BA00432C/07/EN/13.13 71207066 Products Solutions Services Operating Instructions Wastewater assembly
About this document Safety messages 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"). Safety message structure! DANGER Cause (/consequences) Consequences if safety message is not heeded Corrective action! WARNING Cause (/consequences) Consequences if safety message is not heeded Corrective action! CAUTION Cause (/consequences) Consequences if safety message is not heeded Corrective action NOTICE Cause/situation Consequences if safety message is not heeded Action/note Meaning This symbol alerts you to a dangerous situation. Failure to avoid the situation will result in a fatal or serious injury. This symbol alerts you to a dangerous situation. Failure to avoid the situation can result in a fatal or serious injury. This symbol alerts you to a dangerous situation. Failure to avoid this situation can result in minor or medium injury. This symbol alerts you to situations that can result in damage to property and equipment. Symbols Additional information, tips Permitted or recommended Forbidden or not recommended Endress+Hauser
Table of contents 1 Basic safety instructions............. 4 1.1 Requirements for the personnel............... 4 1.2 Designated use............................. 4 1.3 Workplace safety........................... 4 1.4 Operational safety........................... 4 1.5 Product safety.............................. 4 2 Incoming acceptance and product identification...................... 5 2.1 Incoming acceptance........................ 5 2.2 Scope of delivery............................ 5 2.3 Product identification........................ 5 2.4 Certificates and approvals.................... 6 3 Installation........................ 7 3.1 Installation conditions....................... 7 3.2 Installation instructions...................... 8 3.3 Post-installation check..................... 15 4 Maintenance...................... 16 4.1 Immersion pipe support.................... 16 4.2 Maintaining the clamping systems and threads 16 4.3 Cleaning the quick fastener................. 16 5 Repair............................ 17 5.1 Return................................... 17 5.2 Disposal................................. 17 6 Accessories....................... 18 7 Technical Data.................... 28 7.1 Environment............................. 28 7.2 Process conditions......................... 28 7.3 Mechanical construction................... 28 Index............................. 30 Endress+Hauser 3
Basic safety instructions 1 Basic safety instructions 1.1 Requirements for the personnel Installation, commissioning, operation and maintenance of the measuring system must only be carried out by trained technical personnel. The technical personnel must be authorized by the plant operator to carry out the specified activities. The electrical connection may only be performed by an electrical technician. The technical personnel must have read and understood these Operating Instructions and must follow the instructions they contain. 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 directly at the manufacturer's or by the service organization. 1.2 Designated use CYA112 is designed as a modular assembly system for sensors in open basins, channels and tanks. Any other use than the one described here compromises the safety of persons and the entire measuring system and is not permitted. The manufacturer is not liable for damage caused by improper or non-designated use. 1.3 Workplace safety As the user, you are responsible for complying with the following safety conditions: Installation instructions Local prevailing standards and regulations. 1.4 Operational safety Before commissioning the entire measuring point, make sure all the connections are correct. Ensure that electrical cables and hose connections are not damaged. Do not operate damaged products, and safeguard them to ensure that they are not operated inadvertently. Mark the damaged product as defective. If faults cannot be rectified, the products must be taken out of service and secured against unintentional commissioning. 1.5 Product safety The product is designed to meet state-of-the-art safety requirements, has been tested and left the factory in a condition in which it is safe to operate. Relevant regulations and European standards have been observed. 4 Endress+Hauser
