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The Maintenance Guide

Tips and reference information

to keep your installed base up and running
Because your success
is important to us…
As a shift of Endress+Hauser’s ‘Instrument Express’ concept, this
fully revised ‘Maintenance Guide’ aims at providing reference
information to your production, metrology and maintenance
teams. Developed by our experts, it contains some reminders on
the measuring principles and gives answers to frequently asked
questions. And we have included lots of tips to help you make
better use of your installed base!
Keep a copy on your desk all year round!


Tips & Advice 4 At your service 98

Level measurement 7 - 24 W@M - Life Cycle Management

Flow metering 25 - 42 for process automation 100
Liquid analysis 43 - 70 Commissioning 104
Pressure measurement 71 - 80 FieldCare® 105
Temperature measurement 81 - 86 Calibration services 106
Recorders 87 - 90 CompuCal™ 109
Field communication 91 - 97 Maintenance services 110
Audit 113
Training 116

How to get consumables, tools This small catalog contains the price lists
and spare parts? of the electrodes, cables and various other
In addition to the Maintenance Guide, consumables, of the hardware and software
Endress+Hauser issues on an annual basis tools and of the most frequently ordered
‘The Maintenance Store’. spare parts.
 The Endress+Hauser Maintenance Guide
Tips & advice
Helping you to obtain an
even higher availability from
installed instrumentation


Useful definitions 6
Level measurement 7
Flow metering 25
Liquid analysis 43
Pressure measurement 71
Temperature measurement 81
Recorders 87
Field communication 91

Installation Commissioning Operations Migration Re-engineering

Our contribution to your Time to read the chapters

success goes far beyond that cover the measurement
the sale of instrumentation principles you are using in your
Every day our experts help plant will not be wasted time!
you to solve installation,
commissioning, operations, And please keep in mind that
migration or re-engineering we are happy to help you reach
related problems. your objectives.

In this ‘Tips & Advice’ section, Feel free to call on our

they have gathered various service organization.
useful information that will We are at your service!
help you anticipate the most
frequent situations thus
increasing instrumentation

The Endress+Hauser Maintenance Guide 

Useful definitions

Metrology Maintenance (acc. to EN 13306)

Accuracy of a measurement Check Down time according to prescribed criteria
Closeness of the agreement For the purposes of this Time interval during which an and intended to reduce the
between the result of document, we will define a item is in a down state. probability of failure or the
measurement and a true value check as an act of conditional degradation of the functioning
of the reference. maintenance. According to Inspection of an item.
European Standard EN 306, Check for conformity by
Adjustment conditional maintenance is measuring, observing, testing Routine maintenance
The adjustment is the operation preventive maintenance based or gauging the relevant Regular or repeated elementary
of bringing a measuring on monitoring of the proper characteristics of an item. maintenance activities which
instrument into a state of functioning of the device usually do not require special
performance suitable for its use. and/or the critical parameters Note: Generally inspection can qualifications, authorization(s)
associated with its functioning, be carried out before, during or or tools.
Note: adjustment may be including any action which after other maintenance activity.
automatic, semiautomatic or may be required as a result. Note: Routine maintenance
manual. The results of this operation Life cycle may include for example
allow the user to confirm the Time interval that commences cleaning, tightening of
Calibration conformity of the instrument with the initiation of the connections, checking liquid
Calibration is the process of at the various control points in concept and terminates with level, lubrication, etc.
comparing values displayed the procedure. The results are the disposal of the item.
by the device to be calibrated documented in a certificate of
with corresponding reference proper functioning. Preventive maintenance
values (standards). The Maintenance carried out at
result of this operation is predetermined intervals or
documented in a calibration

 The Endress+Hauser Maintenance Guide

Level measurement

Frédéric Willauer
Expert in Level measurement
Endress+Hauser France

“Installation is the key”

“ToF (Time of Flight) and capacitive Like in the other sections, we have also Contents
instruments are the most popular recapped the main questions that you ask
Endress+Hauser level meters. us. With this information, you will be able Basics 8
to prevent or resolve the vast majority of The chapter ‘Basics’ includes information
ToF instruments share common concepts potential problems yourself! which is valid for all level measurement
allowing simplified commissioning, principles described hereafter. Thus you
should read it before any other chapter.
operation and maintenance. There is also plenty of useful information to
Though, the installation conditions are of help you get the best from your instruments Level-radar 10
utmost importance, especially regarding throughout their life cycle. Guided level-radar 14
the nozzle. This is why we have decided to
give you in this guide a reminder of these Note: if you are intending to replace one of Ultrasonic level measurement 17
essential installation conditions. your capacitive devices, please contact us. Capacitive level measurement 20
Each migration project has to be attentively
For capacitive level measurement examined.” FAQ 23
instruments, the situation is pretty different:
due to the physical principle, the key point We also offer training sessions, in classroom
is the connection to the ground, especially and on site. See ‘Training’ in the section
in case of a non-conductive tank. ‘At your service’.

The Endress+Hauser Maintenance Guide 


Information common to all types of level measurement devices

The Time of Flight (ToF) All Endress+Hauser ToF Operation and Maintenance
principle level measurement devices
have the same display. Routine maintenance
• Emission of ultrasound- or The display of the process value ToF devices include no wear
microwave-pulses and the configuration of the part thus require very little
• Reflection of the pulses from device occur locally by means maintenance. However,
the product surface of a large 4-line alphanumeric according to its criticality to
• Reception of the reflected display with plain text the quality, some instruments
pulses information. The guided menu need to be inspected or/and
• Measurement of the Time system with integrated help calibrated periodically.
of Flight : calculation of the texts ensures quick and safe
distance between the device commissioning (see fig. 3). Defining the right maintenance
and the product surface by To access the display the cover frequency taking several
d = (c x t)/2 of the electronic compartment parameters into account is an
may be removed even in expert’s job. Endress+Hauser
Setup - Configuration hazardous area (IS and XP). can also help you with this task!
of level instruments
The VU331 LC-Display can To test the 4 to 20 mA loop
General note: be removed to ease operation (see fig. 4 and 5):
The respect of installation by simply pressing the snap-fit • The 2-wire, 4 to 20 mA with
Fig. 1 : The principle - Time of Flight conditions are of key (see fig. 2). It is connected HART version includes test
importance for level to the device by means of a sockets for testing of the
measurement. Once this is 500 mm cable. signal current.
correctly done, the unit will • On the 4-wire versions
work. Nevertheless it is always The LC-Display VU331 allows (Levelflex and Prosonic),
necessary to configure the configuration via 3 keys directly there are two terminals
measuring point to achieve at the instrument. All device situated at the front of the
correct measurement. functions can be set through electronic module.
a menu system. The menu
consists of function groups and Calibration (all devices)
functions. Within a function, Intrinsically our instruments


U 16...36


(liquid crystal display) application parameters can be offer long-term stability

mA V DC m
A >70°C
Made in Germany

: t

read or adjusted. The user is and repeatability of your

guided through a complete measurements. Nevertheless
configuration procedure. we recommend periodic

calibration for the measurement

You can also configure your points which are critical to the
– + E
ToF instruments from your process and thus are important
3 keys
PC. Remote commissioning, to control the quality of your
including documentation product. From on-site to
of the measuring point and accredited services, you can be
in-depth analysis functions, is sure to find the right method
Fig. 2: On-site operation with VU331
supported via FieldCare Setup. by reaching the right balance
Headline Position indicator
See presentation of FieldCare between the device downtime
ENDRESS + HAUSER on page (S3). and the calibration uncertainty.

Our service team can set up any Calibration can be performed by

Symbol Main value Bargraph Unit
Endress+Hauser level measurement Endress+Hauser either on site or
– + E device for you and thus ensure you in our accredited laboratories.
immediately get the best from your (see ‘Calibration’ in the ‘At your
Selection list
instrument. (see ‘Commissioning’ in service’ section).
the ‘At your service’ section)
Function groups -> Functions

F FG00 X F000 F001 F002 F003 F004 ...
O FG02
O X Help text
FG04 S
FG07 Envelope
... curve


Fig. 3: The ‘Basic Setup’ covers 95% of the situations

 The Endress+Hauser Maintenance Guide

Check of the measurement Maintenance planning Corrective maintenance Instrument and
(all devices) - spare parts spare parts availability
Configuration of the level Do you know exactly which part of The more critical your You will find detailed
measurement instrument your installed instrumentation base instrument to your process, information in the next sections
is often undertaken during is critical to the operation of the the shorter the acceptable (Level-radar, ultrasonic level
plant and how you could maintain or
the commissioning phase. In calibrate it more efficiently? Are you
repair time. measurement etc.)
the majority of cases this is sure that your present actions are • Thanks to the TOF concept,
sufficient. minimizing the risks of unplanned most parts can be easily Migration
In some cases it is useful to breakdowns? Are you sure that replaced by the user (also
your present actions are the most
make additional checks of your cost effective?
for Ex) thus allowing quick You will find detailed
level measurement in order to: repair: display, electronic information in the next sections
• Validate the measured value With Endress+Hauser’s Installed Base module, antenna. (Level-radar, ultrasonic level
related to the real level in Audit, our service Consultant will • Tags on each component
help you to quickly find an answer to measurement etc.)
the tank these questions and move forward in
allow easy identification of
• Eliminate interference echoes a controlled manner to a maintenance spares.
emitted by the installations in plan which improves plant reliability • An installation manual is Re-engineering
an empty tank (for ToF devices) while reducing costs… provided with every spare part.
(see ‘Installed Base Audit’in the See our advice in the next
‘At your service’ section).
If level measurement In case of a highly critical sections. See also our online
instruments are to be instrument, you might consider Applicator tool.
recalibrated following an Maintenance performing stocking a complete new
operational phase, this is often instrument.
done by gauging the capacity of In case you have not internally the
a container in liters, so there is time, the competences or the right tools
to perform efficiently your maintenance,
no need to remove the device with Endress+Hauser service
from the process. We can contracts, you decide the right level
provide you with specific advice of maintenance support you require.
on this.
We provide regular checks on your DC AC / DC

equipment and warranty extensions power display unit, power

alternatively recorder, PCS
providing you with complete peace of
mind and cost control. Commubox
resistor Commubox
From regular support to partnership (> 250 W) communication FXA191/195
resistor DXR375
agreements, we offer four distinct levels (> 250 W)
of service… (see ‘Service Contracts’in
the ‘At your service’ section). 4...20 mA 4...20mA

test sockets for testing

of the signal current

1 2 3 4 ground 5 6 1 2
L- L+ I+ I- I+ I- L1/L+ N/L-

Fig. 4: Terminal assignment - 2-wire, L00-FMxxxxxx-04-00-00-en-015

Fig. 5: Terminal assignment - 4-wire, L00-FMxxxxxx-04-00-00-en-011

4 to 20 mA with HART AC/DC power, 4 to 20 mA with HART

The Endress+Hauser Maintenance Guide 


Micropilot series

It has been already several years since Micropilot M instruments constitute the main part
of the current range of level-radar measurement. FMR 230 (horn antenna) and 231 (rod
antenna) instruments use 6 GHz waves, while FMR 240 (horn antenna, 244 (horn antenna
encapsulated in PTFE), 245 (flat antenna) and 250 (level-radar measurement on solids) use
26 GHz waves.

In this section, you will find essential information and advice that will help you
to perform the optimum follow-up of your Micropilot M instruments throughout
their lifecycle.

Measuring principle flange:

reference point of

The Micropilot is a ‘downward- 20 mA flange:

reference point of
looking’ measuring system, 100% measurement

operating based on the time-

of-flight method. It measures
the distance from the reference D threaded
point (process connection) to the 1 ½” BSPT (R 1½”)
“90% of the product surface. Radar impulses or 1½ NPT:
reference point of
are emitted by an antenna, F measurement

success of the setup reflected off the product surface inactive

depend on proper and received again by the radar L
4 mA
Input (see fig. 1)
The reflected radar impulses are max.level
received by the antenna and
Figure 1: Measuring principle

transmitted into the electronics.

A microprocessor evaluates the
signal and identifies the level
echo caused by the reflection of Installation conditions disassembly is simply done by
the radar impulse at the product means of a tension clamp.
surface. The unambiguous signal Because most problems
identification is accomplished reported by the users are due Tank installations (see fig. 3)
by the PulseMaster® eXact to uncorrect installation and/or • Avoid any installations (1),
software, based on many years initial calibration, we remind like limit switches,
of experience with time-of-flight hereafter the essential points temperature sensors, etc.,
technology. that must be considered. inside the signal beam.
The distance D to the product • Symmetrical installations (2),
surface is proportional to the Orientation (see fig. 2) i.e. vacuum rings, heating
time of flight t of the impulse: • Recommended distance (1) coils, baffles, etc., can
D = c · t/2, wall – outer edge of also interfere with the
with c being the speed of light. nozzle: ~1/6 of tank measurement.
Based on the known empty diameter. Nevertheless
distance E, the level L is the device should not be Optimization options
• Antenna size: the bigger the antenna,
calculated: installed closer than 30 cm the smaller the beam angle, the less
L=E–D (FMR230/231) resp. 15 cm interference echoes.
Refer to figure 1 for the (FMR240/244/245) to the • Mapping: the measurement can be
reference point for E. tankwall. optimized by means of electronic
suppression of interference echoes.
The Micropilot is equipped • Not in the centre (3), inter- • Antenna alignment: refer to ‘optimum
with functions to suppress ference can cause signal loss. mounting position’
interference echoes. The user • Not above the fill stream (4). • Stilling well: a stilling well can always be
can activate these functions. • It is recommended to used to avoid interference.
• Metallic screens (3) mounted at a
They ensure that interference use a weather protection slope spread the radar signals and can,
echoes (i.e. from edges and weld cover (2) in order to protect therefore, reduce interference echoes.
seams) are not interpreted as the transmitter from direct Please contact Endress+Hauser for
Figure 2: Orientation level echo. sun or rain. Assembly and further information.

10 The Endress+Hauser Maintenance Guide

Commissioning of two Micropilot M Figure 3: Tank installations

Installation in tank (free • Align marker towards tank

space) FMR230 - Optimum wall (the marker is always
mounting position (see fig. 4) exactly in the middle between
• Observe installation two bolt-holes in the flange). nozzle
instructions described above. • After mounting, the housing
• Align marker towards tank can be turned 350° in order to
wall (the marker is always simplify access to the display ØD

exactly in the middle between and the terminal compartment.

two bolt-holes in the flange). • For optimum measurement,
• After mounting, the housing the horn antenna should


Figure 4: Optimum mounting position FMR230

can be turned 350° to simplify extend below the nozzle.
access to the display and the Select version with 100 mm
terminal compartment. antenna extension if necessary.
• The horn antenna must
extend below the nozzle, Please contact Endress+Hauser for
otherwise use antenna application with higher nozzle.
extension FAR10. • The horn antenna must be aligned
• Align horn antenna vertically. vertically. The maximum range may
be reduced, if the horn antenna is not
vertically aligned.
Installation in tank (free
space) FMR231 - Optimum Standard installation
mounting position (see fig. 5) FMR244
• Observe installation (see fig. 7 on next page)
instructions decribed above. • Observe installation
• Align marker towards tank instructions described above. 1

wall (the marker is always • Align marker towards

exactly in the middle between tank wall.
spring washers

two bolt-holes in the flange).


• Install the device using the

• Use spring washers (1). threaded boss (AF 60) only.
Note! Observe the max. torque of inactive length
inactive length
beam launched

It is recommended to retighten the 20 Nm. beam launched


flange bolts periodically, depending • After mounting, the housing

on process temperature and pressure.
Recommended torque: 60 to 100 Nm.
can be turned 350° in order L00-FMR231xx-17-00-00-en-002

• After mounting, the housing can to simplify access to the Figure 5: Optimum mounting position FMR231
be turned 350° in order to simplify display and the terminal
access to the display and the compartment.
terminal compartment.
• The inactive part of the rod antenna
• For optimum measurement,
must extend below the nozzle. the tip of the antenna should
• The rod antenna must be aligned extend below the nozzle. marker at instrument flange
or threaded boss
vertically. Nozzle heights up to 500 mm
can be accepted if this


° H

Installation in tank (free should not be possible due to

space) FMR240, FMR244, mechanical reasons. 90
1½” BSPT (R 1½”),
G 1½" (FMR 244)
FMR245 - Optimum 90
ANSI 3…6” 1½ NPT

mounting position (see fig. 6) Note!

Please contact Endress+Hauser for
• Observe installation application with higher nozzle.

Figure 6: Installation in a tank - optimum mounting position

instructions described above. • The antenna must be aligned vertically.

The Endress+Hauser Maintenance Guide 11

Standard installation • Do not weld through the pipe
spring washers

FMR245 (see fig. 8) wall. The inside of the stilling well

must remain smooth. In case of
• Observe installation unintentional welding through
H instructions described above. the pipe, the weld seam and any
• Align marker towards unevenness on the inside need to be
tank wall. carefully removed and smoothened.
Otherwise, strong interference echoes
• The marker is always exactly will be generated and material build-
in the middle between two up will be promoted.
Figure 7: Standard Figure 8: Standard installation FMR245
installation FMR244
bolt-holes in the flange. • Particularly on smaller nominal widths
it needs to be observed that flanges
• Use spring washers (1)
are welded to the pipe such that they
allow for a correct orientation (marker
aligned toward slots).
It is recommended to retighten the
flange bolts periodically, depending
marker at instrument flange
or threaded boss on process temperature and pressure. Installation in bypass
Recommended torque: 60...100 Nm. FMR230, FMR240, FMR245
• After mounting, the housing can
(see fig. 10)

be turned 350° in order to simplify

access to the display and the • Align marker perpendicular
terminal compartment. (90°) to tank connectors.
1½” BSPT (R 1½”), • The antenna must be aligned vertically. • The marker is always exactly
G 1½" (FMR 244)
or Caution! The maximum range may be
ANSI 3…6” 1½ NPT
reduced, if the antenna is not vertically in the middle between two
aligned. bolt-holes in the flange.
Figure 9: Installation in stilling well - optimum mounting position
L00-FMR230xx-17-00-00-en-006 Note! Please contact Endress+Hauser for • After mounting, the housing
application with higher nozzle. can be turned 350° in order
to simplify access to the
Installation in stilling well
display and the terminal
FMR230, FMR240, FMR244,
FMR245 (see fig. 9)
• The horn must be aligned
• Align marker toward slots.
• The marker is always exactly
• Measurements can be
in the middle between two
performed through an open
bolt-holes in the flange.
full bore ball valve without
• After mounting, the housing
any problems.
can be turned 350° in order
• Additional installation
to simplify access to the
instructions described above.
display and the terminal
compartment. Recommendations for the bypass pipe
• Measurements can be • Metal (no plastic or enamel coating)
performed through an open • Constant diameter
Figure 10: Installation in bypass - optimum mounting position

full bore ball valve without • Select horn antenna as big as possible.
For intermediate sizes (i.e. 95 mm)
any problems. select next larger antenna and adapt it
• Additional installation mechanically (FMR230/FMR240 only).
instructions on Page 18. • At any transition (i.e. when using a
ball valve or mending pipe segments),
Recommendations for the stilling well no gap may be created exceeding
• Metal (no enamel coating, plastic on 1 mm (0.04”).
request). • In the area of the tank connections
marker at instrument
flange or threaded boss 1) • Constant diameter. (~ ±20 cm / 8”) a reduced accuracy of
• Diameter of stilling well not larger the measurement has to be expected.
than antenna diameter.


° • Weld seam as smooth as possible and Installation in vessel
on the same axis as the slots. FMR250 with horn antenna
• Slots offset 180° (not 90°).
1½” BSPT (R 1½”)
or • Slot width respectively diameter of (see fig.11)
• Observe installation
° 1½ NPT
DN80…200 holes max. 1/10 of pipe diameter,
ANSI 3…8”
° de-burred. Length and number instructions described above.
do not have any influence on the • Align marker towards vessel
1) measurement.
at version with top target positioner, the marker is at the housing adapter
(opposite the air purge connection) • Select horn antenna as big as possible. wall (the marker is always
For intermediate sizes (i.e. 180 mm) exactly in the middle between
select next larger antenna and adapt it two bolt-holes in the flange.
Figure 11 (above and right): Installation mechanically (FMR230/FMR240 only).
in vessel FMR250 - optimum mounting
• After mounting, the housing
• At any transition (i.e. when using a
position ball valve or mending pipe segments), can be turned 350° in order
no gap may be created exceeding to simplify access to the
1 mm (0.04”). display and the terminal
• The stilling well must be smooth on compartment.
the inside (average roughness Rz ≤
6.3 μm). Use extruded or parallel •The horn antenna should
welded stainless steel pipe. An protrude from the nozzle.
extension of the pipe is possible with If this is not possible for
welded flanges or pipe sleeves. Flange mechanical reasons, larger
and pipe have to be properly aligned at
the inside. nozzle heights can be accepted.

12 The Endress+Hauser Maintenance Guide

Note! Operation and Maintenance Instrument and

• Please contact Endress+Hauser for spare parts availability
application with higher nozzle.
• Ideally, the horn antenna should See ‘Basics’ (page 11).
be installed vertically. To avoid Your Spare part New
interference reflections or for optimum Note for FMR250: In extremely instrument availability generation
alignment within the vessel, the
dusty applications, the
FMR250 with optional top target
positioner can be swiveled by 15° in integrated air purge connection Micropilot II/FMR230V NO - since 09/2005 Micropilot M
all directions. can prevent clogging of the
antenna (see fig. 12). Pulsed Micropilot II/FMR231E NO - since 09/2005 Micropilot M
operation is recommended.
Setup - Configuration • Pulsed operation: max.
If you want to get more information
pressure of purge air: 6 bar abs.
about spare parts availability, please
See ‘Basics’. • Permanent operation: call our hotline.
recommended pressure
The ‘Basic setup’ menu range of the purge air: 200 to air purge connection:

enables a quick and simple 500 mbar. Re-engineering

G ¼ (max. torque 3.5 Nm)

commissioning. The software Caution! Make sure to use dry

helps the user to enter the main purge air. Instruments that operate at
parameters which cover 95% of 26 GHz used to be selected
the cases. By entering the data Calibration for storage applications.
carefully, you will avoid many See ‘Basics’ (page 8). However, thanks to the recent Figure 12: FMR250 integrated air purge

problems. redevelopment, from software
Corrective maintenance version1.05.xx, the new 26 GHz
Note for FMR244/245: Please - Spare parts instruments can now be used
take a blocking distance of See ‘Basics’ (page 9). on process applications. Please
0.2 m into account. (See consult us.
details on the blocking distance Note for all radar devices:
in chapter Ultrasonic level The replacement of either Instruments that operate at
measurement - page 17). the electronic module or 6 GHz, whose cost is higher,
the HF module requires a keep used on demanding
reprogramming. Some of the processes (with turbulent
Our service team can set up any
Endress+Hauser device for you and default parameters have to surface or foam formation).
thus ensure you immediately get the be modified. The relevant
best from your instrument. procedure is delivered with the See also our online Applicator
(see ‘Commissioning’ in the
new module. tool.
‘At your service’ section)

Note for
FMR240/244/245/250: The
replacement of the electronic
module requires specific attention.
If it contains software with
versions 1.02.xx or 1.04.xx,
you need to replace also the
HF module.

The Endress+Hauser Maintenance Guide 13

Guided level-radar

Levelflex series

The current guided level-radar Levelflex M range includes:

• FMP40 for general applications in liquids and solids
• FMP41C for corrosive liquids and for high hygienic requirements
• FMP45 mainly in liquids with pressures up to 400 bar and temperatures from
-200 ... +400°C
• New FMP43 (from 01/07/07) for pharma requirements

With this section we aim at providing efficient help to Levelflex M users throughout
the life cycle.

Measuring principle flange:

reference point of

The Levelflex is a ‘downward- 20 mA

looking’ measuring system that
functions according to the ToF
method (ToF = Time of Flight).
The distance from the reference
point (process connection of probe length LN

“Consider blocking the measuring device) to the F

product surface is measured.

distances and pay High-frequency pulses are L

attention to the nozzle” injected to a probe and led

4 mA
along the probe. The pulses are 0%
reflected by the product surface,
received by the electronic
evaluation unit and converted
into level information.
Figure 1: Measuring principle L00-FMP4xxxx-15-00-00-en-002

This method is also known

as TDR (Time Domain
Input (see fig. 1) The Levelflex comes
The reflected pulses are with functions to suppress
transmitted from the probe interference echoes
to the electronics. There, a (e.g. internals and struts).
microprocessor analyses the
reference point of
measurement signals and identifies the level
echo, which was generated Installation conditions
by the reflection of the high-
frequency pulses at the product Upper blocking distance
max. 20 m /67 ft surface. This clear signal finding (see fig. 2)
benefits from the more than The upper blocking distance
E 30 years of experience with (UB) is the minimum distance
F pulse time-of-flight procedures from the reference point of the
remote display
FHX 40
that have been integrated measurement (mounting flange)
into the development of the to the maximum level. Within
PulseMaster® Software. the blocking distance, a reliable
measurement can not be
Distance D to the product guaranteed (see table p.17).
surface is proportional to the
time of flight t of the impulse: Lower blocking distance
B D = c · t/2, At the lowest part of the
with c being the speed of light. probe an exact measurement
Figure 2: Upper blocking distance L00-FMP4xxxx-17-00-00-en-006 Based on the known empty is not possible. The following
F = measuring span distance E, level L is calculated: measuring error is present in
E = empty distance (= zero)
UB = upper blocking distance
L=E–D the vicinity of the probe end:
LN = probe length Reference point for E see fig. 1. (see fig. 3)
B = minimum distance of the probe to the container wall

14 The Endress+Hauser Maintenance Guide

FMP40 UB [m] min
Rope probe 0.2 (1)
6 mm rod probe 0.2 (1)
16 mm rod robe 0.2 (1)
Coax probe 0
(1) The indicated blocking distances are prearised. At media with DK > 7, the upper
blocking distance UB can be reduced for rod and rope probes on 0.1 m. The upper
blocking distance UB can be entered manually.

LBD [m] if DC>7 if DC<7

Rope probe 0.02 0.25
Rod or coax probe 0.02 0.05

Check of a Levelflex at a chemical plant

If εr (dielectric coefficient) Type of probe installation rod probe and coax probe rope probe
80 80
value is less than 7 for rope (see fig. 5)

sum of non- linearity, non- repeatability

sum of non- linearity, non- repeatability
60 60
probes, then measurement is • Probes are mounted to the 40
DC = 2
DC > 7

and hysteresis [mm]

and hysteresis [mm]
not possible in the area of the process connection with 20
DC > 7
straining weight (0 to 250 mm threaded connections or 0 0

from end of probe; lower flanges and are usually also -20 -20

blocking distance)(see table). secured with these. If during -40 -40

this installation there is -60 -60

General installation the danger that the probe -80
0 50 100 150 200 250 300 0 50 100 150 200 250 300
instructions end moves so much that it distance from probe end [mm] distance from probe end [mm]

(for bulk solids + fluids) touches the tank floor or cone L00-FMP4xxxx-05-00-00-en-001 L00-FMP4xxxx-05-00-00-en-002
Figure 3: Measuring error in the vicinity of the probe end
We remind you hereafter the at times, the probe must, if
most important instructions necessary, be shortened and
(see fig. 4): fixed down. The easiest way to
1 2
• Do not mount rod or rope fix the rope probes is to screw
probes in the filling curtain (2) them to the internal thread on
• Mount rod and rope probes the lower end of the weight.
away from the wall (B) at • The ideal installation is
such a distance that, in the mounting in a screwed joint
event of build-up on the / screw-in sleeve which
wall, there is still a minimum is internally flush with the
distance of 100 mm between container ceiling.
the probe and the build-up. • If installation takes place in a
• In the case of bulk solids in nozzle, the nozzle should be
concrete silos, a large distance 50 to 150 mm in diameter
(B) should be observed and should not be more than
between the probe and the 150 mm high. Installation
concrete wall, if possible adapters are available for C
≥ 1 m, but at least 0.5 m. other dimensions.
• In metal and plastic silos, the • Installation with welding boss
probe can be mounted very is strongly recommended
close to the wall (0.2 m), but when the product εr
ensure that the probe does not (dielectric coefficient) is Figure 4: General installation conditions
low. “90% of the problems 1 = correct installation
touch the wall. L00-FMP4xxxx-17-00-00-xx-003

• Minimum distance of probe encountered in case of a low

end to the container floor (C): εr are due to a bad nozzle”. installation with welding boss installation in nozzle
– Rope probe: 150 mm
– Rod probe: 50 mm Installation in concrete silos
– Coax probe: 10 mm (see fig. 6)
• If the product becomes Installation, for example, into
< 150 mm
highly electrostatically a thick concrete ceiling should (< 4")

charged during processing, be made flush with the lower

an earthing chain should be edge. Alternatively, the probe diameter nozzle:
mounted in the filling curtain can also be installed into a pipe < DN150 (< 6”)

or the end of the probe that must not protrude over the
should be grounded. lower edge of the silo ceiling.
The pipe should be kept at a Figure 5: Type of probe installation

The Endress+Hauser Maintenance Guide 15

minimum length. Installation in a ≥ DN50 / 2” metal flange, Re-engineering
Our service team can set up any
suggestions see diagram. or a metal sheet with diameter Endress+Hauser device for you and
The centering disk should of ≥ 200 mm must be mounted thus ensure you immediately get the FMP45, which is even more
be used for tube diameter under the screw-in piece. best from your instrument. robust, can replace a FMP40.
(see ‘Commissioning’ in the
> 150 mm to prevent build-up ‘At your service’ section)
in the inner part of the tube.
Setup - Configuration
Installation in plastic Operation and Maintenance
containers (see fig. 7) See ‘Basics’.
Please note that the ‘guided Maintenance
level-radar’ measuring principle The ‘Basic setup’ menu See ‘Basics’ (page 9).
requires a metal surface at the enables a quick and simple
process connection! When commissioning. The software Calibration
installing the rod and rope helps the user to enter the main See ‘Basics’ (page 8).
probes in plastic silos, whose parameters which cover 95%
silo cover is also made of plastic of the cases. By entering the Corrective maintenance
or silos with wood cover, the data carefully, you will avoid - Spare parts
probes must either be mounted many problems. See ‘Basics’ (page 9)

Note for all radar devices:

the replacement of either
the electronic module or
≥ 100 mm ≥ 100 mm
the HF module requires
reprogramming. Some of the
default parameters have to
be modified . The relevant
procedure is delivered with the
new module.

Instrument and
metal tube
spare parts availability

Your Spare part New

Ø 80...150 mm
instrument availability generation
Extension rod /
(see accessories)
Levelflex FMP232E NO - since 10/2005 FMP40
Levelflex FMP332E NO - since 10/2005 FMP40
Figure 6: Installation in concrete silos

If you want to get more information

metal sheet or metal flange about spare parts availability, please
call our hotline.

silo roof of plastic

or wood

Figure 7: Installation in plastic containers

metal sheet or metal flange

Wall thickness for GFK/PP

< 15 mm


16 The Endress+Hauser Maintenance Guide

Ultrasonic level measurement

Prosonic series

The current ultrasonic transmitters Prosonic range includes the Prosonic M

FMU40/41/42/43/44 and Prosonic S FMU90.

With this section we aim at:

• providing efficient help to Prosonic M users throughout the life cycle
• answering to the most frequent questions asked by the users of Prosonic S
FMU86x, and giving them key information to successfully migrate to FMU90

Measuring principle
Time-of-flight method 20 mA
The Prosonic M sensor emits
ultrasonic pulses in the direction D

of the product surface. There,

they are reflected back and E F

received by the sensor. The

“The installation of Prosonic M measures the time t
between pulse emissionand L
the sensor and the reception. The instrument
presence of foam uses time t (and the velocity of 4 mA
sound c) to calculate distance D
or bubbles have a between the sensor membrane
strong impact on and the product surface:
D = c · t/2
the measurement” As the device knows the empty
Figure 1: Measuring principle
F = span (full distance)
distance E from a user entry, E = empty distance
it can calculate the level as D = distance from sensor membrane to the product surface
BD = blocking distance
L = level
An integrated temperature
sensor compensates changes in Interference echo ensures that interference
the velocity of sound caused by suppression echoes (e.g. from edges, welded
temperature changes. The interference echo joints and installations) are not
suppression feature of Prosonic M interpreted as level echoes.

ZOOM: why is there a blocking distance?

Waves are emitted at the surface of the sensor membrane. The device
is either emitting or receiving but cannot do both at the same time. In
case of an obstacle located within the area between positions 1 and 2,
the resulting echo would be surrounded by the residual vibration and
could not be differenciated.
As it is impossible to differenciate the echo within this area, the level
to be measured must not approach the membrane. Duration (ms)
This distance is named blocking distance.
Distance (m)

Figure 2 T2: the residual membrane vibration is weakened enough to reflect an echo
T0: Start of the emitted impulsion. An alternating current which frequency and to differenciate it.
corresponds to the system’s resonance, makes cristals oscillate. T3: the echo comes back after 6 ms meaning the total distance represents
T1: End of the emitted impulsion. Membrane continues to vibrate during 1ms 2 m. Therefore the product surface is located 1m under the probe.
and then switches to the receiving position. T4: Double reflection echo or numerous reflections can sometimes be observed.

The Endress+Hauser Maintenance Guide 17

Adjustment Blocking distance, nozzle

Enter the empty distance E and installation (see fig. 5 and

the span F to adjust the device table 2)
(see fig.1). Install the Prosonic M at a
height so that the blocking
Blocking distance distance BD is not exceeded,
Span F may not extend into even at maximum fill level.
blocking distance BD. Level Use a pipe nozzle if you cannot
echos from the blocking maintain the blocking distance
distance cannot be evaluated in any other way. The interior
due to the transient of the nozzle must be smooth
characteristics of the sensor. and may not contain any edges
or welded joints. In particular,
Influence of foam and there should be no burr on the
bubbles on the level inside of the tank side nozzle Surface 1 Surface 2 Surface 3 Surface 4
measurement on liquids end. Note the specified limits for
Fig. 3: reflection of ultrasonic waves on liquids
(see fig. 3) nozzle diameter and length. To Surface 1: ideal conditions
The occasional presence of foam minimise disturbing factors, we Surface 2: very light foam with big bubbles in very thin layers
or the presence of a disparate recommend an angled socket Surface 3: light foam in thick layer
foam layer at the liquid’s surface edge (ideally 45°). Surface 4: very dense foam, small bubbles, compact

has a weak impact on ultrasonic

measurement. However a per- If the blocking distance is
manent thick foam layer absorbs undershot, it may cause device
ultrasonic waves and stops their malfunction. In order to notice 2 3 4

reflection at the liquid’s surface. if the level approaches the

If the foam is quite dense, its blocking distance, you can 7

own surface may often become specify a safety distance (SD). 1


a reflector. If the level is within this safety 1/6D

distance, the Prosonic M outputs D

Installation conditions a warning or alarm message. 6 α

The essentials (see fig. 4) Setup - Configuration

• Do not install the sensor in r
the middle of the tank (3). See ‘Basics’.
We recommend leaving a L00-FMU4xxxx-17-00-00-de-005

distance between the sensor The ‘Basic setup’ menu Figure 4: General installation conditions
and the tank wall (1) of 1/6 enables a quick and simple
of the tank diameter. commissioning. The software
• Use a protective cover, in helps the user to enter the main
order to protect the device parameters which cover 95% of Sensor a Lmax rmax
from direct sun or rain (2). the cases. By entering the data FMU40 11° 5m 0.48 m
• Avoid measurements through carefully, you will avoid many
the filling curtain (4). problems. FMU41 11° 8m 0.77 m
• Make sure that equipment FMU42 11° 10 m 0.96 m
(5) such as limit switches, Our service team can set up any FMU43 6° 15 m 0.79 m
temperature sensors, etc. Endress+Hauser device for you and
are not located within thus ensure you immediately get the FMU44 11° 20 m 1.93 m
the emitting angle a. In best from your instrument.
(see ‘Commissioning’ in the Table 1
particular, symmetrical ‘At your service’ section)
equipment (6) such as FMU 43

heating coils, baffles etc. can FMU 40/41 FMU 42/44

influence measurement. Operation and Maintenance BD

• Align the sensor so that it SD

is vertical to the product Maintenance

surface (7). See ‘Basics’ (page 11).
• Never install two ultrasonic E F
measuring devices in a tank, We recommend a periodical L
as the two signals may affect inspection of the membrane
each other. and the use of a piece of rag to D
• To estimate the detection wipe it if necessary.
range, use the 3 dB emitting L00-FMU4xxxx-17-00-00-en-004

Figure 5: Blocking distance, nozzle installation

angle a (see table 1). Calibration BD: blocking distance; SD: safety distance; E: empty calibration; F: full calibration
See ‘Basics’ (page 10). (span); D: nozzle diameter; L: nozzle length

Corrective maintenance
- Spare parts
See ‘Basics’ (page 11)

18 The Endress+Hauser Maintenance Guide

Instrument and • An installation on a mast can

Prosonic BD Max. Max. Nozzle Max. nozzle
spare parts availability be reused. On the contrary, M family range range bulk diameter length
See right table. you will need to drill again in liquids materials
case of wall mounting. 50 mm approx. 80 mm
If you want to get more information • FMU 90 transmitters are FMU40 0.25 m 5m 2m 80 mm approx. 240 mm
about spare parts availability, please available as field housing or
100 mm approx. 300 mm
call our hotline. cabinet housing (mounting on
DIN rail). 80 mm approx. 240 mm
FMU41 0.35 m 8m 3.5 m
Migration • Because ISO Venturi channels 100 mm approx. 300 mm
were not preconfigured 80 mm approx. 250 mm
S range: FMU 860 (1-channel in the FMU861 (ISO415 FMU42 0.4 m 10 m 5m
100 mm approx. 300 mm
level measurement), 861 to ISO480), many users
(flow measurement) and 862 have asked us about the FMU43 0.6 m 15 m 7m min. 100 mm approx. 300 mm

(2-channel level measurement) curves and about the way to FMU44 0.5 m 20 m 10 m min. 150 mm approx. 400 mm
have been phased-out. program them in the device.
These channels are not Table 2
The new FMU90 transmitters
associated to FDU9X sensors preconfigured in the FMU90.
replace FMU86x transmitters • Matrix programming has
been replaced by a simplified Your Spare part New
and FDU8x sensors. instrument availability generation
The new FMU90 transmitter and user-friendly program-
is fully compatible with the ming concept on the new
FMU2380 NO - since 12/2002 FMU4x*
FDU8x transmitters and can Prosonic S FMU90.
be used in association with • Like for the old generation, FMU2480 NO - since 12/2002 FMU4x*
FDU8x sensors. the maximum distance
Warning: the sensors between the transmitter FMU2680 NO - since 12/2002 FMU4x*
FDU83/84/85/86 with an and the sensor is 300 m.
ATEX, FM or CSA certificate FMU280 NO - since 12/2002 FMU4x*
are not certified for connectiion Re-engineering
FMU130E/A NO - since 10/2005 FMU4x*
to the FMU 90 transmitter.
On the other hand, the new The 2-channel version of
FMU131E/A NO - since 10/2005 FMU4x*
FDU9x sensors cannot be used FMU90 is quite polyvalent:
with FMU86x transmitters. each channel can be affected FMU232 YES - until 11/2008 FMU4x*
either to flow measurement
Advantages or to level measurement thus FMU2780 NO - since 12/2002 FMU90
• FMU90 offers full allowing three combinations:
compatibility with the level + level, level + flow and FMU86x YES - until 03/2012 FMU90
equivalent FMU86x version flow + flow.
FDU8x YES - until 12/2013 FDU9x
e.g. the 1-channel level
measurement FMU90 is 100% DU41C YES - until 12/2010 FMU44
compatible with FMU860.
DU60Z NO - since 10/2006 FMU44

DU61Z NO - since 10/2006 FMU44

* Partly compatible

The Endress+Hauser Maintenance Guide 19

Capacitive level measurement

Liquicap series

The current Endress+Hauser range of capacitive sensors includes some

seventy instruments. In the next future, this range will be shortened to:
• Level detection for liquids: Liquicap M FTI51/52 and probe 11500Z
• Level detection for solids: Solicap M FTI55/56, Nivector FTC968, Minicap
FTC260/262 and probes T12892 and T12894
• Level measurement for liquids: Liquicap T FMI21 and Liquicap M FMI51/52

With this section we aim at:

• providing a concise reminder of the main guidelines for an optimal use of
capacitive sensors
• providing efficient help to Liquicap M users throughout the life cycle.

