Hach-Lange FILTRAX User Manual

DOC023.52.03045

FILTRAX

User Manual

08/2012 Edition 3A

© HACH-LANGE GmbH, 2003, 2010, 2012. All rights reserved. Printed in Germany.

Contents
Section 1 Technical data ...............................................................................................................................................		3
Section 2 General information .....................................................................................................................................		5
2.1	Safety information......................................................................................................................................................	5
	2.1.1 Use of hazard information................................................................................................................................	5
	2.1.2 Precautionary labels ........................................................................................................................................	5
2.2	Applications ...............................................................................................................................................................	6
2.3	Functional description................................................................................................................................................	6
2.4	Items supplied ...........................................................................................................................................................	7
2.5	Instrument layout .......................................................................................................................................................	8
	2.5.1 Control unit.......................................................................................................................................................	8
	2.5.2 Module carrier ..................................................................................................................................................	8
	2.5.3 Sample tubes ...................................................................................................................................................	9
	2.5.4 Filter modules ..................................................................................................................................................	9
Section 3 Installation....................................................................................................................................................		11
3.1	Mechanical installation ............................................................................................................................................	13
	3.1.1 Dimensions ....................................................................................................................................................	13
3.2	Installing control unit with control unit bracket LZX676 ...........................................................................................	16
3.3	Connecting tubes.....................................................................................................................................................	20
3.4	Electrical connections..............................................................................................................................................	25
3.5	Connection to process instruments .........................................................................................................................	27
Section 4 Commissioning...........................................................................................................................................		30
4.1	Placing instrument in operation ...............................................................................................................................	30
4.2	Taking instrument out of operation ..........................................................................................................................	32
	4.2.1 Filter modules ................................................................................................................................................	32
	4.2.2 Control unit.....................................................................................................................................................	32
Section 5 Operation.....................................................................................................................................................		34
5.1	Using the keypad.....................................................................................................................................................	34
5.2	Menu overview ........................................................................................................................................................	35
5.3	[+DEVICEDATA] menu ..........................................................................................................................................	36
5.4	[+SIGNALS] menu...................................................................................................................................................	37
5.5	[+OP.COUNTERS] menu ........................................................................................................................................	38
5.6	[+SERVICE] menu...................................................................................................................................................	39
Section 6 Maintenance................................................................................................................................................		42
6.1	Maintenance work ...................................................................................................................................................	42
	6.1.2 Every 3 months ..............................................................................................................................................	43
	6.1.3 Every 12 or 24 months...................................................................................................................................	44
	6.1.4 Menu-based cleaning.....................................................................................................................................	45
	6.1.5 Cleaning with cleaning container (option) ......................................................................................................	46
Section 7 Faults, causes, rectification ......................................................................................................................		49
7.1	Messages ................................................................................................................................................................	49
7.2	Warnings .................................................................................................................................................................	49
7.3	Faults.......................................................................................................................................................................	50
7.4	Voltage drop (power failure) ....................................................................................................................................	50

1

Contents
Section 8	Spare parts...................................................................................................................................................	51
Section 9	Warranty and liability..................................................................................................................................	53
Section 10 Contact ......................................................................................................................................................		55

2

Section 1	Technical data

Table 1-1 FILTRAX

Supply:	230 V (option 115 V) ±10% AC, 50-60 Hz
	Device with system components: 1500 VA
	Cable		Heater off		Max. (-20° C)	Cont. (-20° C)
					start-up
Power consumption:
	2 m		150 VA		450 VA	< 200 VA
	10 m		150 VA		950 VA	< 300 VA
	20 m		150 VA		1500 VA	< 400 VA
	30 m		150 VA		2100 VA	< 500 VA
Sample volume:	approx. 900 ml/h for up to 3 process photometers
Head:	Module carrier – control unit: 3 m ; control unit – process instrument: 7 m
Outputs:	Fault signalling contact: floating contact (230 V, max. 3 A)
	Warning contact: floating contact (230 V, max. 3 A)
(use screened cable!)
	Service interface: RS 232
	Suction tube:			5 m (heated)
Cable length:	Sample tube:			2 m (unheated)
	Sample tube:			10 m (heated), 20 m (heated), 30 m (heated)
User maintenance:	approx. 1h / month
Medium temperature:	+5° C to +40° C
Ambient temperature	-20° C to +40° C
Enclosure rating:	IP 55
Fuses:	T 4A E; 250V (2 ×)
	T 7A E; 250V (2 ×)
	Control unit:			approx. 22 kg
	Module carrier with 5 m suction tube: approx. 9 kg
Mass:	Sample tube 10 m:			approx. 5 kg
	Sample tube 20 m:			approx. 10 kg
	Sample tube 30 m:			approx. 15 kg
	Mounting pipe 2 m:			approx. 5 kg
Dimensions:	Control unit (W x H x D): 430 x 530 x 220 mm
	Module carrier (W x H x D): 92 x 500 x 340 mm
Certification:	CE. The manufacturer clarifies conformity with the applicable EU safety guidelines
	and EMC guidelines.

