(Ecs Manual - Appendix - Ver.c) Ms Sophie (2022.02.23)

ECS MANUAL [APPENDIXⅡ]
NO. EQUIPMENT NAME MAKER
1 CPC BINCONET
2 ANU Metering pump IWAKI
TRO Sensor TECHCROSS (DTS)
APU FLUIMAC
Ex- TRO Sensor HF SCIENTIFIC, INC. (CLX)

3 TSU
Ex- APU FLUIMAC
SOLENOID VALVE ASSY PARKER
WATER SEPERATOR (Ex-TRO Sensor Air line) MISUMI
4 CSU ENDRESS + HAUSER
5 GDS HONEYWELL
6 FTS DANFOSS
7 FMU ABB
8 Ex- FMU ABB
9 T-Strainer WOOSUNG
10 Mixing pump DESMI
11 FCV Actuator & Spanner EMERSON(V3)
12 Portable TRO colorimeter TECHCROSS (PTS)

CPC
(BINCONET)
ARA-15iXTS-MPPC Panel PC
Binconet Marine Solutions Co., Ltd Issued Date :
Human-Computer Interface 2016-02-11
31, Cheonggangro 91beongil, Gijang-Eup, Gijang-Gun

TO : Busan, KOREA
Page :
TEL : 82-51-513-6950
10 Pages
FAX : 82-51-980-0428
Ver 1.0 English HOME PAGE : http://www.binconet.co.kr
Panel PC ARA-15iXTS-MPPC USER’S MANUAL
ARA-15iXTS-MPPC
Copyright
This publication contains information that is protected by copyright. No part of it may be reproduced in any form or by
any means or used to make any transformation/adaptation without the prior written permission from the copyright
holders.
Trademark
Product names or trademarks (VGA, DPMS, VESA, DVI, PS/2, PC AT, IBM, PIVOT, MS-DOS, WINDOWS,
MICROSOFT, INTEL) are for identification purpose only and are the properties of the respective owners.
1. Introduction
- ARA-15iXTS-MPPC is all-in-one Panel PC that combines 15” LCD panel and Main Board 3rd
Generation Intel® CoreTM processors.
- The resolution is 1024 x 768 and can use touch screen and PS/2 mouse at the same time.
2. Specifications
2.1 General Specifications
Display : 15” TFT LCD 1024 x 768 dots

Disk Drive : 2.5” SSD
Storage Temperature : -
Storage Humidity : 5 ~ 90% RH, non-condensing

Operating Humidity : 20 ~ 90% RH, non-condensing
Mount Type : Panel Mount
Dimension (W x H x D) : 412 x345 x 83.7 mm
Weight Net : 6.7 kg

Chassis Material : Steel
Input Rating : DC24V 6.25A (Max)
2.3 Display Specification
Display Size : 15” TFT Color LCD

Active Area(H x V) : 304.128 x 227.328 mm
Supporting Resolutions : Full display by zooming out on VGA/SVGA/XGA
Driver Element : a-SI TFT active matrix
Pixel Format : 1024 horiz. By 768 vert. Pixels. RGB stripe arrangement
Display Mode : Transmissive mode, normally White
Surface treatment : Anti-Glare
Resolution : 1024 x 768 dots
Aspect Ratio : 4:3
Color : 16.7M Colors
Pixel Pitch(H x W) : 0.297 x 0.296 mm
Luminance : Typ. 400
Contrast Ratio : Typ. 700 : 1
LED Back Light Lifetime : Min. 50,000 Hrs
Viewing Angel : Typ. Hor. 70/70, Ver. 55/65
Response Time(ms) : Typ. 2 (Rise Time) / 6 (Delay Time)
2.4 Touch Screen Specification

Touch Screen Type : Analog Resistive 5-Wire Type
Touch Screen Controller Interface : USB
Touch Screen Drivers : Windows 98/ME/NT/2000/XP/2003/WSE 7
Drift compensation for fluctuations in the temperature and humidity
Antiglare scratch resistant finish
Gloved or Ungloved finger or Stylus activation(Gloves, finger, Pen are available)
Chemically strengthened glass backing panel
Optically bonded buffer layer
Transmittance : Typ. > 80 %
Durability : Point Activation Typ. 1,000,000
Gouge Hardness 4H per ASTM D3363-92a
3. Introduction
3.1 Mother Board Layout

4. External Components
4.1 Bottom I/O view
5. Dimensions
Picture 1. Panel PC Dimensions
7/10
User’s Manual
Cutting Size : 357 x 299 mm
6. BIOS Setup & Software Driver Setup

Please refer to manuals of CD in the package
7. Packing List
 If anything that listed below is absence, please contact retailer your retailer or BINCONET MARIN
E SOLUTIONS Support Help Desk.
Panel PC
Accessories
Panel PC Manual
Software Drivers Install CD-ROM
OS CD ( Windows 7 Pro English Version)
Touch Screen Driver Install CD-ROM
9. Safety Precaution
-The safety recommendations outlined in this section are to be read, understood and followed before operating the
product.
- Keep this information in a safe place for future reference. Failure to comply with any of the following safety
procedures could result in serious hazard.
8/10
User’s Manual
9-1. Set up and General Handling Precaution

 Please set up the system in clean area where there is no dust.
 Do not set up the system on shaky stand, on incline surface or surfaces subject to frequent vibration.
 Do not press heavily the TFT-LCD panel with sharp objects, such as nails.
 When set up the system, be extremely careful. You may get injured from the sharp parts, such as stee
l covers
 When transporting the system, hold the body with both hands and letting LCD screen goes up.
 Do not lift the system up with holding LCD panel itself.
9-2. Operating Precaution

 Do not place the system in areas subject to direct sunlight and radiators or heat registers. Fire or ele
ctrical shock may result.
 Do not block the vent halls on the system. Bad ventilation may cause a breakdown or fire.
 Do not remove cover(or back). This could result electrical shock. Refer servicing to qualified service
personnel.
 If you find any abnormal issue or failure while you are using the system, immediately unplug the po
wer cable and contact your retailer or BINCONET MARINE SOLUTIONS Support Help Desk.
 Do not take apart or modify the equipment for any purpose. Fire or electrical shock may result.
 Never spill liquid of any kind on the system. Do not place in areas where there is high humidity an
d water splashes.
 Do not plug in/unplug the power cable with wet hands. Fire or electrical shock may result.
 Do not plug the system into outlets with voltage other than the specified voltage. Incorrect voltage m
ay result in fire or electrical shock.
 Do not pull the plug out by the wire. This may cause an electric shock or fire.
 Make sure that the power cable is firmly plugged in. Fire or electrical shock may result.
 Unplug the power cable for safety when not in use the system for a long period of time. If dust acc
umulates in this area, it may result in fire.
 Do not connect too many extension cords or plugs to an outlet.Fire or electrical shock may result.
 Use only a properly grounded plug and receptacle.
 Do not spill flammable liquid on the system. Fire or electrical shock may result.
 Set up the outlet in areas where close to the monitor, easily accessible and easily operative.
9-3. Cleaning of the equipment and management

Precaution
 Do not take apart or modify the system. Fire or electrical shock may result.
 When cleaning the system, always unplug the power.
 When cleaning the system, do not use flammable liquids, such as alcohol, benzene or thinners.
9/10
User’s Manual
 If you strongly wipe down the surface of the system with a sponge and a piece of cloth, in case of
plastic equipment,
The coating may be fallen away.
 When cleaning the system case or the surface of the TFT LCD, wipe with a slightly moistened, soft
fabric.
10/10
User’s Manual
ANU Mering pump
(IWAKI)
( )Country codes
IWAKI
IWAKI CO.,LTD. 6-6 Kanda-Sudacho 2-chome Chiyoda-ku Tokyo 101-8558 Japan
Australia IWAKI Pumps Australia Pty. Ltd. TEL : (61)2 9899 2411 FAX : 2 9899 2421 Italy
TEL:(81)3 3254 2935 FAX:3 3252 8892(http://www.iwakipumps.jp)
IWAKI Europe GmbH, Italy Branch TEL : (39)0444 371115 FAX : 0444 335350
Electromagnetic Metering Pump
Austria IWAKI EUROPE GmbH TEL : (49)2154 92540 FAX : 2154 9254 48 Korea IWAKI Korea Co.,Ltd. TEL : (82)2 2630 4800 FAX : 2 2630 4801
Belgium IWAKI Belgium n.v. TEL : (32)1367 0200 FAX : 1367 2030 Malaysia IWAKIm Sdn. Bhd. TEL : (60)3 7803 8807 FAX : 3 7803 4800
China IWAKI Pumps (Shanghai) Co., Ltd. TEL : (86)21 6272 7502 FAX : 21 6272 6929 Norway IWAKI Norge AS TEL : (47)23 38 49 00 FAX : 23 38 49 01
China
China
China
IWAKI Pumps (Guangdong) Co., Ltd. TEL : (86)750 3866228
GFTZ IWAKI Engineering & Trading (Guangzhou) TEL : (86)20 8435 0603
GFTZ IWAKI Engineering & Trading (Beijing) TEL : (86)10 6442 7713
FAX : 750 3866278
FAX : 20 8435 9181
FAX : 10 6442 7712
Singapore
Spain
Sweden
IWAKI Singapore Pte. Ltd.
IWAKI Europe GmbH, Spain Branch
IWAKI Sverige AB
TEL : (65)6316 2028
TEL : (34)93 37 70 198
TEL : (46)8 511 72900
FAX : 6316 3221
FAX : 93 47 40 991
FAX : 8 511 72922
EH-E Type
Denmark IWAKI Nordic A/S TEL : (45)48 24 2345 FAX : 48 24 2346 Switzerland IP Service SA TEL : (41)26 674 9300 FAX : 26 674 9302
Finland IWAKI Suomi Oy TEL : (358)9 2745810 FAX : 9 2742715 Taiwan IWAKI Pumps Taiwan Co., Ltd. TEL : (886)2 8227 6900 FAX : 2 8227 6818
France
Germany
Holland
IWAKI France S.A.
IWAKI EUROPE GmbH
TEL : (33)1 69 63 33 70
TEL : (49)2154 9254 0
IWAKI Europe GmbH, Netherlands Branch TEL : (31)547 293 160
FAX : 1 64 49 92 73
FAX : 2154 9254 48
FAX : 547 292 332
Taiwan
Thailand
U.K.
IWAKI Pumps Taiwan (Hsin-chu) Co., Ltd.
IWAKI (Thailand) Co.,Ltd.
IWAKI Pumps (UK) LTD.
TEL : (886)3 573 5797
TEL : (66)2 322 2471
TEL : (44)1743 231363
FAX : (886)3 573 5798
FAX : 2 322 2477
FAX : 1743 366507
Instruction Manual
Hong Kong IWAKI Pumps Co., Ltd. TEL : (852)2 607 1168 FAX : 2 607 1000 U.S.A. IWAKI AMERICA Inc. TEL : (1)508 429 1440 FAX : 508 429 1386
Indonesia IWAKI Singapore (Indonesia Branch) TEL : (62)21 690 6606 FAX : 21 690 6612 Vietnam IWAKI pumps Vietnam Co.,Ltd. TEL : (84)613 933456 FAX : 613 933399
Read this manual before use of product
T656-2 '13/09
Thank you for selecting the electromagnetic metering pump EH-E series. This instruction
manual deals with “Safety Section” “Product outline” “Installation Section” “Operation
Section” and “Maintenance Section”.
Please read through this manual carefully to ensure the optimum performance, safety and
service of the EH-E series.
Contents
IMPORTANT INSTRUCTION .......................................................... 1
Safety Instruction .............. .............................................................. 2
Outline ........................................................................................... 5
1. Unpacking ............................................................... 6
2. Operating Principle ................................................. 6
3. Identification Code .................................................. 7
4. Features ... .............................................................. 9
5. Specification ......................................................... 10
6. Operating Function 11
7. Display and Keys .................................................. 13
Installation ......................... ............................................................ 16
1. Notes on Installation ............................................. 17

2. Location .... ............................................................ 19
3. Tubing ................................................................... 20
4. Electrical Wiring .................................................... 23
Operation .......................... ............................................................ 27
1. Preparation for Operation ...................................... 28

1-1. Bleeding ........................................................ 28
1-2. Adjustment of Discharge Capacity ................ 30
2. Operation .............................................................. 32
2-1. Overview Operating Scheme ........................ 32
2-2. Setting and Operation of Controller ............... 34
Maintenance .................................................................................. 44
1. Troubleshooting .................................................... 45
2. Maintenance and Inspection ................................. 46
3. Disassembly and Assembly .................................. 49
4. Optional Accessories ............................................ 53
5. Exploded Views and Dimension Drawing .............. 53
Important instructions
For the Safe and
Correct Handling of the Pump
● "Safety Instruction" section deals with important details about handling of the product. Before
use, read this section carefully for the prevention of personal injury or property damage.
● Observe the instructions accompanied with "WARNING" or "CAUTION" in this manual. These
instructions are very important for protecting users from dangerous situations.
● The symbols on this instruction manual have the following meanings:
Nonobservance or misapplication of “Warning” sec-

WARNING tions could lead to a serious accident which may
result in death.
Nonobservance or misapplication of “Caution” sec-

CAUTION tions could lead to a personal injury or property
damage.
Types of Symbols
Indicates that “Warning” or “Caution” must be exercised. Inside this triangle, a con-
crete and practical image provided as a warning or caution message is depicted.
Indicates a prohibited action or procedure. Inside or near this circle, a concrete and
practical image of the activity to be avoided is depicted.
Indicates an important action or procedure which must be performed or carried out

without fail. Failure to follow the instructions herein can lead to malfunction or
damage to the pump.
Export Restrictions
Technical information contained in this instruction manual might be treated as controlled
technology in your countries, due to agreements in international regime for export control.
Please be reminded that export license/permission could be required when this manual is
provided, due to export control regulations of your country.
-1-
Safety instructions
WARNING
● Turn off the power supply
Working without disconnecting the power supply cause an electrical shock. Before
engaging upon any working procedures involving the pump, make sure to turn the
power supply switch off and to stop the pump and other related devices.
Electrical Shock
● Terminate operation
When you detect or become aware of a dangerous sign or abnormal condition during
operation, terminate the operation immediately and start from the beginning again.
● For specified application only

The use of a pump in any application other than those clearly specified may result
in injury or damage to the pump. Use the pump strictly in accordance with the pump
specifications and application range. Prohibited
● No remodeling
Never remodel a pump. Otherwise, a serious accident may result. Iwaki will not be
responsible for any accident or damage of any kind which is caused by the user
remodeling the pump without first obtaining permission or instructions from lwaki. No Remodeling
● Wear protectors
If you touch or come in contact with any type of hazardous chemical liquid, including
but not limited to chemicals, you may experience a serious injury. Wear protective Wear protective
gear (protective mask, gloves, etc.) during the pump operation. gear
● Operating site must be free of water and humidity