Measuring principle 1 2 3

The principle of capacitive level

measurement is based on the CE
change in capacitance of the
capacitor due to the change ∆C
in the level formed by the CA C

probe and the container wall CA

“Ensure good (conductive material). When
the probe is in air (1), a low
connection to the
Figure 1: Measuring principle
initial capacitance is measured. R: Conductivity of liquid
ground in any case” When the container is filled, C: Capacitance of liquid
the capacitance of the capacitor CA: Initial capacitance (probe not covered)
CE: Final capacitance (probe covered): change in capacitance
increases the more the probe
ΔC: Change in capacitance
is covered (2), (3). As of a
conductivity of 100 μs/cm, the
measurement is independent
of the value for the dielectric
constant (DK) of the liquid. As Phase-selective Thus, Liquicap M has buildup
a result, fluctuations in the DK measurement compensation.
value do not affect the measured The electronic evaluation of
value display. Furthermore, the the container capacitance General installation
system also prevents the effect of works along the principle of conditions
medium buildup or condensate phase-selective measurement.
near the process connection for In this process, the amount • The probe may not come into
probes with an inactive length. of alternating current and the contact with the container
phase shift between the voltage wall! Do not install probes in
Note! A ground tube is used as a and current is measured. the area of the filling curtain!
counterelectrode for containers With these two characteristic • When using in agitating
made of non-conductive quantities, the capacitive idle tanks, make sure you install
materials. current can be calculated by at a safe distance from the
the medium capacitor and the agitator.
Function real current by the medium • Rod probes with a ground
The selected electronic insert resistance. Conductive buildup tube should be used in the
of the probe (e.g. FEI50H 4 to stuck to the probe rod/rope event of severe lateral load.
20 mA HART) converts the acts like additional medium • When mounting, ensure
measured change in capacitance resistance and causes an error there is a good electrically
of the liquid into a signal in in measurement. As the size conductive connection
proportion to the level (e.g. of the medium resistance can between the process
4 to 20 mA) and thus makes it be determined with phase- connection and the tank
possible to measure the level. selective measurement, an e.g. use an electrically
algorithm is used to compensate conductive sealing band.
the buildup on the probe.

20 The Endress+Hauser Maintenance Guide

For containers that conduct the tank by means of a short
electricity e.g. steel tanks, cable. (see fig. 5)
see fig. 2. Note! A fully insulated rod
For containers that do not probe may neither be shortened
conduct electricity e.g. plastic nor extended.
tanks, use a probe with Damaged insulation probe
ground tube and ensure proper results in an incorrect
grounding (see fig. 3). measurement result.

When installing in a nozzle, use

a rod probe with ground tube On non-conductive tanks
and inactive length (see fig. 4). (plastic tanks)
Always use a probe with ground
As a general rule, the probe tube (see fig. 6).

Figure 2: Installation on Figure 3: Installation on containers

should neither be shortened nor containers that conduct electricity that do not conduct electricity
lengthened. Only on Liquicap T Tensioning weight (see fig.7)
FMI21, Liquicap M FMI52 / The end of the probe needs
FTI52 and Minicap FTC262 to be secured when the probe
the probe may be shortened be could touch the silo wall or
means of a special kit. another part in the tank. This is
what the internal thread in the
Specific installation probe weight is intended for.
conditions for rod probes The bracing can be conductive
or insulating to the tank wall.
The probes are ‘plug and play’ We strongly recommend to
where the conductivity is secure the end of the probe in
higher than 100 µS/cm. case of high tank or silo and also
Reported measurement errors in case of agitated liquid.
are generally due to: To avoid a too high tensile
• A bad connection to load the rope should be loose L00-FMI5xxxx-11-06-xx-xx-007

the ground or guyed with a feather. The Figure 4: Installation in a nozzle Figure 5: Installation of rod probes on
conductive tanks
• The absence of a maximum tensile load may not
conterelectrode or a ground exceed 200 Nm.
tube in case of containers
made of non-conductive Setup - Configuration
• Customer’s specific Calibration is neccessary only at
constraints startup. There will be no drift
On conductive tanks
(metal tanks) Liquicap M FMIxx
If the process connection of For conductive liquids
the probe is insulated from (>100 µS/cm), the probe is
the metal tank (e.g. through calibrated at the factory to the
seal material), the ground probe length ordered (0 % to
connection at the probe 100 %). For nonconductive

Figure 6: Installation of rod probes on

housing must be connected to liquids (<1 µS/cm), 0% non-conductive tanks Figure 7: Tensioning weight

The Endress+Hauser Maintenance Guide 21

calibration is performed at Remote operation with

the factory. Only the 100% FieldCare

calibration has to be carried out FieldCare is described on
on site. page 105.

Liquicap M FTIxx Maintenance

and Solicap M FTIxx No maintenance is necessary.
Calibration at the detection point You may use the 4 to 20 mA
has to be carried out on site. current pick-off, e.g. for
full/empty calibration with L00-FMI5xxxx-07-05-xx-xx-000
Figure 8: Local operation directly on the electronic insert
Liquicap T multimeter. (No need to • Green LED ( operational status)
For conductive liquids disconnect circuit!) • Red LED ( fault message)
• Key (-)
(> 30 µS/cm), the probe is
• Key (+)
calibrated at the factory to the Adjustment • Mode switch
probe length ordered (0 % to An adjustment is neccessary: 1 : Operation 5 : Measuring range
100 %). For nonconductive • for non-conductive liquids 2 : Empty calibration 6 : Self-test
• if the er of the medium has 3 : Full calibration 7 : Reset (factory settings)
liquids (< 1 µS/cm), 0%
4 : Measuring modes 8 : Upload sensor EEPROM
calibration is performed at changed. • 4 to 20 mA current pick-off, e.g. for full/empty calibration with multimeter.
the factory. Only the 100% (No need to disconnect circuit!)
calibration has to be carried out Instrument and • Display connection
on site. spare parts availability
See table at the right Label

Other probes (T12892,

Measure Value
T12894, 11500Z) If you want to get more information

Measure Value

Calibration of the remote about spare parts availability, please

call our hotline. 64.50 % %
transmitter at the detection point +

has to be carried out on site. Softkeys

Migration Value Bargraph Unit

Our serviceand
can set up any Position

Nothing to be carried
Endress+Hauser device for out.
you and Multicap is phase-out. CX001
thus ensure you immediately get the main menu
Please consult us. output
best from your instrument.
(see ‘Commissioning’ in the
Picklist device properties
basic setup
‘At your service’ section) Re-engineering

Please consult us. Figure 9: Local operation with the display

Operation and Maintenance

Local operation directly

on the electronic insert Your Spare part New
(FEI50H) (see fig. 8) instrument availability generation

Multicap family YES - until 12/2010 Consult us

Local operation with the
display (see fig. 9)
The display can be used
to configure directly at the
device via 3 keys. All device
functions can be set via menu
operation. The menu consists of
function groups and functions.
Application parameters can be
read or set in the functions.

22 The Endress+Hauser Maintenance Guide

Frequently asked questions

Micropilot: How can I adjust the LCD contrast? Prosonic FMU86X: Alignment values cannot be entered, the
Press ‘+ ‘ and ‘E’ or ‘-’ and ‘E’ simultaneously. values keep on going back to alignment empty 10 m and
alignment full 9 m.
Micropilot: How can I unlock the hardware? No sensor has been selected yet. Select sensor and confirm with ‘E’!
No configuration is possible if the device is locked. To unlock the
hardware via the Display, enter the following code: Press ‘+’, ‘-’ and Prosonic FMU86X: Although a different endpoint of the
‘E’ simultaneously. scaling has been entered in V2H7, the device keeps on
indicating in the former units in VOHO.
Levelflex M: The filling level indicated by the device is After changing the endpoint in V2H7, the value entered in V2HO
too high. What can be done? must be confirmed with ‘E’.
• Check the setting of the medium property and correct,
if necessary. Prosonic FMU86X: How to shift the decimal dot?
• Carry out mapping. Press ‘+’ and ‘->’ simultaneously.
(Rope probes: mapping range 2 m,
Rod probes: Define the total probe length as mapping range.) Prosonic FMU86X: Error E641 “Echo lost”. Is there a
Attention: During mapping, the filling level must be below the troubleshooting?
mapping range. Remove the sensor and cable it directly to the transmitter. Then aim
at the ground so that the membrane is approximately 1 m above the
Prosonic S/M and Micropilot M: The level indicated by the ground. If E641 diappears, it means the device is OK.
device is too high. What can be done?
Carry out mapping. Attention: During mapping, the filling level Prosonic: How can I adjust the 0% level of the tank?
must be below the mapping range. As the tank is empty, read the value displayed in V0H8 and type the
same value in V0H1.
Levelflex M, Prosonic S/M and Micropilot M: The device
indicates the correct value on site, but keeps on showing Prosonic: Is there any equivalence between the parameters
4 mA at the output. What can be done? for FMU86X and for FMU90?
Presumably a HART address was assigned and the device works in No. The approach is different.
the Multidrop mode. Set the HART address to 0!
Prosonic FMU90: the sensor is not recognized…
Check which type of sensor is connected. In case this is the old
FDU8x sensor, the sensor has to be selected manually.

Capacitive measurement: I get an incorrect measured value

at commissioning…
Ensure the grounding is correct. In case of a non-metal tank, ensure
the installation conditions are met (see previous pages).

The Endress+Hauser Maintenance Guide 23

24 The Endress+Hauser Maintenance Guide
Flow metering

Thierry Cragnaz
Expert in Flow metering
Endress+Hauser France

“Installation and setup require a particular care”

“Flowmeters are so reliable that users main questions that you ask us. With this Contents
refer to us primarily during installation information, you will be able to prevent
and commissioning; very often it is not for or resolve the vast majority of potential Basics 26
several years that users come back to us. problems yourself! The chapter ‘Basics’ includes information
It is true that there are certain problems which is valid for all flow metering
due to aging, but others can be resolved by There is also plenty of useful information to principles described hereafter. Thus you
should read it before any other chapter.
recalibration. From time to time we also help you get the best from your instruments
find that the flowmeter has been used for throughout their life cycle… and prepare Maintenance of
an application other than that for which for renewing your equipment gradually.” ‘Proline’ flowmeters 28
it had been selected, at the risk of it being Electromagnetic flowmeters 30
unsuited to this application, and creating a For those wanting to go
long term reliability problem… Finally, we further in mastering this Mass flowmeters 33
observe that many apparently maintenance- subject, Endress+Hauser Vortex flowmeters 36
related problems prove to be installation has published the ‘Flow
and setup problems. Handbook’, a genuine flow Ultrasonic flowmeters 38
measurement bible. Thermal mass flowmeters 40
That is why we have decided to give you in FAQ 42
this guide a reminder of the few operating We also offer training sessions, in classroom
constraints and installation conditions for and on site. See ‘Training’ in the section
flowmeters. We have also recapped the ‘At your service’.

The Endress+Hauser Maintenance Guide 25


Information common to any type of flowmeter

Electromagnetic Mass Vortex Ultrasonic Thermal mass

flowmeters flowmeters flowmeters flowmeters flowmeters
Specific information p. 26 Specific information p. 29 Specific information p. 32 Specific information p. 34 Specific information p. 36

Installation requirements • Installation in a siphon Setup - Configuration

overview It sometimes can’t be ensured
that the pipe is always full • General note:
The specification of ANY (i.e. waste water pipes). This If the installation and wiring
flowmeter is based on an could lead to measuring conditions have been
ideal installation. Installation errors or situations where the observed initially, you can
guidelines for all technologies flowmeter will not work at all. be certain of getting correct
exist. They should be viewed as • The flowmeter should then be measurements from the
“Compliance with MINIMUM requirements: installed in a siphon (fig.2). instrument’s first activation.
• If solids are carried with the Configuration will only serve
installation requirements • The flowmeter must remain fluid it is recommended to to optimize the operating
would avoid most completely full at all times. plan a cleaning access. A parameters of the quantities
This is of utmost importance U-tube or a sloping pipe measured (current output
reported errors!” for filling or dosing might be simple solutions. setup, etc.)
applications, since many
flowmeters (except mass Advice: the ideal mount • Since 2007, all
flowmeters) measure the for a flowmeter is in a fluid Endress+Hauser
fluid’s velocity, assuming riser vertical pipe (fig.3) flowmeters belong to the
that the whole section is • The meter must be installed Proline family and thus
flow direction
full of liquid. Measuring with sufficient straight pipe offer a QUICK SETUP.
errors might be particularly up-stream. QUICK SETUP enables quick
important if this is not the • See technology-specific and easy configuration of
case. Please note that this installation conditions for the device’s main functions
rule apply even to mass further details (mainly vortex, (units, outputs…).
Figure 1 flowmeters. F06-5xxxxxxx-11-00-00-xx-000
ultrasonic and thermal mass
flowmeter). You can also configure your
• Installation at the highest flowmeters from your PC.
point of pipe work • Wiring See presentation of FieldCare
• Installation at the top of a Take care with the instrument on page 105.
piping system causes a risk wiring, especially when the
that air will collect and transmitter is mounted remotely. Our service organization can set up
negatively influence the any Endress+Hauser flowmeter for
you and thus ensure you immediately
Figure 2: Installation in a siphon performance (fig.1). Ensure correct tightening of the
get the best from your instrument.
• Avoid installing directly wires and cable glands. In case (see ‘Commissioning’ in the
upstream of a free pipe outlet of humid atmosphere, check ‘At your service’ section)
in a vertical pipe as air is that no water drop may get into
flow direction

potentially rising up through the flowmeter.

the flowmeter causing
measuring errors. Further requirements may apply
• The flowmeter should be for one particular technology.
Figure 3: Ideal mount for a flowmeter installed in a lower part of Please check specific
the pipe work. This ensures installation conditions for

enough head pressure to EMF*, mass flowmeters etc.

avoid cavitation and the in the next sections.
meter will always remain full.

*EMF: Electromagnetic flowmeter

26 The Endress+Hauser Maintenance Guide

Inspection of the
flowmeter pipe

Functional check of a flowmeter using the FieldCare software associated with Flowmeters mounted in a fluid riser vertical pipe
the FieldCheck tool (small right picture)

Operation and Maintenance cleaning of the flowmeter pipe • The most common Maintenance planning
might be necessary. maintenance seems to be the
In most applications, when Do you know exactly which part of
use of electrical devices for
your installed instrumentation base
correctly selected and installed, Calibration simple checking of the input is critical to the operation of the
Endress+Hauser flowmeters Intrinsically our flowmeters and output function of the plant and how you could maintain or
(except mechanical) require offer long-term stability transmitter. calibrate it more efficiently? Are you
very little maintenance as sure that your present actions are
and repeatability of your • They may be checked using
minimizing the risks of unplanned
they are designed without measurements. Nevertheless a flow simulator in the field breakdowns? Are you sure that
any moving mechanical parts. we recommend periodic so that problems can be your present actions are the most
Nevertheless, according to its calibration for the measurement identified. For any flowmeter cost effective?
criticality to the quality, some points which are critical to belonging to the Proline
With Endress+Hauser’s Installed Base
flowmeters need to be inspected the process and thus are family (see next page) we Audit, our service Consultant will help
or/and calibrated periodically. important to control the quality recommend the use of our you to quickly find an answer to these
Defining the right maintenance of your product. From on-site FieldCheck® smart signal three questions and move forward in
frequency taking several a controlled manner to a maintenance
to accredited services, you simulator which facilitates
plan which improves plant reliability
parameters into account is an can be sure to find the right on-site verification. while reducing costs…
expert’s job. Endress+Hauser method by finding the right The user may effect either (see ‘Installed Base Audit’ in the
can also help you with this task! balance between the flowmeter a manual simulation of the ‘At your service’ section).
downtime and the calibration flowmeter functions or a
Periodic inspection to assure uncertainty. full check of the flowmeter, Maintenance performing
reliability of the application of its electronics only or
Calibration can be performed by
After a flowmeter has been Endress+Hauser either on-site or
of its sensor only. The tool If you do not have the time or the
operating for a period of time, incorporates procedures for right tools to efficiently perform your
in our accredited laboratories.
maintenance, an Endress+Hauser
the user may think that just (see ‘Calibration’ in the automatically checking all service contract can provide the
because the flowmeter signal ‘At your service’ section). the electronic operations appropriate level of maintenance
is stable it is correct – but this (linearity of the amplifier, the support you require.
might not be the case. Even an Inspection of seals analog outs and frequency)
We provide regular checks on your
indicated flow that appears to be and gaskets on the one hand, and all the equipment and warranty extensions
within acceptable limits may be In some processes, operational sensor operations on the other providing you with complete peace of
inaccurate and may then affect needs necessitate the use of (magnetic field and measuring mind and cost control. From regular
the quality of the final product. frequent cleaning or sterilization electrode integrity). With support to partnership agreements, we
offer four distinct levels of service…
in place (CIP or SIP). The FieldCare software, the user (see ‘Service Contracts’ in the
Pipeline inspections flowmeter seals and gaskets can upload the test results ‘At your service’ section).
• Deposits in the pipe can cause should then be carefully chosen to a PC, incorporate them in
a slow drift of measured and frequently replaced to avoid a certificate, print them or
values at meter output that is risks of leakage, contamination archive them, thus meeting Corrective maintenance
not detected and rectified. and even process failure. the requirements of quality The more critical your instru-
• According to the type of procedures. ment is to your process, the
flowmeter, anything that Routine maintenance shorter the acceptable time for
alters the shape or diameter The need for routine Moreover, this solution repairing is.
of a pipeline upstream of the maintenance is defined combined with calibration Thanks to the Proline concept
measurement point will cause according to the importance of could allow to reduce the (see opposite), flowmeters offer
errors in the readings. the flowmeter in the process. calibration frequencies and a modular design; one of the
by this way reduce your outcomes is that most parts can
Due to the effects of sedimenta- Flowmeters can be checked in a maintenance costs. be easily replaced thus allowing
tion or deposition, a periodical variety of ways: FieldCheck is presented on page 29.
quick repair.

The Endress+Hauser Maintenance Guide 27

Being more efficient in the repair
process is another way to reduce
downtimes. Our training sessions help
you to diagnose quickly any failure
and to apply the most appropriate
repair method. (see ‘Training’ in the
‘Services’ section).

Spare parts stock

For any flowmeter belonging
to the Proline family (see next
page), we suggest you keep a full
set of electronic inserts in stock.
In case of a highly critical
instrument, you might also
consider stocking a complete
new instrument.
To easily select the right spare
part, we recommend the use
of our Spare Part Finding Tool.
This database is attached to ‘Proline’ flowmeters
the Maintenance Guide as a
CD-ROM. A range of instruments designed
Our specialists can help you to define to make your life easier!
the criticality of all your measuring
instruments (even for other makes).
They will apply a structured Using Proline flowmeters provides you with several benefits
methodology adapted to your own
application (see ‘Installed Base Audit’
throughout their life cycle:
service in the ‘Services’ section).

Instrument and • Unified components and configuration software The Proline family

spare parts availability spare parts minimize storage and replaces FieldTool and
You will find detailed costs TofTool. flowmeters
information in the next sections • Time-saving by easily • Promag 10
(EMF, Mass flowmeters etc.) replaceable components • Better plant availability on • Promag 23
• Promag 50
without recalibration account of self-diagnosis
• Promag 53
• Multi-option control with functions, data backup • Promag 55
local display or configuration (S-DAT, T-DAT), standardized
software (such as FieldCare), spare parts concept, etc. Mass flowmeters
• Promass 40
locally through the service • ‘Quick Setups’ and
• Promass 80
interface or by digital standardized configuration • Promass 83
communication from a routines for user convenience • Promass 84
control center. Note that • FieldCheck for testing
Vortex flowmeters
FieldCare is now the standard flowmeters in-line
• Prowirl 72
• Prowirl 73

Ultrasonic flowmeters
• Prosonic Flow 90
• Prosonic Flow 91
• Prosonic Flow 93
Permanent self-diagnosis • Prosonic Flow 92F
All Proline flowmeters have continous
self-diagnosis during operation. Faults, if Thermal mass flowmeters
they occur, are unambiguously classified. • T-mass 65
So you have maximized process

Data storage /
data transfer
All device parameters
and settings are securely
stored on these data
memory modules in the
form of:
• T-DAT for
transmitter data
(at Promag 53,
Promass 83 and
Prosonic Flow 93)
• S-DAT for sensor data
(all devices)

28 The Endress+Hauser Maintenance Guide

How does it work?

FieldCheck® comprises a signal
generator, connector cables
Smart signal simulator and ‘Simubox’ adapters for
connection to the various types
of flowmeters (see picture).
With FieldCheck®, meter verification can be carried out
without the removal of the Proline flowmeter from the pipe. The user may effect:
Where ISO 9000 requires frequent test cycles, FieldCheck® • A manual simulation of
is an economical alternative to calibration. the flowmeter functions.
The generator simulates a
flow based on several freely
Modular concept Designed especially for Main advantages programmable profiles. This
flowmeter verification*, • All Endress+Hauser PROline allows the user to check the
All Endress+Hauser flowmeters FieldCheck® simulates sensor flowmeters can be tested behaviour of the outs towards
are based on unified electronics signals to test and evaluate directly on-site, without the device, or the supervision
and operating concepts. The the behaviour of an item of removal of the instrument system, without any actual flow
modular Proline device concept equipment. It can also, thanks • Simultaneous verification in the pipe.
provides the user with obvious to its checking procedures, test of process outputs (current, or
advantages, e.g. in service proper flowmeter functioning frequency) • A full check of the flowmeter,
situations: – be it to meet in-house criteria • Large, clear, multivariable of its electronics only or of its
or regulatory requirements. The displays sensor only (see photo). The
• Minimisation of spare parts check and test results obtained • Expanded functionality tool incorporates procedures
costs through standardised with FieldCheck® can then be with the FieldCare® for automatically checking
components. stored in a database and printed software programme: reading all the electronic operations
• Time-saving with easily out for subsequent use, e.g. in and printing of test results (linearity of the amplifier, the
replaceable meter electronics, connection with certification by (verification certificates) analog outs and frequency)
without the need of audit organizations. on the one hand, and all the
recalibration. sensor operations on the other
• Individual retrofitting of (magnetic field and measuring
flowmeters for application- Outputs electrode integrity).
specific modifications.
We can provide checks on your
Service Proline flowmeters as on-site
interface service for your installed devices.
Our specialist staff will carry out
all the test functions directly in the

Your benefits:
• Cost savings by providing the
inspection equipment
On-site connections • No familiaristion required by
operating personnel
• Test certificate as record and proof
of the simulation and verification

FieldCare is presented on page 105.
Time-saving ‘Quick Setups’

The Quick Setup menus

make commissioning fast and
straightforward. It guides you
step by step through all the
operation-relevant parameters.
The suitcase includes the FieldCheck®
Quick Setups are available On-site functional check of a flowmeter using the FieldCheck®. signal simulator and Simubox interfaces.
as follows:

• For standard commissioning

• For metering pulsating flow
• For metering gas flow (Coriolis)
• For filling and dosing
• For sensor installation and
wall thickness
measurement (ultrasonic)
• For configuring the Fieldbus

The Endress+Hauser Maintenance Guide 29

Electromagnetic flowmeters

Promag series

The current Endress+Hauser range of electromagnetic

flowmeters includes Proline Promag 50, 53 and 55.

In this section, you will find essential information and advice

that will help you to perform the optimum follow-up of your
Promag electromagnetic flowmeters throughout their lifecycle.

Measuring principle

To measure flow based on

Faraday’s law of induction an
alternating magnetic field is
produced with coils of copper
wire. A controlled coil current
ensures that the magnetic field
“The meter must strength remains constant during
the measurement. The length
remain completely of the conductor (the distance
full at all times.” between the two measuring
electrodes at the internal
diameter of the measuring tube)
is also a constant value. The only
variable in Faraday’s equation is
the flow velocity of the passing
fluid. The generated voltage is
exactly proportional and linear When installed a short distance electrode is at the highest point
to the velocity of the fluid. An from a profile disturbance an of the pipe and will function
EMF* does not measure volume EMF will suffer measuring correctly. In applications where
but velocity. The induced voltage errors due to the disturbed flow a partially filled pipe is unlikely
of a general purpose EMF at profile entering the meter. The the orientation of the electrodes
Endress+Hauser equals approx. flowmeter should therefore doesn’t matter.
300 µV per m/s velocity. be installed according to the
installation recommendation The grounding of the EMF
Installation conditions with sufficient straight pipe must be according the guidelines
up- and downstream. The (see FAQs). For further
In addition to installation recommended straight lengths information please refer to the
Figure 1: Recommended straight lengths
guidelines for all technologies are measured from the center corresponding chapter in the
(see ‘Basics’), the particular of the flowmeter. This means Operating Manual.
installation requirements of an in small diameter there is often
EMF are: enough straight length within Setup - Configuration
the device itself.
Inlet and outlet runs All Proline flowmeters propose a
The meter must be installed If the Empty Pipe Detection ‘Quick Setup’ program to make
with sufficient straight pipe is used the correct sensor standard commissioning easy.
up-stream. orientation must be considered
F06-5xxxxxxx-11-00-xx-xx-000 If possible, install the sensor well (see figure 2). Our service team can set up any
clear of fittings such as valves, T- The empty pipe detection Endress+Hauser flowmeter for you
and thus ensure you immediately get
pieces, elbows, etc. Compliance electrode must be at the the best from your instrument.
with the following requirements highest point of a horizontally (see ‘Commissioning’ in the ‘At your
for the inlet and outlet runs is installed EMF. If the EMF must service’ section)
necessary in order to ensure be installed in a horizontal
measuring accuracy : F06-5xxxxxxx-11-00-xx-xx-000
pipe the transmitter/terminal
Figure 2: Orientation in case of Empty • Inlet run ≥ 5 x DN housing must be located on
Pipe Detection (1) • Outlet run ≥ 2 x DN top of the pipe. Then the EPD

* EMF: Electromagnetic Flowmeter

30 The Endress+Hauser Maintenance Guide

EMF mounted

EMF mounted
in a siphon

EMF mounted vertically EMF with remote electronics

Operation and Maintenance be obtained by means of • These calibration recommen-

comparison with an ultrasound dations are no substitute for
Preventive maintenance device. This is in no way a the maintenance operations
How can you minimize the calibration. required to keep the device in
risks of failure or drift of your perfect working condition.
measurement point? Calibration
Having no moving parts, EMFs Calibration frequency should Calibration of flowmeters can be
performed by Endress+Hauser either
require very little preventive be in line with the operating
on-site or in our accredited laboratories.
maintenance. conditions. Device calibration (see ‘Calibration’ in the ‘At your
Process conditions may affect procedures and intervals service’ section)
your flowmeters’ lifetime or depend on:
accuracy (abrasive products, • the precision required for
soiling of the electrodes, effects leakage flow monitoring, Instrument and
from high temperatures or high • its criticality to the process, spare parts availability
temperature cycles (e.g. CIP), the legislative constraints
vibration, agressive chemical imposed. Your Spare part New
products etc). So it is important to define the instrument availability generation
If you face one of those calibration intervals and the
situations, you can drastically maximum permissible error of a Promag 30/33 YES - until 12/2007 Promag 50/53
decrease the risk of process measurement point.
downtime by planning The main factors influencing Promag 39F/H NO - since 09/2007 Promag 50/53
periodical checks and flowmeter drift are:
calibrations. Another topic • the process conditions (fluid Dosimag A YES - until 12/2010 Dosimag 5BH
requires particular attention: type, product temperature, etc.)
the seals on H sensors (hygienic Promag 35S YES - until 12/2010 Promag 55S
• the ambient conditions in
or small diameter) which are which the sensors are fitted
exposed to repeated cleaning (ambient temperature,
or sterilization (CIP/SIP) may moisture). If you want to get more information
about spare parts availability, please
quickly deteriorate. Ensure that call our hotline.
they are regularly replaced. In the knowledge that
calibration frequencies should
To control the functional integrity be optimized over time in line Spare parts stock
of the Promag we use special with the operating histories, For any flowmeter belonging to
tools which provide very you need to set an initial the Proline family, we suggest
complete checks of the internal frequency. Hereafter you will you keep a full set of electronic
parameters of the electronics find a table of recommendations inserts in stock.
including elements of the to help you define this
sensor (See full description of frequency, taking into account
FieldCheck® on page 29). the process conditions and
ambient conditions:
Our service contracts can include
such verifications – once a year is Note:
(see ‘Service Contracts’ in the • For abrasive or corrosive
‘At your service’ section) fluids, the calibration
frequency must be lowered
Note: a measurement according to the wear.
consistency check may

The Endress+Hauser Maintenance Guide 31

Please call our sales force for
Migration 0.05 µS/cm
Oil, Hydrocarbons

more information. Water

Ultra pure water

Promag 5X series is 1 µS/cm Pure water

For a more in-depth analysis of your Min. Conductivity
Endress+Hauser’s new
current installed base, we can help you for EMFs
generation of electromagnetic with our ‘Installed Base Audit’ service 10 µS/cm
Industrial water
flowmeters. These new (see the ‘At your service’ section).
instruments offer new ways 100 µS/cm
Potable water
to carry out preventative Re-engineering 1 mS/cm
verification (see FieldCheck on Food Beer
page 25). They can substitute You wish to apply an EMF to 10 mS/cm
Orange juice
all Endress+Hauser’s previous a different application than Apple juice
instruments. the one for which it had been 100 mS/cm Tomato juice

selected? Please take the Process Phosphoric acid

Sulphuric acid
The old generation primarily following advice into account. 1000 mS/cm
Hydrochloric acid
includes the Promag30, Caustic soda

Promag 33 and Promag 35. As No or low conductivity

of December 2007, the parts for If a fluid has a rather low
the Promag 30 and 33 will no conductivity, an EMF cannot
longer be available. be used. The following
liquids can NOT be measured
• With which device should because their conductivity is
you replace your Promag 30? too low: vegetable or mineral
For identical applications, oil, de-mineralized water,
the answer would be the hydrocarbons/solvents, etc. (see
Promag 10, which is much graphics) The effect of build-up
more user-friendly and easy on the electrodes
However, if these liquids are
to use. In addition, you will mixed with even a low quantity
only need to stock a single of a conductive liquid, an EMF • For abrasive slurries suitable the measuring electrodes clean
electronics board. might be used. liners and electrode designs/ and free from build-up
• With which device To apply an EMF successfully materials must be chosen.
should you replace your the fluid must have a minimum Measuring range
Promag 33? For standard conductivity of: >5 µS/cm for Temperature range You also need to check that the
applications it would be Promag 50/53/55 (55 also for All available liner materials are flowmeter’s measuring range
its designated successor, water) >20 µS/cm for water isolating plastics or rubbers with fits the application. In case of
which is the Promag 50. applications in general >50µS/ a limited operating temperature. a different pipe diameter, a
For special applications, the cm for Promag 23/10. This is the limiting factor for the certain flow rate is required
Promag 53 offers a broader applicability of EMF’s. at minimum flow so that
range of options and better Solid Content in a fluid the flowmeter operates with
measurement uncertainty. Since the influence of solids Build-up / ECC the expected accuracy. The
Promag 53 also includes is very much depending on While an EMF is very tolerant Applicator software allows you
passive or active pulse output, concentration, mixture, particle regarding build-up on the to check the device’s accuracy
like Promag 33. characteristics and other measuring tube, there are over the measuring range.
• With which device should parameters, expert knowledge limitations. A layer on the
you replace your Promag is required to select and size the electrodes will eventually lead Again consider proper
35? Replace with the best fitting model and options. to a reduced flow signal and the installation and setup.
Promag 55, typically for Two typical influences must be device might stop functioning.
applications involving high- considered:
load fluids (paper mill, mining • Excessive signal noise If the build-up is conductive
extraction, etc.) due to solids requires a (e.g. Magnetit in heating water
high performing transmitter systems), it is possible to use
(Promag 55) an electronic solution: ECC
(electrode clean circuit) keeps

32 The Endress+Hauser Maintenance Guide

Mass flowmeters

Promass series

The current Endress+Hauser range of mass flowmeters

includes Proline Promass 80, 83 and 40.

In this section, you will find essential information and advice

that will help you to perform the optimum follow-up of your
Promass flowmeters throughout their lifecycle.

Measuring principle

The measuring principle

is based on the controlled
generation of Coriolis forces.
These forces are always present
when both translational and
rotational movements are
“Ensure that cavitation superimposed.

does not occur!” FC = 2 � ∆m (v � w)

FC = Coriolis force
∆m = moving mass
w = rotational velocity
v = radial velocity in rotating or
oscillating system

The amplitude of the Coriolis flow. Electrodynamic sensors density of the oscillating system
force depends on the moving register the tube oscillations at (consisting of the measuring
mass ∆m, its velocity v in the the inlet and outlet. tube and fluid) results in a
system, and thus on the mass corresponding, automatic
flow. Instead of a constant System balance is ensured by adjustment in the oscillation
angular velocity w, the Promass the antiphase oscillation of frequency. Resonance frequency
sensor uses oscillation. the two measuring tubes. The is thus a function of fluid
measuring principle density. The microprocessor
In the Promass F and M operates independently of utilizes this relationship to
sensors, two parallel measuring temperature, pressure, viscosity, obtain a density signal.
tubes containing flowing conductivity and flow profile.
fluid oscillate in antiphase, The temperature of the
acting like a tuning fork. The Note: For Promass I, S and P, measuring tube is determined
Coriolis forces produced at the the system balance required in order to calculate the
measuring tubes cause a phase for proper measurement compensation factor due to
shift in the tube oscillations (see is created by exciting an temperature effects. This
illustration): eccentrically arranged signal corresponds to the
swinging mass to antiphase process temperature and is also
• At zero flow, in other oscillation. This patented available as an output.
words when the fluid is at TMB system (Torsion Mode
a standstill, the two tubes Balanced System) guarantees
oscillate in phase (1). perfect measurements, even
• Mass flow causes deceleration in changing process and
of the oscillation at the inlet of environmental conditions.
the tubes (2) and acceleration
at the outlet (3). The measuring tube is
continuously excited at its
The phase difference (A-B) resonance frequency. A change
increases with increasing mass in the mass and thus the …

The Endress+Hauser Maintenance Guide 33

Commissioning and
configuration with

Mobile flow rig for

on-site calibration
Mass flowmeters mounted vertically

Installation conditions • Select a lower full scale value for abrasive substances such as fluids
with entrained solids (flow velocity <1 m/s).
In addition to installation guidelines for all technologies (see ‘Basics’), • For gas measurement the following rules apply:
here are the specific installation requirements for a mass flowmeter: – Flow velocity in the measuring tubes should not be more than half
the sonic velocity (0.5 Mach).
When using a bent measuring tube and horizontal installation, the – The maximum mass flow depends on the density of the gas:
position of the sensor has to be matched to the fluid properties! formula shown below.