Incoming acceptance and product identification 2 Incoming acceptance and product identification 2.1 Incoming acceptance Make sure the packaging is undamaged! Inform the supplier about any damage to the packaging. Keep the damaged packaging until the matter has been settled. Make sure the contents are undamaged! Inform the supplier about damage to the contents. Keep the damaged products until the matter has been settled. Check that the order is complete and agrees with your shipping documents. The packaging material used to store or to transport the product must provide shock protection and humidity protection. The original packaging offers the best protection. Also, keep to the approved ambient conditions (see "Technical data"). If you have any questions, please contact your supplier or your local sales center. 2.2 Scope of delivery The scope of delivery comprises: Ordered assembly version Operating Instructions, English. If you have any questions, please contact your supplier or your local sales center. 2.3 Product identification 2.3.1 Nameplate The nameplate contains the following information: Manufacturer data Order code Extended order code Serial number Operating conditions Safety icons Compare the order code on the nameplate with your order. 2.3.2 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 To find out the version of your device, enter the order code indicated on the nameplate in the search screen at the following address: www.products.endress.com/order-ident Endress+Hauser 5
Incoming acceptance and product identification 2.4 Certificates and approvals Explosion protection The stainless steel version of the CYA112 assembly (CYA112-*A21*2**) is suitable for use in hazardous zones 1 and 2. The ATEX directive 94/9/EC does not apply because the assembly has no potential ignition source. Accordingly, it is not designated according to ATEX. Potential equalization must be implemented as described in the chapter "Installation conditions". If sensors have accessible metallic surfaces, these surfaces have to be connected to the potential match according to the corresponding operating instructions. 6 Endress+Hauser
Installation 3 Installation 3.1 Installation conditions Install the assembly on a place with enough free space around it so the sensor cannot get damaged. When installing the assembly in a fixed position, make sure that it can be easily accessed and maintained. The immersion pipe has to protrude the holding point by at least 100 mm (3.94") min. 100 (3.94) mm (inch) Fig. 1: Holding point (illustration without splash protection cap) a0011037 The grounding has to be done on-site. All conductive parts have to be connected to each other. For use in hazardous areas: The immersion pipe side of the assembly has to be conductively connected to the corresponding holder or fixing. When the assembly is fixed via chain or mounting bracket a separate conductor for potential match is needed beside the measuring cable. If sensors have accessible metallic surfaces, these surfaces have to be connected to the potential match according to the corresponding operating instructions. Endress+Hauser 7
Installation 3.2 Installation instructions 3.2.1 Mounting the stainless steel parts You have to screw the pipes together finger-tight (without any gaps). The threads are lubricated and provided with an O-ring. 3.2.2 Gluing the PVC parts PVC assemblies up to 1200 mm (47.2") in size are delivered as ready-to-install units and do not have to be glued. Where required, cleaning cloths and glues form part of the scope of supply. Glue the PVC parts as follows: 1. Clean the surfaces to be glued (exterior pipe end, sleeve or internal angle piece) with the cleaning cloth. 2. Allow the cleaned surfaces to dry for approx. 5 minutes. 3. Apply an even film of glue to the surfaces to be glued (sleeve first, then the pipe). 4. Join the parts within one minute (push together until the stop). 5. Remove the excess glue. 6. Allow the glued parts to harden for at least 5 minutes. 8 Endress+Hauser
Installation 3.2.3 Mounting the sensor Preparatory steps: 1. Screw or glue the connecting bracket onto the immersion tube. 2. Where necessary, screw the sensor adapter onto the connection bracket. Mount the sensor as follows: 1. Guide the sensor cable through the immersion tube. 2. Where necessary, connect the sensor cable to the sensor. 3. Screw the sensor into the adapter or into the connection bracket. To prevent the sensor cable from twisting, rotate the assembly and not the sensor. 1 1 2 3 4 Splash protection cap Sensor cable Rubber plug Immersion tube 2 3 4 Fig. 2: Cable run a0011111 4. Shorten the tip of the rubber plug so that it suits the cable diameter. 5. Fit the rubber plug onto the sensor cable and press it onto the immersion tube. 6. Route the sensor cable downwards in a loop (do not bend) and fit on the splash protection cap. The splash protection cap is fixed by the lip of the rubber plug. Endress+Hauser 9