The pump is not designed to be water-proof or dust-proof. The use of the pump in
places where water splashes or humidity is high may result in an electrical shock or
short circuit. Prohibited
-2-
Safety instructions
CAUTION
● Qualified operators only
The pump operator and pump operation supervisor must not allow any operators who
have little or no knowledge of the pump to run and operate the pump. Pump operators
must have a sound knowledge of the pump and its operation. Prohibited
● Specified power only

Do not operate the pump on voltage which is not specified on the nameplate. Failure
to do so may result in damage or fire. Only the specified power level is to be applied. Prohibited
● Do not run the pump dry

Do not run the pump dry (without liquid inside the pump). Heat generated as a result
of abrasion between elements inside the pump during operation without liquid may
damage the inside of the pump. Prohibited
● Do not wet or dampen

If an electric part or wiring gets wet with the liquid spilled over accidentally, a fire or
electrical shock may be caused. Install the system in a place free from liquid spillage
Do not wet
or leakage. or dampen
● Ventilate
Poisoning may result during an operation which involves, toxic or odorous liquid.
Ventilate the operating site sufficiently. Caution
● Spill-out accident
Protective measures should be taken against any accidental spill-out or leakage of
the operating liquid as a result of unexpected damage on the pump or the related pip-
Caution
ing.
● Damaged pump
Never operate a damaged pump. A damaged pump may cause leakage or electrical
shock. Prohibited
● Do not damage or change power cable

Do not scratch, damage, process, or pull the power cable forcibly. An extra load onto
the cable, such as heating the cable or placing something heavy on the cable, may
Caution
damage the cable and finally cause a fire or an electrical shock.
● Frequent stop and start of pump should be done by using STOP function (ON and
OFF of STOP terminal). If you can not use STOP function and are forced to operate
pump by turning OFF and ON of power source, ON and OFF of power source should
be limited to six times an hour.
-3-
Safety instructions
CAUTION
● Arrange grounding
Do not operate the pump without connecting the grounding wire. Otherwise, an elec-
trical shock may result. Make sure the grounding wire is connected with grounding
Grounding
terminal.
● Install an earth leakage breaker

The operation of a pump without using an earth leakage breaker may cause an elec-
trical shock. Please install a leakage breaker in the system. Electrical Shock
● Handling of power cable

Use of a defective or damaged power cable may result in a fire or electrical shock.
Handle the power cable carefully. Electrical Shock
● Follow the instruction manual

Replace the consumable part by following the descriptions in the instruction manual.
Do not disassemble any part of the pump if the disassembling procedure for the part
in question is not included in the instruction manual.
● Limited operating site and storage

Do not install or store the pump in the following places :
Places where a flammable gas or material is used or stored.
Places where the ambient temperature is extremely high (40 °C or higher) or extreme- Prohibited
ly low (0 °C or lower).
● Disposal of used pump

Disposal of used or damaged pumps must be done in accordance with the relevant
local law and regulations. (Consult a licensed industrial waste products disposing
company.)
-4-
Outline
1. Unpacking ........................................... 6
2. Operating Principle ............................. 6
3. Identification Code .............................. 7
4. Features ............................................. 9
5. Specification ..................................... 10
6. Operating Function ........................... 11
7. Display and Keys .............................. 13
-5-
Outline
1. Unpacking
After unpacking the goods, check the following

points to ascertain that the product is exactly as
you ordered.
If you find anything wrong, please get in touch with
your dealer.
(1) Do the model, voltage, etc., shown on the

nameplate represent what you ordered?
(2) Has the goods been damaged in transit? Are
the bolts and nuts loose?
2. Operating Principle
The EH Series electronic metering pump consists
of a pump unit, a drive unit, and a control unit. The
Drive unit drive unit is an electromagnetic solenoid. When the
Stroke length Valve solenoid coil is energized by the control unit the
adjusting dial armature shaft moves forward due to the magnetic
force of the solenoid. The shaft is attached to a
PTFE faced diaphragm which is part of the pump
Pump
unit. The diaphragm is forced into the pump head
Control unit
head cavity decreasing volume and increasing pressure
which forces liquid in the pump head out though
the discharge check valves. When the solenoid
coil is de-energized, a spring returns the armature
to its starting position. This action pulls the dia-
phragm out of the head cavity increasing volume
and decreasing pressure. Atmospheric pressure
Plunger Spring Diaphragm then pushes liquid from the supply tank through
the suction check valves to refill the pump head.
-6-
Outline
3. Identification Code
• Pump identification
EH - E 31 PC - 23U P E 8 -
(1) (2) (3) (4) (5) (6) (7) (8) (9)
(1) Series name EH Series

(2) Drive component E : 48 W
(3) Diaphragm effective diameter 31 : 30 mm 36 : 35 mm 46 : 45 mm 56 : 55 mm
(4) Material of liquid end
Pump head Valve seat &
Codes Valve balls Diaphragm Gasket
& Fittings O-ring (Gasket)
VC PVC CE FKM
V6 PVC SUS316 EPDM
PC GFRPP CE FKM
PTFE
VM M-PVC CE FKM PTFE
Bonded to EPDM
FC PVDF CE PCTFE (PTFE)
SH SUS316 HC276 SUS316 (PTFE)
HP6 GFRPP SUS316 PCTFE (EPDM)
PVC : Polyvinyl chloride (Transparent)

GFRPP : Glass fiber reinforced polypropylene
M-PVC : Polyvinyl chloride (Machined)
CE : Alumina ceramic
SUS316 : 316 Stainless steel
FKM : Fluoroelastomer
EPDM : Ethylene propylene diene methylene
PTFE : Polytetrafluoroethylene
PVDF : Polyvinylidenefluoride
HC276 : Hastelloy C276
(5) Voltage symbol

Codes Voltage Input voltage Frequency
100 100VAC 90-110VAC 50/60Hz
11U 110/115AC 90-126VAC 50/60Hz
20J 200VAC 180-220VAC 50/60Hz
23U 230VAC 207-253VAC 50/60Hz
20E 220/230/240VAC 198-264VAC 50/60Hz
-7-
Outline
(6) Power code
P with a plug
No symbol without a plug
(7) Controller E : E type

(8) Connection
Codes Applicable hose dia. (ID × OD) Type
4 ø8 × ø13 (mm) VC, V6, PC, VM
5 ø9 × ø12 (mm) VC, V6, PC, VM
6 ø10 × ø12 (mm) FC
8 ø3/8" × ø1/2" (inch) VC, V6, PC, VM, FC
9 Rc 1/4" SH
10 NPT 1/4" SH
11 ø10 × ø16 (mm) VC, V6, PC, VM
14 Rc 3/8" SH
15 NPT 3/8" SH
21 IN ø15 × ø22, OUT ø9 × ø12 (mm) HP6
22 IN ø15 × ø22, OUT ø3/8" × ø1/2" (inch) HP6
(9) Special configuration

01-99: Special material, special connection port diameter, etc.
• Controller identification
EHC - 100 P E - * *
(1) (2) (3) (4) (5)
(1) Controller name EH
10 0 100VAC 90-126VAC
11 U 110/115VAC 90-126VAC
(2) Voltage codes 20 J 200VAC 180-220VAC 50/60Hz
20 E 220/230/240VAC 198-264VAC
23 U 230VAC 207-253VAC
P: with a plug
(3) Lead wire
No code: without a plug
(4) Controller E
0-99
(5) Special configuration HV: High viscosity type
Points to be noted in handling

1. Do not detach the control unit unless unavoidable.
2. Never use the control unit with pumps having different symbols for driving unit and power source voltage
specified on the control unit. (Check the nameplate.)
CAUTION
Operation with a pump having different symbols for driving unit and power source voltage other than
those specified may cause failure or trouble in the electronic circuit of the control unit or the driving
unit of the pump.
-8-
Outline
4. Features
Driving unit Stroke length adjusting knob
●Electromagnet and spring force makes diaphragm ●To adjust discharge capacity per stroke in the
reciprocate responding to the command of control range of 20 to 100%.
unit.
Pump body Control unit

●Reciprocating movement of diaphragm changes ●The control part to operate pump stop/start,
the volume of pump chamber to make pumping. adjustment of flow rate and stroke speed.
● Control unit
Pump operation is done electronically by control unit in which microcomputer is built-in.
● Easy operation
Pump operation and flow rate control is done by keys on control unit, which enables simple control of flow
rate.
● Memory back-up function

If power is turned off, memory back-up function puts the set value in memory. When the power is turned
on again, pump operates at the value which had been set before the power was turned off.
-9-
Outline
5. Specification
• Pump specification
Standard types
Output capacity Output per stroke Maximum pressure Stroke frequency Permissible stroke
Model (ml/min) (ml/stroke) (MPa) (spm) length % (mm)
31 340 0.19-0.94 1
36 520 0.29-1.44 0.7 (0.6) 20-100
0-360
46 750 0.42-2.08 0.4 (0.3-1.5mm)
56 1250 0.69-3.47 0.2
High viscosity type

Output capacity Output per stroke Maximum pressure Stroke frequency Permissible stroke
Model (ml/min) (ml/stroke) (MPa) (spm) length % (mm)
20-100
36 300 0.25-1.25 0.7 0-240 (0.3-1.5mm)
NOTE 1. The performance data is based on clean water at 25 deg. C under rated voltage.
NOTE 2. Capacity is that at the max. pressure. (at max. stroke length and max. stroke frequency)
Capacity exceeds the value when pump operates under low pressure.
NOTE 3. Operating ambient temperature : 0 to 40 deg. C
Relative humidity : 35 % to 85 % (Non condensing)
NOTE 4. Liquid temperature : 0 to 40 deg. C (PC/SH/FC/HP6 : 0 to 60 deg. C)
NOTE 5. Permissible voltage fluctuation : Within ±10 % of rating
NOTE 6. Ask us for liquid containing slurries or so.
NOTE 7. Value in ( ) of Maximum pressure is the value for type SH.
NOTE 8. Adjustment range of stroke length for EH-E46, 56SH is 50-100% (0.75-1.5mm).
• Control unit specification

MAN (Manual)
Mode
Mode EXT (External)
Changeover Entering by keys (EXT, START/STOP)
EXT :
Digital input pulse multiply 1:n n = 1 - 999
Digital input pulse dividing n:1 n = 999 - 1
Analog input SET point1 : Current 0 - 20 mA
Parameters Stroke rate 0 - 360 spm
SET point2 : Current 0 - 20 mA
Function Stroke rate 0 - 360 spm
MAN : Stroke rate 1 - 360 spm
Keys 4 keys (START/STOP, EXT, ▲, ▼)
Upper limited spm 360 spm
Stop By receiving stop signal from outside
Display 4 digit LCD Operating condition, set value etc.
Indication
Stroke Green LED (Blinks synchronous with stroke.)
Stop signal Potential free or open collector (NOTE 2)
Input
Pulse (NOTE1) Potential free or open collector (NOTE 2)
Output Power source for sensor 12VDC 10mA or below
Power 100 AC : 90 - 127VAC 110/115AC : 90 - 127VAC
source 200 AC : 180 - 242VAC 230AC : 198 - 264 VAC
NOTE 1. Max. frequency of input pulse : 100Hz
NOTE 2. Max. applied voltage and amperage to open collector : 5V, 1.1 mA
NOTE 3. Max. spm of the high viscosity type : 240spm
- 10 -
Outline
6. Operating Function
• Manual operation
Stroke rate can be set from 0 to 360 spm with keys ▲ and ▼, and pump start and stop can be done with
keys START/STOP. Both setting can be done while the pump stops or operates.
Operation chart
ON ON ON
START/STOP key
run stop run
Operation
• Analog input operation (0 - 20 mA)

0 - 360 spm operation in proportion to 0 - 20 mA current input. Pump is fixed at 360 spm when came the
input signal exceeding 360 spm.
Straight line is automatically made by setting two points. So, the pump may not come to 0 spm even if 0 mA
current comes.
360 spm
SET point 2 spm
SET point 1 spm
0 A1 A2 20 mA
SET point 1 SET point 2
Current Current
Straight line is drawn automatically by setting two points.

0 mA is not always 0 spm. It depends on set point. It is possible that 0 mA or 20 mA does not make 0 spm
or 20 mA respectively because of the error of electronics parts. In this case adjust it by setting value.
- 11 -
Outline
• Digital input (pulse multiply) operation
Pump makes strokes from 1 to 999 responding to external pulse signal. Stroke rate is the spm set for man-
ual operation. The pulses which came while operation are put in memory up to 255 pulses. (It is possible to
make the pulses not to be put in memory.)
Digital input (multiplying) example (× 5)
Ext. pulse
Pump stroke
1 2 3 4 5 1 2 3 4 5
• Digital input (pulse dividing) operation

Pulse dividing operation by external pulse signals for 999 : 1 to 1 : 1. Stroke rate is the one set for manual
operation. When the signals exceeding the set stroke rate came, excessive signals can be put in memory
up to 255 pulses.
Digital input (Dividing) is set at 5 = /5
External pulse
1 2 3 4 5 1 2 3 4 5 1 2 3 4 5
Pump stroke
- 12 -
Outline
7. Display and Keys
• Controller display and panel
START/STOP key Numeric display SET point indicator

Manually starts or stops Set value is shown. Lit when SET point 1 and 2
pump. are set at EXT mode analog
Also used to enter set value input operation.
and to move to wait mode.
EXT indicator UP key
Lit when pump is
To increase set value or to
operated by external
change setting.
input.
To move to mode for toggling
between analog and digital
by two keys pushing (UP key
WAIT indicator START/STOP
and EXT key).
Lit when pump is in 1
2
WAIT mode and DOWN key
stops.
EXT To decrease set value or to
EXT key change setting.
WAIT EXT STOP OVER SET To move to mode to toggle
Push to start between analog and digital
pump for external by pushing two keys (DOWN
input operation. key and EXT key).
Also used for two EH-E ON
keys pushing.
STOP indicator Over indicator ON light SET indicator

Lit when pump is Lit when signal exceeding Lit when power is Lit when toggling
stopped by external 360 spm comes in EXT on and blinks per between analog and
stop signal. Pump mode. stroke. digital also when
stops when lit. external setting mode.
NOTE: Two keys pushing means to push simultaneously two keys of EXT key and UP or DOWN key.
- 13 -
Outline
• Basic display
Display examples Meanings

Running at manual operation mode.
1 Value shows set spm.
2
WAIT EXT STOP OVER SET
Waiting at WAIT mode.

1 Displayed value is set value at manual operation mode.
2
Running at EXT operation mode (Pulse multiply).

1 Display shows running at 1 : 5 multiply.
2
Running at EXT operation mode (Dividing).

1 Display shows running at 5 : 1 dividing.
2
Running at EXT operation mode (Analog input 0 - 20 mA).

Display shows running at 120 spm speed responding to input current.
1
2
In setting mode. (SET lights.)