Measuring ranges for gases

The full scale values depend on the density of the gas. Use the
formula below to calculate the full scale values:
mmax(G) = mmax(F) � rG) / 160 [kg/m3]
mmax(G) = max. full scale value for gas [kg/h]
mmax(F) = max. full scale value for liquid [kg/h]
r(G) = Gas density in [kg/m3] at operating conditions
Here, mmax(G) can never be greater than mmax(F).

Mounting location
Horizontal installation for sensors with a bent measuring tube No special precautions need to be taken for fittings which create
1 Not suitable for fluids with entrained solids. Risk of solids accumulating.
2 Not suitable for outgassing fluids. Risk of air accumulating.
turbulence (valves, elbows, T-pieces etc.), as long as no cavitation
occurs. Entrained air or gas bubbles in the measuring tube can result
System pressure in an increase in measuring errors. Therefore, avoid the following
It is important to ensure that cavitation does not occur, because it mounting locations in the pipe installation:
would influence the oscillation of the measuring tube. No special • Highest point of a pipeline. Risk of air accumulating.
measures need to be taken for fluids which have properties similar to • Directly upstream of a free pipe outlet in a vertical pipeline.
water under normal conditions.
In the case of liquids with a low boiling point (hydrocarbons, solvents,
liquefied gases) or in suction lines, it is important to ensure that
pressure does not drop below the vapor pressure and that the liquid
does not start to boil. It is also important to ensure that the gases that
occur naturally in many liquids do not outgas. Such effects can be
prevented when system pressure is sufficiently high.
Therefore, the following locations should be preferred for installation:
• Downstream from pumps (no danger of vacuum)
• At the lowest point in a vertical pipe F06-xxxxxxxx-11-00-00-xx-004

Recommended measuring ranges: Limiting flow Note : We recommended the vertical orientation with upwardF06-xxxxxxxx-11-00-00-xx-00
Please refer to the ‘Measuring range’ section of the ‘Technical direction of flow. When fluid is not flowing, entrained solids will
Information’ documentation. sink down and gases will rise away from the measuring tube. The
Select nominal diameter by optimizing between required flow range measuring tubes can be completely drained and protected against
and permissible pressure loss. See the ‘Measuring range’ section for a solids buildup.
list of maximum possible full scale values.
• The minimum recommended full scale value is approx. 1/20 of Setup - Configuration
the max. full scale value.
• In most applications, 20 to 50% of the maximum full scale value All Proline flowmeters propose a ‘Quick Setup’ program for
can be considered ideal straightforward commissioning. Promass 83 proposes an application-
specific Quick Setup program.

34 The Endress+Hauser Maintenance Guide

Operation and maintenance Calibration

See ‘Basics’ (page 27) and also page 31 for information regarding
Preventive maintenance calibration.
Having no moving parts, mass flowmeters require very little
Calibration can be performed by Endress+Hauser either on site or in our accredited
preventive maintenance. Though many process conditions may laboratories (see ‘Calibration’ in the ‘At your service’ section).
affect your Promass’ lifetime and accuracy: corrosive and abrasive
mediums, high temperature on the electronic and stress by
vibrations for the whole device. Furthermore the accuracy of Instrument and spare parts availability
the measurement may be affected by: deposit of medium in the
measure pipe, inhomogeneous mediums, gas bubbles and solids. Your Spare part New
Are you faced by one of those situations? By planning periodical instrument availability generation
checks you will drastically decrease the risk of process downtime.
Promass 60F/M/I YES - until 12/2008 Promass 80M
There are two simple ways to check a mass flowmeter:
Promass 63MT/MP YES - until 12/2010 Promass 83M
1 - Zero point adjustment
All measuring devices are calibrated to state-of-the-art technology. Promass 63F YES - until 12/2010 Promass 83F
The zero point determined in this way is imprinted on the nameplate.
Promass 64F/M YES - until 12/2010 Promass 84F/M
Calibration takes place under reference conditions. Therefore, a zero
point adjustment is generally not required!
Experience shows that the zero point adjustment is advisable only in
special cases: If you want to get more information about spare parts availability, please call
• When the highest measuring accuracy is required and the flow our hotline.
rates are very low.
• Under extreme process or operating conditions (e.g. very high Spare parts stock
process temperatures or very high viscosity fluids). For any flowmeter belonging to the Proline family, we suggest you
keep a full set of electronic inserts in stock.
How to check the zero point?
• First you have to set the low flow cutoff to 0 and close the pipe. Migration
• Then check the zero-point in the display, while the flow in the pipe From the Promass 60 and 63, the sensor may in any case be
is definitly 0. In this state, the display has to show ‘0.00’ and has to replaced by the new version. The electronic board must be
be stable. changed at the same time (for Rackbus and DZL363 devices,
please consult us). Endress+Hauser provides upgrade kits including
2 - Compare the displayed and real densities mechanical parts and a new type plate.
You only have to know the density of the medium which is in the
pipe (e.g. d water = 0.998 kg/dm3 at 20°C). You mustn´t stop the Re-engineering
flow. Compare the displayed density to the density of the medium. Pressure loss has to be considered before using a mass flowmeter
The displayed value has to be stable and accurate in the possible in a new application. Pressure loss depends on the fluid properties
tolerance threshold. and on the flow rate. Please refer to the Operating Instructions to
If one of these two methods gives a wrong result, please contact us. calculate pressure loss.
Note: To get a good result with these two methods, it is necessary to
have no air or gas bubbles in the liquid.

To control the functional integrity of the Promass we use

special tools which provide very complete checks of the internal
parameters of the electronics including elements of the sensor
(See full description of FieldCheck® on page 29).

Our service contracts can include such verifications – once a year is recommended
(see ‘Service Contracts’ in the ‘At your service’ section).

The Endress+Hauser Maintenance Guide 35

Vortex flowmeters

Prowirl series

The current Endress+Hauser range of vortex flowmeters

includes Proline Prowirl 72 and 73.

In this section, you will find essential information and advice

that will help you to perform the optimum follow-up of your
Prowirl vortex flowmeters throughout their lifecycle.

Measuring principle

Vortex shedding flowmeters

work on the principle of the
Karman vortex street. When
a fluid flows past a bluff body,
vortices are alternately formed
and shed on both sides with
“Take care of inlet opposite senses of rotation.
These vortices each generate a
and outlet runs” local low pressure. The pressure
fluctuations are recorded by
the sensor and converted to
electrical pulses. The vortices
develop very regularly within
the application limits of the
device. Therefore, the frequency
of vortex shedding is directly
proportional to the volume flow. device. It is independent outlet runs. This is very
of the fluid velocity and its important in order to ensure
The K-factor is used as the properties’ viscosity and density. that the flow profile is free of
proportional constant: K-Factor In this way, the K-factor is also secondary disruptions.
= pulses / unit volume (dm3) independent of the type of fluid • The nominal diameter and
to be measured, regardless of pipe inside diameter have to
Within the application limits of whether this is steam, a gas or a be as close as possible.
the device, the K-factor only liquid. The primary measuring Note: The Reynolds number
Figure 1: Recommended orientations depends on the geometry of the signal is already digital should be >20.000.
(frequency signal) and a linear
function of the flow. Orientation (see fig. 1)
The device can generally be
After manufacturing the meter, installed in any position in the
the K-factor is determined in the piping. In the case of liquids,
factory by means of calibration upward flow is prefered in
and is not subjected to any long vertical pipes to avoid partial
term drift or zero point shift. pipe filling (see orientation A).
Temperature may affect
Installation conditions the long term reliability of
electronic modules. Thus:
Vortex meters require a fully • In the case of hot fluids (e.g.
developed flow profile as a steam or fluid temperature
prerequisite for correct volume ≥ 392°F / 200°C), select
A = Inlet run 3 = 90° elbow or T-piece flow measurement. For this orientation C or D so that
B = Outlet run 4 = 2 x 90° elbow, 3-dimensional reason, please note the following the permitted ambient
1 = Reduction 5 = 2 x 90° elbow points when installing the device: temperature of the electronics
2 = Extension 6 = Control valve
• Welds, burrs and gaskets is not exceeded.
Figure 2: Inlet and outlet runs should not protrude into
the pipe inside the inlet and

36 The Endress+Hauser Maintenance Guide

The use of the remote
version is recommended
for cryogenic applications

Use the remote version in case of a low accessibility to the sensor. Orientation for applications
with hot water

• Orientations B and D are Perfect centering Preventive maintenance Spare parts stock
recommended for very cold The centering rings supplied with The device does not contain For any flowmeter belonging to
fluid (e.g. liquid nitrogen). the wafer style meters are used to any moving parts and requires the Proline family, we suggest
mount and center the instrument. no particular maintenance. you keep a full set of electronic
The arrow indicated on the We recommend the periodic inserts in stock.
device must always point in Setup - Configuration checking of the instrument
the direction of flow in all by means of the FieldCheck Migration
mounting orientations. All Proline flowmeters propose a simulator. (See full description
‘Quick Setup’ program to make of FieldCheck® on page 29). Prowirl 72 is fully compatible
Caution! standard commissioning easy. with Prowirl 77. Please consult
• If fluid temperature is ≥ 392°F In case of vortex flowmeters, Our service contracts can include us in case of a migration from
/ 200°C, orientation B is the Quick Setup can configure such verifications – once a year Prowirl 70H.
is recommended (see ‘Service
not permitted for the wafer the device according to the Contracts’ in the ‘At your service’
version (Prowirl 72 W) with application (liquid, gas, steam). section) Re-engineering
a nominal diameter of 4”/
DN 100 and 6”/DN 150. Our service team can set up any When thinking about using a
• In case of vertical orientation Endress+Hauser flowmeter for you Calibration vortex flowmeter for a new
and thus ensure you immediately get
and downward flowing liquid, the best from your instrument.
See ‘Basics’ (page 27) and application, the following
the piping always has to be (see ‘Commissioning’ in the ‘At your also page 31 for information limitations have to be taken
completely filled. service’ section) regarding calibration. into account, to avoid future
problems :
Inlet and outlet runs Calibration of flowmeters can be • Pulsating flow and swirl
As a minimum, the inlet and Operation and Maintenance performed by Endress+Hauser either have a detrimental effect on
outlet runs shown below must on site or in our accredited laboratories. measuring accuracy.
(see ‘Calibration’ in the ‘At your
be observed to achieve the The measuring range depends service’ section)
• Long inlet and outlet runs are
specified accuracy of the device. on the fluid and the nominal necessary, depending on the
The longest inlet run shown diameter. Do not work outside type of fitting upstream.
must be observed if two or more the measuring range. Note: on-site calibration is • Vortex is not adapted for
flow disturbances are present. possible for liquid applications highly viscous liquids.
Note: A specially designed If temperature and pressure only. Factory calibration also • Measurement with low flow
perforated plate flow conditioner vary during the process, you uses only water as fluid. velocities is not possible
can be installed if it is not possible need to use a calculator to take (Re < 4000).
to observe the inlet runs required. in account simultaneously the Instrument and
volume flow delivered by the spare parts availability
Piping insulation vortex flowmeter, the pressure
When insulating, please ensure and/or the temperature. Your Spare part New
that a sufficiently large area of instrument availability generation
the housing support is exposed. In steam pipes, it is essential
The uncovered part serves to avoid any steam, water or Prowirl 70F/W/D YES - until 12/2008 Prowirl 72F/W/D
as a radiator and protects the pressure shock on the meter.
electronics from overheating (or The effects of such shocks Prowirl 70H YES - until 12/2009 Prowirl 72F
undercooling). would be irreparable.
Prowirl 77 YES - until 12/2008 Prowirl 72
The maximum insulation height Measurement with low flow
permitted is illustrated in the velocities (Re < 4000) is not
diagrams. These apply equally possible.
to both the compact version and
the sensor in the remote version.

The Endress+Hauser Maintenance Guide 37

Ultrasonic flowmeters

Prosonic Flow series

The current Endress+Hauser range of ultrasonic flowmeters includes:

• Proline Prosonic Flow 90 and 93 in both ‘clamp on’ (non-contact measurement technique)
and insertion versions.
• New Prosonic Flow 92 Inline whose installation requirements are similar to those of the
electromagnetic flowmeters
• Prosonic Flow 92 portable ‘clamp on’ flowmeters.

In this section, you will find essential information and advice to obtain the best from ‘clamp on’
ultrasonic devices throughout their lifecycle.

Measuring principle

Prosonic Flow operates on

the principle of transit time
difference. An acoustic
(ultrasonic) signal is transmitted
in both directions from one
measuring sensor to the other. As
“Take care of the the signal propagation velocity
of the waves is less when the
type of fluid and of waves travel against the direction
the pipe material” of flow than along the direction
of flow, a transit time difference
occurs. This difference is directly
proportional to the flow velocity.
Prosonic Flow calculates the flow
from the pipe cross-sectional area
and the measured transit time
difference. Recommended materials: Compliance with the following
• Cast iron, with or without requirements for the inlet and
v ~ ∆t cement coating outlet runs is recommended
Q=v�A • Stainless steel in order to ensure measuring
• Carbon steel accuracy (see figure 2).
v = flow velocity

∆t = transit time difference

v = volume flow • PE Orientation
A = pipe cross-sectional area • GRP (composite material) See figure 3.
• Fibrocement
In addition to the volume flow, Note: If the pipe material does Coupling medium
Figure 1: Mounting location the system measures the sound not conduct sound waves A coupling medium is required
velocity in the liquid. The (e.g. granular concrete), use to ensure the acoustic coupling
sound velocity can be used to insertion sensors instead of between the sensor and the
distinguish different liquids or clamp on sensors. piping. This is applied to
as a measure of product quality. the sensor surface during
Mounting location commissioning. Periodic
Limitations: Correct measuring is possible replacement of the coupling
• Pipes from ½” to 16” only if the pipe is full. Avoid the medium is usually not required.
(DN 15 to 400) following locations (see fig. 1) : Prosonic Flow 93 offers a
• Liquids should not be heavily • Highest point of a pipeline. coupling medium monitoring
contaminated with solids or gas Risk of air accumulating. function as part of its ‘Extended

• Directly upstream of a free Diagnostics’ software package.

Installation conditions pipe outlet in a vertical pipe. This function outputs the signal
strength as a limit value.
Pipe material Inlet and outlet runs
Figure 2: Inlet and outlet runs
1 = Valve, 2 = Pump, 3 = Two pipe
The pipe material should be If possible, install the sensor well Note: with proper mounting,
bends in different directions as homogeneous as possible, clear of fittings such as valves, uncertainty will be less than 2%.
either metallic or synthetic, and T-pieces, elbows, etc.
must conduct sound waves.

38 The Endress+Hauser Maintenance Guide

Prosonic Flow 92 used
for the measurement
consistency check of
an electromagnetic
(see page 29)

Standard horizontal installation Installation of coated pipes Installation in highly

corrosive environment

Setup - Configuration of both sensors as well as the

electronic functionality.
All Proline flowmeters propose a
‘Quick Setup’ program to make Our service contracts can include
standard commissioning easy. In such verifications – once a year

is recommended (see ‘Service
case of ultrasonic flowmeters, Contracts’ in the ‘At your service’
you need to know precisely the section)
pipe material, the pipe external
diameter, the pipe thickness and Figure 3: Orientation
the type of fluid. View A shows the recommended orientation with upward direction of flow.
View B shows the recommended installation range (C ≤ 120°) in a horizontal installation
See ‘Basics’ (page 27) and position
Some fluids have already been also page 31 for information
programmed. For others, the regarding calibration.
sound velocity in the fluid is
requested. The Quick Setup According to quality constraints,
will then help you configure the you may wish to periodically
transmitter and will give you the calibrate your instrument.

exact positioning of the sensors. Ultrasonic flowmeters can
be calibrated on a flow rig.
Operation and Maintenance Please not that the conditions
Figure 4: Sensor replacement in the insertion version
are different from the process 1 = Sensor section in contact with fluid (screwed in), 2 = Sensor element (active
Take care of the sensor cable: if conditions. section), 3 = Connector holder, 4 = Sensor cover, 5 = Sensor connector
it gets twisted or wounded, the
measurement will be impacted Calibration of flowmeters can be
and the replacement is relatively performed by Endress+Hauser either
on site or in our accredited laboratories.
expensive. (see ‘Calibration’ in the ‘At your
service’ section)
Preventive maintenance Your Spare part New
• Check periodically the correct instrument availability generation
tightening of the connectors. Instrument and
• Ensure that the sensors’ spare parts availability DMU93 NO - since 12/2007 DMU90/91/93
position is kept constant. See table to the right.
• Coupling medium should be
periodically changed in the Spare parts stock
following situations: For any flowmeter belonging to
- important variation of the Proline family, we suggest
temperature you keep a full set of electronic
- ambient moisture or inserts and sensors in stock.
streaming on the pipe Note: changing the sensor does
- outside application exposed not affect the electronics; no
to wind, sand or dust recalibration is necessary.

On-site verification is possible Sensor replacement in the

with the FieldCheck simulator. insertion version (see fig. 4)
(described on page 29). The active part of the sensor
The ‘service’ test block offer a can be exchanged without
simple way to test the function interrupting the process.

The Endress+Hauser Maintenance Guide 39

Thermal mass flowmeters

T-mass series

The current Endress+Hauser range of thermal mass

flowmeters includes Proline t-mass 65.

In this section, you will find essential information and advice

that will help you to perform the optimum follow-up of your
thermal mass flowmeters throughout their lifecycle.

T-mass insertion version mounted

on a low pressure air pipe

Measuring principle

The thermal principle operates

by monitoring the cooling effect
of a gas stream as it passes over
a heated transducer (Pt100).
Gas flowing through the
sensing section passes over two
“Ensure the sensor Pt100 RTD transducers one of
which is used conventionally
is mounted at as a temperature sensing
90 degrees to the device, while the other is used
as a heater. The temperature
flow direction and sensor monitors the actual
avoid condensation” process values while the heater
is maintained at a constant
differential temperature above Pipework requirements
this by varying the power Good installation practice
consumed by the sensor. The should be followed at all times:
greater the mass flow, the • Cleaned pipe and flange
greater the cooling effect and welded joints
power required to maintain • Correctly sized gaskets
the differential temperature. • Correctly aligned flanges and
The measured heater power is gaskets
therefore a measure of the gas • The use of seamless pipe
mass flowrate. immediately upstream of the
These devices need to be • The use of pipework with a
programmed for a certain gas matching internal diameter
or gas mixture. In the factory, to that of the flowmeter
calibration is performed on to ensure that no step
air, using a highly accurate disturbance greater than
and repeatable flow rig, and 0.04” (1 mm) can occur at
a dynamic sensor and gas the meter inlet or outlet,
property calculator model ‘Gas 0.12” (3 mm) for diameters
Engine’ determines mass flow > 8” (DN 200).
for the application gas.
As a general comment,
Installation conditions anything that disturbs the
smoothness of the internal
Like Vortex flowmeters, thermal pipe wall should be eliminated;
mass flowmeters require a fully the goal should be a smooth
developed flow profile as a uninterrupted internal surface.
Figure 1: Minimum inlet and outlet runs
For further information please

prerequisite for correct volume

A = Inlet run 3 = 90° elbow or T-piece
B = Outlet run
flow measurement. refer to ISO 14511.
4 = 2 x 90° elbow, 3-dimensional
1 = Reduction 5 = 2 x 90° elbow
2 = Extension 6 = Control valve

40 The Endress+Hauser Maintenance Guide

brand new gas
calibration flow rig

T-mass being calibrated on a gas T-mass measuring Air injection regulation

calibration flowrig N2 consumption in the pond of aeration

Inlet and outlet runs air. The necessary information is presence of impurities in the gas. Spare parts stock
If possible, install the sensor well requested before delivery. Thus In practice, a certain drift can For any flowmeter belonging to
clear of fittings such as valves, commisioning is quite simple. also be noted when the process the Proline family, we suggest
T-pieces, elbows, etc. temperature is higher than you keep a full set of electronic
Compliance with the following Requested information: 122°F (50°C). In all cases, we inserts in stock.
requirements for the inlet and • Gas type if not air recommend having the device
outlet runs is recommended (composition if more than calibrated once a year. Migration
in order to ensure measuring one gas in % Mole)
accuracy (see figure 1). It is • Gas pressure The t-mass flowmeters are Thermal mass flowmeter
recommended to install a • Gas temperature designed to support in-situ t-mass AT70 is no longer
perforated plate flow conditioner • Line size - internal diameter calibration using a reference sold since the end of 2006.
if the recommended inlet runs • 20 mA range required meter signal (mobile rig), With brand new 65F/I series,
are not available. • Flow engineering units thus saving time and cost by Endress+Hauser offers full
(kg/h etc.) reducing the need for factory re- interchangeability. What about
Orientation calibration. An adjustment may the interchangeability with
The device can generally be ‘DELIVERY SETTINGS’ are the complete the calibration work. existing sensors?
installed in any position in the programmed parameters (factory Please discuss your specific
piping. In the case of wet/dirty settings plus customer specific requirements with your From the mechanical side:
gases, upward flow is prefered settings) originally delivered Endress+Hauser service • The t-mass 65I available
in vertical pipes to minimize with the device. representative. process connections are G 1”
condensation/contamination and NPT 1”
on or around the sensing The Quick Setup menu contains For higher precision, t-mass 65 • The t-mass 65F flange length
element. In particular, where the default settings that are flowmeters can be calibrated is identical to the AT70
free condensation can occur adequate for commissioning. with an ISO/IEC 17025
(e.g. Biogas) the sensor should You may use the Quick Setup in accredited specific gas flow rig. From the electrical side: the
be mounted to prevent water order to change parameters or 65F/I series can be supplied
collecting on or around the Calibration of flowmeters can be with 24 VDC, allowing total
to use the device on a different
performed by Endress+Hauser either
sensing elements (e.g. do not application. on site or in our accredited laboratories. interchangeability with AT70.
install the sensor at a low point (see ‘Calibration’ in the ‘At your
in the installation without Operation and Maintenance service’ section) Re-engineering
adequate drainage).
Make sure that the direction Preventive maintenance Corrective maintenance Besides the utilities, t-mass
arrow on the sensor matches Full compatibility with See ‘Basics’ (page 23). 65F/I series is ideally suited for
the direction of flow (direction FieldCheck® (see page 29) will You can change the sensor and air injection regulation in the
of fluid flow through the pipe). allow on-site checking (when the transmitter on-site. Thanks pond of aeration of a wastewater
Note: The best accuracy is the specific SimuBox will be to S-DAT and T-DAT, no further treatment plant. See Installation
obtained only if the gas is dry available). programming is necessary. conditions before you decide to
and clean. change the device’s application.
Calibration Instrument and Use Gas Engine software to
Setup - Configuration See ‘Basics’. spare parts availability change the gas mixture.

The sensor is provided fully The sensor’s aging directly

calibrated with an S-DAT impacts the measurement. Your Spare part New
Each meter is programmed to Aging may be sped up in case of instrument availability generation
individual requirements, i.e. in buildup due to solids deposit, of
particular the gas type or gas shock on any of the transducers t-mass AT70 YES t-mass 65
composition and calibrated with or of abrasion due to the

The Endress+Hauser Maintenance Guide 41

Frequently asked questions

How to achieve proper potential equalization? What to do when faced with measurement drift over time?
Perfect measurement requires the medium and the sensor have • Remove the measuring tube and clean it
the same electrical potential. Most Promag sensors have a standard • Return it to the workshop so that it can undergo the calibration
installed reference electrode which guarantees the required bench procedure
connection and makes additional potential matching measures
unnecessary. Coil current fault?
Special cases are mentioned in the Operating Manual. In particular • Make sure that all the connectors are correctly clipped onto the
the case of plastic pipes and isolating lined pipes. electronics boards
In exceptional cases it is possible that, due • If so: Return the complete device to the workshop
to the grounding plan of a system, large The instrument counts at zero flow. What should I do?
matching currents flow over the reference • Probable cause: air transit
electrodes. This can lead to destruction of • Calibrate DPP with tube empty and tube full
the sensor. In such cases, e.g. for fiberglass or • Activate «product presence detection» function
PVC piping, it is recommended that you use Note: See ‘Process Parameters Menu’ in the Operating Instructions.

additional ground disks for potential matching.

The measurement exhibits peaks or fluctuating values.
Grounding should be ensured at first installation; nevertheless in The measurement is unstable. What should I do?
some cases it may be corrected later. • Check the installation conditions
• Make sure that the pipe is completely filled (no air in the unit)
How to connect a flowmeter to an automaton (PLC) and • High or low fluid load?
then make them talk to each other? • Make sure there are no air bubbles
• Correct electrical wiring. Use a specific cable to connect the • Electrical connection: if electronics separate: earth connection?
sensor to the transmitter (Please read carefully ‘4.1 Wiring Synthetic pipe?
– Connecting the remote version’ in the Promag 50 Operation
Manual). With the Profibus version, are different values displayed on
• Ensure full compatibility between the emitter and the receiver the display and the automaton?
by a proper parameterization of the Pulse/Frequency output • Go to the communication menu
according to your automaton’s settings. • Validate the ‘set unit to bus’ box.
Go to the programming matrix at level ‘(4207) Output signal’ and Note: this is also valid after any programming alteration.
0 = PASSIVE - POSITIVE How do I test the pulse output?
1 = PASSIVE - NEGATIVE • For the test, set a pulse period of 1 second
2 = ACTIVE - POSITIVE • Connect a diode mode multimeter to the unwired (+) and (-)
3 = ACTIVE - NEGATIVE terminals
Factory setting: PASSIVE-POSITIVE • The value changes can be seen on the multimeter
See also the Proline Promag 53 operating manual, p.68 for more (one step = 1 s): Equipment OK
How do I test the current output?
What is the unlocking code for my instrument? • Connect a milliammeter to the unwired terminals 26 (+)
Name of device: e.g. ‘0050’ or ‘50’ for Promag 50 and 27 (-)
• Go to the ‘current output’ menu
How do I set the end of the 4 to 20 mA output scale? • Activate the ‘current simulation’ box
• Go to the ‘current output’ menu • Define the current to be simulated in the ‘sim. curr. value’ box
• Go to the ‘20 mA end of scale’ box
There is a high measurement error. What should I do?
How do I set the Pulse output? • Check the installation conditions
• Go to the ‘pulse output/frequency’ menu • Make sure that the pipe is completely filled (no air in the unit)
• Go to the ‘pulse value’ box • Is the set-up correct?

How do I wire the pulse output on a Promag 50? The Promass shows Error#587 but the tubes do not oscillate.
• Connect the 24 V DC to the + terminal of the pulse output What is the reason for that?
• Retrieve the signal on terminal 25 (Input/Output terminal Perhaps the pipe is only partly filled or there is a too low pressure
numbers). and gas bubbles are in the medium. Please check:
• Is the pipe completely filled?
• Are there gas bubbles in the medium?

42 The Endress+Hauser Maintenance Guide

Liquid analysis

Fabrice Hartmann
Expert in liquid analysis
Endress+Hauser France

“We help you in all situations!”

“Analysis devices typically require more You will also find some recommendations Contents
maintenance than the other measurement related to maintenance intervals to help you
principles. As a consequence, the keep your instruments fit! pH and ORP measurement 44
maintenance staff that takes care of a plant Conductivity measurement 49
generally knows exactly what has to be done. In addition to this, we have included expert
approaches to diagnosis and frequently Turbidity measurement 52
Another consequence is that most asked procedures to help you make the right Chlorine measurement 55
reported questions concern either the diagnosis and actions in case of a trouble.
use of an Endress+Hauser device itself Oxygen measurement 58
or troubleshooting (generally due to the As experts, we also offer training sessions, Analyzers 61
application). in classroom and on site. We would be glad Samplers 64
to meet with you and help you go one step
That is why we have decided to provide further. See ‘Training’ in the section FAQ 70
in this guide a reminder of the different ‘At your service’.”
principles used in liquid analysis.

The Endress+Hauser Maintenance Guide 43

pH and ORP measurement
Liquid analysis

Electrodes and transmitters

A complete pH or Redox measuring system includes:

• an analog or a digital electrode
• a transmitter
• a special measuring cable
• an immersion, flow or retractable assembly

In this section, you will find essential information and advice to obtain the best from
pH and ORP measuring systems throughout their lifecycle.

pH measurement -
Measuring principle

The pH value is used as a

unit of measurement for the
acidity or alkalinity of a liquid
medium. The membrane
glass of the electrode supplies
“You can solve many an electrochemical potential
which is dependent upon the
problems yourself” pH value of the medium. This
potential is generated by the
selective penetration of H+ ions
through the outer layer of the
membrane. An electrochemical
boundary layer with an electric
potential forms at this point.
An integrated Ag/AgCl
reference system serves as
Figure 1: Example of a complete 6 Retractable assembly Cleanfit W
reference electrode. measuring system CPA450
1 Flow assembly CPA250 7 Electrode, e.g Orbisint CPS11
The transmitter converts the 2 Junction box VBA 8 Immersion assembly CPA111
measured voltage into the 3 Liquisys M CPM253 transmitter 9 Extension cable
Electrode Reference
corresponding pH value using 4 Measuring cable e.g. CPK9 Options: extension cable, junction box
electrode the Nernst equation. 5 Liquisys M CPM223 transmitter VBA or VBM

The influences
on pH measurement
Figure 2: The principle of pH/ORP • Temperature influences at two
measurement levels. First on the electrode • Heterogeneous media ORP measurement -
slope sensitivity. Temperature • Soiling measuring principle
compensation serves to bring • Aggressive chemical products
back this sensitivity from The ORP potential is a unit of
its value at the operating The Endress+Hauser range measurement for the state of
temperature to its value at the The current range of pH equilibria between oxidizing
reference temperature 77°F measurement equipment and reducing components
(25°C). Secondly temperature includes: of a medium. ORP potential
influences on pH: the pH • a wide range of pH is measured similarly to the
of a fluid will not be the electrodes, analog and digital pH value. A platinum or gold
same at 194°F (90°C) as at with Memosens technology electrode is used instead of
59°F (15°C). With Liquiline • Liquisys M CPM223/253, pH-sensitive membrane glass.
and Mycom S, you can Mycom S CPM153 Analog to the pH measurement,

Figure 3: Electrode installation; compensate the medium’s and Liquiline M CM42 an integrated Ag/AgCl reference
inclination angle min. 15° from temperature. transmitters system is used as a reference
the horizontal • Contamination of the • their accessories electrode.
reference element (cables and assemblies)
• Electrical phenomena

44 The Endress+Hauser Maintenance Guide

Liquid analysis
The Endress+Hauser range • The cabling should not Cleaning glass pH
The current range of ORP be interrupted (avoid any and Redox electrodes
measurement equipment temporary connection). If an There are 5 levels of cleaning:
includes: extension is necessary, use • Level 1: use water + sponge
• a wide range of ORP a High Impedence junction • Level 2: use water + soap
electrodes, analog and digital box (VBM). (presence of grease)
with Memosens technology • Level 3 (ORP only): carefully
• Liquisys M CPM223/253, Connecting pH and ORP clean the metal pins or
Mycom S CPM153 and sensors (see fig. 4 and 4bis) surfaces mechanically (polish Figure 4: Asymmetrical connection
Liquiline M CM42 transmitters The pH and ORP analog under water using ultra fine
• their accessories (cables and sensors can be connected abrasive paper).
assemblies) both symmetrically and • Level 4: use diluted
asymmetrically. hydrochloric acid HCl
Installation conditions (3 to 5%) and rinse with
Advantages of symmetrical clean water.
Do not install the electrode measurement: Note! After chemical cleaning,
upside down (see fig. 3). • No leak current since the the ORP sensor can require
The inclination angle must be reference and the pH/ORP several hours conditioning
at least 15° from the horizontal. electrode is connected with time. Therefore check the
A smaller inclination angle is not high resistance calibration after a day.
permitted as such an inclination • Safe measurement under • Level 5: use specific products Figure 4bis: Symmetrical connection
results in air cushion forming. difficult process conditions to clean contamination (see
This might impair the contact of (strong flowing and high- the following list).
reference and metal lead. resistance media, partially
Caution! soiled diaphragm) • Oily and greasy films:
Clean with detergent and water or
• Make sure that the assembly’s any grease dissolvers such as alcohol,
threaded connection for Advantages of asymmetrical acetone.
the electrode is clean and measurement: • Inorganic layers:
working properly before • Use of assemblies without Immerse the electrode during 15 min
in diluted hydrochloric acid or soda
installing the electrode. potential matching possible (max 5%).
• Hand tighten the electrode • Lime and metal hydroxide layers: • Check electrical continuity:
(3 Nm)! (Given value only Caution! In the case of a Dissolve layers with diluted establish a short-circuit
applies to installation in symmetrical connection, the hydrochloric or tartric acid (max 10%). between 2 wires at one end
• Layers containing sulphide:
Endress+Hauser assemblies.) potential matching pin must Use mixture of hydrochloric acid (max
of the cable (e.g. between
• Make sure to follow the be connected and always 10%) saturated with urea. ‘Measure’ and ‘Ref’).
installation instructions in the immersed in the medium. • Layers containing proteins: Measure the resistance with
operating instructions of the Immerse the electrode in a mixture of an ohmmeter at the other
hydrochloric acid (max 10%) saturated
used assembly. with pepsin (8500 units) at 98.6°F
end (should be 0.1Ω/m).
Operation and Maintenance (37°C). • Detection of insulation
Cabling Note! Always rinse carefully with default: disconnect both
• Cable should not be longer Maintenance work at the plenty of clear water and wipe with a ends of the cable and
soft piece of cloth.
than 164 ft./50 m (CPK7, transmitter includes: measure the impedance
CPK9, CYK71); for higher • Cleaning of assembly between the different wires
distances use an electrode fitted and sensor Cable and connection check with an insulation meter
with a preamplifier (CPF81 for • Cable and connection check • Check cables and connections that measures with 1000 V
pH, CPF82 for ORP) or use • Calibration and adjustment for moisture, cuts or kinks. (should be R = ∞).
Memosens technology. …

The Endress+Hauser Maintenance Guide 45

Calibration • Keep the electrode immersed Check of the slope after Regeneration of a pH
Liquid analysis

Use the CAL key to access the for a few seconds before you calibration of a pH electrode electrode whose response
‘calibration’ function group. validate the measurement. The theoretical slope is time is too long:
Use this function group to • Rinse the glass bulb with 59.16 mV/pH. The practical Use a mixture of nitric acid
calibrate the sensor. The clean water (do not rub slope of a new electrode is 57 to (10%) and ammonium fluoride
calibration can take place in a it: you might generate 60 mV/pH. (50 g/l). Rinse with clean
number of ways: electrostatic charges!). • If the slope ≤ 55 mV/pH, the water then wipe with a soft
• By measuring in two 3) Immerse the electrode in the electrode must be cleaned. piece of cloth.
buffer solutions with known second buffer solution (pH 4, 9, • If the slope ≤ 50 mV/pH, the
pH value etc.) and start again at step 2. electrode must be checked Storage of an electrode
• By entering data for the slope 4) Rinse the electrode with and replaced if needed. Store in a dry place between
and zero point adjustment clean water. • If the slope ≤ 45 mV/pH, the 50 to 86°F (10 to 30°C).
• By entering an offset value transmitter displays an error Always keep a glass electrode
• In the case of ORP ORP electrode adjustment message: the electrode must be hydrated (if possible in diluted
measurement, by entering 1) Clean the electrode with replaced. KCl 3mol/l). Electrodes are
the mV value or two different water. always delivered with a yellow
% values. 2) Immerse the electrode in a Checking a transmitter cap which contains a sponge
buffer solution (220 mV or - analog technology saturated with a special liquid
pH electrode adjustment 460 mV). (for digital technology, in order to avoid dessication of
1) Clean the electrode with • Measure the container’s see memosens) the bulb.
water (or specific product). temperature By-pass the pH input by
2) First immerse the electrode • In the case of a symmetrical connecting the ‘Measure’
in a pH 7 buffer solution. connection, the potential terminal to the ‘Reference’
• In the case of an automatic matching pin must be terminal (+ the ‘PA’ terminal
temperature compensation, connected and always in case of a symmetrical
the temperature sensor must immersed in the medium. connection). As the pH-meter
be immersed in the medium. • Keep the electrode immersed input has a potential of 0 mV,
• In the case of a symmetrical for 1 min before you validate the display should indicate the
connection, the potential the measurement. Zero value of the last calibration
matching pin must be 3) Enter the actual buffer value (i.e. around pH7).
connected and always in the transmitter (at current You need a pH simulator if you
immersed in the medium temperature). wish to test the whole scale.
• Enter the actual buffer value 4) Rinse the electrode with A pH simulator consists of a
in the transmitter (at current clean water simple voltage generator
temperature). (-500 to +500 mV).