Installation 3.2.4 Fixed installation of the assembly on a transverse pipe Prerequisite: The sensor is already mounted. The cross clamp is mounted in such a way that one closed side points to the center of the basin while the other closed side points upwards. Mount the immersion tube as follows: 1 2 3 1 2 3 4 Immersion tube Cross clamp, closed side to basin center Cross clamp, closed side at top Transverse pipe 4 Fig. 3: Mounting the cross clamp a0011292 Fig. 4: Adjustment of the clamps 1. Adjust the clamps on the cross clamp ( å 4). 2. Slide the cross clamp over the immersion tube. Make sure that the closed side of the cross clamp is at the top ( å 3). 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 antislip 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 ( å 3). 5. Align the assembly and the holder. a0014991 6. Tighten the clamp screws finger-tight (finger-tight corresponds to 13 Nm (9.6 lbf ft)). 10 Endress+Hauser
Installation 3.2.5 Installation of the assembly on a chain retainer Prerequisite: The immersion tube is fitted with a sensor. The transverse pipe is fitted with a chain. Fig. 5: Mounting the chain retainer 1 Mount the multifunctional clamp ring 2 Loop the bracket into the chain 3 Attach the bracket to the multifunctional clamp ring 4 Fit the splash protection cap x 60 to 80 mm (2.35 to 3.15 ") a0011420 1. Insert the weights into the immersion tube (only PVC immersion tubes). 2. Screw the multifunctional clamp ring onto the immersion tube (funnel-shaped side facing downwards). 3. Guide the bracket into the lowest link in the chain. 4. Attach the bracket to the multifunctional clamp ring. 1 1 2 3 4 Splash protection cap Sensor cable Rubber plug Immersion tube 2 3 4 Fig. 6: Cable run a0011111 5. Fit the rubber plug onto the sensor cable and press it onto the immersion tube. 6. Route the sensor cable downwards in a loop (do not bend) and fit on the splash protection cap. 7. Secure the chain on the holder with the triangular carabiner and determine so the maximum immersion depth of the assembly. Endress+Hauser 11
Installation 3.2.6 Installation of the assembly with a float Fig. 7: Float mounting 1 Immersion tube with adhesive fitting and sensor adapter (finished ex works) 2 Float body 3 Second immersion tube with 45 adhesive fitting a0011422 Preparatory steps 1. Slide the float body (item 2) onto the immersion tube (item 1). 2. Glue the second immersion tube (item 3) and the adhesive fitting (item 3) onto the immersion tube (item 1) (see chapter "Gluing the PVC parts"). 3. Adjust the clamps on the cross clamp. 4. Slide the cross clamp over the immersion tube. Make sure that the closed side of the cross clamp is at the top. 5. 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 antislip lock. 12 Endress+Hauser
Installation Installing the sensor and mounting the assembly 1. Guide the sensor cable through the immersion tube. 2. Where necessary, connect the sensor cable to the sensor. 3. Screw the sensor into the adapter. To prevent the sensor cable from twisting, rotate the assembly and not the sensor. 1 1 2 3 4 Splash protection cap Sensor cable Rubber plug Immersion tube 2 3 4 Fig. 8: Cable run 4. Shorten the tip of the rubber plug so that it suits the cable diameter. 5. Fit the rubber plug onto the sensor cable and press it onto the immersion tube. 6. Mount the float assembly on the pendulum holder. 7. Align the assembly and the holder. a0011111 8. Tighten the clamp screws finger-tight (finger-tight corresponds to 13Nm (9.6 lbf ft)). 9. Route the sensor cable downwards in a loop (do not bend) and fit on the splash protection cap. The splash protection cap is fixed by the lip of the rubber plug. Endress+Hauser 13
Installation 3.2.7 Installation of the quick fastener 1 2 3 4 Fig. 9: Quick fastener 1 Bore - makes it easier to screw the adapter tight 2 Adapter 3 Thread adapter nut 4 O-rings a0016947 Install the quick fastener as follows: 1. Provide both O-rings (item 4) with a thin film of lubricant. 2. Screw the adapter (item 2) into the immersion tube connection bracket. 3. Insert a screwdriver or a similar tool through the bores (item 1, serves as lever) to secure the adapter. 4. Slide the thread adapter nut (item 3) over the adapter until the thread adapter nut engages with a click. 5. Guide the sensor cable through the quick fastener and the immersion tube. The Memosens coupling is secured in the quick fastener and cannot slip. 6. Connect the cable to the sensor. 7. The quick fastener allows to install the sensor without twisting the measuring cable. Screw the sensor into the quick fastener until the stop. In doing so, turn the thread adapter nut. Do not turn the sensor. 8. Align the sensor if necessary. 14 Endress+Hauser