1
2
1
2
1
2
1
2
- 14 -
Outline
• Alarm display
Display examples Meanings

Display for excess spm at EXT operation (analog input operation). (OVER
1 lights.)
2
In analog input operation, visible if external signal exceeding 360 spm oper-
ation comes. While visible, pump runs at fixed speed of 360 spm.
Display for excess spm at EXT operation (Pulse multiply operation). (OVER
1 lights.)
2
In multiply operation, visible if next pulse comes when the pump is making
the strokes. While visible, max. 255 pulses can be put in storage. You can
set not to put them in storage.
Display for excess spm at EXT operation (Pulse dividing operation). (OVER
1 lights.)
2
In dividing operation, visible if signal which exceeds max. preset number
of strokes comes. While visible, the pump runs at fixed max. number of
strokes. You can set so that excessive input pulses can be put in storage up
to 255 pulses.
- 15 -
Installation
1. Notes on Installation ......................... 17
2. Installation ........................................ 19
3. Tubing ............................................... 20
4. Electrical Wiring ................................ 23
- 16 -
Installation
1. Notes on Operation
Operators and maintenance service staff must read the instruction manual thoroughly before using the prod-
ucts. Do not operate the pump system unless all of the contents in the manual are completely understood.
CAUTION
• Turn off the power supply

Working without disconnecting the power supply may cause an electrical shock.
Before engaging upon any working procedures involving the pump, make sure to turn
the power supply switch off and to stop the pump and other related devices.
• Terminate operation
When you detect or become aware of a dangerous sign or abnormal condition during
operation, terminate the operation immediately and start it from the beginning again.
• Specified power only
Do not operate the pump on voltage, which is not specified on the name plate.
Failure to do so may result in damage or fire. Only the specified power level is to be applied.
• Keep from heat or flame
Do not place any dangerous materials or flammable objects near the pump for the pre-
vention of fire or accident.
• Damaged pump
Never operate a damaged pump. A damaged pump may cause leakage or electrical shock.
1. Dropping the pump or subjecting it to strong

impacts may result in faulty performance.
Handle the pump with care.
2. When installing the pump, avoid places exposed

to direct sunlight or direct rain with an ambient
temperature of above 40°C, or with a relative
humidity or above 90 %. Though the pump has
a simple waterproof and dust proof structure, a
sheltered location is recommended.
- 17 -
Installation
3. Install the pump at the place convenient for the
maintenance/inspection works in the future.
Securely fix the pump so that the pump can not
vibrate horizontally.
4. Use the tube corresponding to the pump suction

and discharge port sizes. Securely connect the
tube so that liquid can not leak or air can not be
sucked in.
5. Make bleeding when you use the pump for the

first time or when you replaced the chemical
tank.
Refer to item "Bleeding procedure" on page 28.
6. When you disassemble the pump head, replace

diaphragm, O ring, valve gasket and valve unit
by new ones.
7. Do not wipe the pump body with the cloth in

which is soaked by solvent such as benzene,
kerosene or thinner. Otherwise, the body may be
discoloured. To clean pump body, use dry cloth
or the cloth in which are soaked by water or neu-
tral detergent.
CAUTION
Liquid splash on driving unit and control
unit may cause failure or accident. Pay
attention the liquid not to be splashed.
- 18 -
Installation
2. Installation
CAUTION
When you feel danger or abnormality
during installation or mounting works,
stop works immediately to check its
reason.
1) Install pump at place of ambient temperature of
40 deg. C or below and humidity of 40% RH or
below (No dew condensation should be in the
control unit.) where is easy and convenient for
maintenance and inspection works.
Cover the pump when installing it out of doors for
protection against direct sunlight and wind & rain.
2) Install pump as close to a suction tank as pos-

sible in the manner of flooded suction (Pump is
located below the suction tank.).
3) Mount pump securely with M6 bolts at horizontal

and flat place where no liquid splashes on it.
Pump mounted on the slant may cause reduced
discharge capacity or no liquid discharged.
4) If pump is used to handle liquid which apt to

generate bubbles (sodium hypochlorite and
hydrazine solution or so), install pump at cool
and dark place without being exposed to direct
sunlight. Employ flooded suction. (Install pump
below liquid level of suction side.)
5) Cut hose end at right angle as shown on figures

Side view of hose
at left.
- 19 -
Installation
3. Tubing 1. Tubing for types VC, V6, PC, VM, FC
Use PVC braided hose or so which corresponds
Hose to connection bore of pump.
Hose is fixed by hose stopper. Put fitting nut and
hose stopper on hose and insert hose end into
fitting spacer and then push the hose stopper to
the bottom of fitting spacer and tighten fitting nut.
Fitting nut
Make sure that the R-side of the hose stopper is
facing to the fitting spacer.
Hose stopper NOTE: Especially for type FC, make sure to face
the R-side of the stopper to the fitting
spacer. Otherwise, hose may be dam-
aged.
Insufficient or wrong mounted hose stopper may
cause liquid leakage, failed priming or damaged
Face R-side to fitting spacer. hose.
Fitting nut is made of plastics. Pay attention not
Fitting spacer to tighten it excessively. Excessive tightening
may break nut.
CAUTION
Fitting nut · Use specified size of tube. Otherwise
tube may come off.
Remove · Insert the fitting spacer into tube as deep
check valve
as possible. Otherwise liquid may leaks
or tube may come off.
· Pay attention not to lose O ring (gasket
for FC). If O ring (gasket for FC) is not
mounted, it may cause liquid leakage or
Return
to tank failed self-priming.
2. Tubing for SH type
Connections are Rc1/4 or NPT1/4 (EH-E31,
36SH) and Rc3/8 or NPT3/8 (EH-E46, 56SH).
Apply seal tape to connected pipe and securely
tighten it so that liquid can not leak nor air be
sucked in.
Check valve 3. Tubing for bleeding
When you do bleeding, return the discharge
side tube to the suction side tank. Remove
Three way joint the check valve if it is mounted. Refer to item
Air vent "Bleeding" of "Operation" section.
valve Discharge hose
CAUTION
Pump
The EH-E pump is not equipped with built-
in air-vent valve. Mount the air-vent valve
referring to the illustration on left.
Built-in type air-vent valve is available as
an option for types VC, V6 and PC.
- 20 -
Installation
4. Mounting check valve
In case the pump is installed as mentioned
below, make sure to install the check valve
to avoid over-feeding.
1) In case the suction side liquid level is higher

than that of discharge side. (Fig. A)
2) In case the suction side pressure is higher

than the discharge side one. (Fig. B)
Suction side Discharge side 3) In case the discharge side liquid level is high-
Fig. A er than the suction side one but the height
difference between the two levels is 5 meters
or less. (Fig. C)
4) In case the pressure loaded to the pump (due

to pipe resistance, discharge head etc.) is
less than 0.13 MPa.
Fig. B
5m
Fig. C
- 21 -
Installation
Precautions when mounting check valve
1) Install the check valve at the end of discharge
tubing. It should be separated the pump by 1
meter or more.
CA type check valve

2) CA type check valve can be connected to either
tube or threaded pipe of R1/2 and R3/8.
3) Stainless steel check valve CS type has the

connection of RC1/4 or NPT1/4 for pump mod-
els EH-E31 and 36SH, and RC3/8 or NPT3/8
for pump models EH-E46 and 56SH.
For the connection of pipe, apply seal tape to
avoid liquid leakage.
CS type check valve
5. Other precautions for tubing
1) Use the specified size of tube. Otherwise
required pump performance and flow rate
may not be obtained.
2) Suction side tube should be as short as pos-

sible. (Max. length is 1 meter.)
3) Self-priming ability of this pump is 1 meter or

less when the valves are dry.
Install the pump of which the pump head to
be 1 meter or less than the liquid level. The
HP6 type is not designed for self-priming.
4) In case are handled gaseous liquids such as

sodium hypochlorite or hydrogen peroxide
etc., flooded suction is recommended for suc-
Air chamber
tion side. Flooded suction is effective to avoid
gas generation or air pocket in the piping.
6. Install of accumulator or air chamber

To avoid the vibration caused by the pulsation of
Discharge
pump discharge side, install an accumulator or
an air chamber in the piping.
Drain
CAUTION
Vibration of pipe causes the rupture of
pipe.
- 22 -
Installation
4. Electrical Wiring
1. Precautions on wiring
CAUTION
● Only qualified operator/service staff should be in charge of the related electrical
arrangement and control of the power source. Failure to observe this instruction may
result in injury to person or damage to assets.
● Frequent stop and start of pump should be done by using STOP function (ON and OFF
of STOP terminal). If you can not use STOP function and are forced to operate pump
by turning OFF and ON of power source, ON and OFF of power source should be lim-
ited to six times an hour.
Precaution for handling control unit

The control unit can be detached but do
not detach it when unnecessary.
Never combine the control unit with the
driving unit which are different power volt-
ages. Otherwise the electronic circuit or
driving unit may be failed or damaged.
CAUTION
Never use in common the power source of
the pump and that of high power electrical
equipment which generates surge voltage.
The surge voltage may cause the damage
and failure of controller.
● Surge voltage
The electronic circuit of the control unit may be
affected by excessively high surge voltage. So,
Surge absorbing element
do not operate the pump near high-power electri-
cal equipment of 220V or above that generates
high surge voltage.
P Under unavoidable circumstances, take either of
the following measures.
(1) Use a surge absorbing element (such as a
varistor with surge resistance of 2000A or
P more) at the pump power supply connection.
Noise-cut transformer (2) Use a noise-cut transformer.
- 23 -
Installation
2. Wiring
Power cord and external signal cord are connected according to the procedure as bellow.
CAUTION
· Never do the wiring when pump is operating. Otherwise you will get an electric shock or
the pump will be failed due to the short-circuit.
· Wait one minute or more after the power is switched off to start the wiring works
because the internal circuit will be electrified just after it is switched off.
· Use the cord of which outer diameter is 7, 8 mm. If smaller cord is used, enough tight-
ness can not be obtained
· Wiring of external and stop signals
Do not combine cables for EXT and STOP signals with power cable. Do not use coaxial
cable (5-wires cable or so) for wiring power cable, EXT and STOP signals cable all
together. Otherwise noise may be generated in EXT and STOP cables because of
induction effect from power cord, which may result in pump failure or failed operation.
1 2 4 5 6 7 8
Pulse Input
Control unit
Stop Input
Power Ground
+ - Analog Input
Terminal box gasket + - Sensor Power
DC 12 V
Terminal box 10 mA max.
Cord nut
Connector
Cord gasket
Cord
Fig. 5
- 24 -
Installation
1) Remove four screws with screw driver to take off
terminal box.
2) Connector is press-fit to PCB connector.

Remove connector from PCB connector.
3) Remove other cord nut which is not used for wir-

ing and take off blind cap and cord gasket from
it and put cord nut and cord gasket on wired
cord in that order and then insert it through ter-
minal box.
4) Connect wire to connector. Strip wire jacket

by approx. 5mm from its end and insert it into
each terminal and tighten connector screws
(Tightening torque : 0.4 N•m)
5) When wiring is completed, insert connector into

the original position.
CAUTION
Check if connector is securely mounted.
Wrongly or insufficiently mounted connec-
tor may cause failed operation.
6) Mount terminal box on case in the manner the

connection label comes upside and fix it with
attached four screws. Tightening torque is 0.5
N•m.
CAUTION
If terminal box is mounted by other screws
than attached ones, it may cause failed
sealing.
7) Adjust the tension of cord inside terminal box

and insert cord gasket into terminal box.
8) Tighten cord nut.
CAUTION
Use the cord of outer diameter of 7.8 mm.
Smaller diameter cord may cause wrong
sealing resulting in failed pump.
- 25 -
Installation
● Wiring for analog input operation
Analog input operation means the pump operation
by input current signal of 0 to 20 mA to change the
stroke rate in proportion to 0 to 360 spm.
For the wiring, connect the wires to the terminals
and and fix them by screws. Tightening
+ - torque is 0.4 N•m or less. is plus and is
minus. (Inside resistance : 250 Ohm)
CAUTION
Pay attention to polarity. Wrong connection
leads to unintentional operation. If signals
are entered with wrong connection for a
long time, the pump may break down.
+ - ● Wiring for stop function
Stop function means the method to provisionally
stop the pump operation by external potential
free contact signal or open collector signal.
For the wiring, connect the wires to and of the
connector.
ON • When used with open collector
Pump Pay attention to the polarity. is plus and is minus.
(Max. chargeable voltage is 5 V, current 1.1 mA)
CLOSE
External OPEN • When used with mechanical contact such as relay
contact or so. Use the electronic purpose one of which the
minimum applicable load of 1 mA or below.
CAUTION
Frequent stop and start of pump should
be done by using STOP function (ON and
OFF of STOP terminal). If you can not use
STOP function and are forced to operate
pump by turning OFF and ON of power
source, ON and OFF of power source
should be limited to six times an hour.
● Wiring for pulse input function
Pulse input function means the pulse multiply or divid-
+ - ing operation by external potential free contact signal
or open collector input.
For the wiring, connect the wires to and with
screw driver. Tightening torque is approx. 0.4 N•m.
• When used with open collector
Pay attention to the polarity. is plus and is minus.
(Max. chargeable voltage is 5 V, current 1.1 mA)
When mechanical contact such as relay or so is
used, use the one designed for electronic pur-
pose of which the minimum applicable load of 1
mA or below.
- 26 -
Operation
1. Preparation for Operation ......................... 28
1-1. Bleeding ............................................. 28
1-2. Adjustment of Discharge Capacity ..... 30
2. Operation .................................................. 32
2-1. Overview Operating Scheme ............. 32
2-2. Setting and Operation of Controller ... 34
- 27 -
Operation
1. Preparation for Operation
CAUTION
• Do not operate the pump with discharge-side valve completely closed.
Operating the pump with discharge-side valve fully closed may lead to liquid leakage or
pipe rupture.
• Do not run pump dry.
Dry operation of the pump over a long time (longer than 30 minutes) causes the pump
to overheat and the pump unit (pump head, valve guide etc.) to become deformed or the
pump head attachment to become loose, which may result in liquid leakage trouble.
• Keep the pump head firmly assembled.
If mounting bolts on the pump head are loosened, liquid leakage may result.
* Fasten the 4 or 6 hex. socket bolts tightly before starting the initial pump operation.
(The bolts may be loosened during storage or transportation of the pump, depending
upon the condition.)
* Fastening torque: 2.55 N·m.
Tighten all the bolts fully by applying an equal amount of torque in a diagonal order
among the bolts.
• Frequent stop and start of pump should be done by using STOP function (ON and OFF
of STOP terminal). If you can not use STOP function and are forced to operate pump by
turning OFF and ON of power source, ON and OFF of power source should be limited
to six times an hour.
1-1. Bleeding
Bleeding is a process to eliminate the air which remains in the suction tube or pump head.
Make sure to carry the bleeding prior to the initial operation of the pump or when the liquid in the tank was
replaced or the pump rested for a long time.
Starting and stopping pump operation
1) Switch on the power and ON lamp (green)
START/STOP
1
lights and goes to WAIT mode after the ver-
2 sion number was displayed. (When the pump is
EXT
switched on for the first time.)
The word WAIT is lit during WAIT mode.
EH-E ON
ON lamp
START/STOP key
START/STOP 2) Push START/STOP key one time. The word

