PurCon
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3.10 Starting sample preparation
The PurCon is now ready for operation. Before switching on the mains
power, check the following points again:
To start sample preparation, carry out the following steps:
PurCon now begins with the sample preparation. The system is first
vented.Approx.8 minafterswitchingonthe permeatepump,permeate
is fed and the successively connected analyzer can be started.
Caution
Adapt the amount of permeate supply to requirements.
The following settings are recommended:
1Are all the hose clamps used firmly tightened?
2 Are the seals ofthe retentate nozzle seatedcorrectlyand tight?
3Are the manual valves set correctly for operating the sample
preparation instrument?
4 Are all the tension arms of the permeate pump under tension?
5Is the permeate hose correctly connected to the analyzers?
1Switch on the mains switch (green power lamp lights up).
2 Switch on the feed pump (green control lamp lights up).
3Switch on the permeate pump.
Position 1 Operation of one analyzer
Position 2 Operation of two analyzers
Position 3 Operation of three analyzers
Position 4 is only used to accelerate the venting process of sam-
ple preparation