Easier maintenance with Memosens technology

Easy handling
Sensors with Memosens technology have integrated electronics that
allow saving calibration data and further information such as total
hours of operation and operating hours at very high temperatures.
When the sensor is mounted, the calibration data is automatically
transferred to the transmitter and used to calculate the current pH
or ORP potential. Storing the calibration data in the sensor allows for
calibration and adjustment away from the measuring point.

The result:
• The sensors can be calibrated under optimum external conditions
in the measuring lab. Wind and weather do not affect the Memocal T - dedicated Memocheck
calibration quality nor the operator. calibration tool This service tool enables a
• The measuring point availability is dramatically increased by the Memocal T is a calibration quick and easy check of the
quick and easy replacement of precalibrated sensors. instrument for your laboratory: measuring loop by simulating
• The transmitter does not need to be installed close to the • pH measurement using digital fixed sensor status in order to:
measuring point but can be placed in the control room. sensors • control the correct wiring
• Maintenance intervals can be defined based on all stored sensor • Wet or numeric calibration of the system during its
load and calibration data and predictive maintenance is possible. (9.8 ft/3 m of cable) installation
• The sensor history can be documented on external databases and • Readout of all software and
evaluation programs at any time. Thus, the current application of hardware version numbers
the sensors can be made to depend on their previous history. including sensor serial number …

46 The Endress+Hauser Maintenance Guide

Corrective maintenance

Liquid analysis
Diagnosis of common
troubleshootings: see table 1

Generic approach to
diagnose troubleshooting
We suggest five steps:
1) Check that the sensor
fully corresponds to
the application
2) Check the installation
(cabling), the configuration
and the hydraulic mounting
3) Take the environment
(electromagnetic, electrical,
moisture, sun) into account
4) Consider the
metrological level Problem / Possible cause Action
5) Find out which component Calibration is impossible
is out of order
Bulb and/or diaphragm soiled Clean it
1) Installation Bulb broken Replace electrode
• Configuration of analog systems
Cabling error or defective cable Check and replace if needed
(symmetrical or asymmetrical)
has to be coherent with Buffer solution out-of-date Change buffer solution
connection Measurement is unstable
• Review the programming
matrix Incorrect connection Check cable and connections
• Consider the installation Interference Use double-armoured cable;
conditions of the electrode check connection of the
armour plating to the ground;
2) Environment change cable path
• Is the sensor installed inside
Current or parasitic potential in In case of asymmetrical
or outside? Is it protected
the product (for analog systems measurement, connect the
from sunlight? … only) product to the ground; switch
to symmetrical measurement
Sensor responds slowly
Electrode soiled Clean it
Sensor aging Test the measurement chain
with a simulator; replace the
• check the digital data transfer electrode
during commissioning Display blocked on a fixed value
• solve troubleshooting in the
running process Insulation default and/or Test with a pH simulator
short-circuit on the cable or an insulation meter
Moisture on the connectors Check and dry

Memocheck Plus Crack on the inside tube Replace electrode

This tool enables qualification (short-circuit between
of the measuring loop in measurement and reference)
pharmaceutical and Reduction of the reference element (current circulation)
biotechnology industries Insulation default and/or Test with a pH simulator
• with 5 plug-in heads each short-circuit on the cable or an insulation meter
simulating a fixed, defined
sensor status for a dedicated Moisture on the connectors Check and dry
type of sensor: Incoherence between Check
• reading of all relevant configuration and connection
calibration and process data (Symmetrical/Asymmetrical)
after simulation at predefined (for analog systems only)
pH and temperature value
Table 1: Diagnosis of common troubleshootings
• each plug-in head has passed a
stringent test on computerized
inspection unit and a quality
certificate is issued

The Endress+Hauser Maintenance Guide 47

• Take the electrode out of its Cable check: see page 45
Liquid analysis
Your Spare part New
environment and check it in Transmitter check: see page 46
instrument availability generation
another environment
• Electromagnetic phenomena: Instrument and
CPM 220/240 NO - since 01/2004 CPM 223/253
check the cables and the spare parts availability
connection to the ground See table at the right. CPM 221/252 NO - since 01/2005 CPM 223/253
• Does temperature vary a lot?
If yes, check that temperature If you want to get more information MyPro CPM 431 YES - until 10/2010 Liquiline CM42
compensation is active about spare parts availability, please
call our hotline. MyPro CLM 431 YES - until 10/2010 Liquiline CM42
• Moisture: visual check of the
junction boxes watertightness,
look for moisture or oxidation Spare parts stock Mycom CPM 152 YES - until 06/2011 CPM 153
on the connectors, etc. We recommend that you always
keep a new electrode in stock.
3) Metrological level
Is there a drift, is the How to select and order List of consumables
measurement unstable or electrodes and tools: see the
Buffer solutions for pH electrodes
incorrect? selection guide and prices in the Technical buffer solutions, accuracy 0.02pH, acc. to NIST/DIN
• Is the electrode soiled? insert ‘The Maintenance Store’ • pH 4.0 red, 250 ml, order no. CPY20-C02A1
Then clean the electrode attached to this Maintenance • pH 4.0 red, 1000 ml, order no. CPY20-C10A1
(see page 45) Guide. • pH 7.0 green, 250 ml, order no. CPY20-E02A1
• pH 7.0 green, 1000 ml, order no. CPY20-E10A1
• Check the electrode in a • pH 9.2 blue, 250 ml, order no. CPY20-I02A1
well known medium with How to select and order • pH 9.2 blue, 1000 ml, order no. CPY20-I10A1
the actual configuration data buffer solutions and cables: Technical buffer solutions for single use, accuracy 0.02pH, acc. to NIST/DIN
of the transmitter. If there select the right order code from • pH 4.0 red, 20 x 18 ml, order no. CPY 20-C01A1
• pH 7.0 green, 20 x 18 ml, order no. CPY 20-E01A1
is a drift, come back to the the list hereafter; then refer to the
factory configuration. If price list in the insert attached to Redox solutions
this is not sufficient, apply this Maintenance Guide. • +220 mV, pH 7.0, 100 ml (0.026 US gal.); order no. CPY3-0
the procedure to adjust an • +468 mV, pH 0.1, 100 ml (0.026 US gal.); order no. CPY3-1
electrode manually (see page Migration KCl-electrolyte solutions for liquid filled electrodes
46). Read the slope and the • 3.0 mol, T=-10...100°C (14 ... 212 °F), 100 ml (3 oz), order no. CPY4-1
Zero point. According to the How to use a Memosens • 3.0 mol, T=-10...100°C (14 ... 212 °F), 1000 ml (30 oz), order no. CPY4-2
value of the slope you may electrode with your current • 1.5 mol, T=-30...100°C (-22 ... 266 °F), 100 ml (3 oz), order no. CPY4-3
• 1.5 mol, T=-30...100°C (-22 ... 266 °F), 1000 ml (30 oz), order no. CPY4-4
need to clean or replace the pH transmitter?
electrode. A special kit exists to upgrade List of accessories
any Liquisys M CPM 223/253
4) Which component from version 2.5 up and Special cables
is out of order? Mycom S CPM153. This • CPK1 special measuring cable for pH/ORP electrodes with GSA plug-in head
• CPK9 special measuring cable for sensors with TOP68 plug-in head, for high-
Electrode check: upgrade can be done either temperature and high-pressure applications, IP 68
• Visual check of the outside by a service engineer on-site • CYK10 Memosens data cable for digital pH sensors with Memosens technology
condition (damaged, cracked, or you can send it back to the (CPSxxD)
bulb broken, corrosion, Endress+Hauser repair facility. • CPK12 special measuring cable for pH/ORP glass electrodes and ISFET sensors with
TOP68 plug-in head
abrasion, oxydation or moisture
on the connector, etc.)
• Visual check of the inside
condition (Is KCl still
transparent? Has the reference
thread reduced? Is the inside
glass tube damaged?)

48 The Endress+Hauser Maintenance Guide

Conductivity measurement

Liquid analysis
Sensors and transmitters

A complete conductivity measuring system includes:

• a conductivity sensor
• a transmitter
• a special measuring cable

In this section, you will find essential information and advice to obtain the best from
conductivity measuring systems throughout their lifecycle.

Conductive measurement
of conductivity -
measuring principle

The conductivity of liquids is

measured with a measuring
system that has two coaxially
arranged electrodes like
“Always take care of a capacitor. The electric
resistance or its reciprocal
the temperature!” value, the conductance G, is
measured according to Ohm’s
law. The specific conductivity
is determined using the cell
constant k that is dependent on
the sensor geometry.

Inductive conductivity
measurement -
measuring principle
Figure 3: Example of a complete 5 Inductive sensor CLS50 C07-CLM2x3xx-14-06-00-xx-001.eps

A generator (1) generates an measuring system 6 Conductive sensor CLS21

alternating magnetic field in the 1 Conductive sensor CLS15 7 Immersion assembly CLA111
2 Liquisys M CLM253 transmitter Options: extension cable, junction box
primary coil (2) which induces a 3 Liquisys M CPM223 transmitter VBA or VBM
current in the medium (3). The 4 Inductive sensor CLS52
strength of the induced current
Figure 1: The principle of conductive

measurement of conductivity
depends on the conductivity and
AC Power supply thus the ion concentration Installation conditions corrected by multiplication
I Current meter of the medium. The current for inductive conductivity with the installation factor to
U Voltage meter flow in the medium generates measurement ensure correct measurement.
another magnetic field in the The value of the installation
secondary coil (4). For CLS52, the medium should factor depends on the
The resulting current induced flow through the conical diameter and the conductivity
in the coil is measured by the measuring channel in the of the pipe as well as the
receiver (5) and processed to indicated direction. Installation sensor distance from the wall.
determine the conductivity. of the sensor in pipes with If the distance from the wall is
horizontal (middle) and vertical sufficient (a > 0.12 in/15 mm,
Benefits of inductive (right) flow directions. (see fig. 4) from 2½”/DN 65), it is not
conductivity measurement • In narrow installation necessary to consider the
• No electrodes, therefore no conditions, the ion flow in installation factor (f = 1.00).
polarization the medium is affected by If the distance from the wall
Figure 2: Inductive conductivity
• Accurate measurement in the pipe walls. This effect is is smaller, the installation
measurement media or solutions with a high compensated by the so-called factor increases in case of
1 Generator soiling degree and a tendency installation factor. electrically insulating pipes
2 Primary coil
3 Current flow in the medium
to deposition • The installation factor can (f > 1) and decreases in case
4 Secondary coil • Complete galvanic separation be entered in the transmitter of electrically conductive
5 Receiver of measurement and medium or the cell constant can be pipes (f < 1). The installation

The Endress+Hauser Maintenance Guide 49

• Calibration by entering the
Liquid analysis

exact cell constant of the

conductivity sensor (given by
a quality certificate).
• Calibration by comparison
to a reference device
(e.g. CONCAL).

C07-CLS52xxx-11-05-00-xx-001.eps Calibration of inductive

Figure 4: Installation of a CLS52 inductive sensor in pipes with horizontal (middle) and measurement systems
vertical (right) flow directions
b Indicator arrow for the flow direction c Flow direction
Two different types
1 Welding neck 2 Pipe are possible:
• Calibration by measurement
in a calibration solution with a
known conductivity.
• Calibration by comparison to
factor can be measured using a reference device. • For temperature simulation,
calibration solutions or be connect the decade resistor
approximately determined If removing your conductivity instead of the temperature
from a diagram (see fig. 5). transmitter from process for 1 to sensor Pt100, using a
2 weeks is acceptable, the best
• To compensate residual method is to send the instrument three-wire arrangement.
coupling in the cable and to one of our calibration facilities. i.e. connection to terminals
between the two sensor coils, We provide calibration certificates 11 and 12, with a bridge
Figure 5: Dependance of installation perform a zero calibration in (see ‘Calibration’ in the ‘At your from 12 to 13. Check the
factor f on wall distance a service’ section)
air («air set») before installing temperature display versus
1 Conductive pipe
2 Insulating pipe
the sensor. For further the table printed in the
information, refer to the Check of inductive sensors Operating Instructions of your
Operating Instructions of your Testing sending and receiving transmitter.
transmitter. coils: Ohmic resistance should
• Choose immersion depth b be approx. 5 to 7 Ω. To check a transmitter with
of the sensor in the medium and inductivity approx. conductive sensors, please refer
such that the coil body is 260 to 450 mH (at 2 kHz). to your Operating Instructions.
completely immersed (see Shunt between sensor coils is
fig. 6). The pipe has to be not allowed. The measured Our service team can perform such
completely filled with water. resistance should be > 20 MΩ. verifications (see ‘Service contracts’
Gas bubbles will have an Test with ohmmeter between in the ‘At your service’ section)
influence on the displayed red coaxial cable and white
value (avoid installation in an coaxial cable. Instrument and
open falling tube). spare parts availability
Figure 6: Consider the immersion depth Check of transmitter See table below
Operation and Maintenance (inductive sensors)
• Conductivity can be checked If you want to get more information
Maintenance work includes: with standard resistors, e.g. about spare parts availability, please
call our hotline.
• Cleaning of assembly with decade resistors. For
and sensor conductivity simulation, pull
• Cable and connection check a cable through the cleaned Consumables stock
(see ‘pH’ section) sensor opening and check the The calibration solutions must
• Calibration display versus the table be stored in a dry place and
printed in the Operating used within a year.
Cleaning the Instructions of your
conductivity sensors transmitter.
Please clean contamination on
the sensor as follows: carefully
clean with a synthetic brush
and, if needed, with diluted
hydrochloric acid (5 %).
Then rinse carefully with plenty
Your Spare part New
of clear water.
instrument availability generation

Calibration of conductive CLD 130 NO - since 01/2005 CLD 132/134

measurement systems
Three different types CLD 431 YES - until 10/2010 Liquiline CM42
are possible:
• Calibration by measurement CLM 221/252 NO - since 01/2005 CLM 223/253
in a calibration solution with a
known conductivity. Mycom CLM 152 YES - until 06/2011 CLM 153

50 The Endress+Hauser Maintenance Guide

Liquid analysis
List of consumables
Calibration solutions
Precision solutions, traceable to SRM (standard
reference material) by NIST, for qualified calibration of
conductivity measuring systems according to ISO, with
temperature table,
• CLY11-A, 74 μS/cm (reference temperature 25 °C
(77 °F)), 500 ml (16.9 fl.oz), order no. 50081902
• CLY11-B, 149.6 μS/cm (reference temperature 25 °C
(77°F)), 500 ml (16.9 fl.oz), order no. 50081903
• CLY11-C, 1.406 mS/cm (reference temperature
25 °C / 77 °F), 500 ml / 0.13, order no.
• CLY11-D, 12.64 mS/cm (reference temperature
How to select and order then refer to the price lists in 25 °C/ 77 °F), 500 ml / 0.13, order no.
calibration solutions and the insert ‘The Maintenance 50081905
• CLY11-E, 107.0 mS/cm (reference temperature
cables: select the right order Store’ attached to this 25 °C / 77 °F), 500 ml / 0.13, order no.
code from the following list; Maintenance Guide. 50081906

List of accessories
Measuring cables (for conductive sensors)
CONCAL calibration set • CYK71 measuring cable: non-terminated cable for the
connection of sensors (e.g. conductivity sensors) or
Conductivimeter the extension of sensor cables - sold by the meter,
Concal reference tool order numbers:
non-Ex version, black: 50085333
Ex version, blue: 51506616

Measuring cables (for inductive sensors)




• CLK5 measuring cable: Extension cable for

connecting CLS52 and transmitter via the VBM
junction box - sold by the meter, order no. 50085473

Sampling outlet
3m max. Sampling valve


CONCAL is a conductivity calibration set for

ultrapure water applications, factory-calibrated
with certificate, traceable to SRM of NIST and Using CONCAL, our service team can
DKD. CONCAL is suitable for comparative perform the periodic recalibration of
ultrapure conductivity measurement
measurement in ultrapure water applications up
systems. Please contact us.
to 20 μS/cm and temperature < 212°F (100°C).

The Endress+Hauser Maintenance Guide 51

Turbidity measurement
Liquid analysis

Sensors and transmitters

A complete turbidity measuring system comprises:

• an turbidity sensor with a special measuring cable
• a transmitter
• an immersion, flow or retractable assembly

In this section, you will find essential information and advice to obtain the best from
turbidity measuring systems throughout their lifecycle.

Measuring principle

Nephelometric measuring
principle 90° NIR scattered
light according to EN 27027
The 90° scattered light method
with a wavelength in the
near-infrared range (880 nm)
“Be careful when according to ISO 7027 / EN
27027 records turbidity values
cleaning the optics” under standardized, comparable
conditions. A temperature signal
is also recorded and transmitted
in addition to the turbidity
signal. The excitation radiation
of an infrared transmitter (Fig. 2,
Item 1) strikes the medium at a0003125

a defined angle of beam. The Figure 1: Example of a complete 3 Assembly with gas bubble trap
different refractions of light measuring system 4 Liquisys CUM253
between the entrance window 1 Immersion assembly CYA611 5 Liquisys CUM223
2 Retractable assembly CUA451
and the medium (water) are
taken into account.
Particles in the medium (Item 5)
create a scattered radiation
which strikes the scattered • TE/F (Trübungseinheiten 300 g/l). Since the norm
light receivers (Items 3, 4) at Formazin) doesn’t apply any more, you
a defined angle of beam. The 1 FNU = 1 NTU = 1 FTU need to periodically perform
measurement in the medium is = 1 TE/F calibration and adjustment
constantly compared with the Formazine mother solution’s of the measuring system
values of a reference receiver turbidity is 4000 FNU which is with your process water. The
(Item 2). Digital filter functions equivalent to 10000ppm SiO2 3-point calibration is achieved
with excellent interference (1FNU = 2,5 ppm SiO2) after comparison to laboratory
signal suppression and sensor measurements.
self-monitoring ensure additional Note :
measurement reliability. • There is no direct There are two different sensors:
relationship between FNU CUS 31: for drinking water
The standard reference particle and the suspended particles and process water
is formazine (C2H4N2) which is concentration. 0.000 to 9999 FNU
Figure 2: Turbidity measurement carcinogenic and unstable (short • The norm applies up to 0.00 to 3000 ppm
according to ISO 7027 / EN 27027 life time). 10000 FNU; beyond this to 200,0%
A Side view of the sensor
(cutaway scheme)
Various units are used: value, the particles disrupt 0.00 to 3 g/l
1 Infrared transmitter • FNU (Formazine each other and so absorb more
2 Reference diode Nephelometric Unit) than they diffuse. CUS 41: for wastewater
3 Scattered light receiver 1 • NTU (Nephelometric Thanks to a second scattered and sludge
4 Scattered light receiver 2
5 Particles in the medium
Turbidity Unit) light receiver, Endress+Hauser 0.000 to 9999 FNU
B Top view of the sensor surface with • FTU (Formazine Turbidity Unit) sensors cover a much broader 0.00 to 300 g/l
optical windows • JTU (Jackson Turbidity Unit) measuring range (up to 0.0 to 200,0%

52 The Endress+Hauser Maintenance Guide

Liquid analysis
The influences • Two sensor orientations • Other types of soiling:
With water and brush
on turbidity measurement are possible for horizontal

The measurement is altered by: installation (fig. 4): Warning:
• Change of sludge type • parallel to the medium flow • Do not touch the optics with
• Flow variation • against the medium flow sharp-edged objects.
• Do not scratch the optics.
• Presence of air or foam • Orientation parallel to the
bubbles, suspended particles medium flow is required when
deposit using the CUR 3 spray head. Clean the sensor mechanically
• Backscatter (which results • Orientation against the using a soft brush. Then rinse
in a higher signal) due to the medium flow is used to thoroughly with water.
installation of the sensor in increase the self-cleaning
piping or very close to a wall effect in heavily-soiled Calibration and adjustment
• Deposits on the sensor optics media (> 15 FNU). The wall Note: The sensor contains all
Figure 3: Tube implantation
reflection is negligible here the calibration data.
Installation conditions due to the high absorption • In the FNU operating
tendency. mode, the sensor is factory
Pipe installation (see fig. 3) We recommend the CUS 31-xxE calibrated with formazine
• The pipeline diameter must or CUS 31-xxS sensor version traceable to ISO7027.
Figure 4: Installation in flow assemblies
be at least 4” (DN 100) if be used for turbidities < 5 FNU. • In the ppm operating mode, Parallel sensor orientation
reflective materials (e.g. the calibration data records for Sensor orientation against
stainless steel) are used. Operation and Maintenance Kaolin and SiO2 are derived the medium flow

• Install the sensor in places from the FNU data records.

with uniform flow conditions Maintenance work includes: • In the % operating mode, the
and not in places where air • Cleaning of assembly calibration data records are
may collect or foam bubbles and sensor set to the average of various
form or where suspended • Cable and connection check residual concrete waters.
particles may settle. • Calibration They are preset in such a
• The best installation location way that correct values are
is in the ascending pipe. Cleaning the displayed for average clarity. • Recalibration is not
Installation is also possible turbidity sensors However the settings do not required when the
in the horizontal pipe, but Deposits on the sensor optics follow a standard currently transmitter is replaced
should be avoided in the may result in inaccurate applicable. • Customer-specific
down pipe. measurement. Therefore the • In the g/l operating mode recalibration is required,
• Mount the sensor surface sensor must be cleaned at also, the sensor is not however, when the sensor
against the medium flow regular intervals. The intervals calibrated to a fixed value is replaced
(“self-cleaning effect”). are specific to each installation as no standard is directly Three calibration data records are
and must be determined during applicable. You must carry saved in the sensor for each of
Installation operation. Clean the optics with out a calibration because the four main operating modes.
in flow assemblies the following agents depending the media of the various
• If possible, install the flow on the type of soiling: applications differ too When do you need to calibrate?
assembly vertically so that the greatly here. Three-point sensor calibration
medium flows to the sensor • Limestone deposits: is the standard calibration. It is
from below. Alternatively, the Short treatment with commercial The calibration data are saved absolutely essential:
deliming agent in an EEPROM directly in the • When commissioning the
assembly can also be installed • Oily and greasy soiling:
horizontally. Cleaning agents based on
sensor. Therefore: sensor in sludge applications
water-soluble surfactants • Recalibration is not required in • When changing to another
(e.g. household dish detergents) the event of a power failure sludge type

The Endress+Hauser Maintenance Guide 53

Three-point sensor calibration is • Sensor operating voltage is
Liquid analysis
You can send us the sensor and
not necessary: flow assembly for adjustment on o.k. but no measured turbidity
• When commissioning the a calibration bench according to value even with a new sensor.
sensor in the drinking ISO70027. You will be delivered a Replace the transmitter module
quality certificate.
water area (sensor has been MKT1.
calibrated for drinking water
applications in the factory). Installation adjustment Our service team can perform such

Figure 5: Making the samples for a

verifications (see ‘Service contracts’ three-point calibration
• For residual concrete water. In installation adjustment, in the ‘At your service’ section) A Original sample
Density measurement backscatter from the immediate B 1 part sample A + 2 parts water
for determining the sensor environment is C 1 part sample A + 9 parts water
concentration of residual compensated. Installation Instrument and
concrete water is based on adjustment must be performed spare parts availability
%–data records. They are with a medium whose turbidity See table below
preset in such a way that is lower than 2FNU or 5 ppm.
correct values are displayed If you want to get more information
for average clarity. One-point Our service team can perform such about spare parts availability, please
calibration is often sufficient adjustments by means of a reference call our hotline.
tool named TURBICAL.
to adjust the system in the (see ‘Service contracts’ in the
event of deviating values. ‘At your service’ section) How to select and order
• When recalibrating with the accessories: select the right
same sludge type. One-point order code from the list
calibration suffices here if Checking the hereafter; then refer to the
the degrees of lightness and measuring point price lists in the insert ‘The
clarity, for example, do not The sensors CUS31 and CUS41 Maintenance Store’ attached to
differ too greatly. cannot be simulated as they this Maintenance Guide.
contain the complete data
Performing three-point processing and all the measured
calibration (on site) values are transmitted to
You should perform the CUM223/253 using the digital
calibration in the turbidity/ interface RS 485. Therefore a Your Spare part New
solids concentration range in functional sensor is required for instrument availability generation
which you plan to measure. The the measuring point test.
overall calibration characteristic Method for testing a measuring CUM 221/252 NO - since 01/2005 CUM 223/253
of the measuring chain is point:
determined using three samples • Check that device is operable Mycom CUM 151 NO - since 12/2005 CUM 223/253
of known turbidity or known and that the display reacts
solids content. appropriately, e.g. by pressing
Calibration with a very dark, the PLUS key. List of accessories
high-absorption medium returns • Check the current outputs
small slopes while light, clear by carrying out a current Measuring cables
simulation (Field O3(2)). • CYK81 measuring cable: non-terminated measuring cable for extension of sensor
media return big slopes. cables of e.g. Memosens, CUS31/CUS41 - 2 wires, twisted pair with shield and
You can create the requisite • Measure the sensor operating PVC-sheath (2 x 2 x 0.5 mm2 + shield) - sold by the meter, order no. 51502543
probes by diluting a medium voltage: approx. 10 to 16 V at
sample. In general, very good terminals 87 (+) and 88 (–). Other accessories
• The cause for an incorrect • CUY 22 check unit for CUS 31 and CUS 41
calibration results are achieved for checking the stability of the sensor,
with a concentration gradation voltage may be present either order no. 51504477
of 10%, 33% and 100%. The at the device or at the sensor. • CUY 31 service kit 3 spare wiper arms for CUS 31-Wxx: The CUS 31-W sensor is
following condition must be met – Replace the sensor. equipped with a rubber wiper for removing deposits from the sensor carrier plate.
– If the sensor operating The cleaning times and intervals are controlled by means of the transmitter (Liquisys
for the calibration: M CUM 223/253). Order no. 50089252
Sample A > 1.1 x sample B voltage is still too low replace • Calibration kit for CUE 21 Values: 0.02 NTU; 10.0 NTU and 1000 NTU
> 1.1 x sample C (see fig. 5) the power supply module order no. 51518580
LSGA/LSGD (make sure to use • Replacement basin including transducer for ultrasonic cleaning,
the appropriate version). order no. 51518576
• Flow assembly Flowfit CUA250 for CUS31/CUS41
Please contact us

54 The Endress+Hauser Maintenance Guide

Chlorine measurement

Liquid analysis
Sensors and transmitters

A complete chlorine measuring system includes:

• A chlorine sensor
• A transmitter
• A special measuring cable
• A flow assembly
• A reference measuring instrument for determination of free chlorine according to
the DPD method

In this section, you will find essential information and advice to obtain the best from
chlorine measuring systems throughout their lifecycle.

Measuring principle

The concentration of free

chlorine is determined
according to the amperometric
measuring principle. The
hypochlorous acid (HOCl)
contained in the medium
“The measurement diffuses through the sensor
membrane and is reduced to
is strongly influenced chloride ions (Cl-) on the gold
by pH, temperature cathode. On the silver anode,
silver is oxidized to silver
and flow” chloride. The electron release of
the gold cathode and electron
acceptance on the silver anode
result in a current flow which
is proportional to the (active
?) free chlorine concentration
Figure 3: Measuring system in the flow 4 Mounting place for pH/ORP sensors
in the medium under constant mode (example) 5 Chlorine sensor

conditions. The concentration 1 CCA250 flow assembly 6 Medium outlet

of hypochlorous acid in the 2 Medium inlet 7 Sampling tap
medium depends on the pH 3 Inductive proximity switch for flow 8 Fixed measuring cable
monitoring 9 Transmitter
value. On pH fluctuations higher
than ± 0.1 pH, this dependence
has to be compensated by
measuring the pH value in the
flow assembly. CCS141 sensors are used for Installation conditions
The transmitter transforms measurement of active chlorine
the current signal into the or free chlorine (with a pH Installation in flow assembly
measuring unit concentration compensation as an option). CCA 250
in mg/l. To calibrate the measuring The flow assembly CCA
system, determine the content 250 is designed for on-site
Function of free chlorine using the installation of the measuring
The membrane covered DPD method. You need a cell. In addition to the chlorine
CCS140 / CCS141 sensors photometer with the pertaining measuring cell, a pH and ORP
consist of a cathode serving as reagents. The determined value electrode can be installed.
the working electrode and an is the calibration value for the A needle valve regulates the
anode acting as the counter transmitter. flow within the range of 7.9 to
electrode. These electrodes are 31.7 gal/hr (30 to 120 l/hr).
immersed in an electrolyte. The influences
Electrodes and electrolyte are on chlorine measurement If the measured water is fed
separated from the medium by The measurement is influenced back into a surge tank, pipeline
a membrane. The membrane by: or the like, ensure that the
prevents the loss of electrolyte • pH value generated back pressure on the
and the penetration of • flow measuring cell does not exceed
contaminants. The CCS140 and • temperature 14.5 psi (1 bar) and remains

The Endress+Hauser Maintenance Guide 55

constant. Negative pressure the pH value of the measured • Check the measurement at
Liquid analysis

at the measuring cell, e.g. by water. regular intervals, dependent on

feedback of measured water Caution: The DPD method the respective conditions, at
to the suction side of a pump, cannot be applied if organic least once a month.
must be avoided. chlorination agents are used. • Perform recalibration if
In this case it causes a higher required.
Operation and Maintenance measured value compared • If the membrane is visibly
to the actual free active soiled, remove the measuring
Maintenance work at the chlorine value (cf. also note in cell from the flow assembly.
transmitter includes: DIN38408, part 4, section 5). Only clean the membrane
• Calibration mechanically with a gentle
• Cleaning of assembly and Calibration (CCS140/141) water jet or for some minutes
sensor The calibration of a chlorine in 1 to 10% hydrochloric acid
• Cable and connection check measuring unit is performed (observe safety regulations!)
by means of a colorimetric without chemical additives.
Reference measurement comparative measurement Chemicals reducing the surface
according to the according to the DPD method. tension must not be used. • Check the cable with
DPD method DPD no. 1 pills fit for the • Replace a heavily soiled 1000 VDC (at least with
The calibration of the measurement of free chlorine. or damaged membrane (see 500 VDC) testing voltage.
measuring system requires chapter 5.2). • If the cable is intact, the
a colorimetric reference Calibration according to the • Refill the measuring cell with insulation resistance > 100 GΩ.
measurement according pH value electrolyte once per season or • If the cable is defective
to the DPD method. Free When 4 < pH < 6, only active every 12 months. Depending (moist), there is flashover. The
chlorine reacts with diethyl- chlorine exists in water, so the on the chlorine content on cable must be replaced.
p-phenylenediamine(DPD) active chlorine measured value site, this period can be reduced
by producing a red dye, the = the free chlorine measured or extended (procedure see Test and simulation
intensity of the red color being value. According to DPD no. 1 BA058C/07/en chapter 5.3). Chlorine sensors
proportional to the chlorine method, the analyzed water Chlorine sensors work according
concentration. is buffered at a pH value of Maintenance of pH/ORP to the amperometric principle
Simple visual methods using 6.3, thus the measurement is sensors (version EP) and supply very small direct
comparators are inaccurate and independent from the pH and See pH/ORP section current as measuring signals. A
depend on the considerably no compensation is necessary. chlorine sensor can be simulated
varying subjective evaluation by Maintenance pH connecting by a DC source. Due to the
the operator. When 6 < pH < 8, the quantity lines and junction boxes (EP) small currents, however, the
Today, the chlorine of active chlorine (HClO) Check the cables and simulation is highly sensitive.
concentration can be decreases, while the quantity connections for moisture. Lines should be screened and
determined objectively and of hypochlorite (ClO-) ions Moisture is indicated by a the simulator grounded. You will
accurately using low-cost increases. Without any pH sensor slope that is too small. find typical slope values in the
microprocessor photometers compensation, the displayed If no more display is possible table hereafter.
(order code CCM 182). value (active chlorine) would or if the display is fixed at pH7,
be lower than the value please check the following Sensor Typical slope value
An important fact must be kept obtained with the DPD no. 1 components: CCS120 ≈ 115 nA per mg Cl/l
in mind: The DPD method method (free chlorine). • Sensor head
CCS140 ≈ 25 nA per mg Cl/l
is not a selective measuring To display the value free • Sensor connector
method for free chlorine alone, chlorine, a pH compensation is • pH measuring cable CCS141 ≈ 80 nA per mg Cl/l
but other oxidants present necessary if the pH varies. • Junction box, if fitted CCS240 ≈ 100 nA per mg ClO2/l
in the medium can also be To display active chlorine, do • Extension cable CCS241 ≈ 350 nA per mg ClO2/l
registered (see DIN38408, not compensate the pH but
963 ≈ 20 µA per mg Cl/l
part 5, section 4). Moreover, measrue it and use a conversion Caution! If there is moisture in
the measuring range of the table with DPD no. 1 method. the measuring cable, the cable
photometers has a lower must be replaced! Temperature measurement
limit and does not permit Maintenance of chlorine The transmitter uses the NTC
measurements in the very low sensors A shunt in the cable of > 20 MΩ sensor of the chlorine sensor
trace range. In addition to the Corrective maintenance for can no longer be measured to measure the temperature.
chlorinated probe, a sample chlorine sensors and assemblies with normal multimeters Due to the relatively high
of the medium without added is described in the operating but is damaging for the pH sensor resistance, a two-
chlorine should be checked by instructions. Use and refer measurement. A reliable test wire connection is sufficient.
a DPD measurement if possible. to the operating instructions can be carried out with a usual Simulation can take place with
The measured value must lie relating to your measuring commercial insulation meter: a normal decade resistor. The
near zero and differ significantly system: • Make sure to disconnect the following table contains some
from the chlorinated sample. pH measuring cable from the simulation values.
CCS120 BA388C/07/en
CCS140/141 BA058C/07/en
sensor and device!
The measured water is always CCS240/241 BA114C/07/en • If you are using a junction
buffered to a pH value of 6.3 963 BA039C/07/en box, check the infeed and
with the DPD method, so the outfeed measuring cable
measurement is independent of Routine check for CCS140/141 separately.

56 The Endress+Hauser Maintenance Guide

Liquid analysis
Temperature NTC simulation Instrument and
value spare parts availability
32°F/0°C 29.490 kΩ
Your Spare part New
50°F/10°C 18.787 kΩ
instrument availability generation
68°F/20°C 12.268 kΩ
77°F/25°C 10.000 kΩ CCM 221/252 NO - since 01/2005 CCM 223/253
86°F/30°C 8.197 kΩ
104°F/40°C 5.594 kΩ
If you want to get more information
about spare parts availability, please
pH/ORP measurement call our hotline.
Simulation takes place with a
pH/mV simulator or an mV
voltage source. How to select and order List of consumables
(see pH/ORP section) accessories: select the right
For measurement of chlorine CCS140 and CCS141
order code from the following
• Set of 2 remplacement cartridges CCY14-WP, order no 50005255
Flow monitoring list; then refer to the price lists • Electrolyte (50 ml) CCY14-F, order no 50005256
Use and refer to the operating in the insert ‘The Maintenance
instructions relating to your Store’ attached to this For measurement of total chlorine CCS120
measuring system. Maintenance Guide. • Electrolyte (50 ml), order no 51516343
• Kit containing 2 membranes and electrolyte (50 ml), order no 51517284

Our service team can perform such

verifications (see ‘Service contracts’
List of accessories
in the ‘At your service’ section)
Calibration accessories
• Photometer CCM182; microprocessor-controlled photometer for chlorine, pH value,
cyanuric acid; Chlorine measuring range: 0.05 to 6 mg/l
pH measuring range: 6.5 to 8.4

Measuring cables
• CMK measuring cable: cable for the CCS 140, 141, 240 and 241, order no. CMK
• CYK71 measuring cable: non-terminated cable for the connection of sensors
(e.g. conductivity sensors) or the extension of sensor cables -sold by the meter, order
non-Ex version, black: 50085333
Ex version, blue: 51506616

The Endress+Hauser Maintenance Guide 57

Oxygen measurement
Liquid analysis

Sensors and transmitters for dissolved oxygen

There are four variations of measuring systems:

• The transmitter Liquisys M COM223 or COM253 – DX or DS with oxygen sensor COS41
• The transmitter Liquisys M COM223 or COM253 – WX or WS with oxygen sensor COS31,
COS61 or COS71
• The transmitter Liquisys M COM223 or COM253 – HX or HS with oxygen sensor COS21
• The transmitter Liquiline CM42 with oxygen sensor COS21D
Each of them can include an immersion, flow or retractable assembly.
In this section, you will find essential information and advice to obtain the best from oxygen
measuring systems throughout their lifecycle.