Subject to change without notice.

3

Technical data

4

Section 2 General information

2.1 Safety information

Please read this entire manual before unpacking, setting up or operating this equipment. Pay attention to all danger, warning and caution statements. Failure to do so could result in serious injury to the operator or damage to the equipment.

Make sure that the protection provided by this equipment is not impaired, do not use or install this equipment in any manner other than that specified in this manual.

2.1.1 Use of hazard information

D A N G E R

Indicates a potentially or imminently hazardous situation which, if not avoided, will result in death or serious injury.

WA R N I N G

Indicates a potentially or imminently hazardous situation which, if not avoided, could result in death or serious injury.

C A U T I O N

Indicates a potentially hazardous situation that may result in minor or moderate injury.

N O T I C E

Indicates a situation which, if not avoided, may cause damage to the instrument.

Information that requires special emphasis.

Note: Information that supplements points in the main text.

2.1.2 Precautionary labels

Read all labels and tags attached to the instrument. Personal injury or damage to the instrument could occur if not observed. A symbol on the instrument is referenced in the manual with a precautionary statement.

This is the safety alert symbol. Obey all safety messages that follow this symbol to avoid potential injury. If on the instrument, refer to the instruction manual for operation or safety information.

This symbol indicates that a risk of electrical shock and/or electrocution exists.

Electrical equipment marked with this symbol may not be disposed of in European domestic or public disposal systems after 12 August 2005. In conformity with European local and national regulations (EU Directive 2002/96/EC), European electrical equipment users must now return old or end-of life equipment to the manufacturer for disposal at no charge to the user..

Note: For return for recycling, please contact the equipment producer or supplier for instructions on how to returnend-oflife equipment, producer-supplied electrical accessories, and all auxiliary items for proper disposal.

5

General information

2.2 Applications

The FILTRAX sampling system is a device for the filtration and pumping of waste water samples from the activated sludge tank or final clarification tank for supplying process instruments with samples free of solids.

N O T I C E

Any use other than use in accordance with requirements defined in the user manual leads to the loss of the warranty claims and can lead to personal injury and property damage, for which the manufacturer assumes no liability.

2.3 Functional description

The FILTRAX sampling and sample conditioning system comprises two components: a control unit and module carrier.

The module carrier (1) is immersed at the place the samples are to be taken using a special tank edge fastening. Inside the module carrier there are two filter modules (2); a filter membrane (3) is stretched over both sides of each of the modules. The waste water sample is fed to a special duct system (4) via this membrane.

Two tube metering pumps inside the control unit draw the sample alternately from the two filter modules using a common 5 m long heated suction tube to the control unit that is installed in close proximity to the sampling point. From there the sample is pumped 2 m, 10 m, 20 m or 30 m, depending on the sample tube connected, to the process instruments.

A venting device (5) underneath the filter modules largely prevents the adhesion of solids to the filter membranes and significantly reduces the maintenance effort. Two signal lamps (green and red) provide continuous visual indication of normal operation, warnings and faults - this information is also provided electrically by two floating relay contacts.

Fig. 2-1	Layout of the filter modules

6

General information

2.4 Items supplied

Fig. 2-2

Items supplied

	1.	Control unit									9.				Operating instructions
	2.	LZX670 (230 V) module carrier with 5 m suction tube									10.				Factory test certificate
	3.	Sample tube 2 m, 10 m, 20 m, 30 m									11.				DOC273.xx.04006 Maintenance calendar
	4.	LZX677 Filter module (2)									Included in accessory set LZX702
	5.	EYV017 Plastic bag for filter module (4)									12.				Mounting bracket for sample tube
											13.				Blanking plugs (2) + sealing rings (2)
	6.	Cable gland M20 x 1.5 (2)
											14.				HLS191 2/4 tube 6 m
	7.	LZX702 Accessory set
											15.				Cleaning sponge
	8.	LZX701 Tube adapter set									16.				Clip

7

General information

2.5 Instrument layout

2.5.1 Control unit

Fig. 2-3

Control unit

1.	Suction tube connection (left or underneath on the left)	5.	Air filter cover (air outlet)
	(Blanking plugs and sealing ring for the unused
		6.	Door lock
	opening)
2.	Connection for equipotential bonding	7.	Green and red signal lamps
3.	Air filter cover (air inlet)	8.	Sample tube connection (right or underneath on the right)
			(Blanking plugs and sealing ring for the unused opening)
4.	Cable gland for electrical connecting cable (2)