1
2 WAIT disappears and pump starts operation.
EXT Every time START/STOP key is pushed, opera-
WAIT EXT STOP OVER SET tion and stopping is repeated.
EH-E ON
- 28 -
Operation
Fitting nut Bleeding for types VC, V6, PC and FC
1) Return the discharge side hose to the tank and
start the pump. Remove the check valve if it is
Remove mounted.
check valve
2) Run the pump for 10 minutes for bleeding.
3) When the air is removed and pump head is

completely filled with liquid, return the discharge
tube to the normal piping.
Return
to tank
4) Check if no liquid leaks from any part.
Bleeding for SH (stainless steel head) type

Before the bleeding is done, tighten the nut and
Air vent discharge fitting.
adjusting screw Tightening torque : E31, 36SH…5N•m
E46, 56SH…7N•m
1) Connect hose to bleeding hose connection part
Nut return the hose to the suction tank.
Discharge
Bleeding hose should be open without any load.
fitting Pay attention that the air and liquid come out
together when bleeding is done.
2) Turn an adjusting screw counter clockwise. (by

half to one turn)
3) Run the pump for ten minutes for bleeding.
To tank
4) Close the adjusting screw by turning it clockwise.
5) Check if no liquid leaks from any part.
AV-E air vent valve
To tank or Bleeding for types VC, V6 and PC with AV-E air

reserver vessel vent valve (Option)
To discharge
line
- 29 -
Operation
1-2. Adjustment of Discharge Capacity
Adjustment of the discharge capacity can be done by adjusting the stroke length and by adjusting the stroke
rate but basically it is done by adjusting the stroke rate. Stroke length adjustment is an auxiliary way when
the stroke rate adjustment is not enough.
Pay attention to the following for the correct adjustment.
1) For the gaseous liquid such as sodium hypochlorite and hydrazine solution, set the stroke length at 100 %
or near. Discharge flow may be reduced if the stroke length is short.
2) When the back pressure is high at discharge side, set the stroke length at 100 % or near to adjust dis-
charge capacity by stroke rate.
In case the reaction is greatly influenced by discharge capacity per pump shot in the application of neu-
tralization or titration, adjust discharge capacity by stroke speed with shortened stroke length to minimize
discharge capacity per shot.
1. Procedure to adjust the discharge capacity

Appropriate stroke length and stroke rate are decided considering the pump operating condition and liquid
characteristics or so. Following ways are recommended for proper calibration.
(1) Set the stroke length at 100 % to roughly adjust the discharge capacity by adjusting the stroke rate.
(2) Measure the discharge capacity.
(3) If the measured capacity is below the wanted value, increase the stroke rate and measure again the
discharge capacity.
(4) Adjust the stroke length to do the fine adjustment of the capacity.
(5) Measure again the discharge capacity to confirm the wanted capacity is discharged.
Stroke rate fixed 360spm
100
%
270spm
75
Disch. capacity
50 180spm
25
0 2025 50 75 100
Stroke length is adjusted. %
2. Adjustment of stroke rate

Stroke rate is adjusted by keys operation on the control unit. Stroke rate is adjusted from 1 to 360 spm.
Stroke length fixed

100
%
75
Disch. capacity
50
25
0
180 360
Stroke rate spm
- 30 -
Operation
3. Adjustment of stroke length
(1) Power on the pump to start and adjust the discharge capacity by turning the stroke length adjustment
knob.
(2) Figure below shows the relation between the stroke length and discharge capacity.
Stroke length can be adjusted from 0 to 100 % but actually set the length between 50 and 100 %.
Fixed stroke rate

100
%
75
Disch. capacity
50
25
0 25 50 75 100
Stroke length %
CAUTION
Do not turn the stroke length adjusting knob while pump stops.
● Full operation
Start pump for full operation after bleeding and discharge adjustment are finished.
Operation is done by manually or by any function of control unit.
● Manual operation
Starting pump : Turn on power to light ON lamp (green) to come to WAIT mode.
Push START/STOP key (for the first time to turn on power) for WAIT lamp to go out and
start pump.
Stop pump : Push START/STOP key to light WAIT lamp to stop pump. Every time to push START/STOP
key, pump starts and stops.
● EXT operation
Refer to next section of "Operation".
● When the pump is stopped for a long period (more than 1 month)
When the pump is stopped for a long period, clean the wet-end of pump and tubing by operating the pump
with clean water for 30 minutes before stopping the pump.
When the pump is started after stopping, if it does not suck up and discharge the liquid, clean the valve set
and remove foreign matters adhered. Do bleeding and adjust the discharge capacity.
- 31 -
Pulse memory switching over
Pulse dividing memory ON Pulse multiplying memory OFF

1 1
2. Operation
Power ON
/ -- ON 2 X -- OF 2
WAIT EXT STOP OVER SET WAIT EXT STOP OVER SET
▲ ▼ ▲ ▼
Program Ver display
1
EXT
1 1
EXT OP.
V3.0E 2 EXT OP. mode setting / -- OF 2 X -- ON 2
WAIT EXT STOP OVER SET WAIT EXT STOP OVER SET WAIT EXT STOP OVER SET
EXT
Pulse dividing memory OFF Pulse multiplying memory OFF
EXT OP. display EXT

Wait
EXT EXT + ▲
2-1. Overview Operating Scheme
▲
Pulse dividing op. 1 1 1
EXT OP. 360 2 dIG 2 ANA 2
1 WAIT EXT STOP OVER SET WAIT EXT STOP OVER SET WAIT EXT STOP OVER SET
/ 1 START START ▼
2 STOP STOP Digital mode setting display Analog mode setting display
WAIT EXT STOP OVER SET START
MANUAL OP. STOP
Pulse multiply op. EXT + ▼ Set value change

Manual spm setting Manual op. display
▼
1 START
1 1
X 1 2 359 360 STOP
2 2
WAIT EXT STOP OVER SET WAIT EXT STOP OVER SET WAIT EXT STOP OVER SET
▲
- 32 -
at digital mode set at analog mode set
Analog input op.

Pulse dividing op. mode Analog op. input set mode
1 ▲ ▲
120 2 1 1 1 1
Operation
/ 2 2 / 1 2 A04.0 2 A04.1 2
MANUAL OP. spm change WAIT EXT STOP OVER SET WAIT EXT STOP OVER SET WAIT EXT STOP OVER SET WAIT EXT STOP OVER SET
▼ ▼
EXT
EXT EXT ▲
Set value change
1 1
P 0 2 P 1 2
▲ WAIT EXT STOP OVER SET WAIT EXT STOP OVER SET
1 1 ▼
X 2 X 1 EXT
2 2 EXT
▼
Pulse multiply op. mode ▼
1 1
A20.0 2 A19.9 2
▲
EXT
▼
1 1
P360 2 P359 2
▲
Operation
Notes to Overview Operating Scheme
1) ------> means automatic movement. After the program Ver is displayed, it automatically moves to the sta-
tus at which the power was off last time. (When the pump is powered for the first time, it comes to WAIT
mode.)
2) For the pump start by manual operation, push START/STOP key at WAIT mode. To stop the pump, push
START/STOP key again.
3) EXT operation starts by pushing EXT key at WAIT mode and stops by pushing START/STOP key.
4) For the switching over between analog and digital operation, push EXT and ▲ keys simultaneously.
Parameter is changed by ▲ and ▼ keys and the set value is fixed by START/STOP key.
5) To move to pulse memory switching mode, push EXT key while dIG is selected at analog/digital switching
mode. (If ANA is selected, you can not come to this mode.)
Figures are changed by ▲ and ▼ keys and switching between multiply and dividing is done by EXT key.
Push START/STOP key to return to WAIT mode.
6) To go to EXT setting mode, push EXT and ▲ key simultaneously at waiting mode.
Parameter is changed by pushing ▲ and ▼ keys when you are in analog operation, and when you are in
digital operation, by pushing ▲ and ▼ keys to change parameter and push EXT key to toggle between
dividing and multiplying operation.
Default parameter value

Mode Parameter Default value Setting range Step
Manual spm 360 1 - 360 1
A/D toggle Digital/Analog dIG dIG, ANA
Pulse memory Dividing /OF ON, OF
toggle Multiply × ON OF, ON
Dividing /1 1 - 999 1
Multiply ×1 1 - 999 1
Set point 1 Amp. : 4.0 0.0 - 20.0 0.1
EXT operation
Set point 1 spm : 0 0 - 360 1
Analog
Set point 2 Amp. : 20.0 0.0 - 20.0 0.1
Set point 2 spm : 360 0 - 360 1
- 33 -
Operation
2-2. Setting and Operation of Controller
■ Manual operation
(1) Power ON
START/STOP
1 When the power is on, a green lamp lights up and the word-
2
ing "V3.0E" appears, then the stroke rate for manual opera-
EXT
tion is displayed and comes to WAIT mode. (In case the
pump is powered on for the first time.) If it does not come to
EH-E ON
WAIT mode, push once START/STOP key to come to WAIT
mode.
(2) Stroke rate can be changed by pushing ▲ or ▼ key at wait

START/STOP
1 mode or during operation. Push ▲ key to increase stroke
2
EXT rate and ▼ key to decrease. If you push the key in a short
WAIT EXT STOP OVER SET time, the spm figures changes slowly by one spm and if you
continue to push over three seconds, they change quickly.
EH-E
The pump is shipped set at 360 spm.
When the spm value is changed, the value is not put in
memory unless you push START/STOP key or EXT key, or
until three or more seconds have passed.
(3) Push START/STOP key to start the pump.

START/STOP
1 WAIT word disappears and ON lamp blinks.
2
EXT
EH-E ON
Blink
(4) Stop the pump.

START/STOP
1 When START/STOP key is pushed once, the pump stops
2
EXT and WAIT word appears to come to WAIT mode.
EH-E ON
- 34 -
Operation
■ Automatic operation
1. Analog signal operation
(1) Power ON
When the power is on, a green lamp lights up and the
START/STOP
1
2 wording "V3.0E" appears, then the stroke rate for manual
EXT
operation is displayed and comes to WAIT mode. (In
case the pump is powered on for the first time.) If it does
not come to WAIT mode, push once START/STOP key to
EH-E ON
come to WAIT mode.
(2) Change over at EXT operation mode

START/STOP
1 Push EXT key and ▲ key simultaneously.
2 Display shows "dIG" and SET lights. (If ANA is displayed,
EXT
go to next item (3)).
EH-E ON
The display changes to ANA if ▼ key is pushed.

START/STOP
1
(Every time ▼ key is pushed, the display changes ANA
2 to dIG.) When the pump is shipped from the factory, it is
EXT
set at dIG.
EH-E
(3) Push START/STOP key to confirm the analog mode and

START/STOP
1 move to WAIT mode.
2
EXT
EH-E ON
(4) Value input at analog mode

Push EXT key and ▼ key simultaneously.
START/STOP
1
2 Display shows the initial set value A04.0 and SET and 1
EXT
light.
EH-E
(5) Setting of input amperage at SET point 1.

START/STOP Set the input amperage at SET point 1 by ▲ and ▼ keys.
1
2 The value increases with ▲ key pushed and decreases
EXT with ▼ key pushed. Amperage changes slowly by 0.1
WAIT EXT STOP OVER SET mA when the key is pushed briefly, and changes quickly
if pushed 3 seconds or more.
EH-E Setting range is 0.0 - 20.0 mA.
When the pump is shipped, it is set at 4.0 mA.
- 35 -
Operation
(6) Push EXT key to confirm the value at SET point 1 and
START/STOP
1
move to the setting of stroke rate for the current value of
2 SET point 1. The words PO is displayed and SET and 1
EXT
light.
EH-E ON
(7) Setting of stroke rate for the current value at SET point 1
START/STOP
1 Set the stroke rate for the current value at SET point 1 by
2
▲ and ▼ keys. Setting range is 0 - 360 spm. The pump
EXT
is set at 0 spm when it is shipped from the factory.
EH-E
(8) Push EXT key to confirm the set current value at SET
START/STOP
point 1 and move to the setting of the input current value
1
2 at SET point 2.
EXT
Display shows A20.0 and SET and 2 light.
EH-E ON
(9) Setting of current value at SET point 2

START/STOP
1 Push ▲ and ▼ keys to set the current value at SET point
2
2. Do not set the value which is set at SET point 1.
EXT
Set range is 0.00 - 20.00 mA.
The pump is set at 20.00 mA when it is shipped from fac-
EH-E
tory.
(10) Push EXT key to confirm the set current value at point 2
START/STOP
1
and move to the setting of stroke rate vs current value of
2 SET point 2. Display shows P360 and SET and 2 light.
EXT
EH-E ON
(11) Setting of stroke rate for the current value of SET point 2
START/STOP
1 Push ▲ and ▼ keys to set the stroke rate for the current
2 value at SET point 2. Do not set the value which is set for
EXT
SET point 1.
Set range is 0 - 360 spm.
EH-E
The pump is set at 360 spm when it is shipped.
- 36 -
Operation
(12) Push START/STOP key to confirm the set value and
move to WAIT mode.
START/STOP
1
2
EXT
EH-E ON
(13) Push EXT key to start the pump.