Measuring principle

Amperometric principle
The oxygen molecules diffused
through the membrane are
reduced to hydroxide ions
(OH-) at the cathode. Silver is
oxidized to silver ions (Ag+) at
“Periodically clean and the anode (this forms a silver
bromide layer, AgBr).
check the system.” A current flows due to the
connected electrode release at
the cathode and accepted at the
anode. In equilibrium, this flow
is proportional to the oxygen
content of the medium.
This current is converted in
the measuring instrument and
Figure 2: Sensor head - C07-COS41xxx-16-05-07-xx-001.eps indicated on the display as an
Amperometric principle oxygen concentration in mg/l, Figure 1: Examples of complete 4 Weather protection cover CYY101

1 Thread for protection guard as a saturation index in % SAT measuring systems 5 Liquisys M COM253 transmitter
2 Sealing ring 1 Oxygen sensor 6 Liquisys M COM223 transmitter
or as an oxygen partial pressure 2 Immersion assembly CYA611 7 Retractable assembly COA451
3 Thread for membrane cap
4 Electrolyte in hPa. 3 Universal hanging assembly holder
5 Gold cathode CYH101
6 Membrane
7 Membrane cap
Fluorescence quenching
8 Anode
• Sensor design: • Measuring process: • Measurement result:
– Oxygen-sensitive molecules – The sensor optics send – The sensor returns a signal
(markers) are integrated green light pulses to the that is in proportion to the
in an optically active layer fluorescence layer. oxygen concentration in the
(fluorescence layer). – The markers «answer» medium.
– The surface of the (fluoresce) with red light – The fluid temperature and
fluorescence layer is in pulses. air pressure are already
contact with the medium. – The duration and intensity of calculated in the sensor.
– The sensor optics are directed the response signals is directly
at the underside of the dependent on the oxygen
fluorescence layer. contents and the partial
•There is an equilibrium pressure.

Figure 3: Sensor design -

Optical principle between the oxygen partial – If the medium is free from
1 Sensor cable
2 Sensor shaft
pressure in the medium and oxygen, the response signals
3 O-ring that in the fluorescence layer: are long and very intense.
4 Protection guard – If the sensor is immersed in – Oxygen molecules «quench»
5 Threaded connection the medium, the equilibrium the marker molecules. As a
6 Detector
7 Emitter diode
is established very quickly. result, the response signals
8 Fluorescence cap are shorter and less intense.

58 The Endress+Hauser Maintenance Guide

Liquid analysis
Operation and Maintenance Calibration and adjustment Calibration and adjustment The following methods help
To access the ‘Calibration’ in air you determine how long the
Maintenance work includes: function group, press the CAL 1. Remove the sensor from the calibration intervals should be:
• Cleaning of assembly key on your transmitter. This medium. 1. Check the sensor one month
and sensor function group is used to calibrate 2. Clean the outside of the after being put into operation
• Cable and connection check and adjust the measuring point. sensor with a damp cloth. Then by taking it out of the fluid,
• Calibration and adjustment The sensor is calibrated in air or dry the sensor membrane e.g. by drying it and then measuring the
in the medium. using a tissue. oxygen saturation index at air
Cleaning the sensor Note! 3. If the sensor is removed from after 10 minutes.
To ensure reliable measurement, • At first start-up, sensor a closed pressure system with a Decide using the results:
the sensor must be cleaned at calibration of amperometric process pressure greater than a. If the measured value is not at
regular intervals. sensors is absolutely required atmospheric pressure: 102% SAT (for an amperometric
Depending on the type of in order for the measuring – Open the membrane cap to system) or not at 100.6% SAT
soiling, proceed as follows: system to be able to generate equilibrate the pressure and (for an optical system), you have
accurate measuring values. clean the cap if necessary. to calibrate the sensor.
• Salt deposits
Immerse the sensor in drinking water
• The optical oxygen sensor – Replace the electrolyte filling b. Otherwise, double the length
or in 1-5% hydrochloric acid for a few COS61 does not need a and close the membrane cap of time to the next inspection.
minutes. Afterwards, rinse it well with calibration at first start-up. again. 2. Proceed as per Point 1 after
plenty of water. – Wait for the polarization time two, four and/or eight months.
• Dirt particles on the sensor body
(not on the membrane!)
Calibration and adjustment to end. In this way, you can determine
Clean the sensor body mechanically of amperometric systems 4. Then wait while the sensor the optimum calibration interval
with water and a suitable brush. Calibration is a means of adjusts to the temperature of for your sensor.
• Dirt particles on the membrane cap adapting the transmitter to the ambient air. This takes about
or the membrane
Clean the membrane with water and a
the characteristic values of the 20 minutes. Check that the Calibration and adjustment
soft sponge. sensor. As no zero calibration is sensor is not in direct sunlight of optical systems
After cleaning, rinse the sensor well required for the sensor, a single- during this time. Calibration is a means of
with plenty of clean water. point calibration is carried out in 5. If the measured value display adapting the transmitter to
the presence of oxygen. on the transmitter is stable, carry the characteristic values of
Cleaning the optics The sensor requires out the calibration in accordance the sensor. Normally, sensor
The optics only need to calibration after: with the Operating Instructions calibration is seldom necessary.
be cleaned if medium has • first commissioning of the transmitter. It is necessary after changing the
penetrated through a defective • replacing a membrane or 6. Place the sensor in the fluorescence cap.
fluorescence cap. electrolyte medium again.
To clean it, proceed as follows: • cleaning the cathode The slope calibration of
1. Unscrew the protection guard • long breaks in operation Note: Calibration and the oxygen sensor COS61
and fluorescence cap from the without power supply adjustment in air is only will be performed in air or
sensor head. • typical time intervals dependent possible if air temperature in air saturated water. The
2. Carefully clean the optical on operating experience ≥ 23°F (– 5°C). Make sure you calibration of the zero point
surface with a soft cloth until comply with the instructions will be performed in nitrogen
the buildup is fully removed. Three different types of for calibration in the Operating or in oxygen-free water (water
3. Clean the optics with calibration are possible: Instructions of the transmitter. enriched with zero solution).
drinking or distilled water. • Calibration in water.
4. Clean the optics and screw on • Calibration in air The calibration intervals depend The sensor identifies unassisted
a new fluorescence cap. • Calibration by comparison to a heavily on: the slope calibration
Caution! The optical surface reference device • The application and (75 to 140%SAT) and the
may not be scratched or Calibration in air is the easiest • The installation position of the calibration of the zero point
damaged in any way! method of calibration. sensor. (0 to 10%SAT). No further

The Endress+Hauser Maintenance Guide 59

selection is necessary. These Simple check of the
Liquid analysis

limits are valid for the three zero point

types of calibration ‘air’, ‘water’ Place the sensor in a recipient
and ‘ref’. which can be hermetically
Maintenance intervals Add fresh water and sodium
Amperometric sensor: bisulphite (Na2SO3) as powder
suggested maintenance (‘zero calibration solution’, order
intervals* number 50001041)

Weekly: clean the sensor. Close hermetically and let the
Monthly: calibration in air. powder dissolve for 1 to 2 hours.
Annually: clean the gold The measured value should be
cathode with specific abrasive at 0.3% SAT (current is < 1 nA).
paper and change the electrolyte
the membrane, and the O-ring. Our service team can perform such
verifications (see ‘Service contracts’

in the ‘At your service’ section) Figure 4: Changing the electrolyte and the membrane (Amperometric sensors)
Optical sensor: suggested
maintenance intervals*
Weekly: clean the sensor. Spare parts stock Your Spare part New
Annually: change the sensor Amperometric system: instrument availability generation
cap and the O-ring and We recommend to keep
membranes and electrolyte COM 220/240 NO - since 01/2005 COM 223/253 WX/WS
calibrate in air.
filling on stock. COM 221/252 NO - since 01/2005 COM 223/253 DX/DS
* intervals may differ according to Optical system:
the application
We recommend to keep a sensor COM 121/151 NO - since 01/2005 COM 223/253 WX/WS
cap on stock.
Changing the electrolyte
and the membrane Instrument and
(Amperometric sensors) List of accessories
spare parts availability
See fig. 4 and the list of See right table Measuring cables for sensors COS21D
consumables. • Cable for COS21D; length: 5 m - order no. CYK10-A051;
If you want to get more information length: 10 m - order no. CYK10-A101
Simple check of the about spare parts availability, please Measuring cables for sensors COS21
• COK21; length: 3 m - order no. 51505870; length: 10 m - order no. 51505868
measuring function call our hotline.
Measuring cables for sensors COS31 and COS71 with TOP 68 connector
1. Remove the sensor from the • COK31; length: 1.5 m (4.92 ft) - order no. 51506820; length: 7 m (22.97 ft) - order
medium. How to select and order no. 51506821; length: 15 m (49.22 ft) - order no. 51506822
2. Clean and dry the membrane. accessories: select the right
3. After about 10 minutes, List of consumables
order code from the list
measure the oxygen saturation hereafter; then refer to the For measurement of dissolved oxygen COS3, COS4
index in air (without price lists in the insert ‘The • COY3-WP Set of 2 cartridges with pretensioned membrane, order no. 50053348
recalibration). Maintenance Store’ attached to • COY3-F Electrolyte filling (10 doses of 5 ml), order no. 50053349
4. The measured value should this Maintenance Guide.
• COY3-TR Trapezoidal seal (supplied in packs of 3), order no. 50080252
For measurement of dissolved oxygen Oxymax-H COS21, COS21D
be at
• Electrolyte for COS21D,version COS21D-A, order no. 51505873
• 102% SAT for an version COS21D-B, order no 51518701, version COS21D-C, order no. 51518703
amperometric system • Electrolyte for COS21, order no. 51505873
• 100.6% SAT for an optical For measurement of dissolved oxygen Oxymax-W COS31, COS41
• COY31-WP Set of 2 cartridges - std response, order no. 51506976
• COY31S-WP Set of 2 cartridges - fast response, order no. 51506977
• COY31-OR Sealing ring (supplied in packs of 3), order no. 51506985
• COY31-PF Polishing foil (supplied in packs of 6), order no. 51506973
• Zero calibration solution, order no. 50001041
• COY31-Z Accessory kit - standard response (containing 1 x COY3-F, 1 x COY31S-WP,
1 x COY3-OR and 1 x COY31-PF), order no. 51506784
• COY3-S-Z Accessory kit - fast response (containing 1 x COY3-F, 1 x COY31-WP,
1 x COY3-OR and 1 x COY31-PF), order no. 51506785
For oxygen measurement with optical sensor COS61
• Sensor cap, order no. 51518598
• Set of 2 sealing rings, order no. 51518597

60 The Endress+Hauser Maintenance Guide

Online analyzers

Liquid analysis
The current Endress+Hauser range of analyzers includes:
• The Stamolys range of colorimetric analyzers for ammonium, iron, manganese,
chlorine, silica, etc.
• The Stamosens range of UV analyzers
• The STIP analyzers for BOD (biological oxygen demand), TOC (total organic
carbon), COD (chemical oxygen demand), toxicity and multiparameter UV
In this section, you will find essential information and advice that will help you
to perform the optimum follow-up of your Stamolys analyzers throughout their

measuring principle

Light is shone through the

aqueous sample. The light
intensity is attenuated by the
coloration of the constituent
substances. Every substance
“Periodic maintenance has a characteristic coloration.
The more there is of this
is essential.” substance in the water, the
more these light beams
are attenuated. Detectors
measure the attenuation of
light at a coloration typical for
this substance. A reference
measurement (sample without
chemicals) is performed
before every measurement
so that interferences caused
by inherent color, turbidity
or contamination can be
compensated for. The

Figure 1: Typical Stamolys analyzer 7 Dosage loop (with CA71SI only)

concentration of the substance (housing version, without hoses) 8 Valve V2
is ascertained using this 1 Reagents pump, inlet from canister 9 Sample resp.reagents mix outlet(left
information. 2 Display or right acc. to version)
3 Serial interface RS 232 10 Valve V1
4 Photometer optical cell 11 Channel switch
When using colorimetric 5 Static mixer (acc. to version) 12 Sample pump
analyzers, a reagent is added to 6 Valve V4 (version with sample outlet
Figure 2: Photometry measuring the water sample to chemically rightside only)
“dye” the substance that is to
be analyzed.
is proportional to the takes place within a short
Stamolys analyzers design concentration of the specified period of time.
After sample conditioning, the parameter in the sample.
analyzer sample pump conveys Additionally, the absorption of Installation conditions
a part of the filtrate to a mixing a reference light is determined
vessel. The reagent pump adds to receive a genuine measuring • Ambient temperature :
reagent at a specific ratio. As result. The reference signal is 41 to 104°F (5 to 40°C)
a result of the reaction, the substracted from the measuring • Below the condensation limit,
sample turns a characteristic signal to prevent any effects due the device must be installed
color. The photometer to turbidity, contamination and in usual, clean rooms
Figure 3: Stamolys analyzers design determines the sample’s aging of the LEDs. • The device is IP43 and must be
1 Reference LED absorption of an emitted light at The temperature in the protected from rain and frost.
2 Emitter LED
3 Sample
a specific wavelength. photometer is controlled • Outdoor installation is only
4 Reference detector The wavelength is parameter automatically so that the possible with protective
5 Measuring detector specific. The absorbance reaction is reproducible and devices (customer supplied)

The Endress+Hauser Maintenance Guide 61

Operation and Maintenance
Liquid analysis
Sample pump Reagents pump

Maintenance intervals Photometer

See table below. Valves

All maintenance duties that
have to be carried out during
normal operation of the

Reagent 1

Reagent 2

Reagent 3

analyzer are explained below
(intervals may differ according
to the application). Outlet

Period of time Duty Who?

weekly • Check and note User
calibration factor (for
service purposes) Instrument and How to select and order
• Move valve hoses into spare parts availability reagents and other
their position and spray See table below. consumables:
with silicone (extends Select the right order code from
the service life). the following list; then refer to
If you want to get more information
monthly • Flush the sample tubing User about spare parts availability, please the price lists in the insert ‘The
system with 12.5% call our hotline. Maintenance Store’ attached to
bleaching lye (sodium this Maintenance Guide.
hypochlorite) and reflush
thoroughly with water
Your Spare part New
• Replace reagents and
instrument availability generation
standard solutions, if
required CA70?? YES - since 0x/200x CA71?
• Clean the sample
collector CA70?? YES - since 0x/200x CA71?
every 3 months (in addition to all the User
actions described above)
• Spray pump hoses with List of consumables and reagents (Stamolys range)
silicone spray (order no.
51504155) for CA70/71AM (ammonium)
• for CA70/71AM (ammonium)
• Replace pump hoses
Active reagent set A1+A2, 1 l each - order no. CAY140-V10AAE
• Check manually the Inactive reagent set A1+A2, 1 l each - order no. CAY140-V10AAH
different parts (pump, Cleaning solution, 1 l - order no. CAY141-V10AAE
etc.) Standard sol. 5 mg/l NH4-N, 1 l - order no. CAY142-V10C05AAE
Standard sol. 10 mg/l NH4-N, 1 l - order no. CAY142-V10C10AAE
every 6 months (in addition to all the User or Standard sol. 15 mg/l NH4-N, 1 l - order no. CAY142-V10C15AAE
actions described above) Endress+Hauser Standard sol. 20 mg/l NH4-N, 1 l - order no. CAY142-V10C20AAE
Standard sol. 30 mg/l NH4-N, 1 l - order no. CAY142-V10C30AAE
• Replace all hoses and ‘T’ service in the
Standard sol. 50 mg/l NH4-N, 1 l - order no. CAY142-V10C50AAE
connectors scope of a service Maintenance kit CAV740 - order no. CAV740-2A
contract Standards under 5 mg/l not available, because of the low stability

annually (in addition to all the Endress+Hauser for CA70/71PH (phosphate) - standard documents, ready to use
actions described above) service in the Active reagent set P1 + P2, 1 l each (A) - order no. CAY240-V10AAE
• Replace the static mixer scope of a service Inactive reagent set P1 + P2, 1 l each (A) - order no. CAY240-V10AAH
Active reagent set P1 + P2, 1 l each (B) - order no. CAY243-V10AAE
(order no. 51512101) contract
Cleaning solution, 1 l (A) - order no. CAY241-V10AAE
• Replace the photometer Standard sol. 1 mg/l PO4-P, 1 l (A) - order no. CAY242-V10C01AAE
optical cell (if necessary) Standard sol. 1,5mg/l PO4-P ,1 l (A) - order no. CAY242-V10C03AAE
(order no. 51505778) Standard sol. 2 mg/l PO4-P, 1 l (A) - order no. CAY242-V10C02AAE
Standard sol. 5 mg/l PO4-P, 1 l (B) - order no. CAY242-V10C05AAE
Standard sol. 10 mg/l PO4-P, 1 l (B) - order no. CAY242-V10C10AAE
Standard sol. 15 mg/l PO4-P, 1 l (B) - order no. CAY242-V10C15AAE
For the annual inspection, Calibration
Standard sol. 20 mg/l PO4-P, 1 l (B) - order no. CAY242-V10C20AAE
please provide the maintenance Please refer to the Operating Standard sol. 25 mg/l PO4-P, 1 l (B) - order no. CAY242-V10C25AAE
kit relating to your analyzer Instructions relating to your Standard sol. 30 mg/l PO4-P, 1 l (B) - order no. CAY242-V10C30AAE
(order no. CAV740-xxx, see the Stamolys analyser. Standard sol. 40 mg/l PO4-P, 1 l (B) - order no. CAY242-V10C40AAE
Standard sol. 50 mg/l PO4-P, 1 l (B) - order no. CAY242-V10C50AAE
following list) and also a can of
Maintenance kit CAV740 - order no. CAV740-1A
demineralized water. (A) = for CA70PH-A, (B) = for CA70PH-B

for CA70/71NO (nitrite)

Reagent, 1 l - order no. CAY343-V10AAE
Cleaning solution, 1 l - order no. CAY344-V10AAE
Standard sol. 250 mg/l NO2-N, 0,5 l (821,5 mg/l NO2)
- order no. CAY345-V05C25AAE
Maintenance kit CAV740 - order no. CAV740-1A

62 The Endress+Hauser Maintenance Guide

Liquid analysis
for CA70/71CR (chromate) for CA70/71CU (copper)
Reagent set CR1+CR2, 1 l each - order no. CAY846-V10AAE Reagent set CU1+CU2, 1 l each - order no. CAY850-V10AAE
Standard sol. 1,00 mg/l CrVI, 1 l - order no. CAY848-V10C10AAE Standard sol. 1.00 mg/l Cu, 1 l - order no. CAY852-V10C10AAE
Standard sol. 2,00 mg/l CrVI, 1 l - order no. CAY848-V10C20AAE Standard sol. 2.00 mg/l Cu, 1 l - order no. CAY852-V10C20AAE
Maintenance kit CAV740 - order no. CAV740-1A Maintenance kit CAV740 - order no. CAV740-1A

for CA70/71SI (silicate) for CA70/71HA (hardness)

Reagent set SI1+SI2+SI3, 1 l each - order no. CAY640-V10AAE Reagent set HA1+HA2, 1 l each - order no. CAY743-V10AAE
Cleaning solution, 1 l - order no. CAY641-V10AAE Standard sol. 10 mg/l CaCO3, 1 l - order no. CAY745-V10C10AAE
Standard sol. 500 ppb, 1 l - order no. CAY642-V10C50AAE Standard sol. 20 mg/l CaCO3, 1 l - order no. CAY745-V10C20AAE
Maintenance kit CAV740 - order no. CAV740-4A Standard sol. 50 mg/l CaCO3, 1 l - order no. CAY745-V10C50AAE
Maintenance kit CAV740 - order no. CAV740-2A
for CA70/71AL (aluminium) - standard documents, ready to use
Active reagent set AL1+AL2+AL3, 1 l each - order no. CAY940-V10AAE for CA70/71CL (chlorine)
Standard sol.100 µg/l Al, 1 l - order no. CAY942-V10C10AAE Reagent set CL1+CL2 (free), 1 l each - order no. CAY543-V10AAE
Standard sol. 250 µg/l Al, 1 l - order no. CAY942-V10C25AAE Reagent set CL1+CL2 (total), 1 l each - order no. CAY546-V10AAE
Standard sol. 500 µg/l Al, 1 l - order no. CAY942-V10C50AAE Cleaning solution, 1 l - order no. CAY544-V10AAE
Maintenance kit CAV740 - order no. CAV740-1A Maintenance kit CAV740 - order no. CAV740-1A
Maintenance kit CAV740 - order no. CAV740-4A
for CA70/71FE (iron)
Reagent set FE1, 1 l - order no. CAY840-V10AAE for the maintenance
Standard sol. 500 µg/l Fe, 1 l - order no. CAY842-V10C05AAE Silicon spray - order no. 51504155
Standard sol. 2 mg/l Fe, 1 l - order no. CAY842-V10C20AAE
Maintenance kit CAV740 - order no. CAV740-1A for other analyzers
Filter element for CAT430/431 - order no. 51509236
for CA70/71MN (manganese) Hose set for CAT430 - order no. 51509225
Reagent set MN1+MN2+MN3, 1 l each - order no. CAY843-V10AAE Filter membrane (2 pcs.) for CAT411 - order no. 51511288
Cleaning solution, 1 l - order no. CAY844-V10AAE
Standard solution 100 µg/l Mn, 1 l - order no. CAY845-V10C10AAE For STIP analyzers: see ‘the Maintenance Store’.
Standard solution 500 µg/l Mn, 1 l - order no. CAY845-V10C50AAE
Maintenance kit CAV740 - order no. CAV740-1A

The Endress+Hauser Maintenance Guide 63

Water samplers
Liquid analysis

The current Endress+Hauser range includes:

• The stationary water sampler ASP Station 2000
• The portable water sampler Liquiport 2000

In this section, you will find essential information and advice to obtain the best from these
devices throughout their lifecycle.

Measuring principle Hydraulic connection Liquiport 2000 ASP Station 2000

Maximum suction height 19.7 ft/6 m 19.7 ft./6 m
The ASP station 2000 is a (optional: 26.2 ft/8 m) (optional: 26.2 ft/8 m)
stationary sampler for fully
Maximum hose length 98.4 ft. (30 m) 98.4 ft (30 m)
automated sampling, defined
distribution and thermostatic Hose connection 0.39 in. (10 mm) 0.51”, 0.63” or 0.75”
diameter (13 mm, 16 mm or 19 mm)
storage of liquid media. The
internal diameter
Liquiport 2000 is a portable
Suction velocity > 1.64 ft/s (0.5 m/s), > 1.64 ft/s (0.5 m/s),
“Keep wear parts device.
to EN 25667 to EN 25667
on stock” Sampling mode (see fig. 1) Table 1
The timer function enables
sampling at defined times.
Quantity or flow proportional 01:15 04°C 30.05.02
sampling is available. A sample unit off
sequence can also be initiated
by an external signal, for
on Switch unit on with ON.
Q example on an alarm limit set
1 point. man aut on ..-> Using the right push button change to SET.
t 1 Flow curve Select SET.
<-.. set rep stat
Q 2 Time proportional:
2 In SETUP select QUICK-SETUP using the
A constant sample volume is Setup right hand push button.
t taken in constant time spans Quick-Setup
Q 3 Quantity proportional: Basic Settings
A constant sample volume is Program Selection Quick-Setup
Creating Programmes date 14.05.02
t taken in variable time spans time 15:15 none
4 4 Flow proportional: Esc <-' program 1

Variable sample volumes are Select one of the 4 main program 2...
Figure 1: Sampling mode taken in constant time spans. ===SAMPLING:=== time
Select sample mode. time quantity
time 00:10
Installation conditions Select the required distribution flow
mode. The bottle change is done
dependent on time, number of time
When mounting the device, samples taken or by an active time
please observe the following external signal time 24:00 ext.sig.

points : Enter the number and volume of 1

the bottles. bottle 4*12l 4*12l
• Position the device on a level 12l 4*20l...
surface. Enter start time. When selecting
• Protect the device against the AUT function the programme
starts immediately once the AUT start aut-button
additional heat (e.g. radiators push button has been operated. time
or sun). stop prog.end
• Protect the device against Enter STOP mode: time
mechanical vibration. ===START PROGR.===
• Protect the device against Start programme start! : aut
strong magnetic fields Esc <-'

Hydraulic connection Figure 2: Quick Setup of ASP Station 2000

See table 1.

64 The Endress+Hauser Maintenance Guide

Liquid analysis
Check of the suction
pressure (<-0.6 bar) by
means of a manometer
(left picture).

Check of the sampling

volume repeatability
(bottom right picture)


Special suitcase equipped

for sampler control 6

Sampling point 4
we recommend a stainless steel Table 2: Maintenance intervals
• Do not connect the sampling cleaner. For any parts conveying
hose to pressurized systems media, use water or soap.
• Fit a filter if the medium Thorough, regular cleaning of 5 1
contains large and abrasive the parts which convey media is
solids essential for reliable operation.
• Always install the hose in the You can mount and disassemble
flow direction all the parts which convey media
• Always choose a representative easily and without tools. (Please
sampling point (turbulent flow; refer to the Operating Instructions
not at the channel base) related to your device).
• Thorough, regular cleaning of
Specific installation conditions the dosing unit is essential for
for ASP Station 2000 reliable operation
Period of time Part to be changed
• Ensure that air can circulate • The sample compartment has
unhindered at the back of a permeable inner plastic shell. Every 6 months • The dosing 1chamber Acryl (6)
the cabinet. Do not position Once you have removed the (order no. 50072149)
the device directly against a bottle trays, the distribution Every year • The seal set for dosing system (5)
wall (the distance between pan and the tap (open the (order no. 50079747)
the wall and the rear side of connector of the distribution • The membrane hose clamp (4)
the cabinet should be at least drive), you can clean the (order no. 51002657)
3.94 in/100 mm) whole sample compartment • The air filter (3) (order no. 50086064)
• Do not position the cabinet easily using a water hose.
directly above the inflow • Depending on the ambient Every 2 years • The air manager (2) (order no. 51003139)*
channel to the wastewater conditions (e.g. high level of • The seals of the vacuum pump (1)
treatment plant (sulphurous dust formation), you should (order no. 51003140)
vapors!). purge the ventilator and the * It is recommended to have this done by our field service engineers.
liquifier with compressed air
Commissioning at regular intervals.

A quick setup menu gives Maintenance intervals is recommended to check it To carry out this check in
access to a short procedure to See table 2. In addition to this, periodically (twice a year is a optimal conditions, you need
configure the device (see fig. 2). • The lid should be checked minimum). In order to comply several tools like a thermometer,
Thanks to PC interface RS232, for leakage and cleaned every to ISO 5667-10, you have a chronometer, a manometer
it is especially easy to configure 6 months. to prove three criteria: and measuring glasses.
the ASP station 2000 (as well • The conductivity probes have • The cooling temperature
as other Endress+Hauser to be checked for corrosion inside the sampler is kept at a All these operations can be part of
instruments) with the PC once a year. max of 39.2°F (4°C). a maintenance contract where our
software ReadWin® 2000. Note: these are average figures • The suction air flowrate skilled technical engineers deliver
specific certificates which prove your
and should be adapted to your should be higher than sampler’s compliance to the local
Operation and Maintenance application. 1.64 ft/s (0.5 m/s). This can authorities (see ‘Service contracts’
See also the FAQs on next page. be controlled by means of in the ‘At your service’ section)
Cleaning a manometer (<-8.7 psi/
Use only a safe cleaning agent Simple checks 0.6 bar). If this is not reached,
which will not damage the for your sampler see FAQ. Corrective maintenance
mechanical and electrical As a sampler has a lot of • The sampling volume See ‘Frequently asked questions’.
equipment. For the cabinet body, moving mechanical parts, it repeatability is ± 5 %.

The Endress+Hauser Maintenance Guide 65

Spare parts stock How to select and order the
Frequently asked questions
Liquid analysis

Several parts of the sampler main spare parts:

have to be considered as wear select the right order code from
parts and thus should be kept the list hereafter; then refer to
in stock (see ‘Maintenance the price lists in the insert ‘The When do I have to calibrate the distribution tap?
intervals’). Maintenance Store’ attached to • when the tap motor was replaced
this Maintenance Guide. • when the error message ‘tap calibration’ appears in the display.
Instrument and
spare parts availability Migration How to calibrate the distribution tap?
See right table.
The spare parts for several 1 Switch the device on
If you want to get more information instruments will no longer 2 Under ‘SET/SERVICE/CALIBRA-
about spare parts availability, please be available after October TION’, select the item ‘DIST.TAB’
call our hotline.
2008 (see table). Reminder: 3 When you select ‘START’, the tap
ASP Station 2000 meets the turns and stops just before the
actual regulatory requirements! calibration position
A new generation will be 4 At the controller, keep selecting
launched in 2009. ‘1step’ until the arrow on the
front side of the tap is located
exactly in the notch in the middle
of the distribution pan (point A).
Your Spare part New
In the picklist, select the menu
instrument availability generation
option ‘SAVE’.
ASP 9260 NO Liqui-Box A2 5 The tap is calibrated.

ASP 9461 NO Liqui-Port 2000

ASP 9461 D NO Liqui-Port 2000

ASP 9465 NO ASP-Stat. 2000

ASP 9465 D NO ASP-Stat. 2000

ASP 9565 NO ASP-Stat. 2000

Liqui Box D YES - until 10.2012 Liqui Box D2

Liqui Box A YES - until 10.2012 Liqui Box A2

Then quit all sub menus (press ‘ESC’)
Liqui Compact A/A2 YES - until 10.2012 Liqui-Port 2000 and come back to the main menu.
Press ‘AUTO’ and check that the
ASP Port A/A2 YES - until 10.2012 Liqui-Port 2000
tap goes to the right position.
ASP Port D/D2 YES - until 10.2012 Liqui-Port 2000 Otherwise, try the procedure again.
After the second try, replace the tap
ASP-Station A/A2 YES - until 10.2012 ASP-Stat. 2000 motor.

ASP-Station D/D2 YES - until 10.2012 ASP-Stat. 2000

Figure 3

List of the main spare parts

• Vacuum pump
single head / KNF023, order no. RPS20X-PC
double head / KNF023.1, order no. RPS20X-PE
• Seals set
for KNF023, order no. 51003140
(You need two sets for KNF023.1)
• Dosing chamber, Acryl 200 ml, order no. 50072149
• Flange with dosing tube 200 ml, order no. 50090342
• Silicon hose, for distribution 15 x 2, l = 1 m, order no. 50031916
• Dosing bracket cpl., including hose clamp, order no. RPS20X-DA
• Membrane, order no. 51002657
• Air filter, order no. 50086064
• Air manager, order no. 51003139
• Seal set for dosing system, order no. 50079747
• Tap drive, order no. 51003682
• Dosing system, 200 ml, order no. RPS20X-DC
• LF probe, order no. RPS20X-DD
• Pneumatic hoses, order no. RPS20X-PA
• Controller/CPU ASP 2000, 1 programme, order no. RPS20X-1CA

66 The Endress+Hauser Maintenance Guide

‘ERROR : AIR MANAGER’ try again by adding a second ‘blow out’ phase. Moreover each

Liquid analysis
Replace the air manager. If the error remains, test by exchanging sampling sequence duration can be adjusted manually.
the mainboard RPS20X-GA (version without RS485), or RPS20X- Modification:
GB (version with RS485) and/or the connection cable distribution SET/BASIC SETTINGS/SAMPLING/DOSING/
tap drive (order no. RPS20X-VC) WITH PRESSURE.
‘ERROR : Conductivity 2’ • If the sampling point is under pressure, the sampler needs to be
There are three conductivity probes in the dosing funnel lid. During modified. Please contact our sales department.
the suction process, the sample liquid first reaches the longer • The sampled medium contains much foam or grease, or its
conductivity probes (item A and B). In this way, the filling of the conductivity is lower than 30 µS/cm, the sampler needs to be
dosing funnel is detected and the suction process is stopped. If the modified. Please contact our sales department.
conductivity probes 1 (item A and B) fail, safety switch off takes place • Ask our field service for a complete check.
by means of the shorter conductivity probe 2 (item C).

Contact on probe 2 may be due to:

• condensation or dirt on the probes contacts Trouble with the cooling system
• a connection default Unscrew the display circuit board to access to the mainboard.

Anyway, the first step consists of X1 X2 X3 X4 X5 X7 X8 • Check the fuses:

cleaning the dosing system F1 (circuit board) = 630 mAT
• Clean the flange on both sides. (slow blow)
If the probes are too oxidized, F2 (pump) = 3.15 AT
exchange the flange (order no. (slow blow)
50090342) F3 (compressor) = 6.3 AT
• Clean, if necessary exchange the (slow blow)
dosing tube (order no. 50042898) F4 (heating + fan) = 3.15 AT
and exchange the seals (slow blow)
(order no. 50079747)
• Clean the pins situated at the • Check the temperature sensors:
dosing bracket, exchange dosing
bracket if there is too much Temperature of the
oxidation (order no. RPS20X-DA) lower compartment
• Clean the contacts behind Figure 5: The mainboard and its Unplug connector X7 and
the dosing bracket (cable and connectors measure on the cable :
tightening screws), exchange At 32°F/0°C: 1599 Ω
dosing bracket, if there is too At 68°F/20°C: 1876 Ω
much oxidation At 104°F/40°C: 2183 Ω
(order no. RPS20X-DA)
Figure 4: Level detection synopsis
• Clean the distribution motor Temperature of the
Item A : Conductivity probe (long) upper compartment
Item B : Conductivity probe (long) connector situated against the
Item C : Conductivity probe (short) sampler background wall above Unplug connector X8 and
Item D : Dosing pipe the distribution. Exchange the measure on the cable
connection cable distribution tap (terminals 1 and 2):
drive (order no. RPS20X-VC) if it At 32°F/0°C: 1599 Ω
is oxidized too much. At 68°F/20°C: 1876 Ω
• If the suction height is small At 104°F/40°C: 2183 Ω
(<4.9 ft/1.5 m) and the diameter
of the suction hose is < 3/4” • Check the condensator of the
then this error can occur. Then compressor.
use a suction hose 3/4” or bigger. • ‘SET/SERVICE/TEST’
-> Service code: 7049
If the default remains, several supplementary tests will be necessary: -> Test temperature elements:
•Disconnect the sensors cable from terminal X8 of the mainboard fan and compressor
(after unscrewing the board, you will find the connectors at
the rear side). The device will display error messages: ‘ERROR: Note: the whole cooling system can
‘temperature upper compartment too high’ and error ‘temp be replaced on-site.
sensor’. Press ’Enter’.
If the message ‘Error : conductivity 2 or 1’ appears, then press
‘Enter’. If the message remains, the trouble comes from the
controller (order no. RPX20-1CC for 1-program version,
RPX20-1EC for 7-program version)
• Fine tuning of the sensitivity of the probes
low or high
• If during the suction phase, bubbles appear in the dosing chamber,
check if the suction hose is blocked or deformed; otherwise

The Endress+Hauser Maintenance Guide 67

ASP station 2000 with vacuum system Also check if the suction circuit is blocked; and maybe the seals
Liquid analysis

– check of the pressure circuit need to be changed (order no. 51003970).

There are four stages in the sampling process: Press ‘ENTER’ to go to the next step.
1. Blow out f) ‘SAMPLING : dosing’
The diaphragm pump blows the suction line clear via the dosing Press ‘ENTER’ to go to the next step.
system. g) ‘SAMPLING : open clamp’
2. Suction The jack should release the hose otherwise exchange the air
The “Airmanager”, a pneumatic ratchet gear, switches the air pipe manager.
of the diaphragm pump to suction mode. The sample liquid is h) ‘SAMPLING : end’
drawn into the dosing chamber until the conductivity probes of the
dosing system are reached.
3. Dose
The suction process is stopped. Depending on the position of the Tips for the ASP Station 2000
dosing pipe (item D), the excess sample liquid flows back to the
sampling point. How to connect the passive pulse output of a
4. Drain Endress+Hauser Proline electromagnetic flowmeter to
The hose constriction is opened and the sample is drained into the enslave an ASP Station 2000?
sample bottle. • Connect terminal 24 at the flowmeter to terminal 2 of
connector X2 at the ASP 2000
• Connect terminal 25 at the flowmeter to terminal 4 of
connector X2 at the ASP 2000.