2.5.2	Module carrier
Fig. 2-4	Module carrier

1.	Module carrier	4.		Sample suction tube 3.2 mm OD (2)
2.	Suction tube 5 m	5.		Connecting cable for the tube heater
3.	Air tube 6 mm OD (2)

8

General information

2.5.3 Sample tubes

Fig. 2-5

Sample tubes

1.	Sample tube 2 m, 23 mm (0.91 inch), not heated	4.	Sample pressure tube 3.2 mm OD
2.	Sample pressure tube 3.2 mm OD	5.	Connecting cable for the tube heater
3.	Sample tube 10 m, 20 m, 30 m, 23 mm (0.91 inch), heated

2.5.4 Filter modules

The two filter modules should only be installed during commissioning. Once moistened, the filter membranes must not be allowed to dry out again and are sealed in a plastic bag for protection.

N O T I C E

The surface of the membrane is very delicate!

9

General information

Fig. 2-6

Filter module

10

Section 3	Installation

D A N G E R

Only qualified experts should conduct the tasks described in this section.

D A N G E R

Select an appropriate installation location for the instrument.

Plan out the mechanical mount before positioning poles or drilling holes. Make sure the mount has a sufficient bearing capacity. The dowels must be selected and authorized according to the condition of the wall.

The manufacturer shall accept no liability if the instrument is installed incorrectly.

Plan how to lay cables and tubes and their path in advance. Lay the tubes, data cables and power cables without any bends and so they do not pose a tripping risk.

Do not connect the electrical supply to the mains until the instrument is completely wired and protected against short circuits.

Sufficiently protect the electrical power supply against short circuits.

For the external power supply, always connect a residual-current circuit breaker (trip current max.: 30 mA) between the mains and the system.

If the instrument is to be installed outdoors, connect a surge arrester between the mains and the system.

Products intended by the manufacturer for outdoor use offer a higher level of protection against the penetration of liquids and dust. If these products are connected to a mains outlet with a cable and plug rather than a permanently connected cable, the plug and outlet are much more susceptible to liquid and dust penetration. The operator must sufficiently protect the plug and outlet against liquid and dust penetration in accordance with local safety regulations. If the instrument is to be used outdoors, it must be connected to a suitable outlet with a protection type of at least IP44 (splash protection).

WA R N I N G

Electrical dangers and fire hazard. Use only the supplied power cable.

Only qualified experts may perform the tasks described in this section of the manual, in compliance with all locally applicable safety regulations.

N O T I C E

Protect the device against extreme temperatures from heaters, direct sunlight and other heat sources.

C A U T I O N

Note the weight (control unit approx. 22 kg, module carrier with 5 m suction tube approx. 9 kg) of the instrument. Do not try to carry the instrument without help. Use only suitable lifting devices for the transport.

11

Installation

Fig. 3-7

Installation overview

1.	Module carrier																			5.					Process instrument
2.	Bracket FILTRAX module carrier (option)																			6.					Sample tube
3.	Suction tube 5 m																			7.					Bracket FILTRAX control unit (option)
4.	Control unit

12

Installation

3.1 Mechanical installation

D A N G E R

Select an appropriate installation location for the instrument.

Plan out the mechanical mount before positioning poles or drilling holes. Make sure the mount has a sufficient bearing capacity. The dowels must be selected and authorized according to the condition of the wall.

The manufacturer shall accept no liability if the instrument is installed incorrectly. Plan how to lay cables and tubes and their path in advance.

Lay the tubes, data cables and power cables without any bends and so they do not pose a tripping risk.

N O T I C E

For information on installation with optional accessories, refer to the relevant installation instructions.

N O T I C E

The filter module should only be unpacked directly before commissioning and quickly attached to the module carrier.

The filter membranes are shrink-wrapped in protective plastic; once they have been moistened they must not be allowed to dry out.

3.1.1 Dimensions

Fig. 3-8	Control unit

13

Installation

Fig. 3-9

Module carrier and filter module

14

Installation

Fig. 3-10 Control unit bracket components

			6	7
				8
1.	HRO304 supporting pipe 1.8 m	Included in hardware LZX416:
2.	Setscrew M8 x 10 (2) in LZX416
		6. Cheese head bolt M8 x 16 (4)
3.	ATS010 base
		7.	Blanking plug
4.	HHH277 bracket (2)
		8.	Plug
5.	EHK063 pipe clamp (2)

15

Installation

3.2 Installing control unit with control unit bracket LZX676

Fig. 3-11 Installation of control unit bracket

1.	Rear of control unit													6.						Bracket (2)
2.	Supporting pipe 1.8 m													7.						Nut M8 (2)
3.	Base													8.						Pipe clamp (2)
4.	Setscrew M8 x 10 (2)													9.						Cheese head bolt M8 x 16 (2)
5.	Anchor (4)																			+ washer (2)

16