wtw PurCon Operating instructions

Brand: wtw

Model: PurCon

Type: Operating instructions

PurCon

Sample preparation

ba43107e10 11/2004

Operating manual

Accuracy when

going to press

The use of advanced technology and the high quality of our instruments

are the result of continuous development. This may result in differences

between this operating manual and your instrument. Also, we cannot

guarantee that there are absolutely no errors in this manual. Therefore,

we are sure you will understand that we cannot accept any legal claims

resulting from the data, figures and descriptions.

Reprinting - even as excerpts - is only allowed with the explicit written

authorization of WTW GmbH, Weilheim.

Printed in Germany.

PurCon Contents

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

PurCon Introduction

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

PurCon

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Introduction PurCon

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 by using

gravity to run it into the PurCon from a vessel placed higher than the

PurCon.

Housing The sample is prepared inside the PurCon housing.

1 Mains switch 7 Mains supply 115/230 VAC

2 Selector switch of permeate

supply

8 Fuse holder

3 Permeate pump 9 Locking

4 Feed / inlet ball valve 10 Filler nozzle for cleaning

solution

5 Outlet ball valve 11 Compressor lid

6 Permeate nozzle 12 Anchoring lug

PurCon Introduction

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 disposed of 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 obtained via a compressor. 4 permeate

tracks are operated alternately via a valve. The PurCon is connected to

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

PurCon

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Introduction PurCon

Fig. 4 Valve setting for emptying the sample preparation instrument

Fig. 5 Valve setting for cleaning the sample preparation instrument

PurCon

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PurCon

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PurCon Safety instructions

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 T

ECHNICAL DATA must be 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

The failure-free function and operational safety of the instrument is 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, T

ECHNICAL 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, T

ECHNICAL 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 If safe operation is no longer possible, the instrument must be taken out

Safety instructions PurCon

of operation and secured against inadvertent operation.

Safe operation is no longer possible if the instrument:

l has been damaged in transport

l has been stored under adverse conditions for a lengthy period of

time

l is visibly damaged

l no 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

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. Wear suit-

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

PurCon Commissioning

3 Commissioning

Scope of delivery l PurCon sample preparation instrument

l Operating 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

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290 575

735

D=8,4 mm

Commissioning PurCon

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, T

ECHNICAL

ATA).

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 it to the floor. Use the screws that

are supplied.

Fig. 7 PurCon with mounting stand

1 Fetch 4 suitable screws (Ø 8 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).

PurCon

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PurCon Commissioning

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 T

ECHNICAL DATA of this operating manual. We rec-

ommend to use the 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 drinking water or surface water. Dispose of

the detergent as described in the safety datasheets.

1 Fetch 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

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

3 Disable the feed transport.

4 Switch off the power switch of the PurCon.

5 Unscrew 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.

7 To 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

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

PurCon

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Commissioning PurCon

3.7 Power supply

Warning

Have the loading capacity of the mains socket checked by a qualified

electrician before connecting the instrument. The mains socket must be

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, T

ECHNICAL 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.

1 Fetch the power cable that was supplied.

2 Use the power cable to connect the PurCon to an easily

accessible mains socket.

1 Fetch the permeate hose that was supplied.

2 Connect the analyzer to the permeate nozzle on the front of the

instrument.

PurCon Commissioning

3.9 Inserting the pump hoses

Proceed as follows:

Fig. 11 Inserting the pump hoses

1 Take the pump cassette out of the holder by pressing the clamp

strap.

2 Fix the pump hoses supplied between the first and second

stopper in the pump cassette.

3 Replace the pump cassette in the holder and snap in the clamp

strap.

4 Fix the pump cassette on the gripping lever.

5 Repeat this procedure for all 4 permeate hoses.

Commissioning PurCon

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 min after switching on the permeate pump, 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:

1 Are all the hose clamps used firmly tightened?

2 Are the seals of the retentate nozzle seated correctly and tight?

3 Are the manual valves set correctly for operating the sample

preparation instrument?

4 Are all the tension arms of the permeate pump under tension?

5 Is the permeate hose correctly connected to the analyzers?

1 Switch on the mains switch (green power lamp lights up).

2 Switch on the feed pump (green control lamp lights up).

3 Switch 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

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wtw PurCon Operating instructions

wtw PurCon Operating instructions

wtw PurCon Operating instructions

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