Installation 3.2.8 Dismount the quick fastener 2 2 Fig. 10: Dismounting the quick fastener 1 quick fastener - thread adapter nut Dismount the quick fastener as follows: 1. Move the thread adapter nut in the direction of the arrow to the stop position ( å 10). This pushes the connection clips towards the center ( å 11). 2. Stick the mounting tool onto the connection clips ( å 12) and push the mounting tool very hard in the direction of the arrow. 3. The connection clips are unlocked. Pull off the thread adapter nut and the mounting tool( å 13). 4. Unscrew the adapter from the immersion pipe. a0016950 Fig. 11: 2 Connection clips Dismounting the quick fastener a0016951 3 Fig. 12: 3 Mounting tool Dismounting the quick fastener a0016952 Fig. 13: Dismounting the quick fastener 1 Quick fastener - thread adapter nut 3 Mounting tool 4 Quick fastener - adapter 4 1 3 a0016953 3.3 Post-installation check After mounting, check whether all the screws are tightened correctly. If mounting using a pendulum holder, ensure the assembly has sufficient clearance. Endress+Hauser 15
Maintenance 4 Maintenance! WARNING There is a risk of infection when working with wastewater Wear protective gloves, goggles and protective clothing. 4.1 Immersion pipe support Fig. 14: Immersion tube tray for assembly service position 1 Immersion tube tray a0011372 The immersion tube tray makes it easier to perform maintenance tasks with rail mounting involving a pendulum holder and cross clamp. 4.2 Maintaining the clamping systems and threads Lubricate the clamping systems and threads at regular intervals. Proceed as follows to do so: 1. Clean the clamps and threads with soapy water. 2. Dry the clamps and threads. 3. Provide the cleaned parts with a thin film of lubricant (e.g. Syntheso Glep1). 4.3 Cleaning the quick fastener Preparatory steps: 1. Remove the sensor and cable. 2. Insert the removal tool (see "Accessories" section) into the thread adapter nut so that the thread adapter nut is disengaged and can be removed. Clean the quick fastener with soapy water. 16 Endress+Hauser
Repair 5 Repair 5.1 Return The device must be returned if repairs or a factory calibration are required, or if the wrong device has been ordered or delivered. According to legal regulations, Endress+Hauser, as an ISO-certified company, is required to follow certain procedures when handling returned products that are in contact with medium. To ensure swift, safe and professional device returns, please read the return procedures and conditions on the internet site: www.services.endress.com/return-material 5.2 Disposal Please dispose of the device in accordance with the local regulations. Endress+Hauser 17
Accessories 6 Accessories Multifunctional clamp ring Chain retainer in conjunction with the triangle carabiner Working height adjustment of the main pipe (version main pipe with transverse pipe) The multifunctional clamp ring acts as an anti-slip lock on transverse pipes, main pipes and assemblies. Material: POM - GF Order No. 71092049 Fig. 15: Multifunctional clamp ring a0016879 18 Endress+Hauser
Accessories Immersion pipe support Immersion pipe support for comfortable maintenance Material: stainless steel 1.4404 (AISI 316L) Order No. 71092054 Fig. 16: Immersion pipe support a0016880 Endress+Hauser 19
Accessories Wall mounting set 2 pipe clamps D 40; material: PE 1 worm-drive hose clip for height adjustment Order No.: 71132469 Fig. 17: Pipe clamp a0016767 Triangle carabiner Used to fix the chain (together with multifunctional clamp ring) Material: stainless steel Order No. 71092052 Fig. 18: Triangle carabiner a0016873 Hook-and-loop cable ties (set of 4 pieces) To fix the cables Material: PE / PA (polyethylene / polyamide) Order No. 71092051 20 Endress+Hauser
Accessories Mounting tool Tool to remove the quick fastener Material: stainless steel Order No. 71093438 Fig. 19: Mounting tool a0016305 Quick fastener For the quick and easy installation and exchange of sensors Material: POM - GF Order No. 71093377 G 1 128 (5.04) 90 (3.54) Fig. 20: Quick fastener mm (inch) 44.5 (1.75) a0016286 Endress+Hauser 21
Accessories Sensor adapter NPT ¾" Sensor adapter G1 to NPT ¾" Material: POM - GF Order No. 71093382 Fig. 21: Sensor adapter G1 to NPT¾" a0016285 Sensor adapter G¾ Sensor adapter G1 to G¾ Material: POM - GF Order No. 71093383 Fig. 22: Sensor adapter G1 to G¾ a0016284 22 Endress+Hauser
Accessories Sensor adapter Pg 13.5 Sensor adapter G1 to Pg 13.5 Material: POM - GF Order No. 71093384 Fig. 23: Sensor adapter G1 to Pg 13.5 a0011169 Immersion pipe Connection thread: M36 Material: stainless steel Fig. 24: Immersion pipe a0011042 length x = 600 mm (23.6"): Order No. 71073767 length x = 1200 mm (47.3"): Order No. 71073706 Endress+Hauser 23