START/STOP
Pump operates according to the set current value. WAIT
1
2 disappears and ON lamp blinks.
EXT
Display shows the stroke rate at which the pump oper-
WAIT EXT STOP OVER SET ates and EXT word lights. Stroke rate changes corre-
sponding to input current.
EH-E ON
To stop the pump, push START/STOP key and WAIT
Blink word lights.
To start the pump next time, push EXT key.
Alarm indication
At the analog input operation, if the current exceeding
START/STOP
360 spm comes, the word OVER lights. While the OVER
1
2 is lighting, the pump operates at 360 spm.
EXT
EH-E ON
When analog input being set, if the same value (current

START/STOP
or stroke rate) is put for SET point 1 and 2, ERR 1 is dis-
1
2 played for three seconds and then returns to set display.
EXT
EH-E ON
2. Pulse multiply operation

(1) Power ON
START/STOP
Power on and green lamp lights, display shows "V3.0E"
1
2 and then shows stroke rate of manual operation and
EXT
goes to WAIT mode.
WAIT EXT STOP OVER SET (In case the pump is powered for the first time)
The word WAIT is lit at WAIT mode. If it does not show
EH-E ON
WAIT, push START/STOP key once to change to WAIT
mode.
- 37 -
Operation
(2) Move to EXT operation mode.
Push ▲ key and EXT key simultaneously.
START/STOP
1
2 The word dIG is displayed and SET lights.
EXT
(If the word ANA is displayed, push ▼ key to change to
dIG. Every time you push ▼ key, the words ANA and dIG
switch over.) When the pump is shipped from the factory,
EH-E ON
it is set at dIG.
(3) Move to pulse memory (The function to put in memory

START/STOP
1
the pulses (max. 255 pulses) which come while the
2 pump does the multiply operation.)
EXT
Push EXT key and /-- OF or / -- ON is displayed and
SET lights. (If X -- ON or X -- OF is displayed, go to next
(4). When the pump is shipped from the factory, it is set
EH-E ON
at / -- OF.
Push EXT key and the display changes to X -- ON or X

START/STOP
--OF. (Every time you push EXT key, / -- OF or / -- ON,
1
2 X -- ON or X -- OF switches.) When the pump is shipped
EXT from the factory, it is set at X -- ON.
EH-E ON
(4) Setting of pulse memory ON, OFF

START/STOP
1 Push ▲ key and ▼ key to set ON and OFF of pulse
2 memory. Display X -- ON is memory ON and X -- OF is
EXT
memory OFF status.
When the pump is shipped from the factory, it is set at X
-- ON.
EH-E
(5) Push EXT key to confirm ON, OFF of pulse memory and
START/STOP
1
return to EXT operation mode.
2 The display shows dIG and SET lights.
EXT
EH-E ON
(6) Push START/STOP key to confirm the digital mode and

START/STOP
1 move to wait mode.
2
EXT
EH-E ON
- 38 -
Operation
(7) Switching of operation mode
START/STOP
Push EXT key and ▼ key simultaneously and / 1
1
2 (Dividing operation mode) is displayed and SET lights. (If
EXT X 1 is displayed, go to next (8).
EH-E
If you push EXT key, the display changes to X 1

START/STOP
1
(Multiplying operation). Every time EXT key is pushed, X
2 1 and / 1 are switched over.
EXT
EH-E ON
(8) Setting of stroke number to be counted

START/STOP
1 Set the stroke number with ▲ key and ▼ key.
2 ▲ key increases the number and ▼ key decreases the
EXT
number. The number changes slowly one by one if key
is pushed in a short time and changes rapidly if pushed
more than 3 seconds. Set range is 1 to 999. The pump is
EH-E
set at 1 when it is shipped from the factory.
(9) Push START/STOP key to confirm the operation mode

START/STOP
1 and stroke number.
2
EXT
EH-E ON
(10) Setting of stroke rate

START/STOP
1 Stroke rate at multiply operation is the one which is set
2 for manual operation mode. At WAIT mode, push ▲ key
EXT
and ▼ key to set the stroke rate. Refer to the item of
Manual Operation for details.
EH-E
The pump is set at 360 spm when it is shipped from the
factory.
- 39 -
Operation
(11) Push EXT key to operate the pump.
START/STOP
Pump starts to operate, WAIT goes out and ON lamp
1
2 blinks when a pulse comes.
EXT The pump automatically stops after it operated for the
WAIT EXT STOP OVER SET stroke number which is set at above item (8). During the
operation, the display shows pre-set stroke number and
EH-E ON
EXT lights. Push START/STOP key to stop the pump
Blink and go to WAIT mode. To start the pump again, push
EXT key.
Alarm indication
If next pulse comes during the multiplying operation,
START/STOP
OVER lights. If the pulse memory is set to ON, max. 255
1
2 times pulse is put in memory and the pump continues
EXT
operation.
EH-E ON
3. Pulse dividing operation

(1) Power ON
START/STOP
1
Power on and green lamp lights, display shows "V3.0E"
2 and then shows stroke rate of manual operation and
EXT
goes to WAIT mode.
(In case the pump is powered for the first time)
The word WAIT is lit at WAIT mode. If it does not show
EH-E ON
WAIT, push START/STOP key once to change to WAIT
mode.
(2) Move to EXT operation mode.

START/STOP
1 Push ▲ key and EXT key simultaneously.
2 The word dIG is displayed and SET lights.
EXT
(If the word ANA is displayed, push ▼ key to change to
dIG. Every time you push ▼ key, the words ANA and dIG
switch over.) When the pump is shipped from the factory,
EH-E ON
it is set at dIG.
- 40 -
Operation
(3) Move to pulse memory (The function to memorize the
START/STOP
pulses (max. 255 pulses) which come while the pump
1
2 does the multiply operation.)
EXT
Push EXT key and / -- OF or / -- ON is displayed and
WAIT EXT STOP OVER SET SET lights.
EH-E ON
If X -- ON or X -- OF is displayed, push EXT key and

START/STOP the display changes to / -- ON or / -- OF. (Every time
1
2 you push EXT key, / -- OF or / -- ON, X -- ON or X -- OF
EXT switches.) When the pump is shipped from the factory, it
WAIT EXT STOP OVER SET is set at X -- OF.
EH-E ON
(4) Setting of pulse memory ON, OFF

START/STOP
1 Push ▲ key and ▼ key to set ON and OFF of pulse
2
memory. Display X -- ON shows the pulse memory ON
EXT
and X -- OF shows memory OFF status.
When the pump is shipped from the factory, it is set at /
EH-E
-- OF.
(5) Push EXT key to confirm ON, OFF of pulse memory.

START/STOP
1
The display shows dIG and SET lights.
2
EXT
EH-E ON
(6) Push START/STOP key to confirm the digital mode and

START/STOP
1 move to wait mode.
2
EXT
EH-E ON
- 41 -
Operation
(7) Switching of operation mode
START/STOP
Push EXT key and ▼ key simultaneously, and / 1 (Pulse
1
2 dividing operation mode) is displayed and SET lights.
EXT
EH-E
If X1 (multiplying mode) is displayed, push EXT key to

START/STOP change to / 1.
1
2 (Every time EXT key is pushed, the display changes
EXT from X1 to / 1.)
EH-E ON
(8) Setting of dividing ratio

START/STOP
1 Set the dividing ratio with ▲ key and ▼ key.
2 ▲ key increases the number and ▼ key decreases the
EXT
number. The number changes slowly one by one if key
is pushed in a short time and changes rapidly if pushed
more than 3 seconds. Set range is 1 to 999. The pump is
EH-E
set at 1 when it is shipped from the factory.
(9) Push START/STOP key to confirm the operation mode

START/STOP
1 and dividing ratio.
2
EXT
EH-E ON
(10) Setting of upper stroke rate

START/STOP
1 Stroke rate at pulse dividing operation is the one which is
2
set for manual operation mode. At WAIT mode, push ▲
EXT
key and ▼ key to set the stroke rate. Refer to the item of
Manual Operation for details.
EH-E The pump is set at 360 spm when it is shipped from the
factory.
NOTE) In case pulse memory is set for OFF

Pump operation may become unstable if divid-
ing operation stroke rate according to input pulse
exceeds the set value of upper limit stroke rate.
Set the upper limit stroke rate at the value more
than the stroke rate at dividing operation accord-
ing to input pulse.
- 42 -
Operation
(11) Push EXT key to start the pump. WAIT disappears and
START/STOP
ON lamp blinks.
1
2 Dividing ratio is displayed and EXT lights.
EXT Stop the pump, push START/STOP key to come to WAIT
WAIT EXT STOP OVER SET mode.
When the pump is started next time, push EXT key.
EH-E
Alarm indication
If pulses which exceeds upper stroke rate come in divid-
START/STOP
ing operation, OVER lights.
1
2 If the pulse memory is set at ON, max. 255 inputs are put
EXT in memory and the pump continue to run for this pulses.
EH-E
- 43 -
Maintenance
1. Troubleshooting ................................ 45
2. Maintenance and Inspection ............. 46
3. Disassembly and Assembly .............. 49
4. Optional Accessories ........................ 53
5. Exploded Views and
Dimension Drawing .......................... 53
- 44 -
Maintenance
1. Troubleshooting
WARNING
● Wear protector
You may be injured if you touch chemical liquid. When you work on
pump, be sure to wear protector such as protective mask, safety gloves Wear protective
or so. gear
● Turn off power

You may be electrically shocked if you do the works without turning off
power of pump. Before you start working, be sure to turn off power to
Power off
stop pump or equipment.
Problem Possible Cause Corrective Action

Pump does not start. Faulty wiring or disconnected Correct wiring
Power voltage went down. Check power source.
Electronic control unit is damaged. Replace control unit
Pump does not prime. Pump stroke length is too short. Operate pump with stroke length set at
Discharge is not 100 % until primed. Then set stroke length
sufficient. as needed to obtain desired output.
Air sucked in suction tubing Correct tubing.
Valve gasket is not mounted. Install valve gasket
Valve set assembly direction is wrong. Reassemble valve set
Pump is air locked. Do air elimination.
Suction or discharge valve is clogged by Disassemble, inspect, clean
foreign matters.
Ball stuck to valve seat Disassemble, inspect, clean
Discharge capacity Suction or discharge valve is clogged by Disassemble, inspect, clean
fluctuates. foreign matters.
Air is trapped in pump. Do air elimination.
Overfeeding Install check valve or back pressure valve
at discharge side.
Diaphragm is damaged. Replace diaphragm
Worn check valves Replace valve cartridges
Liquid leaks. Fitting or coupling nut is loose. Tighten
Pump head is loose. Tighten pump head bolts
Torque: 2.55 N•m
Diaphragm is damaged. Replace diaphragm
O-ring or valve gasket is not mounted. Install O-ring or valve gasket
* It is recommended pump head bolts are tightened regularly at tightening torque of 2.55 N•m.
* When you find pump head bolts are loosened, liquid may goes inside driving unit. In this case remove a
diaphragm and check to see if liquid does not get into driving unit.
- 45 -
Maintenance
2. Maintenance and Inspection
2-1. Daily inspection
Pay attention to following items during pump operation and if you find any abnormality, stop pump immedi-
ately to take countermeasures referring to Troubleshooting on page 45. When the time comes to replace the
wear parts, replace it by new one.
No. Check item Description Check method
If pump discharges liquid ● Check if liquid is discharged. ● Flow meter or visual.
normally. ● Check if suction or discharge pressure is ● Refer to figures on
1 normal. nameplate.
● Check if liquid characteristics are not ● Visual or auditory
changed, crystallized nor adhered.
Abnormal noise or vibration. ● Pump may generate abnormal sound or ● Visual or auditory
2
vibration when it runs abnormally.
If no liquid leaks through pip- ● Tighten the parts where leakage happens. ● Visual inspection
3 ing or any pump parts or if ● Air is sucked in if you see many bubbles in
no air is not sucked in pump. discharged liquid.
Check pump head tightening bolts periodically and tighten them when necessary.
2-2. Wear parts

When pump is to be operated for a long period, the parts should be replaced appropriately, above all the
wear parts shown below are recommended to be stocked always.
VC, V6, PC and VM types

Parts Q'ty Time to replace Remarks
EH-E31 • E36 EH-E46 E56
14
14
11 14
31
13 14 11
Valve set 12 2 set
11 13
11 13 12
13 12
17
12 17
17
Approx.
8000 hrs
Diaphragm 7 1
*Refer to
"Exploded
O ring 30 * views" for quan-
tity required.
- 46 -
Maintenance
FC type
EH-E31 • E36 EH-E46 • E56
14
11
14
13
12 11
Valve set 14 2 set
13
11 12
13 14
12 17
14
17
Approx
8000 hrs
Diaphragm 7 1
*Refer to
"Exploded
Gasket *
30 views" for quan-
tity required.
SH type
EH-E31 • E36 EH-E46 • E56
14
11
14
13
14 11
Valve set 12 2 set
14 13
11 14
12
13
31 Approx
14 8000 hrs
12
31
Diaphragm 7 1
- 47 -
Maintenance
HP6 type
EH-E36
14
11
Valve set 52 2 set
13
12
14
Approx
8000 hrs
Diaphragm 7 1
*Refer to
"Exploded
Gasket 17 *
30 views" for quan-
tity required.
- 48 -
Maintenance
3. Disassembly and Assembly
WARNING
• Inspection and maintenance
Inspection, maintenance, disassembly and assembly of pump must
be done within the procedure and extent described in this instruction
manual. Never disassemble the parts beyond the extent described in
this manual (Do not disassemble electromagnetic driving part and elec-
tronic circuit board). The product is not guaranteed if it is disassembled
or modified beyond the extent described in this manual. IWAKI is not
responsible to the damage and accident caused by the disassembly and
modification beyond the extent.
• Wear protector
You may be injured if you touch chemical liquid directly or chemical liq-
uid splashes on you. Wear protective cloth, mask or safety gloves or so Wear protective
when you do works on pump and piping.

gear
• Turn off power

You may be electrically shocked if you do the works with the power
turned on. When the works are done, be sure to turn off power to stop Power off
pump or system.
• Before piping is removed or pump is disassembled, be sure to depressu-
rize pump and discharge piping. Chemical liquid gushes out and danger-
ous if pump or piping is disassembled without depressurizing.
• When pump is disassembled, pay attention to residual liquid.
3-1. Disassembly and assembly of pump head

When pump head is disassembled, turn off power of pump and remove piping after pump and piping are
depressurized to atmospheric pressure and disassemble pump head referring to exploded views on pages
53 to 56.
● How to depressurize
EH-E pump has no air vent valve except SH type. Install an air vent valve at discharge side to open it to
release pressure. (Refer to item "Tubing" on page 20.
SH type has an air vent valve and can release pressure by following procedure.
(Take the same procedure to release air for types VC, V6 and PC which equip air vent valve as option.)
1. Stop pump.
2. Turn an air vent adjusting screw to left by two turns to fully open air vent port.
3. Confirm that liquid came out from air vent port and pressure was released.
NOTE : When the liquid does not come out, it is possible the pressure is not released. In this case continue
to run pump until you confirm the liquid came out from air vent port and the pressure was released.
- 49 -
Maintenance
3-2. Replacement of valve set
<Disassembly>
Fitting nut
1. Loosen fitting nut to remove hose paying
attention to liquid coming out.
Connection port
2. Loosen connection port by wrench to remove
it and take valve set out of pump head.
Pump head WARNING

● Liquid may injure your hand, fingers
or pump component. Wipe off quick-
ly the liquid adhered to your hand or
pump component.
<Assembly>
Assemble valve set in reverse order to disassembly
paying attention to the following.
● Arrange and insert valve set in correct order and
direction.
● Wrongly ordered and directed valve set causes
failed pumping such as leakage and reduced flow
rate or so.
● Do not forget to put O ring.
1. Assembly of discharge side valve set