My sampler is enslaved
to an electromagnetic
Earth flowmeter and the
Digital inputs U+
Digital input 1
sampling does not
Simulation of each operation phase Digital input 2
Digital input 3 operate any more…
Go to ‘SET/SERVICE/TEST/SAMPLING/START/CODE7049/ • Simulate the pulses by
START’ Relay 1 shunting terminals 2 and
a) ’SAMPLING : zero point’ Press ‘ENTER’ 4 of
b) ‘SAMPLING : pump on’ Relay 2
connector X2 by means
The pump should start. Check the pressures delivered at the of a cable
pump: 29 psi/ 2 bar at the ‘outside’ arrow, around -8.7 psi to • Check if there is a
Relay 3
-11.6 psi (-600 to -800 mbar) at the ‘inside’ arrow. direct voltage between
• If the pressures are not correct, exchange the pump seals terminals 1 and 2 of
(order no. 51003140) connector X2
• If the pump does not start, check the fuses situated on the
rear side of the mainboard. Then check the filtering capacitor
situated close to the pump (order no. 51005067)(see figure 5
on previous page). If the capacitor is OK, then you should Tips for the Liquiport 2000
exchange the pump.
(order no. RPS20X-PC, single head, RPS20X-PE, double head). How to connect the pulse output of a Endress+Hauser Proline
Press ‘ENTER’ to go to the next step. electromagnetic flowmeter to enslave a Liquiport 2000?
c) ‘SAMPLING : cl.clamp’ • Connect terminal 24 at the flowmeter to the brown cable of a
If the jack situated under the dosing chamber does not hold the non-Ex Liquiport 2000
hose tight enough, check the pressure before the jack. If the • Connect terminal 25 at the flowmeter to the green cable.
pressure falls under 21.8 psi (1.5 bar), you should exchange the • Shunt the yellow and white cables.
membrane (order no. 51002657). Otherwise exchange the air
manager (order no. 51003139).
If the jack opens slowly during the sampling phase in spite of the There is a pressure sensor default…
pressure, you should exchange the membrane Change the pressure sensor (order no. 51003194).
(order no. 51002657).
Press ‘ENTER’ to go to the next step.
d) ‘SAMPLING : purge’ Calibrating the sample volume
If no blow out occur, exchange the air manager A calibration of the sample volume must be run if:
(order no. 51003139). • the volume set-up in the controller does not correspond with the
Press ‘ENTER’ to go to the next step. sample taken,
e) ‘SAMPLING : suck’ • the pump hose has been changed.
The liquid should be drawn into the dosing funnel. In order to calibrate the sample volume, a measurement beaker
If this is not the case, check the depression at the level of the with a volume of at least 6.76 oz./ 200 ml is required.
filter (around -8.7 psi/-600 mbar). If you do not measure this
value, check that the flange is OK and correctly tightened (order 1. Switch unit on
no. 50072149), exchange the seals of the dosing system (order 2. Connect the sampling hose to the unit and submerse one end
no. 50079747), clean the angled link, change the suction filter if in a container full of water
it is dirty (order no. 50086064), exchange the air manager.

68 The Endress+Hauser Maintenance Guide


Liquid analysis
Pos. A: Calibration volume
Pos. B: Dosing volume
Pos. C: Hose volume (Fixed value
0.81 oz/ 24 ml)
Pos. D: Selection list at DOSING VOL

3. Remove the already installed pump hose from the hose feeder
(pos. A on picture) and feed it into the measurement beaker
(pos. B on picture).
4. Select the menu level CALIBRATION in the controller (over:

5. Enter the required calibration volume into the menu point

CAL.VOL. (pos. A on screenshot).
6. Select menu point ‘DOSING VOL’ (pos. B).
7. Start a sample sequence by selecting the function SAMPLE in
the selection list (pos. D). Wait until the sampling sequence has
8. Read off the sample volume in the measurement beaker.
9. In the menu level CALIBRATION the menu point MEAS. VOL
appears instead of DOSING- VOL.. Select MEAS. VOL. Search
for the command ‘ENTER’ from the selection list.
10. Enter the measured sample volume into the controller.
11. Control the calibration sequence by repeating steps 7 and 8
and if required repeat the calibration sequence.
12. Now leave the menu levels CALIBRATION and SERVICE.
13. Replace the pump hose into the hose feeder until it hits the
end stop.

The Endress+Hauser Maintenance Guide 69

Frequently asked questions related to liquid analysis devices
Liquid analysis

pH 1. Membrane rupture monitoring

• Sensors COS3/31 include conductivity measurement between
I have a tolerance between the laboratory and the inline stainless steel body and an inner electrode (see fig. 1)
measurements which is > 0.3 pH. The labor electrode and
the inline electrode in the same probe. If the tolerance is
± 0.2 pH is it OK? Conductive path no. 1
If this influence is to be compensated for, the temperature
coefficient of the measuring solution must be known. This value Conductive path no. 2
must be determined in the laboratory since different measuring
solutions have different ion compositions and concentrations. The
values thus determined can be entered in high-tech measuring
instruments (medium temperature compensation, Mycom 3,
Liquiline CM42) and used in computing the pH value. • Step 1 detects looseness on conductive path no. 1
(membrane rupture)
Practical significance of this:
• The temperature of the measuring solution must always be
specified for pH values to be processed by process control
systems. Auxiliary wire
• pH comparisons are only valid for identical medium temperatures.
Water (not of low

• Step 2 detects looseness on conductive path no. 1+2
I have a tolerance between the laboratory and the inline
measurements… If there was no alarm on conductive
1. Alpha is not the same. path no. 1 it is clear that an alarm
2. Temperature is not the same. occuring now relates to conductive
3. The probe is not the same. path no. 2.
Solution: Always measure without compensation in the same probe.

2. DO sensor functionality check
I have a tolerance between DPD and the inline • Perform calibration in air (see page 59)
measurements… • Perform “simple check of the zero point” (see page 60)
1. pH is not compensated (fluctuations higher than ±0.1 pH must
be compensated). 3. Degradation of the reference electrode
2. The pH value is unstable. Sensors produced before April 2000 can be subject to AgBr
3. pH > 8.7 degradation when exposed to a medium containing a high amount
4. The temperature is unstable. of H2S / NH3.
5. There is a chemical reaction to the DPD Typical behaviour: Signal increase up to overflow within 1 to
3 hours (check on a recorder if possible !).

Remedy: Repair at Endress+Hauser

Dissolved Oxygen Measurement
Typical failures, methods of detection and failure removal 4. Error possibilities on a hand-held meter
• Sensors of hand-held meters include very thin membranes
Typical errors in DO measurement (e.g. 12.5 µm) for fast response. Therefore, hand-held sensors
1. Membrane rupture monitoring need high flow (e.g. 7.87 - 11.8 in/s (20-30 cm/s)).
2. Measuring value deviates from a reference meter (e.g. hand-held • Insufficient flow on hand-held meters results in a too low signal.
instrument) Make sure that there is sufficient flow. Move or stir the sensor if
3. Degradation of the reference electrode necessary.
4. Error possibilities on a hand-held meter • Due to the fast response hand-held sensors show too high signals
when immersed into aeration basins with small bubble aeration

Remedy: immerse the sensor upside down (e.g. attached to a stick

of wood or similar)

70 The Endress+Hauser Maintenance Guide

Pressure measurement

Frédéric Willauer
Expert in Pressure measurement
Endress+Hauser France

“Proper commissioning ensures peace of mind”

“Pressure measurement uses various You will also find plenty of useful Contents
principles and can, according to the information to help you get the best from
application, serve to calculate a flowrate or a your instruments throughout their life Basics 72
level. Thus these devices are in frequent use cycle… and prepare for renewing your The chapter ‘Basics’ includes
in a broad scope of applications. equipment gradually.” information which is valid for all
pressure measurement devices principles
described hereafter. Thus you should
Most of the reported questions occur during read it before any other chapter.
commissioning. Therefore we have decided
to focus on this in the following pages. In Absolute/relative pressure
95% of the cases, proper installation and transmitters 74
cabling enables immediate operation! Differential pressure
measurement 77
Hydrostatic pressure
measurement 79
FAQ 80

The Endress+Hauser Maintenance Guide 71


Information common to any

type of pressure sensors
The current Endress+Hauser range of pressure measurement
devices includes:
• The Cerabar S and M absolute/relative pressure
• The Deltabar S differential pressure transmitters
• The Deltapilot S hydrostatic pressure transmitters

Installation instructions - Setup - Configuration insensitive to the medium.

general notes Thus they require very little
• General note: maintenance.
Seal for flange mounting If the installation and wiring
Warning! The seal is not allowed conditions have been We recommend to periodically
to press on the diaphragm as this observed initially, you can be proceed to a visual check of the
could affect the measurement certain of receiving correct devices:
result (see fig.1). measurements from the • check the cap and housing’s
“It’s even easier with instrument’s first activation. condition
The device specific instructions Configuration will only serve • check the diaphragm’s
the new ‘Evolution’ are described in the next pages. to optimize the operating condition
generation!” parameters of the quantities • check the cable gland’s
measured (current output watertightness
setup, etc.) • ensure there is no
condensation inside the
• Cerabar S, Deltabar S and housing
1 2
Deltapilot S offer a QUICK • check the connections to the
SETUP. electronic module
Instead of the matrix
programming present on the Taking 4 to 20 mA
first generation of Cerabar S, test signal - Cerabar S,
Deltabar S and on the Deltabar S, Deltapilot S
Deltapilot S DB5x, the new A 4 to 20 mA signal may be
Fig. 1: Mounting the versions with flange or diaphragm seal
Fig. 11: Mounting the versions with flange or diaphragm seal
‘Evolution’ generation offers a measured via the positive

1 Diaphragm 2 Seal QUICK SETUP. and test terminal without
2 Seal QUICK SETUP enables quick interrupting the measurement.
and easy configuration of The minimum supply voltage
the device’s main functions of the device can be reduced
(units, outputs…). by simply changing the position
of the jumper. As a result,
• You can also configure operation is also possible with
your flowmeters from lower voltage sources. Observe
your PC. See presentation of the position of the jumper in
FieldCare on page 105. accordance with the following
table. (fig. 3)
Our service organization can set up
any Endress+Hauser device for you
and thus ensure you immediately get

Configuration with operating keys Fig. 2: insert HART

the best from your instrument.
situated either on the exterior of the Cerabar
1 S, Deltabar
Operating keys S and Deltapilot S: (see ‘Commissioning’ in the Hydrostatic pressure
device (see photo) or below the 4-lines Operating
2 keys
Slot for anddisplay
optional elements located ‘At your service’ section) measurement sensors need
3 Slot for optional HistoROM ®/M-DAT
display. Data are stored in a HistoROM / internally on the electronic insert (HART)
M-DAT allowing easy duplication from a
4 DIP-switch for locking/unlocking
1 Operating keys
calibration at start-up.
measured-value-relevant parameters
device to another. 25Slot DIP-switch
for optional display
for damping on/off All pressure sensors require
6 Green LED to indicate value being accepted
3 Slot for optional HistoROM®/M-DAT Operation and Maintenance periodic calibration; the
4 DIP-switch for locking/unlocking calibration’s frequency
measured- value-relevant parameters
5 DIP-switch for damping on/off
Pressure measurement depends on the expected
6 Green LED to indicate value being instruments contain no wear precision. Calibration can be
accepted parts. Furthermore they are performed either on-site or

72 The Endress+Hauser Maintenance Guide

in the laboratory (for greater Corrective maintenance Our specialists can help you to define
precision and/or for accredited The more critical your the criticality of all your measuring
calibration). instrument is to your process, instruments (even for other makes).
the shorter the acceptable They will apply a structured
methodology adapted to your own
Endress+Hauser can help you time for repair. Thanks to the application (see ‘Installed Base Audit’
calculate the right calibration Endress+Hauser’s spare part service in the ‘At your service’ section).
frequency and perform calibration concept (see hereafter), most
either on site or in accredited
parts can be easily replaced by
laboratories. (see ‘Calibration’ in
the ‘At your service’ section). the user thus allowing quick Instrument and
repair. spare parts availability
You will find detailed
Maintenance planning information in the next pages.
Being more efficient in the repair
process is another way to reduce
Do you know exactly which part of downtimes. Our training sessions help
your installed instrumentation base you to diagnose quickly any failure and
is critical to the operation of the to apply the most appropriate repair
plant and how you could maintain method. (see ‘Training’ in the ‘At your You will find detailed
or calibrate it more efficiently? Are service’ section). information in the next pages.
you sure that your present actions are
minimizing the risks of unplanned
breakdowns? Are you sure that your Spare parts stock Re-engineering
present actions are the most cost
As members of the Evolution
range, Cerabar S, Deltabar S You wish to use an instrument
With Endress+Hauser’s Installed Base and Deltapilot S use the same for a new application? We can
Audit, our service Consultant will help electronic modules (for HART help you check the relevant
you to quickly find an answer to these
output, for Profibus output etc.), parameters. See our online
three questions and move forward in
the same housings, caps, display, Applicator tool.
a controlled manner to a maintenance
plan which improves plant reliability terminal compartment, mounting
while reducing costs… (see ‘Installed set, and Histo-ROM. Only the
Base Audit’in the ‘At your service’
sensor and its electronic board
vary from one device to another.
This allows a consistent spare
Maintenance performing parts stock reduction.

In case you don’t have the For each device type, we P01-xMx7xxxx-04-xx-xx-xx-001

manpower, the competences or the

right tools to efficiently perform your
suggest you keep a full set of connectionJumper
Electrical 4 to 20 position
mA HART, forhere
signalwith aluminum housing (T14)
maintenance, with Endress+Hauser electronic inserts in stock.
1 Housing
– Taking 4...20 mA test signal via plus and test
2 Jumper for 4 to 20 mA test signal
service contracts, you decide the See also Page 19, "Taking 4 to 20 mA test signal". terminal: possible. (Thus, the output current
right level of maintenance support On each part you will find
3 a Internal ground terminal can be measured without interruption via the
you require. 4 External ground terminal diode.)
sticker with the part number,
4 to 20 mA test signal between positive and test terminal
– Delivery status
We provide regular checks on your easy spare parts ordering6 Minimum supply voltage 10.5 V DC, if the jumper is–inserted in accordance
minimum with the11.5
supply voltage: illustration.
equipment and warranty extensions 7 Minimum supply voltage 11.5 V DC, if the jumper is inserted in "Test" position.
8 Devices with integrated overvoltage protection are labelled OVP (overvoltage protection) here ( see also Page 25).
providing you with complete peace of In case of a highly critical
mind and cost control. From regular – Taking 4...20 mA test signal via plus and test
support to partnership agreements,
instrument, you might also terminal: not possible.
we offer four distinct levels of consider stocking a complete – minimum supply voltage: 10.5 V DC
service… (see ‘Service Contracts’ new instrument.
in the ‘At your service’ section).
Fig. 3: Taking test signal

The Endress+Hauser Maintenance Guide 73


pressure transmitters
Cerabar series
The current Endress+Hauser range of absolute/relative
pressure transmitters includes Cerabar M and S series.

In this section, you will find essential information and advice

that will help you to perform the optimum follow-up of your
Cerabar M and S transmitters throughout their lifecycle.

Measuring principle
Cerabar S specific information
Ceramic measuring For PMP75
diaphragm (PMCxx devices) The operating pressure acts on Installation instructions for Pressure measurement
The ceramic sensor is a dry the diaphragm of the diaphragm devices without diaphragm in liquids
sensor, i.e. the process pressure seal and is transferred to the seals – PMP71, PMC71 Mount Cerabar S with shut-off
acts directly on the robust separating diaphragm of the device below or at the same level
ceramic diaphragm and deflects sensor by a diaphragm seal fill Pressure measurement as the tapping point. (see fig. 6)
it. A pressure-dependent fluid. The separating diaphragm in gases
change in capacitance is is deflected and a fill fluid Mount Cerabar S with shut-off Level measurement
measured at the electrodes of transfers the pressure to a device above the tapping point • Mount Cerabar S below the
the ceramic carrier and the resistance measuring bridge. so that the condensate can flow lowest measuring point.
diaphragm. The measuring The pressure-dependent change into the process. (see fig. 4) (see fig. 7)
range is determined by the of the bridge output voltage • Do not mount the device at
thickness of the ceramic is measured and processed Pressure measurement the following positions: In
diaphragm. (See figure 1) further. in steams the fill flow, in the tank outlet
• Mount Cerabar S with or at a point in the container
Metallic measuring Level measurement (level, siphon below the tapping which could be affected by
diaphragm (See figure 2) volume and mass) point. The siphon reduces pressure pulses from the
For PMP71 Design and operation mode is the temperature to almost agitator.
The operating pressure deflects shown in figure 3. ambient temperature. • The calibration and functional
the separating diaphragm and a (see fig. 5) test can be carried out more
fill fluid transfers the pressure • Fill the siphon with fill fluid easily if you mount the device
to a resistance measuring bridge before commissioning. after a shut-off device.
(semi-conductor technology).
The pressure-dependent change
of the bridge output voltage
is measured and processed further.

h= g

p p p p

P01-PMC71xxx-03-xx-xx-xx-000 P01-PMP7xxxx-03-xx-xx-xx-000
sensor Metal
Fig. 5: Measuring arrangement for pressure measurement in gases
Fig. 1: Ceramic sensor
only) 1
Fig. 2: Metal sensor
diaphragm with
Fig. 3: Level measurement Fig. 4: Measuring arrangement for
1 Atmospheric vent
1 Measuring element
fill fill
with Cerabar S pressure measurement in gases

(gauge pressure only) 2 Measuring

Level diaphragm
measurement with
with Cerabar S h Height (level) 1 Cerabar S
2 Ceramic substrate Wheatstone bridge p Pressure 2 Shut-off device
h Height (level)
3 Electrodes 3 Channel with fill fluid ρ Density of the medium
p Pressure
4 Ceramic diaphragm 4 Process diaphragm, Metal g Gravitation constant
ρ Density of the medium
Gravitation constant

74 The Endress+Hauser Maintenance Guide

Operations and Maintenance (see ‘Basics’) and the explosion
protection. (see fig. 8)
Taking 4 to20 mA test signal
A 4 to 20 mA signal may be Calibration
measured via the positive See ‘Basics’. Fig. 6: Measuring arrangement for
and test terminal without pressure measurement in liquids
1 Cerabar S
interrupting the measurement. Instrument and 2 Shut-off device
(see page 72) spare parts availability
(see table below)
Load – 4 to 20 mA

Fig. 7: Measuring arrangement for pressure measurement in liquids

and 4 to 20 mA HART If you want to get more information 1

Cerabar S
Shut-off device
Load diagram, observe the about spare parts availability, please
call our hotline.
position of the jumper

Your Spare part New

Fig. 7: Measuring arrangement for level P01-PMP75xxx-11-xx-xx-xx-000

instrument availability generation Fig. 8: Measuring arrangement for level

PMC731 YES - until 12/2010 PMC71 RLmax RLmax ≤

U – 10.5 V RLmax RLmax ≤
U – 11.5 V
23 mA 23 mA
[ ] [ ]
Test Test
PMP731 YES - until 12/2010 PMP71 1500

PMP635 YES - until 12/2010 PMP75 847 804

PMC631 YES - until 12/2010 PMP75 413 369

10.5 20 30 40 45 U 11.5 20 30 40 45 U
[V] [V]

RLmax U – 11 V RLmax U – 12 V
RLmax ≤ RLmax ≤
[ ] 23 mA [ ] 23 mA
1478 1434
1260 1217

826 782

391 347

11 20 30 40 45 U 12 20 30 40 45 U
[V] [V]

Fig. 8: Load diagram

1 Jumper for the 4 to 20 mA test signal inserted in ‘Non-test’ position
2 Jumper for the 4 to 20 mA test signal inserted in ‘Test’ position
3 Supply voltage 10.5 (11.5) to 30 V DC for 1/2 G, 1 GD, 1/2 GD, FM IS, CSA
IS, IECEx ia, NEPSI Ex ia and TIIS Ex ia
4 Supply voltage10.5 (11.5) to 45 V DC for devices for non-hazardous areas,
1/2 D, 1/3 D, 2 G EEx d, 3 G EEx nA, FM XP, FM DIP, FM NI, CSA XP, CSA

Fig. 6: Measuring arrangement for pressure measurement in steams Dust-Ex, NEPSI Ex d, TIIS Ex d
Fig. 5: Measuring arrangement for pressure measurement in steams
1 Cerabar S 5 Supply voltage 11 (12) to 45 V DC for PMC71, EEx d[ia], NEPSI Ex d[ia] and
1 Cerabar S
2 Shut-off device TIIS Ex d[ia]
3 2 Shut-off
U-shaped device
4 Circular siphon RLmax Maximum load resistance
3 U-shaped siphon
U Supply voltage
4 Circular siphon

The Endress+Hauser Maintenance Guide 75

Cerabar M specific information

Operations and Maintenance

Taking 4 to 20 mA test signal

A 4 to 20 mA signal may be measured via the positive
and test terminal without interrupting the measurement.
(see figures 1 and 2)

Load – 4 to 20 mA and 4 to 20 mA HART

Load diagram, observe explosion protection. (see fig. 3)
Figure 1: analog electronic insert
Figure 2: 4 to 20 mA HART P01-PMx4xxxx-04-xx-xx-xx-001

Analog electronic
• Remove insert
the sensor from the 4 tomA
4 to electronic
20 HART electronic
electronic insertinsert
process and take the display off • Remove the sensor from the
• Connect a multimeter to the process and take the display off
terminal lugs • Connect a multimeter to the
• Generate the pressure that terminal lugs
corresponds to the lower range • Generate the pressure that
value corresponds to the lower range
• Check that I = 4 mA value
• Use ‘Zero potentiometer to correct • Check that I = 4 mA
the value • To correct the value, please press
• Generate the pressure that twice the ‘Zero’ button or confirm
corresponds to the upper range the value in the matrix
value • Generate the pressure that
• Check that I = 20 mA corresponds to the upper range
• Use ‘Span’ potentiometer to value
correct the value • Check that I = 20 mA
• To correct the value, please press
twice the ‘Span’ button or confirm
the value in the matrix

[Ω] Figure 3: Load diagram
1522 1 Power supply 11.5 to 45 V DC for
devices for non-hazardous areas,
1/3 D, EEx d, EEx nA, FM XP,
FM DIP, CSA XP and CSA Dust-Ex
840 2 RLmax
PowerU – 11.5 V
≤ supply 11.5 to 30 V DC for
22 mA
EEx ia, 1 D, 1/2 D1/2G, FM IS
386 and CSA IS
RLmax Maximum load resistance
0 U Supply voltage
11.5 20 30 40 45 U

76 The Endress+Hauser Maintenance Guide

Differential pressure

Deltabar series
The current Endress+Hauser range of differential pressure
measurement includes Deltabar S series.

In this section, you will find essential information and advice

that will help you to perform the optimum follow-up of your
Deltabar S devices throughout their lifecycle.

Measuring principle Specific installation

Ceramic measuring
diaphragms used for PMD70 We remind you hereafter the
and FMD76 main installation requirements
The ceramic measuring cell is regarding the most frequently
based on the principle of a plate used applications.
capacitor with an electrode on
(1) and a movable electrode on Flow measurement in steam
the interior of the diaphragm with PMD70/PMD75
(3). Standard silicone oil or • Mount the Deltabar S below P01-FMD

Fig. 12: Fig. 3:entMeasuring

Measuring layout for level measurem in a closed layout forwith
container level
mineral oil filling oils for this the measuring point. measurement in a closed container
1 Deltabar S, here FMD78
Fig. 1: Measuring layout for flow measuring cell. P01-PMD75xxx-11-xx-xx-xx-001
(see fig.1) with FMD78
layout for flow measurement
measurementin steam withwith
in steam PMD75
PMD75 A differential pressure (p1 ≠ • Mount the condensate 1 Deltabar S, FMD78 shown here
ps 1 Condensate traps p2) causes a corresponding traps at the same level as
2 Orifice plate or pitot tube
pitot tube
3 Shut-off valves
deflection of both diaphragms. the tapping points and at
4 Deltabar S, PMD75 shown here Both capacitance values are the same distance to the
e PMD75
5 Separator converted and are fed to Deltabar S.
6 Drain valves the microprocessor of the • Prior to commissioning, fill the
7 Three-valve manifold
anifold transmitter as a digital signal. impulse piping to the height of
the condensate traps.
Metallic measuring
diaphragms used for Level measurement in
PMD75, FMD77 and FMD78 a closed container with
The separating diaphragms (3/9) superimposed steam with
are deflected on both sides by PMD70/ PMD75
the acting pressures. A filling oil
(4/8) transfers the pressure to a • Mount the Deltabar S P01-FM

Fig. 9: Measuring layout for level measurement in open containers with FMD76
resistance circuit bridge (semi- below the lower measuring Fig. 4: Measuring layout for level
1 Deltabar S, here FMD76
conductor technology). The connection so that the measurement in open containers
2 The negative side is op en to atmospheric pressure
with FMD76
differential-pressure-dependent impulse piping is always filled 1 Deltabar S, FMD76 shown here
change of the bridge output with liquid. (see fig.2) 2 The negative side is open to
voltage is measured and further • Always connect the negative side atmospheric pressure
processed. above the maximum level.
• A condensate trap ensures
constant pressure on the
Fig. 2: Measuring layout for level P01-PMD75xxx-11-xx-xx-xx-005 negative side.
easuring layout for level measurement
measurement in aincontainer with superimposed
a container with steam with PMD75
• When measuring in media
superimposed steam with PMD75
nsate trap
1 Condensate trap
with solid parts, such as dirty
f valves
ar S, here PMD75 2 Shut-off valves liquids, installing separators
or 3 Deltabar S, PMD75 shown here and drain valves is useful
valves 4 Separator
valve manifold for capturing and removing
5 Drain valves
6 Three-valve manifold

The Endress+Hauser Maintenance Guide 77

Level measurement Operations and Maintenance Fig. 1: Operating keys and elements

in a closed container located internally on the electronic insert

with FMD78 Taking 4 to 20 mA test signal 1 Operating keys
• Mount the Deltabar S below A 4 to 20 mA signal may be 2 Slot for optional display
the lower diaphragm seal. measured via the positive 3 Slot for optional HistoROM®/M-DAT
(see fig.3) and test terminal without 4 DIP-switch for locking/unlocking
measured- value-relevant parameters
• The ambient temperature interrupting the measurement. 5 DIP-switch for damping on/off
should be the same for both (see page 72) 6 Green LED to indicate value being
capillaries. accepted
Note! Level measurement Load – 4 to 20 mA
is only ensured between and 4 to 20 mA HART P01-xxxxxxxx-19-xx-xx-xx-104

Electronic insert HART

the upper edge of the lower Load diagram, observe the posi- 1 Operating keys
diaphragm seal and the tion of the jumper (described 2 Slot for optional display
R RLmax
3 Slot forLmax
optional HistoROM ®/M-DAT
lower edge of the upper on page 73) and the explosion [ ]
4 Test DIP-switch for locking/unlocking Test
[ ]
1500 1456
diaphragm seal. protection. (see fig. 2) 5
measured-value-relevant parameters
1282 for damping on/off
DIP-switch 1239
6 Green LED to indicate value being accepted

Level measurement Instrument and 847 804

in an open container spare parts availability 413 369

with FMD76/FMD77 See table below.
• Mount the Deltabar S directly 10.5 20 30 40 45 U 11.5 20 30 40 45 U
[V] [V]
on the container. (see fig.4) If you want to get more information
• The negative side is open to about spare parts availability, please RLmax ≤
U – 10.5 V
23 mA
RLmax ≤
U – 11.5 V
23 mA
atmospheric pressure. call our hotline. P01-xMD7xxxx-05-xx-xx-xx-005

Fig. 31: Load diagram, observe the position of the jumper and the explosion protection ( ? See also page 25, "Taking
Fig. 2: Load
mA test signal" part.)
1 Jumper
1 Jumper for the
for 4...20 4 to
mA test 20inserted
signal mA test signal inserted
in "Non-Test" position in ‘Non-test’ position
2 Jumper
2 Jumper for the
for 4...20 4 to
mA test 20inserted
signal mA test signal
in "Test" inserted in ‘Test’ position
3 Supply
Supplyvoltage 10.5 (11.5)...30
voltage V DC forto
10,5 (11,5) 1/2
DC1/2 forGD,
1/2FM IS,
1 GD, 1/2ia,GD,
Ex iaIS,
TIIS Ex ia
Your Spare part New 4 Supply voltage 10.5 (11.5)...45 V DC for device for non-h azardous areas, 1/2 D, 1/3 D, 2 G EEx d,
ia Ex, NEPSI Ex d und TIIS Ex d
instrument availability generation 4 Maximum
RLmax Supply loadvoltage 10,5 (11,5) to 45 V DC for device for non-hazardous areas,
U Supply voltage
1/2 D, 1/3 D, 2 G EEx d, 3 G EEx nA, FM XP, FM DIP, FM NI, CSA XP, CSA
PMD230 YES - until 12/2010 PMD70 Dust-Ex, NEPSI Ex d and TIIS Ex d
RLmax Maximum load resistance
PMD235 YES - until 12/2010 PMD75 U Supply voltage

FMD230 YES - until 12/2010 FMD76

FMD630 YES - until 12/2010 FMD77

FMD633 YES - until 12/2010 FMD78

78 The Endress+Hauser Maintenance Guide

Hydrostatic pressure

Deltapilot series
The current Endress+Hauser range of differential pressure
measurement includes Deltapilot S series.

In this section, you will find essential information and advice

that will help you to perform the optimum follow-up of your
Deltapilot S devices throughout their lifecycle.

Measuring principle Specific installation

(see figure 1)
Due to its weight, a liquid Note!
column creates hydrostatic • Do not clean or touch
pressure. If the density is diaphragm seals with hard or
constant, the hydrostatic pointed objects.
pressure depends solely on the
height h of the liquid column. • Always install the device
The CONTITE™ measuring under the lowest measuring
cell which works on the point.
principle of the gauge pressure • Do not install the device at
sensor constitutes the core the following positions:
of Deltapilot S. In contrast to – in the filling curtain
conventional gauge pressure – in the tank outlet
sensors, the precision – or at a point in the tank
measuring element (2) in the that can be reached by
CONTITE™ measuring cell is pressure pulses from
absolutely protected between agitator. Deltapilot S hydrostatic level meas urement and measuring principle

Figure 1: Deltapilot S hydrostatic level p tot Total pressure = hydrostatic pressure

the process diaphragm (3) and 1 Measuring diaphragm
measurement and measuring principle + atmospheric pressure
the measuring diaphragm (1). The calibration and functional 2 Measuring element
3 1 Process
Measuring diaphragm
diaphragm (separating diaphragm) p atm Atmospheric pressure
Thanks to this hermetic sealing test can be carried out more g 2 Gravitational
Measuring element
acceleration p hydr. Hydrostatic pressure
h 3 Level Process diaphragm
height p meas Measured pressure in the measuring
of the measuring element, easily if you mount the device p tot Total pressure = hydrostatic pr essure + atmospheric pressure
pressure diaphragm) cell = hydrostatic pressure
the CONTITE™ measuring after a shut-off device. p atm Atmospheric
p hydr.g Hydrostatic
pressure acceleration ρ Density of fluid
cell is absolutely insensitive to p meas Measured pressure in the meas uring cell = hydrostatic pressure
h Density
Level height
of fluid
condensate, condensation and Deltapilot S must be included
aggressive gases. The pressure in the insulation for media that
applied is transferred from can harden when cold.
the process diaphragm to the
measuring element by means
of an oil without any loss in Operations and Maintenance
Taking 4 to 20 mA test signal
Two temperature sensors are A 4 to 20 mA signal may be
arranged between the process measured via the positive
diaphragm and measuring and test terminal without

element which measure the interrupting the measurement. P01-FMB70xxx-11-xx-xx-xx-000

distribution of temperature in (see fig. 2)

the cell. The electronics can
compensate any measuring Load – 4 to620 mA Endress+Hauser
errors resulting from and 4 to 20 mA HART
fluctuations in temperature Load diagram, observe the posi-
with these measured tion of the jumper (described
temperature values. on page 73) and the explosion
protection. (see fig. 3)

The Endress+Hauser Maintenance Guide 79

Corrective maintenance Fig. 2: Operating keys and elements
Changing the sensor’s electronic located internally on the electronic insert
module Deltabar S FMB70x The Deltapilot S FMB70 is fully 1 Operating keys
requires no calibration. compatible with DB50 and 50L. 2 Slot for optional display
3 Slot for optional HistoROM®/M-DAT
Instrument and 4 DIP-switch for locking/unlocking
measured- value-relevant parameters
spare parts availability 5 DIP-switch for damping on/off
• The FMB70 compact version 6 Green LED to indicate value being
was launched in 2006. accepted
• DB50 and 50L will be phased
out 10/2008. P01-xxxxxxxx-19-xx-xx-xx-104

• Spare parts: See table below. Electronic insert HART

1 Operating keys
2 Slot for optional display
3 Slot for optional HistoROM ®/M-DAT
Your Spare part New 4 DIP-switch for locking/unlocking
measured-value-relevant parameters
instrument availability generation 5 DIP-switch for damping on/off
6 Green LED to indicate value being accepted

DB50L YES - until 10/2011 FMB70

DB50S YES - until 10/2011 FMB70

DB50A YES - until 10/2011 FMB70


Load 3: Load diagram
observe the position of the jumper and the explosion protection. ( ? See also page 19, section "Taking
1 mAJumper
4...20 test signal"for
.) the 4 to 20 mA test signal inserted in ‘Non-test’ position
If you want to get more information
12 Jumper
Jumper for thefor themA4 test
4...20 to signal
20 mA testinsignal
inserted inserted
"Non-test" position in ‘Test’ position
about spare parts availability, please 23 Jumper for the 4...20 mA test signal inserted in "Test" position
Supply voltage 10.5 (11.5) to 30 V DC for 1/2 G, 1 GD, 1/2 GD, FM IS, CSA IS
call our hotline. 3 Supply voltage 10.5 (11.5) to 30 V DC for 1/2 G, 1 GD, 1/2 GD, FM IS, CSA IS, TIIS Ex ia and IEC Ex ia
4 andvoltage10.5
Supply TIIS Ex (11.5)
ia to 45 V DC for devices for no n-hazardous areas, 1/2 D, 1/3 D, 3 G EEx nA, FM DIP,
4 FMSupply
NI, CSA voltage10.5
Dust-Ex (11.5) to 45 V DC for devices for non-hazardous areas,
RLmax Maximum load resistance
1/2 D, 1/3 D, 3 G EEx nA, FM DIP, FM NI, CSA Dust-Ex
Supply voltage
RLmax Maximum load resistance
U Supply voltage

Frequently asked questions

What to do in case of warning or alarm in the display? The pressure is about 1 bar too high!
See error codes listed in documentation/operating instructions. An absolute cell is built in instead of a relative cell.

The local display is dark – why? Current permanently at 20.5 mA and possibly display
• With analogue output: Only the display is defective. flashing!
• With current = 0 mA: Check terminal voltage or plug to the E-board Measuring cell selected too small, possibly confused relative with
• If there is no voltage on the plug, but on the terminals: absolute!
defective terminal module (filter/interlock diode)
• If there is a voltage on the plug: defective electronics Tanks with a conical outlet
- entry of the linearization
Display/current does not show 0 % value upon start-up… table
Perform additional position alignment (position, temperature) as Please refer to the Operating
decribed in the manual. Instructions Manual of your
The current is too low…
The sensor is not connected in 2-wire technique, but probably in P01-PMP75xxx-19-xx-xx-xx-002

4-wire technique by testing terminals, which is forbidden!

80 The Endress+Hauser Maintenance Guide

Temperature measurement

Laurent Avorio
Expert in Temperature measurement
Endress+Hauser France

“Finding the right balance in calibration”

“Temperature is the most frequently You will also find plenty of useful Contents
measured parameter in the process industry. information to help you get the best from
your instruments throughout their life Basics 82
Maintenance of temperature measurement cycle… and prepare for renewing your FAQ 86
consists mostly of periodic calibration. This equipment gradually.
is why we have focussed on calibration in
the following pages. As experts, we also offer training sessions,
in classroom and on site. We would be glad
Please note that new transmitters like to meet with you and help you to go one
TMT162 include advanced diagnostics step further. Ses ‘Training’ in the section
functions (like drift or corrosion detection) ‘At your service’.”
which can increase the system’s
performance and availability.