Accessories Immersion-pipe connection straight M36 to G1 Material: stainless steel Order No. 71073768 Fig. 25: Immersion-pipe connection straight a0016270 Immersion-pipe connection 45 M36 to G1 Material: stainless steel Order No. 71073769 Fig. 26: Immersion-pipe connection 45 a0016271 24 Endress+Hauser
Accessories Immersion-pipe connection 90 M36 to G1 Material: stainless steel Order No. 71073770 Fig. 27: Immersion-pipe connection 90 a0016273 Protective cap Connection thread: M36 Cable gland Pg 13.5 Material: stainless steel Order No. 71115553 Fig. 28: Protective cap a0016283 Endress+Hauser 25
Accessories PVC protector for flexible mounting of CUS71D The PVC protector protects the ultrasonic sensor from getting damaged by the surface skimmer. Order number: 71178584 Ø 41 (1.61) 1 271 (10.67) 2 44 (1.73) 129 (5.08) 3 Ø 74.3 (2.93) Ø 99 (3.9) mm (inch) a0016892 Fig. 29: PVC protector for CUS71D 1 Assembly CYA112 2 PVC-protector 3 Ultrasonic sensor CUS71D 26 Endress+Hauser
Accessories CYA112 spray cleaning for installation on immersion pipe Versions in 600 mm and 1200 mm For assembly CYA112 version: 600 to 2400 mm, straight Material: Pipe: PVC-U Spacers: PA Worm drive hose clips: stainless steel 1.4401 (AISI 316) Order No. for 600 mm - version: 71158245 Ordet No. for 1200 mm - version: 71158246 Fig. 30: Spray cleaning for CYA112 A Version: 1200 mm B Version: 600 mm a0017182 Fig. 31: Example of an installed spray cleaning a0017805 Endress+Hauser 27
Technical Data 7 Technical Data 7.1 Environment Air temperature -20 to +60 C (-4 to 140 F) 7.2 Process conditions Process temperature range 0 to 60 C (32 to 140 F) Process pressure range unpressurized 7.3 Mechanical construction Dimensions Immersion pipe (PVC): Ø 40 mm (1.57"), length: 600, 1200, 1800 and 2400 mm (23.6", 47.2", 70.9" and 94.5") Immersion pipe (stainless steel): Ø 40 mm (1.57"), length: 600, 1200, 1800, 2400 and 3600 mm (23.6", 47.2", 70.9", 94.5" and 142") Weight Immersion pipe (stainless steel) (length 1 / 2 / 3 / 4 / 5): Immersion pipe (PVC) (length 1 / 2 / 3 / 4): Multifunctional clamp ring: Weights for immersion pipe (PVC): 0.6 / 1.2 / 1.8 / 2.4 / 3.5 kg (1.3 / 2.6 / 4.0 / 5.3 / 10.8 lbs) 0.3 / 0.6 / 0.95 / 1.3 kg (0.7 / 1.4 / 2.1 / 2.8 lbs) 0.15 kg (0.33 lbs) 0.32 kg (0.71 lbs) Materials Immersion pipe: stainless steel 1.4404 (AISI 316 L) Connection angle: stainless steel 1.4404 (AISI 316 L) Welded threads stainless steel 1.4571 (AISI 316 Ti) Sensor adaption: POM - GF Quick fastener: POM - GF Multifunctional clamp ring: POM - GF Cap: PE Chain bracket: stainless steel 1.4571 (AISI 316 Ti) or 1.4404 (AISI 316 L) O-rings: EPDM Floater, yellow: PVC (up to middle of 2012) Floater, black: EPP (from middle of 2012 on) 28 Endress+Hauser
Technical Data Endress+Hauser 29
Index A Accessories..................................... 18 C Checking Installation.................................. 15 D Designated use.................................... 4 Dismount the quick fastener...................... 15 F Fixed installation on transverse pipe............... 10 Float Installation.................................. 12 S Scope of delivery.................................. 5 Sensor installation................................ 9 Stainless steel pipes Installation.................................... 8 T Technical Data................................... 28 U Use............................................. 4 W Workplace safety.................................. 4 G Gluing the PVC parts............................... 8 I Immersion pipe support.......................... 16 Incoming acceptance............................... 5 Installation.................................... 7 8 Assembly on chain retainer.................... 11 Fixed installation on transverse pipe............ 10 Float........................................ 12 PVC parts..................................... 8 Quick fastener............................... 14 Sensor........................................ 9 Stainless steel pipes............................. 8 M Maintenance................................... 16 N Nameplate....................................... 5 O Operational safety................................. 4 P Product identification.............................. 5 Product safety.................................... 4 Q Quick fastener Dismount................................... 15 Installation.................................. 14 R Repair......................................... 17 Requirements for the personnel..................... 4 Return......................................... 17 30 Endress+Hauser
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