Put valve set in pump head, screw connection
port in pump head by hand and then tighten it
with wrench by approx. 1/4 turns.
EH-E46(VC, V6, PC)Valve set 2. Assembly of suction side valve set
Discharge side Valve gasket Put valve set in connection port, screw connec-
Spacer tion port in pump head by hand and then tighten
Valve gasket it with wrench by approx. 1/4 turns.
Valve guide
Valve ball NOTE: Pay attention to up and down direction of
Valve seat spacer of EH-E46 (types VC, V6 and PC).
O ring Put chamfered side downward for suction
side valve and upward for discharge side
Suction side
Valve gasket valve. Refer to figures on left.
O ring
Valve guide
Valve ball
Valve seat
Spacer
Valve gasket
- 50 -
Maintenance
Exploded views of valve set
VC, V6, PC, VM types FC type SH type
17
14 31 · 36 31 · 36 31 · 36
14
Same for 11 Same for Same for
11
disch. and 13
disch. and disch. and
13 suc. 12 suc. suc.
14
12
11
11 13
12
13
12
14 14
31
31 46 · 56
14
Same for
Disch.
14 11 disch. and
Disch.
10 suc.
11
11
13 14
17
12
17 46
46
17
17
14 14
11
Suc.
11
Suc.
13
13 12
14 HP6 type
12 31
31 14
14
14
11
Same for
52 disch. and
13 suc.
17 56 56 12
14 Same for
14 Same for 14
disch. and disch. and
11
suc. suc.
13
11
12
14
13
17
12
- 51 -
Maintenance
3-3. Replacement of diaphragm
<Disassembly>
1. Set stroke adjusting knob at zero.
2. Remove four or six hex. socket head bolts with
hex. wrench and take pump head off.
3. Hold periphery of diaphragm and turn it coun-
ter clockwise to remove it from plunger pin.
(Diaphragm is screwed in plunger pin.)
WARNING
● Do not lose diaphragm spacer. Zero
to several diaphragm spacers are put
between retainer and plunger pin for the
purpose of adjusting the position of dia-
phragm. Number of spacer depends on
each pump and there is the pump which
has no spacer.
<Assembly>
Assemble pump in the reverse order to disassem-
bly paying attention to following.
1. Confirm that a stroke length adjusting knob is set
at 0%.
2. Put a retainer and diaphragm spacer on the
threaded part of new diaphragm and screw it in
plunger pin. Put the recessed side of retainer on
stepped part of diaphragm. Pay attention for the
retainer not to drop.
3. Start pump and adjust stroke length at 50% and
then stop pump and turn off power.
4. Mount pump head on pump body with hex. sock-
et head bolts. (Tightening torque : 2.55 N•m)
- 52 -
Maintenance
4. Optional Accessories
Specification of check valve and back pressure valve
Set pressure Wet-end Applicable Pump wet-end
Model MPa material pump model code
CA-2VC VC
PVC
CA-2VE V6
0.17±0.04 EH-E31, E36
CA-2V
GFRPP PC
CA-2E
CA-3VH VC
PVC
CA-3VEH 0.17±0.04 EH-E46 V6
CA-3VH GFRPP PC
CA-3VCL VC VM
PVC
CA-3VEL 0.05±0.04 EH-E56 V6
CA-3VL GFRPP PC
CS-1S 0.2±0.03 SUS316 EH-E31, E36 SH
CS-2S 0.2±0.03 SUS316 EH-E46 SH
CS-2SL 0.1±0.02 SUS316 EH-E56 SH
0.2±0.02 EH-E31, E36 FC
BVC-1TV PVDF
0.1±0.02 EH-E46, E56 FC
5. Exploded Views and Dimension Drawing

Exploded view of whole pump
The view shows completely exploded components for your easy understanding.
Do not disassemble pump beyond the extent shown in the item “Disassembly and assembly”.
Pump body
(Backup retainer :
for E56 only)
Valve set
Base gasket
Pump head
Pump base
Retainer
Diaphragm
Valve set Control unit

Blind cap
Gasket
Cord nut
Cord gasket
Terminal box
Connector gasket
Controller body
- 53 -
Maintenance
Exploded view of pump head (VC, V6, PC, VM, FC types)
EH-E31 · 36 EH-E46 EH-E56
4 4 4
28 28
28
29
29 30
30 29
30
3
3
14 3
14
11 31
14 14
13 18
12 11 11 10
14 9
13 18 13
11 9 12 7
12
13 18 7 14
12 9 14
7 17 17
14
17
1 1 1
17
20 21 14 17
19 17
11 21 14 14
13
20 20 21
19 11 19
12 11
14 13
13
11 12 12
13 14 14
12 31
14 14
3
3 3
30
30 30 29
29 29
28
28 28
4 4 4
No. Parts Q'ty No. Parts Q'ty

1 Pump head 1 17 O ring (FC type : Gasket) 2
3 Connecting port 2 18 Diaphragm spacer (NOTE 5)
4 Fitting nut 2 19 Hex. socket head cap bolt 4(NOTE 6)
7 Diaphragm 1 20 Spring washer 4(NOTE 6)
9 Retainer 1 21 Plate washer 4(NOTE 6)
10 Backup retainer 1(NOTE 2) 28 Hose stopper 2
11 Valve guide 4(NOTE 3) 29 Connecting port spacer 2
12 Valve seat 4(NOTE 3) 30 O ring (FC type : Gasket) 2
13 Valve 4(NOTE 3) 31 Spacer 2(NOTE 7)
14 Valve gasket NOTE 4
NOTE 1: Valve gasket 14 marked by (*) on above views is used only for FC type.
2: Only for E56.
3: 2 pcs for E46 and E56.
4: 2 pcs for VC,V6, PC, VM types of E31, E36, E56.
4 pcs for VC, V6, PC, VM types of E46 and FC type of E56
6 pcs for FC type of E31, E36, E46
5: Number of diaphragm spacer depends on shipped pump (from zero to several pieces).
6: 6 pcs for E46 and E56
7: Only for E46.
- 54 -
Maintenance
Exploded view of pump head (SH type)
EH-E31 · 36 EH-E46 · 56
No. Parts Q'ty No. Parts Q'ty

1 Pump head 1 21 Spring washer 4(NOTE 5)
3 Connecting port IN 1 31 Gasket 2
4 Connecting port OUT 1 32 Lock nut 1
7 Diaphragm 1 33 Joint 1
9 Retainer 1 34 Gasket 1
10 Backup retainer 1(NOTE 1) 35 Gasket 1
11 Valve guide 4(NOTE 2) 36 Air vent body 1
12 Valve seat 4(NOTE 2) 37 Air vent adjusting valve 1
13 Valve 4(NOTE 2) 38 Seal nut 1
14 Valve gasket 6(NOTE 3) 39 Seal gasket 1
18 Diaphragm spacer (NOTE 4) 40 Seal ring 1
19 Hex. socket head bolt 4(NOTE 5) 41 Gasket 1
20 Plate washer 4(NOTE 5) 42 Hose joint 1
NOTE 1: Only for E56.
2: 2 pcs for E46, E56
3: 4 pcs for E46, E56
4: Number of diaphragm spacer depends on shipped pump (from zero to several pieces).
5: 6 pcs for E46, E56
- 55 -
Maintenance
Exploded view of pump head (HP6 types)
EH-E36
No. Part names # of parts

1 Pump head 1
3 Fitting 1
4 Fitting nut 1
7 Diaphragm 1
9 Retainer 1
11 Valve guide 2
12 Valve seat 2
13 Valve 2
14 Valve gasket 4
17 O ring 2
Hex. socket head bolt
19 4
[PW•SW]
28 Hose stopper 1
29 Fitting spacer 1
30 O ring 1
51 Inlet 1
52 Valve spring 2
*The number of diaphragm spacers
varies with pump model.
- 56 -
Maintenance
■ Outline dimension (VC, V6, PC, VM, FC)
● EH-E31 (243)
(198) 16.5
OUT
(246)
163
(78)
IN
17
154 (28) 146
114 25.5
7 7
132
● EH-E36 (243)
(198) 16.5
OUT
(246)
(79)
IN
17
154 (27) 146
114 25.5
7
132
- 57 -
Maintenance
● EH-E46
(247)
(199) 19
OUT
(255)
163
(70)
IN
17
154 (29) 146
114 25.5
7 7
132
● EH-E56 (259)
(209) 21.5
OUT
(266)
163
(59)
IN
17
154 (39) 146
114 25.5
7 7
132
- 58 -
Maintenance
■ Outline dimension (SH)
● EH-E31SH (249)
(197) (23)
Rc1/4"
OUT
AIR
ODØ4
(300)
(256)
163
Rc1/4"
(97)
IN
17
154 (27) 146
114 25.5
7 7
132
(249)
● EH-E36SH (197) (23)
OUT
AIR
(303)
(259)
163
(94)
IN
17
154 (27) 146
114 25.5
7
132
- 59 -
Maintenance
● EH-E46SH (254)
(198) (27)
OUT
AIR
(328)
(276)
163
(92)
IN
154 (27) 17 146
114 25.5
7 7
132
● EH-E56SH (265)
(208) (28)
OUT
AIR
(331)
(279)
163
(79)
IN
17
154 (38) 146
114 25.5
7 7
132
- 60 -
Maintenance
● EH-E36HP6 (245)
(196) (20)
OUT
(255)
163
IN
(75)
17
154 (26) 146
114 25.5
7 7
132
- 61 -
( )Country codes
IWAKI
Electromagnetic Metering Pump
IWAKI CO.,LTD. 6-6 Kanda-Sudacho 2-chome Chiyoda-ku Tokyo 101-8558 Japan
TEL:(81)3 3254 2935 FAX:3 3252 8892(http://www.iwakipumps.jp)
Australia IWAKI Pumps Australia Pty. Ltd. TEL : (61)2 9899 2411 FAX : 2 9899 2421 Italy IWAKI Europe GmbH, Italy Branch TEL : (39)0444 371115 FAX : 0444 335350
Austria IWAKI EUROPE GmbH TEL : (49)2154 92540 FAX : 2154 9254 48 Korea IWAKI Korea Co.,Ltd. TEL : (82)2 2630 4800 FAX : 2 2630 4801
Belgium IWAKI Belgium n.v. TEL : (32)1367 0200 FAX : 1367 2030 Malaysia IWAKIm Sdn. Bhd. TEL : (60)3 7803 8807 FAX : 3 7803 4800
EH-E Type
China IWAKI Pumps (Shanghai) Co., Ltd. TEL : (86)21 6272 7502 FAX : 21 6272 6929 Norway IWAKI Norge AS TEL : (47)23 38 49 00 FAX : 23 38 49 01
China IWAKI Pumps (Guangdong) Co., Ltd. TEL : (86)750 3866228 FAX : 750 3866278 Singapore IWAKI Singapore Pte. Ltd. TEL : (65)6316 2028 FAX : 6316 3221
China GFTZ IWAKI Engineering & Trading (Guangzhou) TEL : (86)20 8435 0603 FAX : 20 8435 9181 Spain IWAKI Europe GmbH, Spain Branch TEL : (34)93 37 70 198 FAX : 93 47 40 991
China GFTZ IWAKI Engineering & Trading (Beijing) TEL : (86)10 6442 7713 FAX : 10 6442 7712 Sweden IWAKI Sverige AB TEL : (46)8 511 72900 FAX : 8 511 72922
Denmark IWAKI Nordic A/S TEL : (45)48 24 2345 FAX : 48 24 2346 Switzerland IP Service SA TEL : (41)26 674 9300 FAX : 26 674 9302
Instruction Manual
Finland IWAKI Suomi Oy TEL : (358)9 2745810 FAX : 9 2742715 Taiwan IWAKI Pumps Taiwan Co., Ltd. TEL : (886)2 8227 6900 FAX : 2 8227 6818
France IWAKI France S.A. TEL : (33)1 69 63 33 70 FAX : 1 64 49 92 73 Taiwan IWAKI Pumps Taiwan (Hsin-chu) Co., Ltd. TEL : (886)3 573 5797 FAX : (886)3 573 5798
Germany IWAKI EUROPE GmbH TEL : (49)2154 9254 0 FAX : 2154 9254 48 Thailand IWAKI (Thailand) Co.,Ltd. TEL : (66)2 322 2471 FAX : 2 322 2477
Holland IWAKI Europe GmbH, Netherlands Branch TEL : (31)547 293 160 FAX : 547 292 332 U.K. IWAKI Pumps (UK) LTD. TEL : (44)1743 231363 FAX : 1743 366507
Hong Kong IWAKI Pumps Co., Ltd. TEL : (852)2 607 1168 FAX : 2 607 1000 U.S.A. IWAKI AMERICA Inc. TEL : (1)508 429 1440 FAX : 508 429 1386
Indonesia IWAKI Singapore (Indonesia Branch) TEL : (62)21 690 6606 FAX : 21 690 6612 Vietnam IWAKI pumps Vietnam Co.,Ltd. TEL : (84)613 933456 FAX : 613 933399
Read this manual before use of product
T656-2 '13/09
Date of preparation Document No. Version
2020-10-20 TCSH-002 Rev.3
Prepared by Reviewed by Approved by QC
Lim, Heonjin Lee, Gwangho Kwon, Kyungahn
Subject Document type
DPD TRO Sensor Manual Technical document
DPD TRO Sensor
Manual
Techcross
Confidential
Document
i
i 페이지 1/4/2021
2020-10-20 TCSH-002 Rev.3
Table of contents
1. Overview ....................................................................................................................... 4
1.1. Revision History ............................................................................................................ 4
2. Product specification ..................................................................................................... 4
3. Safety ............................................................................................................................ 5
3.1. Safety information labelling ........................................................................................... 5
4. Product component ....................................................................................................... 6
5. Measuring principle ....................................................................................................... 7
5.1. Analytical method .......................................................................................................... 7
5.2. Measurement procedure ............................................................................................... 7
6. Installation ..................................................................................................................... 8
6.1. Installation of the product .............................................................................................. 8
6.2. Installation of pipes ....................................................................................................... 8
6.3. Electrical connections ................................................................................................... 9
6.3.1. Power connection ............................................................................................. 10
6.3.2. Communication (RS-485) linkage .................................................................... 10
6.3.3. Analog output (4~20mA) connection ................................................................ 10
6.3.4. DI and DO connection .......................................................................................11
6.4. Installation of reagents ................................................................................................ 12
7. Product operation ........................................................................................................ 14
7.1. Operation .................................................................................................................... 14
7.2. Keypad and Display information ................................................................................. 16
7.3. Calibration ................................................................................................................... 16
7.4. Setting ......................................................................................................................... 18
7.4.1. Menu configuration ........................................................................................... 18
7.4.2. Communication settings ................................................................................... 19
7.4.2.1. Modbus address setting ................................................................................. 19
Confidential
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2020-10-20 TCSH-002 Rev.3
7.4.2.2. Baud rate setting ............................................................................................ 20