The Endress+Hauser Maintenance Guide 81


Information common to all types

of temperature sensors
The current Endress+Hauser range of temperature measurement
devices includes:
• The family of RTD (Resistance Temperature Detectors) thermometers
• The family of TC (thermocouples) thermometers

Measuring principle thermocouples reference tables normally consists of a mineral

(see IEC 584) the temperature insulated cable, Ø 0.12” or
RTD-sensors at the connection (measuring 0.24” (3 or 6 mm), including
(See figure 1) junction) can be concluded. 4 or 6 copper wires embedded
In RTD-sensors the electrical Thermocouples are suitable for in stone hard pressed MgO
resistance changes with a temperature measurement in powder, surrounded by a very
Fig. 1: Measuring principle of
change in temperature. They are the range of 32°F to 3272°F thin sheath in stainless steel.
RTD-sensors suitable for the measurement of (0°C to 1800°C). They stand On one end of the stem the
temperatures between -328°F out due to the fast response sensing element is welded to
(-200°C) and approx. 1472°F time and high vibration the wires and encapsulated;
(800°C) and stand out due to resistance. the sensitive zone of an insert
high measurement accuracy and has a length of about 0.98” (25
long-term stability. The mechanical construction mm) from the closed end (tip).
The resistance sensor element of a thermometer used in On the other end a ceramic
most frequently used is a Pt100 process plants is the same for terminal board or a free wires
which has a nominal value of resistance thermometers and connection system is mounted
100 Ω at 32°F (0°C). Pt100 thermocouples and consists of on a metal flange; the spring
Fig. 2: Measuring principle of
sensors are manufactured in the following components: loaded mounting screws,
thermocouples different formats: • Measurement insert with integral with the metal flange,
• Wire wound ceramic sensors: ceramic terminal block or guarantee the insert coupling to
A spiral of platinum wire is head transmitter (A) the terminal housing and a tight
wound and embedded in • Thermowell: The contact between the insert end
ceramic powder within a thermowell is the process tip and the thermowell.
capillary and is fed to the wetted component of the Inserts are generally equipped
outside by platinum wires. thermometer (B) with single or double resistance
• Thin film sensors: A platinum • Process connection: The sensing elements.
layer is vaporized on a process connection is the Twin resistors are normally
C ceramic plate (sputtered). connection between the used to split the destination of
The connection wires and process and the thermometer. the output signals.
the platinum layer are • Neck: The neck is the The use of a double sensing
encapsulated in glass. connection between element to increase the
As a standard, Endress+Hauser connection head and process measuring point reliability is
RTD-sensors fulfill the connection / thermowell. not recommended because the
A B IEC 60751 accuracy class F 0.15. • Connection head with cable two elements are embedded
glands: The connection head in the same point: therefore,
TC - Thermocouples is fitted to the thermowell or when a mechanical or electrical
(See figure 2) the neck of the thermometer. cause damages the insert
A thermocouple is a component construction, the complete
made of two different metals Insert resistor set goes out of order.
connected with each other at (See figure 3) This problem can be solved
one end. An electrical potential First step of Pt100 protection with two independent
(thermoelectric force) is caused consists in making an thermometers.
due to the Seebeck effect at the insert, which will be used
Fig. 3: Construction of temperature
sensors open end if the connection for installation in the final Thermowell
A Insert and the free ends are exposed assembly and which has a A second protection of
B Thermowell to different temperatures. great advantage of being thermometer assembly consists
C Terminal head With the help of the so-called interchangeable. The insert of installing the insert in

82 The Endress+Hauser Maintenance Guide

appropriate metal thermowells for the electrical output wiring. a thermal drift, due to
(i.e. thermowells or pockets). This component can provide a heat dissipation through
This component is normally protective housing for built-in the connection mass,
required for medium and heavy transmitters or can act as a that can effect the correct
duty applications but it can be junction box if remote mounted measurement: this problem
employed also for light duty transmitters / receivers are can be solved with a longer
services whenever the insert used. The head allows a immersion length.
replacement is possible without complete compact thermometer • Process requirements
any plant shut-down. assembly and makes it easier for should also be considered to
In order to reduce the sensor insert replacement. guarantee a representative
response time lag due to A wide choice of terminal measuring point for sensing
Fig. 4: Pipe installations:
thermowells, tapered end heads covers general purposes, and for control efficiency. a) at elbows, against the flow
constructions are available. heavy duty, explosion proof and • For a correct temperature b) in smaller pipes, leant against the flow
The thermometer thermowell sanitary applications. A widely measurement the c) perpendicular to the flow
can be mounted in tanks or used version of connection thermowell / thermometer
pipes by means of threaded, heads is constructed in light immersion length must be
flanged or welded connections. metal alloy, usually aluminum, at least 20 times its diameter
Since the thermowell is the and conforms to DIN (30 times if not M.I. cable
component that comes into standard 43729 type B. The type). Shorter immersion
contact with the process, exact Endress+Hauser metallic heads lengths can be specified but
specification is most important are delivered with gaskets the thermometer requires an
as it determines the lifetime to withstand a temperature external (process connection,
of assembly. The appropriate of 266°F (130°C). Some neck and connection head)
selection depends upon the connection heads can include thermal insulation.
chosen method of mounting, a built-in transmitter and / or • Furthermore, if a calibration
the space available, the an indicator: in this case the certificate is requested,
pressure, the temperature, the temperature has to be checked the probe design (length
Fig. 5: Thermal insulation examples:
flow speed and the nature of considering the electronic and diameter) has to be a) insulating material
the product. device limits. defined also according to b) pipe
Among different international the certification Lab size c) thermowell with insert
and corporate standards, the Installation instructions requirements. d) external plate
DIN 43763 defines a series of
standard thermowell designs Immersion length Pipe installations
including: The thermometers should (See figure 4 and 5)
• threaded thermowells type B insert in the medium where the In small diameter pipes the
or C temperature has to be measured most suitable immersion length
• flanged thermowells type F at such a depth that a good can often be achieved only
• weld-in thermowells type D. compromise among different by installing the assembly at
measuring problems is obtained. an angle to the pipe axis or in
Terminal head • The heat conducted into bends. In this case the inserted
A terminal head is sensors from ambient may assembly must be mounted
recommended to protect the alter the temperature of the against the flow.
connections between the insert sensing tip: for this reason a …
and the external circuit wires. short sensor is preferable.
The heads are normally • The thermometer /
provided with two connections, thermowell process
one for the thermowell and one connection may introduce

The Endress+Hauser Maintenance Guide 83

Internal wiring of
1xP t10 0 Class Toierance (°C)
Pt100 inserts
A 0.15+0.002 ltl
According to IEC751, three
R ed B 0.3 +0.005 ltl
W hite configurations are possible:
R ed
R ed Notes:
3 w ires
• ‘2 wires’ configuration ltl = modulus of temperature in °C
This configuration generates without regard to sign.
W h ite Tolerance value for each temperature
an error which equals to
point can be calculated with the above
2 times the resistance of the formula.
R ed
wire. This configuration is Example: class A tolerance value at
recommended only when no -50°C = 0.15 + 0.002 x 50 = 0.25°C
1xP t100 high precision is required.
• ‘3 wires’ configuration Tolerance values vary with the
This configuration introduces temperature.
W h ite a compensation which reduces
R ed W h ite
W h ite We recommend the use of
the error to approx. zero. This
4 w ires configuration is commonly the ‘4 wires’ configuration
R ed used in industry today. combined with class A
R ed tolerance for high measurement
• ‘4 wires’ configuration
Provided as a standard precision.
R ed W hite connection for the single
Pt100’s, this configuration Device configuration
Fig. 6: Internal wiring of Pt100 inserts excludes additional errors in (see fig.7)
every condition. Generally PCP (PC-programmable):
in the ‘4 wires’ configuration Online configuration with
there is an higher guarantee TXU10 SETUP connector,
of accuracy. socket and ReadWin® 2000
operating software.
The TPR insert series is HART®:
available in two basic versions HART® signal for on-site or
(see fig. 6). The connections centralized device set-up using
of the first one, with free a hand-held terminal (DXR375)
wires for mounting of in-head or PC. Operation, visualization
transmitters, are shown in the and maintenance at the PC
left side of the figure, while the using FieldCare, AMS, PDM or
connections of the second one, ReadWin® 2000 software (valid
with ceramic terminal block, for TMT184 and TMT85).
are shown in the right side of
the figure. On the left side, Operations and Maintenance
the internal wiring of Pt 100 is
shown. Maintenance mostly consists
of periodic calibration. We
Resistances and tolerances also recommend that you
IEC 751 standard periodically check (visually) the
Nominal resistance is the installation’s watertightness.
specified resistance value
at a given temperature. Thermometer calibration
Thermometers of 100Ω A calibration means the
nominal resistance value at determination of a deviation
32°F (0°C) shall be classified compared to a reference that
according to degree of shows a known uncertainty.
conformity with So when calibrating, the ‘right’
the values of the complete value of the measurement is
reference table of temperature predefined by a reference with
vs. Ω for Pt100 resistance which the measurement to
elements. be calibrated is compared. In
Class A and B tolerances are the case of thermometers this
given in the following table. happens either at the defined
Class A tolerances shall not fixed points of the international
be applied to Pt100 resistance temperature scale (ITS90) or by
thermometers at temperatures the comparison with a normal
above 1202°F (650°C) and it thermometer.
Fig. 7: Device configuration is valid only for 3 and 4 wires So a redundant sensor cannot
thermometers. replace any calibration, because
both measurements may drift
and neither of the two sensors
are a traceable reference.

84 The Endress+Hauser Maintenance Guide

An accredited calibration curve drifts slightly. This

Old generation New Description Spare part
is carried out under a strict drifting is usually particularly availability
compliance with national marked with new devices, TST10/TST111/TST221 TR10 RTD-sensor until 10/2010
or international norms and while later on a certain TST42 TR24 RTD-sensor until 10/2011
guidelines. The normals stabilization is observed.
and gauges used as well as Therefore, calibration should TST425 TR25 RTD-sensor NO

the calibration process and be performed somewhat more TST11/TST211 TR11 RTD-sensor until 10/2010
algorithms of the evaluation often in the beginning (about TST12/TST221 TR12 RTD-sensor until 10/2010
and measuring accuracy every 3–6 months). Later on,
TST13/TST131 TR13 RTD-sensor until 10/2010
calculation were checked and having gained experience
approved and confirmed in with the drifting behavior of TST140/TST141 TR15 RTD-sensor until 10/2010
the accreditation authority one special thermometer, the TST288 TR88 RTD-sensor until 01/2013
approval. The compliance is recalibration intervals may TST44N TR44 RTD-sensor until 10/2009
regularly supervised by an certainly be prolonged (about
TST14 TR45 RTD-sensor until 10/2009
accreditation authority by every 9-12 months).
audits and tests. In Europe TST74 TR47 RTD-sensor NO
the national accreditation Thermocouples: The user TST76 TR48 RTD-sensor NO
authorities have united might be recommended (if a TST262 until 10/2009
themselves within the EU (e.g. particularly high precision of TR62 RTD-sensor
TST264 until 01/2013
DKD: Germany, SIT: Italy; measurement is required), to
SCS: Switzerland) to the EA buy only a TC calibrated by us TST266 TR66 RTD-sensor until 10/2013
(European Cooperation of and to recalibrate it himself, TET100 NO
Accreditation). in the beginning maybe every TET102 TPR100
2-3 months. measurement insert
The factory calibration is
carried out in dependance If the TC turns out to be stable, TSC110S TC10 Thermocouple until 10/2010
on production norms and after some time the calibration TSC130S TC13 Thermocouple until 10/2010
sets of rules or according to cycles may certainly be TSC140T TC15 Thermocouple until 10/2010
requirements of the customers. prolonged to 9-12 months.
TSC288 TC88 Thermocouple until 10/2011
The results are documented It absolutely depends on
in a calibration certificate. the individual case. After TSC262/TSC264 TC62 Thermocouple until 10/2012
Of course all test equipment all, drifting is different with TSC266 TC66 Thermocouple until 10/2012
used is traceable to national/ every TC, therefore general TEC100/TEC105 TPC100 Thermocouple, NO
international standards. The recommendations regarding measurement insert
measurement accuracy of a calibration cycles can hardly TMT136/TMT137 TMT180 Head transmitter NO
device is not influenced by a be made. If precision is of
TMD831 TMT181 Head transmitter NO
calibration. Just the opposite, major importance to him, the
during an adjustment (defined customer will have to monitor TMD832 TMT182 Head transmitter NO
on page 6) a measurement the drift himself and decide TMD834 TMT184 Head transmitter NO
device is adjusted and calibrated then, how often he will have TMD842 TMT112 Transmitter NO
in such a way that the the TC recalibrated - or not. TMT122 DIN-rail transmitter
measurement deviation does
TMD833 TMT162 Field transmitter NO
not exceed predetermined error Note: with nearly all
limits (defined by the user). transmitters you can compensate TMT165 TMT162 Field transmitter until 10/2010
The following are part of any the drift via ReadWin® 2000 TMT165 TMT85 Head transmitter until 10/2010
adjustment: Trim, offset and (‘sensor matching’). TMD833T TMT162R Compact NO
sensor-transmitter matching. thermometer,
Spare parts RTD-sensor and
Field transmitter
How often must a
thermometer be calibrated? The insert, the thermowell, the TMD833C TMT162C Compact NO
At which intervals is terminal head and the transmitter thermometer,
Thermocouple and
recalibration required? can be exchanged if necessary. Field transmitter
How often a thermometer should
TA10 TW10 Thermowell NO
be recalibrated depends on: Migration
• the user’s requirements TA11 TW11 Thermowell NO
regarding precision. You will find detailed TA12 TW12 Thermowell NO
• which thermal (maximum information regarding the new TA13 TW13 Thermowell NO
temperature, possible thermo generations of temperature
TA573/TA574 TW15 Thermowell NO
shocks, frequent changes sensors in the following table.
of temperature etc.) or TA250 TW251 Thermowell NO
mechanical strains (vibrations, Re-engineering
jolts etc.) the thermometer
will be exposed to. You wish to use an instrument
• legal requirements. for a new application? We can
help you check the relevant
As we know, RTD is affected by parameters. See our online
aging, i.e. their characteristic Applicator tool.

The Endress+Hauser Maintenance Guide 85

Frequently asked questions

The PLC doesn’t display the right temperature value… • For TMT122/142/182 (HART products) and TMT162 (HART
• Check the Pt100 signal by means of an Ohmmeter. version only), ensure that the load resistance at the Commubox’s
• Thermocouple: terminals equals 250 Ω. If the loop is overloaded (due to
• Is the right thermocouple selected? the PLC’s impedence or the presence of a recorder) the load
• Is the right temperature for the reference junction used? resistance can be much higher thus reducing the signal’s intensity.
• Ensure that both 4-20 mA ranges of the transmitter and the PLC • You are using TXU10:
correspond. • Is the USB driver installed in the PC? The driver is stored on
• Check or calibrate the thermometer. the Readwin® 2000 CD-ROM. You can download the latest
• Check the installation (see fig. 4 and 5 on the previous pages). version from
• To install the driver you need ‘admin’ rights on your PC
• Also take care of the selected communication port: From
I have no communication to the transmitter from Windows®, ‘START’/’CONTROL PANEL’/’SYSTEM’/
• Ensure that your transmitter can communicate. From this window, use the port number that corresponds to the
• Is the latest version of Readwin® 2000 installed in the PC? connected communication interface (FXA195 if you are using a
You can download it from HART modem).
• Ensure that the power supply is min. 9 V for TMT181 and
• For TMT182 (HART) and TMT122 (HART), switch of the ‘FIFO
active’ setting. In order to do this proceed as follows:
• Windows NT® Version 4.0:
‘CONNECTIONS’ select the menu point ‘COM-Port’. Switch
off the ’FIFO active’ command off using the menu path
• Windows® 2000:
Select ‘Advanced settings for COM1’ from the ‘START’/
‘Use FIFO buffer’.
• Windows® XP:
Select ‘Port settings’ from connections Port (Com 1)/’START’/
(COM1)’/‘PORT SETTING’/‘ADVANCED’ menu. Deactivate
‘Use FIFO buffer’.

86 The Endress+Hauser Maintenance Guide


Laurent Avorio
Expert in recorders
Endress+Hauser France

“The advantages of switching to paperless recorders”

“Today, maintenance of strip chart These devices are maintenance free. So in Contents
recorders is considered as (too) high. The the next pages we focus on suggestions for
need for many consumables (paper and better operation. Basics 88
pens) and the fact that data isn’t stored FAQ 90
electronically are big inconveniences in the Nevertheless paper recorders still
process world. constitute a pretty big part of the market.
Endress+Hauser will keep providing
This is why electronic (paperless) recorders consumables for its recorders.
have rapidly become very ‘popular’.
Whereas the first generation stored the data As experts, we also offer training sessions,
on diskettes, the new range uses Compact in classroom and on site. We would be glad
Flash or Secure Digital cards for even more to meet with you and help you go one step
reliability and storage capacity. further. See ‘Training’ in the section
‘At your service’.”

The Endress+Hauser Maintenance Guide 87


Information common to any type

of modern recorders
The current Endress+Hauser range of recorders includes:
• Ecograph RSG20/22/24 and Ecograph T RSG30 multi-channel
electronic (paperless) recorders
• Memograph S RSG10/12 and Memograph M RSG40, system
compatible data managers with a unique safety concept for critical
applications. Compliant to the high FDA requirements laid down in
21 CFR Part 11.

Measuring principle • Display of historical data 21 CFR 11 the device to put the device into
and main features on site • Memograph M and S together service / configure it via PC.
• Display of statistics with ReadWin® 2000 You can also download the
The electronic recorders carry • Various display modes fulfil the requirements of latest software version directly
out the electronic acquisition, 21 CFR 11 concerning from the internet under the
display, recording, analysis, Memory (fig.1) electronic documents and following address:
remote transmission and • Redundant memory electronic signature.
archiving of analog and digital ensures safe data recording: For further information on
input signals. internal Flash memory + CF Installation instructions ReadWin®2000, refer to
(CompactFlash) or SD (Secure the operating manual of the
Communication Digital) cards and USB stick + Outside installation software (BA137R/09).
• Communication interfaces data transfer to a PC The front side seal should be
available: USB, RS232, RS485, Note: Please use the correctly positioned to ensure Advantages of configuration
Ethernet, Profibus DP and original memory cards from watertightness and avoid any via PC:
MODBUS (RSG40) Endress+Hauser, because these problem due to condensation. • The device data is saved in a
are industrial proved. And the backside should also be database and can be accessed
Input/Outputs protected against humidity. again at any time.
• Galvanically isolated universal Analysis/archiving • Text entries can be carried out
inputs (U, I, TC, RTD, and • Long-term archiving is carried Cabling more quickly and efficiently by
frequency) out at the PC, whereby the • Please cable the unit keyboard.
• Digital input (high/low) data is transferred to the with care. Many reported • Measured values can also
• Digital output database, via Ethernet or problems come from wrong be read out, archived and
(relay/open collector) serially to the PC. connections. We remind you displayed on the PC with this
• Mathematic channels for • Using the supplied PC that the cabling synopsis is program.
calculations software package, the devices printed on the rear side of the
can be operated, read-out and recorder. Operations and Maintenance
Display of measured values the measurement data can be • Please use shielded cables.
• Electronic recorders are easy archived and visualized. Electronic recorders are
to program via the ‘Set up’ Surge arrester maintenance free.
window or from a PC We recommend the use of If your unit includes a floppy
surge arrester(s) (HAW56x disk drive, we recommend that
family) to protect the you clean the disk drive once a
instrumentation against year with a cleaning disk (several
overvoltage. times a year in dusty areas).

Set-up Using the ‘screensaver’ mode

increases the display’s lifetime.
Set-up can be performed at
Copy saved on
the unit by using the ‘Set Tips for safe and
Compact Flash up’ window at main menu. comfortable operation
or SD card Nevertheless setting up using a • Use Readwin® 2000 to
PC is much more comfortable. analyze and print the
Data transfer recorded data.
using CF Set-up using PC Note: the operating
or SD card
You can use the PC software instructions documentation
ReadWin® 2000 provided with related to Readwin® 2000 is
Fig. 1: Measuring system on new generation recorders available on the delivered CD.

88 The Endress+Hauser Maintenance Guide

• Use the ‘Safely remove RS232/RS485, Ethernet or Interface connection
CF/SD/USB’ function (on USB. Start the provided PC
Ecograph T and Memograph software. Select ‘Read out
M) to ensure safe removal of -> Read out memory card by
the memory card: all internal interface/modem’. Select
access is ended and you the appropriate unit from
receive a message when the the PC data base. Select
card can be safely removed. ‘Unit -> open unit(s)’. The
To prevent possible loss of connection is developed.
data, this function must be Select the appropriate file on CompactFlash or SD Secure Digital
memory card
the only method used to the memory card and confirm
remove the card. with ‘OK’. The measured Fig. 2: Data transfer to the PC
values are read out. The
Data transfer to the PC measured values remain on
(see fig.2) the memory card. Program update (mechanically locked) on the
We recommend to periodically We recommend that you recorders. No data loss even
transfer the recorded measured We recommend the following always use the latest version of in event of power failure!
data and the configuration data procedure for saving data: software. Please note that all • Communication interfaces:
to a PC. Data can be transferred • Always have a memory card data stored in unit memory as see table 1 (next page)
to the installed PC software in inserted well as memory card or diskette • Available worldwide:
one of the following ways: • Periodically read out the is deleted on a program update. integrated Web server function
• Using USB, RS232/485 or memory card with the PC for remote monitoring e.g.
Ethernet. Communication software Spare parts stock with Endress+Hauser Fieldgate
and download of data to PC • Protect the access to the Viewer®
using the function ‘Read out recorder’s configuration via We recommend to keep a power • Reliable: inputs are galvanically
-> Read measured values a service code to prevent supply board in stock if you have isolated from the system
using interface/Modem’. unintentional modification. no surge arrester installed to • Complete: ReadWin® 2000
• Save the data to Note: the data on the memory protect the instrumentation. PC software package
CompactFlash in the unit card are compressed (10 to 1). delivered with the recorder
using the function: for RSG40 Migration for professional, tamper-proof
‘Extras -> SD Card -> ...’ or Changing the configuration data processing
‘Extras -> USB Stick -> ...’, Changing the configuration The shift to electronic recorder • Flexible: direct access to
for RSG30 ‘Main menu -> at the unit implies the loss offers many advantages: archived data also with MS®
CompactFlash (CF) functions of the recorded data and • Economical: electronic Excel or in ReadWin® 2000
-> Update CF’ the need to create a new recording replaces strip chart for example
Now insert the memory card unit in ReadWin® 2000. recorder, saves on consumables
into the PC and read the data Thus we recommend to • Versatile: up to 6 (RSG30) or Re-engineering
using the function ‘Read out change the configuration via 20 (RSG40) universal inputs
-> Read out measured values ReadWin® 2000 and to read out record all measuring signals You wish to use an instrument
using PC card drive’. measured values before. • Clear layout: multi-coloured for a new application? We can
• Read out the memory display, digital, bargraph and help you check the relevant
card with the provided Calibration curve display parameters. See our online
PC software: In principle Calibration must only be • Compact: low installation Applicator tool.
the values can be read out carried out by skilled and depth, saves space and money
directly from the memory trained personnel. Malfunctions • Safe: reliable data archiving
card. The connection are possible if calibration is not with internal memory and
to the unit is made by performed correctly! separate memory card

The Endress+Hauser Maintenance Guide 89








Ecograph RSG20 • • •
Ecograph RSG22 • • •
Ecograph RSG24 • • •
Ecograph T RSG30 • • • •
Memograph RSG10 • • • •
Memograph S RSG12 • • • •
Memograph M RSG40 • • • • • • •
Table 1: communication interfaces available

Frequently asked questions

How to start with Readwin® 2000? (see also BA137R) The display of the % of external memory is not correct after
• Create a unit ‘Group/plant’ read out to a PC…
• ‘Unit\Display/Change unit setup/Add new unit\Unit group plant’ The displayed percentage will be refreshed after the first new
memory block is sent to the external memory.
How to insert and configure the unit? (see also BA137R)
• ‘Unit\Display/Change unit setup/Add new unit\Unit\ I have no communication via USB to the recorder…
Add new unit’ • Is the USB driver installed in the PC? You can download the latest
version from
How to store and display measured values on the PC? • To install the driver you need ‘admin’ rights on your PC
There are two ways to read out data: • Also take care of the selected communication port: From Windows®,
Click ‘Read out/Read out measured values using PC card drive’ MANAGER’/’PORTS’
then ‘New unit’ and give it a name. Data will then be transferred. From this window, use the port number that corresponds to the
• Via the interface connected communication interface (FXA195 if you are using a
Click ‘Read out/Read out measured values using interface/modem’ HART modem).
then ‘New unit’ and give it a name. Data will then be transferred.
Will the database of measured values be deleted after an
To display the data, click ‘Display/Display measured values from update of Readwin® 2000?
database’ No.
Choose the unit to be displayed, then the data timescale etc.
Will the configuration and the measured values be deleted
How to export data from Readwin® 2000 to Excel®? after a software update?
• To display the data, click ‘Display/Display measured values from Yes. Please read out and save data before.
Choose the unit to be displayed, then the data timescale etc. Can the language be changed on the recorder?
• Click ‘Tabular’ at the bottom left of the screen then click on the Yes. Please ask the helpdesk for the right software.
‘Display’ tag at the top left then choose ‘Save table’ (choose .txt
or .xls file format) Can I define different levels of user rights in Readwin® 2000?
Yes: ‘Extras\Program options\Set-up\Security\Password protection’
How long can we store measured values on the external and must be activated
internal memories?
Please refer to the Operating Instructions of your device. The terminals on the back side of the unit are missing…
Only the terminals that correspond to the options you have ordered
are delivered.

90 The Endress+Hauser Maintenance Guide

Field communication

Laurent Avorio
Expert in digital communication
Endress+Hauser France

“An introduction to the maintenance of fieldbus networks”

“The use of digital communication We have issued ‘Guidelines for planning Contents
and fieldbus networks provides lots of and commissioning’ for both Profibus and
advantages in terms of maintenance. Foundation Fieldbus networks. For further Basics 92
details, please refer to BA034S (Profibus) FAQ 94
Digital instrumentation can exchange and to BA013S (Foundation Fieldbus). You
simultaneously lots of data with PLC’s and can download these documents from our Zoom: hardware tools
computers in both ways. web site. for the maintenance of
fieldbus networks 96
Once the instruments have been installed, As experts, we also offer training sessions,
their parametrization can be performed in classroom and on site. We would be glad
remotely, from technical premises, a control to meet with you and help you go one step
room or at any point of the network with a further. See page ‘Training’ in the section
laptop - which is nice in case of hazardous ‘At your service’.”
environments or difficult access.

In case of troubleshooting, the diagnosis

can also be performed in the same way,
even at a long distance, thanks to gateways
or modems.

The Endress+Hauser Maintenance Guide 91

Field commuincation

Helping you to maintain fieldbus networks

Endress+Hauser’s instrumentation is involved in networks that may combine:

• the HART® protocol
• Profibus DP/PA architectures
• Foundation Fieldbus architectures

HART is a point to point protocol protocol differs -, the ‘low output control commands. The PROFIBUS PA is used at field
(see fig.1): a PC talks to a level’ maintenance is identical asset management program, level. The segment coupler
single instrument (or to several in both networks. e.g. FieldCare, serves as a serves both as interface to the
instruments via a multiplexer). Class 2 master. It uses the PROFIBUS-DP system and as
Profibus DP/PA typical acyclic services and serves power supply for the PROFIBUS
Conversely, Foudation Fieldbus architecture (Fig. 2) to parameterize the bus PA field devices. Depending
and Profibus fit for the data participants during installation upon the type of segment
exchange to a programmable The process is controlled by and normal operation. coupler, the PROFIBUS PA
logic controller (PLC) or a a process control system or a segment can be installed in safe
process control system (PCS). programmable logic controller The PROFIBUS DP system or hazardous areas.
(PLC). The control system or is used to handle the
Since Foudation Fieldbus and PLC serves as a Class 1 master. communication at the control Foundation Fieldbus typical
Profibus use the same electric It uses the cyclic services to level. Drives, remote I/Os etc. architecture (Fig. 3)
signal and encoding - only the acquire measurements and may all be found upon the bus.
It is also possible to connect The Foundation Fieldbus system
externally powered field devices architecture has been designed
to this level, e.g. the flowmeters to promote interoperability
e.g. e.g.
Promass and Promag. between and among devices of
PROFIBUS DP ensures that data different manufacturers. Since
4…20 mA 4…20 mA
interface is quickly exchanged, whereby Foundation Fieldbus supports
in mixed PROFIBUS DP/PA both a high speed and low speed
4…20 mA 4…20 mA

systems the baudrate supported (H1) network, two architectures

HART Multidrop (up to 15 devices)

by the segment coupler is often exist. These provide the same

the limiting factor. basic functionality but differ in
Fig. 1: Typical HART architecture

Process operation and PROFIBUS

visualisation with P View Visualisation Network
master for cyclic
Plant Asset Management process data and Monitoring engineering
with FieldCare communication e.g. P View e.g. ControlCare
Ethernet (I/O) Configurator
PROFIBUS master for
acyclic communication

AS-Interface High Speed Ethernet
Devices from third-party vendors
(Remote I/O, drives, pumps, etc.)
Field Controller/ Field Controller

4x 4x
Safe Area FOUNDATION Fieldbus H1 FOUNDATION Fieldbus H1
Hazardous Area

Fig. 2: typical architecture of a Profibus DP/PA network Fig. 3: standard Foundation Fieldbus architecture

92 The Endress+Hauser Maintenance Guide

Field commuincation
the communication stack. The •T-boxes with switchable PLC
H1 layer is IEC 61158-2 based
and the high speed layer uses
terminators may not be used in
explosion hazardous areas. The
FieldCare A Connection Commubox FXA195

High Speed Ethernet (HSE). terminator requires the

corresponding FISCO approval
Installation instructions and is a separate unit. Commubox 270



•For a segment with a tree Switch Commubox FXA195

Cabling and termination are architecture, the bus ends at A
at the origin of most reported the device that is the furthest
problems. from the segment coupler. Transmitter power-
supply unit,
Measured Value

64.50 %

e.g. RMA422
•If the bus is extended by or RN221N
(with communication
Cabling the use of a repeater, then Display and
df das.
asdas fa
asas la.

DELTABAR: * * * * * * * *

3 PV 352 mbar

operating module
4 SV 0 °C


When installing a PROFIBUS the extension must also be

Bksp Delete



1 2 3
Copy Paste Hot Key


4 5 6

network, particular attention terminated at both ends.

Insert + Hot Key


HART handheld terminal

7 8 9
RMA 422 ,()‘ _<> +*/
. 0 -

or 375
must be paid to the cabling. This The beginning and end of DXR375

covers both choice of cabling, the PROFIBUS DP segment

and the way in which the cables must also be terminated. Fig. 4: HART connection of a PC to a field device using Commubox FXA191/195
are laid in the plant. Thus by The terminating resistors are
careful routing, e.g. avoidance already built into most of the
of potential sources of intense connectors on the market and
electromagnetic interference, use must only be switched in. Operations and Maintenance Re-engineering
of metal trays or separation of Note: branch lines are allowed
power and bus cables in the cable in Profibus PA segments but not HART devices • When adding fieldbus
tray, a significant contribution can in Profibus DP segments. As the HART signal modulates networks to an existing
sometimes be made to the fault- the 4-20 mA current, if the installation, consider
free running of the bus. Set-up latter operates, the former exchanging basic remote I/O
Note: never use Profibus DP should also operate. You just devices with smart I/O devices
cables for cabling PA devices and Device Parametrization using need to check the presence of thus allowing centralized access
vice versa. FieldCare Asset Management the current with a multimeter. to HART devices.
FieldCare is Endress+Hauser’s By using a Commubox • Also consider using the
Termination FDT based Plant Asset FXA191/195 (see fig. 4), you FXA720 gateway to link
The start and end of every Management Tool. It can should see the instrument from Profibus networks to Ethernet
PROFIBUS PA segment must configure all intelligent field FieldCare, otherwise there is a networks.
be fitted with a bus terminator. devices in your plant and problem with the cabling. • Take care of the maximum
For non-hazardous areas, some supports you in managing them. output current supplied by the
T-boxes have an integrated By using status information, Profibus network segment coupler when adding
terminating element that can be it also provides a simple but See diagnosis on next page. a new device otherwise the
switched in when required. If effective means of checking segment might fail.
this is not the case, a separate their health. FieldCare supports
terminator must be used. Ethernet, HART, PROFIBUS, Our ‘Solutions’ teams can help you
•The segment coupler at the and in future FOUNDATION from the start of your revamping
beginning of the segment has a Fieldbus etc. project. Please contact us.
built in terminator. FieldCare ensures that devices
•The terminator in the T-box can be integrated and configured
at the end of the segment must quickly and easily, with the
be switched in, or a separate transparency demanded by good
terminator must be used. manufacturing practice.

The Endress+Hauser Maintenance Guide 93

Diagnosis of Profibus networks • Do I use the correct GSD* file?
Field commuincation

• Enable ‘Set unit to bus’ at the device to ensure correct scaling

• Is the decoding correct at the PLC?
If you are facing a problem (be it during commissioning or be it a
troubleshooting) with a device installed in a Profibus network: * The PROFIBUS system requires a description of the device parameters, e.g. output
• First search for addressing errors data, input data, data format and supported transmission rate, so that it can inte-
• Then search for connection problems grate the field devices into the bus system. This data is contained in a PROFIBUS
device description file (GSD file) which is placed at the disposal of the PROFIBUS-DP
• Then check the correct integration of the device in the system master when the communication system is being commissioned. Device bitmaps,
(how data is transferred to the PLC): which appear as symbols in the network tree, can also be integrated. See Chapter
7-2 of BA034S

Frequently asked questions

HART protocol • The bus is terminated by using a separate terminator or a
T-piece/junction box with a switchable terminating element
I have no communication to the device from the PC… PROFIBUS DP:
• Ensure that the load resistance at the Commubox’s terminals • Termination switches are located in the devices. We recommend
equals 250 Ω. If the loop is overloaded (due to the PLC’s the use of PROFIBUS connectors with integrated terminators
impedence or the presence of a recorder) the load resistance can (in cabinet).
be much higher thus reducing the signal’s intensity.
• Switch of the ‘FIFO active’ setting. In order to do this proceed as When a device is added to the bus, the segment fails.
follows: The segment coupler supplies a defined maximum output current
• Windows NT® Version 4.0: to the segment. Every device requires a particular basic current (see
Using the menu ‘START’/‘SETTINGS’/‘SYSTEM CONTROL’/ Chapter 5.3 of BA034S). If the sum of the basic currents exceeds
‘CONNECTIONS’ select the menu point ‘COM-Port’. Switch the output current of the coupler, the bus becomes unstable.
off the ’FIFO active’ command off using the menu path • Diagnosis: Measure the current consumption of the devices with
‘SETTINGS’/’EXPANDED’. an amperemeter.
• Windows® 2000: • Remedy: Reduce the electrical load on the segment concerned,
Select ‘Advanced settings for COM1’ from the ‘START’/ i.e. one or more devices must be disconnected.
‘DEVICE MANAGER’/‘CONNECTIONS (COM and PROFIBUS-PA slave with address 2 cannot be found.
LPT)’/‘COMMUNICATION CONNECTION (COM1)’/ • If a Siemens DP/PA-link Type IM 153/157 is used, the internal
‘CONNECTION SETTINGS’/‘ADVANCED’ menu. Deactivate address must be taken into consideration. On the PROFIBUS-PA
‘Use FIFO buffer’. side, the link has the fixed internal address 2. For this reason, the
• Windows® XP: address 2 may not be assigned to any of the PROFIBUS PA slaves
Select ‘Port settings’ from connections Port (Com 1)/’START’/ connected to the link.
’SETTING’/’SYSTEM’/‘HARDWARE’/‘DEVICE MANAGER’/ • Two devices (slave or master) have the same address. Disconnect
’PORTS (COM and LPT)’/‘COMMUNICATION PORT the slave with address 2 from the bus and check whether there
(COM1)’/‘PORT SETTING’/‘ADVANCED’ menu. Deactivate are others on the bus with the same address (e.g. with FieldCare
‘Use FIFO buffer’. of Commuwin II). Readdress as appropriate. Check the settings
• Also take care of the selected communication port: of the PROFIBUS master as to whether the address 2 has been
From Windows®, ‘START’/’CONTROL PANEL’/’SYSTEM’/ allocated twice.
From this window, use the port number that corresponds to the PLC planning on Profibus networks
connected communication interface (FXA195 if you are using a
HART modem). The measured value in Siemens S7 PLCs is always zero
• Check the minimum voltage required for your HART • The function module SFC 14 must be used. The SFC 14 ensures
communicating transmitter(s); the voltage is related to the device. that e.g. 5 bytes can be consistently loaded into the SPS. If the
SFC 14 is not used, only 4 bytes can be consistently loaded into
Commissioning of Profibus networks the Siemens S7.
• Newer versions of the S7 series can access the I/O buffer directly.
How can I assign an address to a device? The SFC 14 is no longer required.
• With the exception of the analysis device Mypro, all
Endress+Hauser devices have an address switch that allows hard- The measured value at the device display is not the same as
ware or software addressing. that in the PLC.
• Software address changes can be made via the PROFIdtmDPV1 The parameters PV_SCALE and OUT_SCALE are not set correctly.
CommDTM of FieldCare, the DPV1-DDE server of Commuwin OUT_SCALE_Min. = PV-Min.
II or any other PROFIBUS operating tool. See also Chapter 6.6 of OUT_SCALE_Max. = PV-Max.
BA034S. Instructions on how to adjust the parameters PV_SCALE and
OUT_SCALE in the function block can be taken from the device
Where is the device termination switch? operating instructions.
PROFIBUS PA: Note: we recommend to use FieldCare for this adjustment.
• There is no termination switch on the device itself.