7.4.3. System setting .................................................................................................. 20
7.4.3.1. Bypass time setting ........................................................................................ 20
7.4.3.2. Reagent injection ........................................................................................... 21
7.4.3.3. 4~20mA output setting ................................................................................... 22
7.4.4. Factory reset .................................................................................................... 23
8. Trouble shooting.......................................................................................................... 24
8.1. Alarm ........................................................................................................................... 24
9. Maintenance ................................................................................................................ 25
9.1. Periodic maintenance.................................................................................................. 25
9.2. Replace reagents ........................................................................................................ 25
9.3. Measurement cell cleaning ......................................................................................... 26
9.4. Strainer cleaning ......................................................................................................... 27
Confidential
Document
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2020-10-20 TCSH-002 Rev.3
1. Overview
This manual explains DPD TRO Sensor that measures TRO(total residual oxidant) content in the water. The manual’s
contents are correct by thorough inspection or repair. However, they can be a little bit different from the product if
it is improved.
1.1. Revision History

Version Date Progress Prepared by Remarks
Rev.0 2017-02-13 First prepared Lim, Heonjin
Rev.0 2017-11-01 Modified product specification Lim, Heonjin
Rev.1 2018-01-09 Modified calibration item Lim, Heonjin
Rev.1 2018-01-17 Modified calibration item Lim, Heonjin
Rev.2 2019-02-13 Added new component changes Lim, Heonjin
1. Modified size of drain tube connection
(page 8-9 : 8mm -> 10mm)
Rev.3 2020-10-20 Lim, Heonjin
2. Added period of maintenance
(page 25 : table 4.)
2. Product specification
Table 1. Product specification
No. List Description Remarks

1 Measuring range 0 ~ 15 mg/L
2 Accuracy ±10 % or 0.05 ppm, whichever is greater
3 Resolution 0.01 mg/L
4 Measuring cycle Can set 60 to 600 seconds.
5 Display 6 types of FND display mode
6 Rated voltage 24 VDC
7 IP class IP44
Analog Output (4~20mA)
RS-485 Modbus Communication
8 I/O
1 Digital Input
2 Digital Output
9 Sample Temperature 1℃ to 40℃
10 Installation form Wall-mounted
11 Water pressure 0.5bar to 2.0bar
12 Weight about 8.9 kg
13 Dimension 290 x 327 x 190 mm
14 Storage temp. range -10 ~ 60 ℃
15 Operation temp. 0 ~ 55 ℃
Confidential Document -4- 4/27

2020-10-20 TCSH-002 Rev.3
range
16 Humidity 0~95% Relative Humidity (Non-Condensing)
17 Altitude ≤ 2000 m
3. Safety
This manual explains the basic guidelines that must generally be implemented in the product including the
installation, operation, and maintenance. Please make sure to read all the contents of the manual before unpacking,
installing, or operating the product. Please make sure to pay attention to all kinds of danger and warnings. Please
be informed that noncompliance may result in user or equipment damage.
3.1. Safety information labelling

Please refer to the marks attached to this equipment. If you will not follow the indicated guidelines, you may get
injured or equipment may be damaged.
Caution : Potential risk that may cause slight or serious injuries
Confidential Document 5/27

2020-10-20 TCSH-002 Rev.3
4. Product component
Product component can largely be divided into 6 parts as shown in the following Figure 1.
1) Sample water inlet section: This section plays a role of supplying sample water to measurement cells according
to measurement procedures.
2) Reagent supply section: This section plays a role of supplying reagents to measurement cells by compressing
pleated reagent packs.
3) Measurement section: This section consists of LED and a photo sensor, and a peristaltic pump and plays a role
of mixing sample water with reagents in measurement cells and analyzing TRO concentration.
4) Control section : This section is responsible for overall operation and control of this equipment and plays a role
of providing user interface.
5) Sample water outlet section : This plays a role of discharging sample water in the measurement cells.
6) Air vent : This vent prevent sample water from flowing backward being connected to the measurement cells and
makes them smoothly discharged.
Control
section
Air vent
Reagent
supply section
Sample water
inlet section
Measurement
section
Sample water
Figure 1. Block diagram of the product
drain port

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5. Measuring principle
5.1. Analytical method
DPD TRO Sensor (Hereafter, referred to as ‘DTS’) is equipment that measures TRO in the water. It uses the DPD
colorimetric method that does DPD(N,N-diethyl-p-phenylenediamine sulfate), the indicator, and buffer solutions.
When the suitable amount of an indicator and a buffer solution are mixed with a sample water, they are changed
to red in proportion to concentration of TRO in the water. It measures and digitizes the concentration by using
LED(Sources of light) and inform users of them. TRO concentrations are calculated by differences in absorbance.
5.2. Measurement procedure

DTS was designed to collect sample water and analyze part of them. Sample water is collected in the measurement
cell through the input Solenoid valve passing through a strainer of the inlet. For the sample water collected in the
measurement cell, TRO gets to be measured through the process to analyze absorbance by measuring zero points
(Blank measurement) and inputting the reagents. The injection of sample water is controlled by the input Solenoid
valve in the inlet. The sample water are discharged from the discharge Solenoid valve after finishing the
measurement.
The reagents injected in the process to analyze absorbance are distributed to two replaceable pleated packs. There
is the buffer solution that adjusts PH of the sample water in one and the indicator including DPD in the other.
The sample water developed by the two reagents are analyzed by the LED (Sources of light) and the Photo Sensor
(Photo diode). They are displayed being digitized so that users can check them. The above process is simply shown
as follows:
1) Flushing : When measurement begins, open the inlet and outlet valves and flush it.
2) Measure the zero (0) point: Put the suitable quantity of the sample water in a measurement cell by closing the
discharge valve and adjusting the inlet valve and measure the zero point.
3) Discharge: Discharge the sample water measured to be the zero point and prepare the following procedure.
4) Measure the inflow rate of the sample water : Check the flow rate of the sample water that are now flowed into
equipment by controlling the inlet valve.
5) Put a reagent in equipment : Put the suitable amount of the sample water in the measurement cell by controlling
the inlet value according to the quantity that they are flowed into equipment. Put the reagent in equipment in the
middle of this process so that the it can react to the sample water.
6) Measure TRO : Analyze absorbance of the sample water developed by the reagent.
7) Discharge: When measurement ends, discharge the sample water from the measurement cell and wait for the
next measurement command.

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6. Installation
6.1. Installation of the product
This product was designed to be installed by attaching it to the wall surface. If there is no wall surface, you can use
it by installing it on a good place for adhesion. But, it is recommended to install it in the closest place to the
position of sample water sampling.
When equipment is installed, it is recommended to fix it with M6(1/4”) screws by using mounting holes. Please see
the following Figure 2.
Figure 2. Size and position of the surface that equipment is attached
6.2. Installation of pipes

For the installation of pipes, connect standard products to equipment as shown in the following Figure 3. For the
connection of sample water to the inlet, connect it to a 6mm (1/4”) Tube passing through the strainer to prevent
the product from being broken. When the injection of sample water due to foreign substances is not smooth, the
strainer can simply be separated and cleaned. For the injection of the inlet when putting sample water in equipment,
it is good that it does not exceed 2.0 bar. If it exceeds 2.0 bar, the wrong measurement values can be shown and
it can contribute to equipment failure.
Connect the Drain connection to a 10mm(3/8”) Tube for smooth discharge of sample water. The outlet must not
be blocked. If smooth discharge is not done, the wrong measurement values can be shown and it can contribute
to equipment failure.
Connect the air vent to equipment by using a 10mm(3/8”) Tube. The connection length of the air vent should be
shortest. And it must always be exposed to the air.

2020-10-20 TCSH-002 Rev.3
When sample water are discharged, they are discharged being mixed with reagents. It is the best method
to ask local authorities about how to dispose of waste even though used chemicals are in low concentration.
Connection
of the air vent
(10mm Tubing connection)
Connection of the drain Connection of the inlet
(10mm Tubing connection) (6mm Tubing connection)
Figure 3. Position and specifications to connect pipes
6.3. Electrical connections

All types of electrical connections should be done through the cable grand in the top left of equipment. They can
be connected to internal PCB by removing screws of the terminal access cover in the product. For cable specifications,
it is recommended to use 16 to 24 AWG.
For the connection of

power supply to
communication
For the connection Cable grand

(7mm ~ 13mm)
of the analog output
to DI and DO

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Separation of the Terminal Access Cover
Figure 4. Position and specifications of electrical connections
Electrical wiring must be worked by specialists according to the instructions. Please connect equipment
according to electricity rules of countries, states, and regions.
6.3.1. Power connection

This product uses 24VDC voltage and should be No.1(+) and No.2(-) of the terminal block fixed to PCB
The wiring type of the terminal block is PUSH IN SPRING which can be inserted into equipment by pressing cable
on the applicable position. For cable specifications, it is recommended to use 18 AWG. Please see the following
Figure 5.
6.3.2. Communication (RS-485) linkage

Connect the cable to the No.4(485A), No.5 (485B), and No.6 (Signal Ground) of the terminal block in order. For
cable specifications, it is recommended to use 20AWG. Please see the following Figure 5.
6.3.3. Analog output (4~20mA) connection

Connect the cable to the No.7(+) and No.8(-) of the terminal block in order. For cable specifications, it is
recommended to use 20AWG. Please see the following Figure 5.

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6.3.4. DI and DO connection

In this product, the DI function starts measurement by using the voltage of 24VDC with a control signal.
Users can adjust starting measurement as they like. Connect the cable to the No.9(+) and No.10(-) of the terminal
block in order. For cable specifications, it is recommended to use 20AWG.
The DO function shows the measurement and abnormal state of this equipment. When the outputs are enabled,
the voltage of 24VDC is output. Connect the cable to the No.11(+ Output of 24VDC – DO1) and No.12(+ Output
of 24VDC - DO2)에 of the terminal block in order. For cable specifications, it is recommended to use 20AWG. Please
see the following Figure 5.
Figure 5. Position and specifications of electrical wiring

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6.4. Installation of reagents

Two reagents of a buffer solution and an indicator are required for this equipment. It is provided to install it in a
pleated reagent pack of 250ml. Powdery forms of reagents available with the product are used by mixing them
with each distilled water. Powder is used by being completely dissolved. Install the reagents according to the
procedure of the following Figure 6.
1) Connect the pipes of the reagent pack : Put the reagents dissolved in the reagent pack and connect it to a
Pharmed tube and Reducer Barb fittings.
- If the pharmed tube connected to the reagent pack is not inserted into the peristaltic pump, the reagents can
be leaked. Please be careful.
- Please close the lid tightly to prevent reagent from leaking.
Barb fitting
Barb fitting
1/16”
3/16”
Barb fitting Pharmed Tube

3/16”
Figure 6. Connection of pipes of the reagent pack
2) Lift the lever of Peristaltic pump to prepare for inserting the pharmed tube.
Figure 7. Lever operation of peristaltic pump

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3) Insert the tube into the peristaltic pump as shown in Figure 8. and lower the lever to secure the pharmed tube.
Figure 8. Loading procedure of tube
4) Secure the block to the top of the pump so that the pharmed tube is fully seated. (secure with screw)
Figure 9. Fixing tube through fixed block
5) Install the reagent pack: Lift up the compressor of the reagent pack.
And insert the Silicon tube(1/8”) into Barb fittings of the reagent pack which were in advance prepared.
Lift up the upper part

of the compressor of
the reagent pack by
Pharmed tube hand.
(OD : 1/8”)
Figure 10. Installation of the reagent pack

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6) Fix the reagent pack: Insert the reagent pack into the compressor by lifting it upside down.
If the pharmed tube connected to the reagent pack is not inserted into the peristaltic pump, the reagents
can be leaked. Please be careful.
Check if the tube

is fixed.
Figure 11. Fix the reagent pack
7) Inject reagents: Execute the automatic injection of reagents by pressing the top menu button. For more
information, please see the contents of 7.3.4.2.
7. Product operation
7.1. Operation
Check if all the pipes and electrical wiring were completely installed before operating the product. When
everything’s all set, prepare for measurement by powering equipment. When you power equipment, the software
version is shown and is changed to the screen to prepare measurement in the product and. Please see Figure 12.
You can start measurement after that. Measurement is done according to the normal procedure. The following
procedure explains the general measurement procedure.
Figure 12. Display of the Version and the start-up screen
1) Start measurement : You can start measurement with two methods in this product. When measurement starts,

2020-10-20 TCSH-002 Rev.3
measurement is arranged during a cycle and all the process is automatically done.
1-1) Supply DI signal: The voltage of 24VDC is referred to a start signal through the DI terminal block. When
the start signal is referred, the product immediately starts measurement.
1-2) RS-485 Communication : It’s the method to give a start signal by using RS-485 communication. When the
start signal is transmitted to communication like DI input, measurement immediately begins.
2) Bypass & Flushing : When measurement begins, Bypass is arranged as sample water are discharged from the
outlet. And at the same time, the measurement cells are flushed. The bypass time can be set by 5 second in the
Menu by users.
3) Measure the 0 point: Put a sample water in the measurement cell and start measuring the zero point by
turning on LED while it is not mixed with a reagent after stopping equipment. The zero point is adjusted every
cycle. And when measurement ends, the sample water is discharged from the outlet.
4) Analyze TRO: Put the flow rate of the sample water that is now flowed into equipment in the measurement cell
by dividing it into proper amounts. Operate equipment by putting liquid forms of the buffer solution and the
indicator simultaneously so that they can well be mixed with the sample water. When the proper amount is put in
the measurement cell, measure and analyze current TRO.
5) Discharge the sample water: When the analysis of TRO of the sample water is done, it is digitized through the
display window and is shown to users. And the sample water that the analysis is finished is discharged. After that,
it waits for next measurement.

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7.2. Keypad and Display information
1 2 3 4
Figure 13. Keypad and Display
Table 2. Explanation of the Keypad
No. Key Description Remarks

Can change the measurement screen to the Menu mode.
1 MODE
Can move from the Menu mode to the previous screen.
Can move from the Menu mode to the top menu.
2 Up arrow
Can raise the editable numerical values.
Can move from the Menu mode to the submenu.
3 Down arrow
Can lower the editable numerical values.
Can move the Menu mode to the menu currently displayed.
4 SET
Can enter the editable numerical values.
5 FND Display Show the TRO measured value and setup menu.
7.3. Calibration
When the measured values of the instrument need to be calibrated, can adjust the values according to the following
procedures.
1) For the samples of sample water that you try to measure, measure TRO by using other equipment(Use equipment
that has been calibrated) that becomes the criteria (Pocket photometers, iodometry, etc.).
2) Press the mode key after measurement of the product is at least once done. Values cannot be adjusted while
TRO never be once measured.