94 The Endress+Hauser Maintenance Guide

No connection between the PLC and the PROFIBUS PA network. FieldCare

Field commuincation
• The bus parameters and baudrate were not set when the PLC was
configured. The baudrate to be set depends upon the segment FieldCare cannot open connection to the PROFIBUS PA
coupler used (Chapter 7-5 of BA034S). devices…
- Pepperl+Fuchs SK1: 93.75 kBit/s FieldCare is a Class 2 master that allows the transmission of acyclic
- Siemens: 45.45 kBit/s values. The PROFIBUS-DP baudrate to be set depends upon the
- PA-link (Siemens IM 153/157): freely selectable segment coupler used.
- Pepperl+Fuchs SK1: 93.75 kBit/s
- Pepperl+Fuchs SK2 and SK3: freely selectable The connection to the devices cannot be opened.
• For Pepperl+Fuchs SK2 and SK3, the PROFIBUS PA GSD has not • If the PLC and FieldCare are used in parallel, the bus parameters
been converted must be mutually compatible. The bus parameters must be
• The bus parameters require adjustment identical for all connected masters.
• The polarity of the PROFIBUS-DP line is reversed (A and B)? If FieldCare is used, the Token Rotation Time (TTR) calculated by
• PROFIBUS-DP bus not terminated? the PLC configuration tool must be increased by 20 000 bit times
• Both the beginning and the end of the bus must be terminated. and the corresponding value entered in the FieldCare Profibus
configuration and in the PLC.
Data transmission on Profibus networks • The HSA parameter (Highest Station Address) must permit
the FieldCare address. The HSA specifies the highest address
How are data transferred to the PLC? permitted for active participants (masters) on the bus. Slaves can
• The measured values are transmitted in 5 byte long data blocks. have a higher address.
4 bytes are used to transmit the measured value. The fifth • Is the FieldCare address free or is it being used by another device?
byte contains standardized status information. Error codes for • Is the correct baudrate set?
Endress+Hauser device faults, e.g. E 641, are not transmitted • Have the drivers and cards been correctly installed? Is the green
with the status. LED on the TAP of the Proficard or Profiboard lit?
• For limit switches, the information is transmitted in two bytes: • Is the GAP update to high (the result is longer waiting times)?
Signal condition and status information.
A device does not appear in the live list.
How can the PLC switch on the positive zero return of the • Device is not connected to segment.
Promag 53? Via the output word of the cyclic services. • Address used twice.

How can the totalizer of the Promag 53 / Promass 83 be reset? Device cannot be fully operated.
Via the output word of the cyclic services for the totalizer in • The device version is not supported by FieldCare. An appropiate
question, see corresponding operating manual. DTM is necessary. The default parameters of the PROFIBUS-PA
profile are offered.
How can I suppress a measured value in cyclic communication?
By using the placeholder ‘EMPTY_MODULE’ or ‘FREE_PLACE’ A change of unit at the device has no effect on the value on
during configuration. the bus.
If the measured value at the device display is to be the same as that
How can I write a value to the local display? transmitted to the PLC, the parameters PV_SCALE and OUT_
By using the Display_Value model from the GSD (if supported). SCALE must be matched.
General note: You can refer to Chapters 7.2 and 7.3 of BA034S - OUT_SCALE_MAX = PV_SCALE_MAX
(Profibus) for more details. See the device operating instructions.

The Endress+Hauser Maintenance Guide 95

Zoom: hardware tools for the
Field commuincation

maintenance of fieldbus networks

Commubox FXA191/FXA193 and USB HART interface

Commubox FXA191 is an intrinsically safe interface for Smart

transmitters. It converts INTENSOR and HART protocols to
RS-232 signals.

The Commubox FXA191 The USB HART interface makes

connects intrinsically safe Smart it possible to connect SMART
transmitters with INTENSOR transmitters with HART protocol
or HART protocol to the serial to the USB port of a PC.
port of a PC. This allows the
transmitters to be remotely The Commubox FXA193
configured using for example connects all the Endress+Hauser Main advantages: • Connection of the
the Endress+Hauser Commuwin transmitters with a service plug • Simple connection of HART Endress+Hauser transmitters
II operating programme. The to the serial port of a PC. For and INTENSOR transmitters to to a PC by means of the
Commubox FXA 191 is powered example it’s easy to configure the serial port of a PC Service plug in the connection
over the serial port. and service the PROline series • Intrinsically safe input housing of the instrument
If the computer, e.g. a notebook flowmeters with the FieldTool® (FXA191) (FXA193)
or laptop, is unable to supply software or the Micropilot M • Connection of HART
enough power, the Commubox with ToF Tool® / Fieldtool (see transmitters to the USB
can be supplied with an external page 80). port of a PC (USB HART
power pack. interface)

Technical data Commubox FXA191

Power supply Either from RS232 port or external power
pack (accessory)
Electrical connection 9 pin DIN female connector for computer;
4 mm plug terminals for transmitter, po-
larity protected, supply (optional): clutch
socket, 9VAC / VDC, polarity protected Typical application of Commubox FXA191: HART connection to a Micropilot
Intrinsic safety [EEX ia] IIC BVS 95.D.2060X for
connection to intrinsically safe circuits
EEx IIC with voltages up to 30V
Operating range -20 °C...+50 °C
Storage -40 °C...85 °C
Humidity 0 %...95 % (no condensation)
Dimensions Housing 143 x 60 x 30 mm with plastic
housing for industrial use

How to order this tool:

Refer to the price lists in the insert ‘The Maintenance Store’ attached Typical application of Commubox FXA193: connection to the service plug in the
to this Maintenance Guide. connection housing of a Micropilot

96 The Endress+Hauser Maintenance Guide

Field commuincation
Fieldgate FXA520 - Modem for remote maintenance

Fieldgate FXA520 enables remote monitoring, diagnosis and

configuration of connected HART field instruments (sensors/
actuators) by telephone lines (analogue), Ethernet TCP/IP or
mobile communications (GSM). The measured data is web-
compatible (http, html) and can therefore be displayed in your
web browser without additional software. Fieldgate FXA520
has many possibilities from remote maintenance to inventory
management (VMI).

GSM antenna on a solar panel

Main advantages • Event message via e-mail and Avoid on-site service operations by
using remote monitoring, diagnosis
• Worldwide access to SMS
and configuration:
measuring points with HART • Efficient employment of
protocol via the Internet standby and maintenance staff
• Simple configuration with • The Fieldgate FXA520 has
web browsers without standard two channels for
additional software HART devices and two
• Visualisation of all sensor data channels for analogue inputs
• Remote monitoring, diagnosis 4...20 mA (use of multiplexers
and configuration is possible up to 30 channels)
• Uses standard Internet • DAT module for configuration
protocols (http, html) data backup

How to order this tool:

Refer to the price lists in the insert ‘The Maintenance Store’ attached
to this Maintenance Guide.

The Endress+Hauser Maintenance Guide 97

98 The Endress+Hauser Maintenance Guide
At your service
An extended set of tools and services
to manage efficiently your assets


W@M - Life Cycle

Management for
process automation 100
Commissioning 104
FieldCare ®
Calibration services 106
CompuCal™ 109
Maintenance services 110
Audit 113
Training 116

The Endress+Hauser Maintenance Guide 99

At your service

Life Cycle Management for process automation

Knowledge is a critical factor in driving productivity and Management from Endress+Hauser provides up-to-date and
competitiveness - and full knowledge of your plant status complete information on all your assets, including products
allows for good maintenance planning. W@M – Life Cycle from other suppliers.

Reorder Selection

Replacing Configuration
spare parts

Order tracking


Spare part planning


Condition monitoring

What is W@M – technical and operational management of replacement of individual components,

Life Cycle Management? your plant completely, conveniently, and W@M is an open and flexible information
W@M – Life Cycle Management, is an at any time or place. From engineering, platform with on-site tools and services
open information management system procurement and commissioning through supporting you throughout your plant’s
providing data flow and archiving for the to operation, maintenance and the life cycle.

100 The Endress+Hauser Maintenance Guide

How does W@M support

At your service
your internal processes?

During the procurement phase, W@M helps you check availability

and prices quickly and efficiently – simply place the configured
instrument in the shopping cart and place your order. Immediately,
the status of the order or shipment can be monitored online. What’s
more, the preparation of catalogues and spare part files makes
ordering as easy as possible. Your orders can be prepared and fully
completed in the Endress+Hauser e-shop.

• Up-to-date information:
365 days a year / 24 hours a day Engineering
• Effectively service, maintain and • Fast and safe selection and sizing of
optimize your installed base the correct measuring instrument for
• Constant planning reliability your application
• Documentation and administration
of projects

• Simplified remote commissioning
• Increased safety of your personnel
• Eliminate the need for time Procurement
consuming testing • Reduce procurement costs
• Optimize the quality and speed
of your procurement processes
• Your price and delivery data is
always available on-line

• Product documentation is available in
different languages
• Software versions are always up-to-date

In the commissioning phase, W@M – Life Cycle Management During the operations phase, W@M provides updated and quickly
provides all the information you need for safe installation and available information: be it on spare parts, the verification of
commissioning. You can quickly download documentation, software software versions, tracing instrument history records or viewing the
or certificates in a variety of different languages. plant database with its installed instruments. Using tools such as
FieldCare, CompuCal and the Installed Base Assistant, data can be
freely exchanged with the equipment record within W@M. So, you
can safely comply with continually increasing quality requirements
through traceable and certified calibration and documentation.

The Endress+Hauser Maintenance Guide 101

With help of the tree
At your service

view navigation, any

combination of location
or sub-locations,
applications, loops and
bus systems can be
mapped, allowing W@M
to reproduce the exact
structure of your plant.

Spare part lists for

instruments are made
available automatically.
Exploded view drawings
Live data and great functionality help to easily identify the
right parts.
What makes the W@M concept so very special is the
unique combination of a software tool with a lot of
features and functionality, and the ability to connect to
a supplier’s database to display up-to-date data.

This means that you automatically benefit from the

information recorded and stored by Endress+Hauser
about your instruments e.g. product availability, original
calibration certificates, operating manual etc.

In addition to this, you can archive your own

informations and documentations related to your assets.
Therefore, W@M is the centrally organized information
management for you and your colleagues.

Easy integration into your existing tools

Integration into CMMS systems SAP PM module
recognizes an
The information content of W@M can be integrated
Endress+Hauser device
into existing CMMS (Computerized Maintenance and offers a link to the
Management Systems) installations such as SAP PM, W@M Portal. Login
Maximo from IBM, Datastream7i from Infor or any details and serial number
are automatically
other system.
transferred allowing
Users do not have to learn how to use a new system: information about the
they keep working in their familiar environment but get current asset to be
access to much more information about their assets. displayed in a browser

Integration into Endress+Hauser tools FieldCare using

its device-in-web
You already use FieldCare or CompuCal, Endress+Hauser’s
functionality connects to
device configuration and calibration tools? With your your W@M application
W@M application, you may access detailed device and shows device related
information directly from those tools with one single information with its
integrated web browser.
click. Of course this also works for 3rd party instruments
managed in the W@M environment.

102 The Endress+Hauser Maintenance Guide

W@M Portal or W@M Enterprise?

At your service
W@M is declined under two versions: W@M Portal and W@M Enterprise. Depending on
factors like IT requirements, security level and internet availability at the plant, you may choose
which IT architecture will provide the optimum solution for the end user.

Endress+Hauser W@M Portal Endress+Hauser W@M Portal

www 128 bit

www 128 bit
Local server W@M

Plant users access W@M via Internet Plant users access W@M via your intranet

W@M Portal features W@M Enterprise features

• Your W@M application is hosted by Endress+Hauser - No local • Your W@M application is available through a local client/server
installation is required. installation at your site.
• The W@M Portal is accessible worldwide from any computer • W@M Enterprise automatically connects to Endress+Hauser
with internet access via secure login (username/password). servers for data download (pictures, product availability
• You benefit from a 128 bit encrypted internet connection. information, spare parts, etc).
• W@M Portal offers an easy integration into existing CMMS • W@M Enterprise replicates with W@M Portal: newly purchased
systems (see previous page). instruments and service or repair events are added automatically.
• Sensitive third party device data is stored locally, Endress+Hauser
data is stored locally and remotely.

Main Benefits of W@M - Life Cycle Management

Overall benefits of Endress+Hauser’s W@M specific benefits
“Life Cycle Management” • W@M portal technology – no need to purchase and install
• A comprehensive life cycle management approach for process expensive software...You just need an internet connection and
automation that can be easily adapted to support your individual can have secure access to all your information.
business processes. • Not ready to connect up to W@M today – then rest assured that
• Optimised management of information around process we continue to collect data on all devices that you procure from
automation tasks ensure guaranteed time and cost savings. The Endress+Hauser … if you log on in five years time you will get
value of the information clearly allows you and your organisation instant access to all your new and old devices within our archives.
to gain competitive edge. • The equipment record is a unique information platform unlike
• A constant access to automatically updated databases ensure other asset management systems which are often highly
that the latest information of your automation equipment is functional but empty tools – Endress+Hauser undertake to hold
always at hand all necessary information on your devices.
• Our technology platform is open and collaborative – this allows
you to link the information into your existing engineering or
maintenance tools. It is also an open platform for third party
device management.

The Endress+Hauser Maintenance Guide 103

At your service

Start-up and commissioning

Optimize your instruments performance right from the start

The demands on your engineering and maintenance staff Your main benefits
are higher than ever before. They are expected to be able to • Short start-up times performed by experienced service
maintain existing equipment yet still be able to accommodate staff
the start up of new plants often faced with the latest technology • Cost-efficient packages focused to your start-up
and equipment that they have never seen before. requirements
• Device performance guaranteed from the beginning of
This is where Endress+Hauser can help - our experienced start-up
service staff can reduce the time to commission to the essential • Briefing and documentation by Endress+Hauser
minimum. That saves costs and your own resources. • All test equipment and special tools provided

Not only a start-up - we offer more …

Sophisticated Loop check Commissioning of Custody transfer Commissioning of
• The installation is checked • A final report / certificate is measurement
non Endress+Hauser
to confirm optimum location issued detailing equipment
of the measuring instrument set-up and advising future Optional
– ensuring best product maintenance requirements. Extended Linearisation of Extended on-site Measuring point
performance. hands-on training measuring points service* certificate

• The application is reassessed You decide about the scope of

to define exact ínstrument commissioning services required. Standard
settings and confirm instru- Beside the standard components Short Functional Verification of

ment choice. each start-up contains, we offer introduction checks measurement

• All electrical connections are optional services to you for Installation

Configuration Service
tested to verify operational special measuring instruments or
safety of the system and com- customized solutions, for example
pliance to EMC regulations. the start-up of complete commu- * Extended Warranty *** Fieldbus
• Hands-on training is carried nication or fieldbus network. with repair service instruments incl.
on-site, 1 year after Profibus PA/DP,
out for your operators and commissioning Rackbus, FF
technicians. ** E.g. for radioactive devices
level and density **** For witness testing
systems to comply of a system in
with local laws and conjunction with
regulations outside officials

104 The Endress+Hauser Maintenance Guide

At your service
Commissioning in the Other example Other example
regulated industries demands a high level demands a high level
demands a high level of experience and of experience and
of experience and documentation to documentation to
documentation to ensure that your IQ/OQ ensure that your IQ/OQ
ensure that your IQ/OQ requirements are fulfilled. requirements are fulfilled.
requirements are fulfilled. Our service Engineers are
Our service Engineers are trained in accordance to
trained in accordance to GMP and we can offer
GMP and we can offer full validation services as
full validation services as required.

From device configuration to plant asset management
FieldCare can be used in direct
connection to W@M in order to
enhance the management of your assets.
FieldCare is Endress+Hauser’s ‘FDT
based Configuration and Plant Asset
Management Tool’ that will gradually Main advantages
replace all Endress+Hauser device • Supports Ethernet, HART and PROFIBUS
operation tools. It is an open platform (Foundation Fieldbus in preparation)
that enables third party device operation • Operates all E+H devices (please contact
(via DTM) because it is based on an open your local service Endress+Hauser
standard. department)
• Operates all third party sensors, actuators,
Fit to your own needs remote I/Os, drives delivering FDT
FieldCare starts from a simple device standard compliant DTMs
configuration and parametrisation tool • Ensures full functionality for all devices
(FieldCare Lite) that can be upgraded to via their DTMs
offer advanced device operation and • Offers Generic HART and Profibus Profile
management functionalities (FieldCare operation for any third party fieldbus
Standard) as well as Plant Asset Management devices that do not have a vendor DTM
functionalities (FieldCare Professional in

The Endress+Hauser Maintenance Guide 105

At your service

Calibration services
A complete range of calibration services to suit your requirements

Does the instrumentation that controls your Quality Critical Endress+Hauser covers all these critical aspects, and can
processes need regular checking, validation and calibration? perform and advise on all aspects of calibration from in-situ
Do you need a cost-effective service that is fast, of high quality, testing through to fully accredited factory calibration. We
traceable and accredited? Do you need clear and concise calibrate your equipment at just the right time. This ensures
calibration certificates? optimal process performance at minimum cost.

Calibration Endress+Hauser performs instrument calibrations across a variety

Parameter Equipement type of measuring principles. We even extend our calibration service to
third party equipment to reduce time, effort and cost in terms of
• Resistance thermometer On site coordination and documentation.
• Probe + temperature
transmitter Accredited facilities
• Probe + display In the laboratory
Thanks to accredited laboratories installed in our factories and our
• Manometers On site service organization, we can offer the accredited calibration of:
Pressure • Pressure sensors • flow (SCS accreditation), • moisture
• Pressure transmitters In the laboratory • pressure (DKD accreditation) • voltage, current
• temperature (SIT accredita-
• Electromagnetic
tion) measurement devices
flowmeters On site
• Vortex flowmeters On-site calibration
Flow • Coriolis flowmeters Having also invested in mobile reference tools and in the
• Ultrasonic flowmeters deployment of a powerful Service organization in many countries,
• Thermal flowmeters In the laboratory
Endress+Hauser can also perform on-site calibration of the
• Mechanical flowmeters following parameters:
Conductivity measuring • flow • time
Conductivity chain including cell, On site • pressure • length
transmitter and cable • temperature • speed
• weight • conductivity
pH measuring chain
• viscosity • voltage, current
pH including cell, transmitter On site
and cable We suggest that you ask your local Sales Center about any particular
On request, we can calibrate other parameters. request.
Please contact your local Endress+Hauser
partner for further information.

106 The Endress+Hauser Maintenance Guide

At your service
Calibration Equipment

7 Circle of quality
calibration Trained

6 SOPs
Calibration Calibration
Documentation Work

Calibration Equipment

Endress+Hauser has carried out more than one million calibrations.
Above all we see our calibration service as part of your repair and
maintenance planning. Our aim is to provide you with complete Trained
calibration management solutions. At the forefront of this is
the tuning of calibration cycles, planning dates for carrying out Employees
calibration work, the co-ordination of personnel and certified

calibration equipment.

Calibration specification
Endress+Hauser will help you to establish

1 your metrology plan by fixing your

calibration specifications per parameter
(maximum permissible errors, periodicities) Test equipment
or by defining the right reference tools Local service centers provide a one-stop
according to their uncertainty.
Together, we will work out which
parameters have to be calibrated on site and,
3 calibration and repair service to a wide
range of test, measurement and process
control instrumentation. So whether you
in the case of high accuracy requirements, need pressure, analytical, temperature or
which need calibrating in the laboratory. flow calibration, look no further.
All of our facilities are traceable to national
and international standards. This means you
Calibration SOPs are guaranteed the highest level of service
We offer a full range of Standard Operating compliant with the ISO 17025 standard.

2 Procedures to support our on-site work.

SOPs ensure that our work is repeatable all
over the world. We also provide site specific Trained employees
SOP’s noting which measuring parameters On-site calibration is performed by specialist,
have to be calibrated on-site and in case of
high acccuracy requirements, which need
calibrating in the laboratory.
4 highly trained staff. This relieves your in-
house maintenance staff from routine time
consuming tasks and allows them to focus
on improving plant availability. For you this
means reliable advice, optimum performance
of your instruments and true cost-
effectiveness. Our service engineers
are trained in accordance to GMP
and we can offer full validation
services if required.

Discussion around the metrology plan SOPs, calibration certificates, labels and
electronic recordings

The Endress+Hauser Maintenance Guide 107

At your service
Calibration work
All of our primary calibration facilities

5 operate and are accredited to ISO17025

and are located around the world. We own
and operate more calibration laboratories
than any other instrumentation supplier.
As a leading supplier of field instrumentation
we not only can calibrate, but also quickly
and efficiently adjust, repair or replace
equipment that is failing to meet the specified
Calibration criteria. Our specialists have the necessary
software skills and equipment to calibrate all makes of

Calibration Calibration
Documentation Work

Calibration management software

CompuCal™ is a high performance

7 scheduling and electronic software tool that

help to control the scheduling activity around Calibration documentation
We support our service with certified and

your installed base, providing traceable and
auditable records. traceable documentation.
A calibration certificate compliant with the
ISO 17025 standard is issued. It details
all required data in form that is easy to
understand. Importantly, it also satisfies all
relevant authorities.

On-site calibration of temperature On-site calibration of pressure devices Laboratory calibration of level instruments On-site calibration of analysis devices

We fulfill the needs of all industries:

Oil & gas industries Life sciences industry Food & beverage industries
• On-site flow calibration rigs up to DN150 As a compliant partner, we: • Calibration within HACCP requirements
• Calibration of all kinds of custody transfer • Perform calibration of any kind of process • Calibration management strategies to
devices measuring point according to cGMP support production costs concepts
• Calibration of flowmeters up to DN2000 regulations and universal guidelines
• Document any service provided Chemical industries
Enviromental industry • Prove traceability by ensuring the • On-site flow calibration rigs up to DN150
• Calibration of all kinds of measurement conformity to Standard Operating • Calibration of all kinds of safety relevant
equipment Procedures measuring points
• Verification of flowmeters • Keep service staff trained to GxPs. • Calibration of flowmeters up to DN 2000
• Calibration of custody transfer instruments
• Calibration of flowmeters up to DN2000 Renewable fuels industry
• On-site flow calibration rigs up to DN150

108 The Endress+Hauser Maintenance Guide


At your service
Calibration & maintenance management software
CompuCal can be used in
direct connection to W@M

If we consider on-site calibration, the

needs are to schedule the activities,
arrange with the production personnel
to make the plant available and then
plan the tools and the technician. Once CompuCal™ and life cycle management
the job is done, the user has to edit CompuCal will dramatically improve
and archive a calibration certificate. calibration planning, improve the efficiency
of your metrology department, reduce the
CompuCal, Endress+Hauser’s calibration cost of maintenance and at the same time
management software, is fully able to satisfy the requirements of your auditors.
handle all these demands. Developed CompuCal also provide links to W@M,
with key users and proven in use in the Endress+Hauser’s life cycle management
pharmaceutical and regulated industries, solution. This connection allows the user
Compucal™ is high
CompuCal allows to efficiently maintain access to enhancement possibilities for your
performance scheduling and
electronic software tools that and calibrate your on-site instrumentation. installed base.
helps to control the scheduling
activity around your installed CompuCal is a fully validated to 21 CFR According to the serial number of your
base providing traceable and
Part 11 solution, used for many years by equipment on the plant, the link allows the
auditable records.
well-known pharmaceutical companies such user to download the calibration certificate
as Roche, GlaxoSmithkline and Pfizer for the issued in the Endress+Hauser’s laboratories,
management of their quality critical devices. to find out technical information on status of
the product, to search for the spare parts list
with exploded view of the equipment and
even to access to the price and delivery time
of spares or a new device etc.

Special tools
for unique calibration services
Precision calibration
of conductivity
measurement on
ultra-pure water
using ‘Concal®’.
CONCAL calibration set Mobile flow rigs
CONCAL is a conductivity calibration set Traceable to international standards, they
for ultrapure water applications, factory- provide calibration of flowmeters up to
‘In-situ’ precision
calibration of flowmeters calibrated with certificate, traceable to SRM DN 100. Available for hygienic applications,
by using mobile flow rigs of NIST and DKD (See full description in they are also suitable for calibration of safe
which are traceable the ‘Analysis/Conductivity’ section). and hazardous areas. Mobile flow rigs allow
to international totalization for tank volume calibration.

The Endress+Hauser Maintenance Guide 109

At your service

Maintenance services
The right maintenance support for all your measuring points

With Endress+Hauser service contracts, you decide the From regular support to partnership agreements, we offer
right level of maintenance support you require. We provide four distinct levels of service:
regular checks on your equipment and warranty extensions
providing you with complete peace of mind and cost control.

Preventative service Extended service Total service Tailor-made service

We test and certify the operating In addition to the features of In addition to the features Peace of mind, reliability and
integrity of the equipment to the preventative service, we of the extended contract, security of your installed base -
ensure optimum performance guarantee to support all we cover any costs for spare we can help you to achieve all
and full compliance to specific contracted instruments. parts in the event of equipment these with a tailor-made service
regulatory requirements. This covers any callout costs failure. As option, we can agreement. In consultation
Periodic checks according to our for travel and time on-site. support all the contracted with you, we define and agree
Standard Operating Procedures Furthermore, commissioning instruments for on-site repairs a scheduled package of services
(SOP) can be combined with costs for new instruments within a quick response time to and guarantees to ensure we
annual replacement of wear under contract agreement will be defined between each of us. meet all your maintenance
parts or consumables, telephone be covered by Endress+Hauser. needs and provide a customised
support during non-opening Your additional benefits service solution.
hours. An independent report Your additional benefits • Commissioning spares callout For example, this kind of
confirms the instrument’s • Reliable back-up and covered contract can include calibration
performance and reliability. instrument operation • Complete control of your activites, remote services,
between preventative maintenance budget maintenance of software
Your benefits maintenance visits updates etc.
• The necessary maintenance • Any pre-arranged extra visits
tasks to ensure an optimal for the commissioning of Your additional benefits
instrument performance newly contracted equipment • Endress+Hauser Support
• The delivery of documented are included in the costs Services perfectly complement
reports to ensure you comply your internal resources.
to audited quality procedures

110 The Endress+Hauser Maintenance Guide

A gradual level of features

At your service
Standard Options

Functional Commissioning* Travel & Spare Wear Consumables Phone Calibration On-site
checks labour parts parts support services response
costs** *** obligation time

Total service • • • • • • • • •

Extended service • • • • • • •

Preventative service • • • • •
* for new instruments entering within the scope of the contract
** for on-site repairs
*** annual change of wear parts for instruments like samplers, automatic pH measurement system…

Within the scope of these contracts, we can take the responsability to maintain devices of any other manufacturers. Please contact your local Endress+Hauser company to evaluate
the technical possibilities.

Special tools
for unique maintenance services

These pocket meters are dustproof and waterproof and Automatic switch-off combined with an energy saving system
can also be submerged. The large clear multifunctional permits continuous operation for up to 3000 hours.
display allows the values to be read safely and comfortably.

CPM280 - pH/Redox measurement CLM280 - conductivity measurement CPM280 - dissolved O2 measurement

Main advantages Main advantages Main advantages

• Easy to use, waterproof • Waterproof • Waterproof
• Simple calibration procedure with • Simplified operation via 5 push-buttons • Simplified operation via 5 push-buttons
automatic buffer recognition • Joint measurement of both conductivity • Ideal for wastewater treatment and the
• ‘Autoread’ function with and temperature fish farming industry
reproducibility better than 0.05 pH • 4-electrode technique • Manual calibration is possible using the
• Simplified 1, 2 or 3-point calibration with Winkler method
automatic buffer recognition Measuring range/accuracy
• Operating period: 3000 h supplied by • Conductivity: 0.0 µS/cm…500 mS/cm; Measuring range/accuracy
4 x 1.5 V batteries with 5 ranges in AutoRange • O2 Conc.: 0.00…9.9 mg/l
(± 0.5 % of value) (± 0.5 % of value)
Measuring range/accuracy • 0.00…19.99 µS/cm (for K = 0.1cm-1) • 0.0…90 mg/l
• pH: -2.00…+16.00 pH • Temperature: -5.0…+15 °C (± 0.1 K) • 02 Sat.: 0.0…199 % (± 0.5 % of value)
(± 0.03 at 15 °C…+35 °C) • Salinity: 0.00.....70.0 • 0.0…600 %
• mV: -1999…+1999 mV • Resitivity: 0.00…19.99 MΩ x cm • Temp.: -5.0…+50 °C (± 0.1 K)
• Temperature : -5.0…105.0 °C (± 0.1K) • Reference Temp. 25 °C • Temperature compensation: 2% at
• Cell constant: Fixed 0.475 cm-1, 0.1 cm-1 0…+40 °C

The Endress+Hauser Maintenance Guide 111

Special tools for unique maintenance services (cont’d)
At your service

Prosonic Flow 92
portable ultrasonic flowmeter

The Prosonic Flow 92 gives you the

possibility to efficiently verify and optimise
your process, wherever and whenever you
want, without interrupting the process.
This portable ultrasonic flowmeter
convinces because of its sophisticated
‘clamp on’ sensor technology and allows
you to take temporary measurements from
outside anytime you like.

Main advantages W sensor

• Ideally suited for bidirectional measurements • DN100...DN4000
of pure and slightly soiled liquids (gas • -20 °C...+80 °C
content <1% or solids content < 5%) • Stainless steel sensor holders
• Portable transmitter battery operated • Protection:
• Built-in datalogger with a capacity of Sensor IP67
40000 measuring values BNC adaptor IP52
• Simultaneous logging of volume flow,
flow velocity, totalizer and one external
value (4...20mA)
• Site setup operating menus for
straightforward of up to 20 measurement
• Clamp on sensors,
non-contact measurement technique
• Very wide range of nominal diameters
DN15...DN4000, temperature range - U sensor
20 °C ...+80 °C • DN15...DN100
• Data readout software for use with • -20 °C...+80 °C
personal computer • Plastic/aluminium sensor
• Current in and outputs (4...20mA) assembly
• Protection: IP52

With FieldCheck®, FieldCheck® smart signal simulator to its checking procedures, test proper
meter verification can be flowmeter functioning – be it to meet in-
carried out without the Designed especially for flowmeter house criteria or regulatory requirements.
removal of the Proline
flowmeter from the
verification*, FieldCheck® simulates sensor
pipe. Where ISO 9000 signals to test and evaluate the behaviour FieldCheck smart signal simulator is
requires frequent test of an item of equipment. It can also, thanks presented on page 31 (‘Flow/Basics’).
cycles, FieldCheck® is an
economical alternative to

112 The Endress+Hauser Maintenance Guide

At your service
Installed Base Audit
Auditing and analyzing your installed base of process instrumentation

Ask yourself three simple questions: Finding the right balance

Our objective is to help you reach the optimum point where the
overall costs are at their minimum level. We understand that too little
• Do you know exactly which part of your installed maintenance and no back-up can result in costly downtime, but on
instrumentation base is critical to the operation of the plant and the other hand, too much maintenance is unnecessary and leads to
how you could maintain it more efficiently? additional expense.

• Are you completely sure that your present actions are minimizing
Total cost

the risks of unplanned breakdowns?

Target zone:
• Are you sure that your present preventative actions are the most Optimized relationship,
cost effective? minimum cost

With Endress+Hauser’s Installed Base Audit, you will

quickly find an answer to these three questions and move
forward in a controlled manner to a maintenance plan No Too much
which improves plant reliability while reducing costs. maintenance maintenance

Degree of preventative maintenance

ARC studies point out new ways to optimize maintenance costs

Asset Management can reduce unplanned equipment related incidents.
The targets People and process related incidents could be reduced by better
decision support tools found in Asset Management

Installed Base Audit allows you: • To point out your out-of-date

% Total equipment costs

• To make the right decisions plant documentation not

in terms of focusing the reflecting the actual status
needed maintenance efforts • To define the necessary
according to your available actions to handle higher
resources and production demands on production
requirements quality and availability Initial
• To help you to decrease the • To fulfil the highest safety Maintenance and operation costs
high complexity of your older requirements
plant with different brands of
equipment and large variety Time
of instrument types
Companies are looking for lower Total Cost of Ownership (TCO)
Optimizing maintenance costs and increasing equipment life cycles are
priorities today.

The Endress+Hauser Maintenance Guide 113

How we work with you
At your service

Step 1 - Collecting data Step 2 - Revealing process critical

in the plant instruments
Consists of: on-site inventory of the main technical data issued Consists of: definition of the critical measuring points, the
from your installed instrumentation (all manufacturers) maintainability of all your instruments

Involves: an Endress+Hauser Audit Technician and one of your Involves: typically the Endress+Hauser consultant and the
technicians who knows the assets’ location and the applications Production, Quality and Maintenance Departments’ representatives

Equipped with a dedicated Personal Digital Assistant, the • During a meeting, the Endress+Hauser Advisor
Endress+Hauser Audit Technician collects and records: has the moderator role asking the relevant questions
• Instrument data (serial number, tag, order code, manufacturer, to define the critical point.
type and model, location, age, measuring principle, process • Each measuring point is assigned with the criticality level (High,
conditions) Medium, Low).
• Application data (pressure, temperature, medium)

Step 4 - Analysis and

recommendations definition
Consists of: a detailed analysis of your installed base focussed on
the maintenance activities you decided to deepen in the step 3

Involves: the Endress+Hauser consultant

• Based on your wishes expressed in step 3, the Endress+Hauser
Consultant realizes a thorough study of the activities to improve
• The Endress+Hauser consultant then defines the
recommendations and proposes one or more possibilities in order
to give you further on the choice for the better one.

114 The Endress+Hauser Maintenance Guide

At your service
• He defines and presents the global improvement you could bring
to the different areas of your maintenance activities (preventative
and corrective maintenance, standardization, migration).
• He opens your W@M portal (see right picture and back page)
- there you will find the status report and the collected data
presented in a structured manner.

Step 3 - Highlighting
potential improvements
Consists of: assessment of the status report giving you an overview
of the status of your installed base with global improvement

Involves: the Endress+Hauser Consultant and all the Installed Base Audit gives you an access to the W@M Portal. The data collected
representatives the Endress+Hauser Advisor and all the during the on-site inventory are presented here in a structured format. The
representatives of your company who participated to the first steps. W@M portal also includes additional information linked to the serial number
of the instrument.

• The Endress+Hauser Consultant studies the data collected

during steps 1 and 2.

Step 5 - Presentation of the

results and action plan
Involves: the Endress+Hauser Consultant and the interested
representatives of your company

• Presentation of the detailed analysis and the different possibilities
for each topic to optimize
• Decisions catches and action plan definition
• Delivery of the final Installed Base Audit report taking back the
detailed analysis and its recommendations

At the conclusion of step 5, you are delivered the

final Installed Base Report allowing you to go for
an action plan.

Concerned about improving constantly the quality of our

services, we periodically form and audit our staff according
to Endress+Hauser’s standards. We do our best to satisfy
your expectations.

The Endress+Hauser Maintenance Guide 115

At your service

Investing in people

Have you recently purchased new instrumentation that is

operated using unfamiliar principles? Do you want to improve
your response times in case of possible measurement failure?
If the answer is ‘yes’, why not improve your technical
knowledge and apply to your maintenance schedule.

Our specialists can provide your maintenance staff with the technical We provide training for: Training topics include:
product knowledge they require to run the plant efficiently and • Engineers and technicians • Theoretical and hands-on
cost-effectively. • Plant operators knowledge
• Maintenance engineers • Installaton advice
Training can be performed in-house or on-site. Your maintenance • New recruits, apprentices, • Start-up and maintenance
personnel will benefit from professional, up-to-date and hands-on refresher courses diagnostics
training, using a range of working instruments. • Troubleshooting tips
• Practical exercises using a
The training programme will be pre-defined according to your range of working instruments
requirements and participants will receive supplementary
literature and a certificate of attendance.
Your main benefits
• Learn how to operate and maintain your equipment
efficiently and effectively
• Discover methods for preventative and corrective
planned maintenance
• Increased plant efficiency

116 The Endress+Hauser Maintenance Guide

Three complementary tools to help with everyday problems

• The Maintenance Guide: this fully revised manual is the

reference text for your production, metrology and maintenance
teams. Keep a copy on your desk all year round. The content is
updated every year.

• ‘Maintenance Today’ is a magazine for all instrument users

and anyone with responsibility for quality issues. Printed once
or twice a year, it contains a selection of in-depth articles, case
studies and useful information. Provides guidance on handling
the challenges and developments you are likely to meet, and on
choosing the tools and services best adapted to your needs.

• ‘Maintenance Actions’ is a handy collection of information sheets

dealing with a specific subject of direct relevance to your day-to-day
operations. Each sheet identifies your option(s) for immediate
action. We publish several sheets each year.

Coming soon: dedicated web pages!

To receive the next issues …

You subscribe already but would like to receive the electronic version (PDF)?
A colleague told you about “Maintenance Today” or “Maintenance Actions”? You’d like a subscription for a colleague?

Fax the coupon below.

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Instruments International

Instruments International AG
Kaegenstrasse 2
4153 Reinach
Tel. +41 61 715 81 00
Fax +41 61 715 25 00

EC 003H/29/ae/11.07