2020-10-20 TCSH-002 Rev.3
3) When it is changed to the ADJUST screen, go to it by pressing the set key. At this moment, the screen to ask
your password appears. This means that you cannot adjust values except the permitted users. The first setting
password is ‘1111’.
4) When you go to the screen to enter a password, the positional number farthest to the right flickers. Can adjust
the numbers with Up and Down keys and move the set key to the left positional number. Enter 1111 in the screen
with the same method and press the set key for more than 2 seconds. If you enter the wrong number, the display
of entering the right password is again shown with an expression, ‘WRONG’.
5) When you get to enter the right password, you can go to the screen to be able to adjust measured values of
TRO. The different point from the measurement screen is that ‘A’ to display ‘Adjust’ is shown in the very left. The
measured value of TRO that was lastly measured is shown. And the measured value can be adjusted by Up and
Down keys.
6) When you press the set key for more than 2 seconds after finishing the adjustment of the measured values, the

2020-10-20 TCSH-002 Rev.3
measurement screen is changed into the adjusted values.
7.4. Setting
7.4.1. Menu configuration
This product provides various setting menus to do convenience of measurement and each menu’s movement and
setting can be executed through the keypad under the display window. General menu configuration is shown in
the following figure 14. And the keypad information necessary for moving the menu is shown. For more information,
please see the contents after 7.3.2.
Figure 14. Menu configuration

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7.4.2. Communication settings

Go to the COMM. Screen by pressing the mode key in the measurement screen and the down key in the ADJUST
screen.
7.4.2.1. Modbus address setting

1) Go to the M.ADDR. screen by pressing the set key in the COMM. Screen.
2) Go to the screen to be able to adjust Modbus address by pressing the set key in the M.ADDR. screen.
3) When the number displayed in the screen flickers by the set key, you can adjust the Up and Down keys.
4) Designate the set value by pressing the set key after finishing the adjustment.

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7.4.2.2. Baud rate setting

1) Go to the B.RATE screen by pressing the Down key two times in the COMM. Screen..
2) Go to the screen to be able to change the baud rate by pressing the set key in the B.RATE screen.
3) When the number displayed in the screen flickers by pressing the set key you can adjust the Up and Down key.
4) Save the set value by pressing the set key for more than 2 seconds after the adjustment.
7.4.3. System setting

Go to the System screen by pressing the mode key in the measurement screen and the down key in the ADJUST
screen twice.
7.4.3.1. Bypass time setting

1) Go to the B.TIME screen by pressing the set key in the SYSTEM screen.

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2) Go to the screen to be able to adjust Bypass Time by pressing the set key in the B.TIME screen.
3) When the number displayed in the screen by pressing the set key flickers, you can adjust the numbers with the
Up and Down keys.
4) Save the set value by pressing the set key for more than 2 seconds after finishing the adjustment.
7.4.3.2. Reagent injection
This Menu must be executed after installing or changing new reagent packs.
1) Go to the INJECT screen by pressing the Down key once in the B.TIME screen.
2) Go to the FILL screen by pressing the set key in the INJECT screen.

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3) When you press the set key for more than 2 seconds in the FILL screen, reagents are automatically injected. And
after finishing them, the OK screen is displayed and the injection of the reagents ends.
7.4.3.3. 4~20mA output setting

1) Go to the 4-20mA screen by pressing the Down key in the B.TIME screen. Your password is required to adjust
4~20mA (Please see 7.3.2.)
2) Go to the 4mA screen by pressing the set key in the 4-20mA screen. At this moment, when pressing the Down
key, go to the 20mA screen.
3) Go to the screen to be able to adjust 4~20mA output to match measured TRO by pressing the set key in the

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4mA or 20mA screen.
4) When the number displayed in the screen by pressing the set key flickers, you can adjust the number with the
Up and Down keys. Save the set value by pressing the set key for more than 2 seconds after the adjustment.
7.4.4. Factory reset

1) Go to the F.RESET screen by pressing the Down key in the SYSTEM screen. Your password is required for factory
reset (Please see 7.3.2.)
2) Go to the execution screen by pressing the set key in the F.RESET screen. Factory reset is executed when pressing
the set key for 2 seconds in the YES screen. When factory reset is executed, the set values in the product are
initialized as the state that all the things are released.

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8. Trouble shooting
8.1. Alarm
DTS has its own function to monitor and judge errors. If you the problems are solved, the alarms are automatically
released. For the Alarm lists and how to solve problems, please see the following table.
Table 3. Alarm list
Alarm list Causes How to solve
- Replace the reagents. Please see

- If all the reagents are used,
9.2.
- Clean the discharge line.

- Place the discharge line in the
- If the discharge line is blocked, lower position than the product so
- If the discharge line is not smoothly that sample water are well
installed. discharged from the discharge line
and remove foreign substances
in the end of the discharge line.
- No sample water that are flowed - Check if sample water are properly
into equipment flowed into equipment.
- If the inlet solenoid valve is broken - Check the Solenoid valve’s
or blocked connection or change it to the new
- The strainer before the inlet is one.
blocked. - Strainer cleaning (See 9.4.)
- LED(Sources of light) or the Photo - Replace LED or the photo sensor
sensor(Photo transistor) is broken. PCB.
- LED or the photo sensor is not well - Check if LED or the photo sensor
connected. is well connected.
- Measurement cells are - Measurement cell cleaning(See

contaminated. 9.3.)

2020-10-20 TCSH-002 Rev.3
9. Maintenance
9.1. Periodic maintenance
Table 4. List of periodic maintenance
Item Maintenance schedule Method
Reagent replacement 2 month Please refer to 6.4 and 9.2
Measurement cell cleaning 4 month Please refer to 9.3
Strainer cleaning 2 month Please refer to 9.4
If necessary when changing reagents

Calibration or Please refer to 7.3
6 month
Tubing Replacement every year (recommend) Please refer to 6.4 2), 3), 4)
9.2. Replace reagents

1) Replacement by exhaustion of reagents :
When the top of the reagent compressive zone touches the switch as shown in the following figure 15, the alarm
that all the reagents were used is shown so that users can check it. When the reagent’s level reaches about 10 ~
20%, the switch is installed so that users can be notified. Then, the users should stop operation of DTS and
replace the reagents by referring to 6.4 the installation of reagents. (※ We recommend 2 months for the
reagent replacement period in the liquid state.)
Alarm switch
for using
Figure 15. Switch to monitor reagents
reagents.

2020-10-20 TCSH-002 Rev.3
2) Abnormal condition of reagent : reagent replacement must be performed in the following cases
- Exceeds the recommended replacement cycle of two months.
- If the color of the reagent is excessively discolored.
- When measured TRO concentration is significantly lower than portable TRO sensor.
- If the ambient temperature where the DTS is installed is too high and more than one month after the reagent
change.
9.3. Measurement cell cleaning

1) Method of periodic maintenance :
If the measurement cell is not used for a long time or is contaminated by contaminants, it became a serious
major hindrance that DTS exactly measures TRO. Therefore, users must clean the measurement cell according to
the following procedure.
First, stop operation of DTS. Open the cap on the top of the measurement cell by turning it. Coat the cleaning
brush provided with glass cleaning fluid and clean the cell by putting it in the inside of it.
Cover of the
measurement cell
Brush for
washing
Figure 16. Measurement cell cleaning
2) Abnormal condition of measurement cell : Cell cleaning must be performed in the following cases.
- If the cell is contaminated by foreign matter when visually checked.
- There is no problem with the reagents, but the measured TRO concentration is significantly lower than the other
sensor.
- If an alarm occurs. ( please see 8.1 “E.SENSE” )

2020-10-20 TCSH-002 Rev.3
9.4. Strainer cleaning

1) Method of periodic maintenance :
The strainer must be installed to protect equipment from external foreign substances. However, if the strainer is
blocked, the sample water that you try to measure are not smoothly supplied to equipment. It is recommended
to clean the strainer periodically so that the sample water can well be supplied to equipment.
Clean the
Figure 17. Strainer cleaning filter.
2) Abnormal condition of strainer : Strainer cleaning must be performed in the following cases.
- If the filter of strainer is contaminated by foreign substance when visually checked.
- If the strainer is clogged by foreign objects.

TSU APU
(FLUIMAC)
DIAPHRAGMS PUMPS
POMPEPUMPS
A MEMBRANA
USER MANUAL
MANUALE D’USO
 PHOENIX
 PHOENIX ATEX
 PHOENIX FOOD
 PHOENIX FOOD ATEX
INDEX indice
4 IDENTIFICATION CODE sigla di identificazione
5 LEGEND legenda TECHNICAL DATA dati tecnici
37 GENERAL NOTES note principali
39 OPERATING PRINCIPLE principio di funzionamento
39 PNEUMATIC CONNECTION connessioni pneumatiche
40 INSTALLATION AND USE INSTRUCTION istruzioni di installazione ed uso
TRANSPORT trasporto
STORAGE stoccaggio
INSTALLATION installazione
START UP avviamento
USE utilizzo
STOP arresto
44 MAINTENANCE manutenzione
RECOMMENDATIONS raccomandazioni
DISASSEMBLY smontaggio
INSPECTION ispezione
46 SAFETY RISKS rischi per la sicurezza

48OPERATORS FOR INSTALLATION AND START UP operazioni per installazione e avviamento
OPERATORS FOR USE AND MANTENANCE operatori per uso e manutenzione
OPERATORS FOR REPAIR operatori per la riparazione
DISPOSAL smaltimento
49 TROUBLESHOOTING AND POSSIBLE CAUSES anomalie di funzionamento e
possibili cause
2 Rev.02
DICHIARAZIONE DI CONFORMITA’
DECLARATION OF CONFORMITY
FABBRICATO DA: FLUIMAC S.r.l

VIA TICINO 2/4 - 21043
MANUFACTURED BY CASTIGLIONE OLONA (VA) –
ITALY
TIPO/SERIE POMPA PNEUMATICA A
DOPPIA
TYPE / SERIES MEMBRANA SERIE:
PHOENIX
MODELLO
MODEL P07-18-30-50-65-100-101-160-250-400-500-700-
1000
MARCATURA ATEX
MARKING ATEX II 3/3 GD c IIB T135ºC
MARCAR ATEX
PHOENIX
Questo prodotto è conforme alle seguenti direttive CE/EX e relativi standard armonizzati:
This product complies with the following European Community Directives CE/EX and relating harmonized standards:
2006/42/CE Direttiva Macchine / Machinery Directive / Maschinenrichtlinie / Directive Machines / Directiva Máquinas
2014/34/UE: Direttiva ATEX, concernente il ravvicinamento delle legislazioni degli Stati Membri relative agli apparecchi e sistemi di protezione destinati a essere utilizzati in
atmosfera potenzialmente esplosiva.
UNI EN ISO 12100:2010 – Sicurezza del macchinario. Concetti fondamentali, principi generali di progettazione. Parte 1: terminologia di base, metodologia.
UNI EN ISO 12100:2010 – Safety of the machinery. Fundamental notions, design general principles. Part 1: Basic terminology, methods.
UNI EN ISO 12100:2010 – Sicurezza del macchinario. Concetti fondamentali, principi generali di progettazione. Parte 2: principi tecnici.
UNI EN ISO 12100:2010 – Safety of the machinery. Fundamental notions, design general principles. Part 2: Technical principles.
UNI EN ISO 3746: 2011 – Acustica. Determinazione dei livelli di potenza sonora delle sorgenti di rumore mediante misurazione della pressione sonora. Metodo di controllo con una superficie
avvolgente su un piano riflettente.
UNI EN ISO 3746: 2011 – Sound. Determination of sound power levels for noise sources by measuring the sound pressure. Monitoring method with an enveloping surface on a reflecting plate.
UNI EN ISO 11200: 2014 – Acustica. Rumore emesso dalle macchine e dalle apparecchiature. Linee guida per l’uso della norme di base per la determinazione dei livelli
di pressione sonora al posto di lavoro e in altre specifiche posizioni.
UNI EN ISO 11200: 2014 – Sound. Noise done by the machines and the equipments. Guidelines for using the basic norms for determining the sound pressure levels in
the working place and in other specific positions.
UNI EN ISO 4414: 2012 - Sicurezza del macchinario. Requisiti di sicurezza relativi a sistemi e loro componenti per trasmissioni oleoidrauliche e pneumatiche. Pneumatica.
UNI EN ISO 4414: 2012 - Safety of the machinery. Safety requirements concerning the systems and their components for hydraulic and pneumatic transmissions. Pneumatic.
UNI CEI EN ISO 80079-36:2016 - Apparecchi non elettrici destinati ad essere utilizzati in atmosfere potenzialmente esplosive. Parte 1: metodo e requisiti di base.
UNI CEI EN ISO 80079-36:2016 - Non-electrical equipments to be used in potentially explosive environments. Part 1: Method and basic requirements.
UNI CEI EN ISO 80079-37:2016 - Apparecchi non elettrici per atmosfere potenzialmente esplosive. Parte 5: protezione per sicurezza costruttiva “c”.
UNI CEI EN ISO 80079-37:2016 – Non-electrical equipments for potentially explosive environments. Part 5: protection for building safety “c”.
LA SEGUENTE CONFORMITA’ E’ RIFERITA AL PROTOTIPO DELLA PHOENIX 100 MATRICOLA NR. P0001 DEL 16.01.2012.
THIS COMPLIANCE REFERS TO PHOENIX 100 PROTOTYPE, SERIAL NUMBER P0001 OF 16.01.2012.
ESTENSIONI: la presente dichiarazione si estende anche ai modelli PHOENIX 7, PHOENIX 18, PHOENIX 30, PHOENIX 50, PHOENIX 65, PHOENIX 100, PHOENIX 101, PHOENIX 160,PHOENIX
250, PHOENIX 400,PHOENIX 500, PHOENIX 700, IN PLASTICA E METALLO.
EXTENSION: this declarations is also valid for the following versions PHOENIX 7, PHOENIX 18, PHOENIX 30, PHOENIX 50, PHOENIX 65, PHOENIX 100, PHOENIX 101, PHOENIX 160,PHOENIX
250, PHOENIX 400,PHOENIX 500, PHOENIX 700, MADE OF METAL OR PLASTIC.
ATTENZIONE: data l’innumerevole varietà di prodotti e composizioni chimiche, l’utilizzatore è ritenuto il maggior conoscitore delle reazioni e compatibilità con i materiali
costruttivi della pompa. Pertanto, prima dell’impiego, eseguire con perizia tutte le verifiche e prove necessarie al fine di evitare situazioni pericolose anche se remote che
non possono essere conosciute ed imputabili al costruttore. Per ogni controversia il Foro Competente è quello di Varese.
WARNING: since there exists an endless variety of products and chemical compositions, the user is presumed to have the best knowledge of their reaction and
compatibility with the materials used to build the pump. Therefore, before using the pump, all the necessary checks and tests must be performed with great care to avoid
even the slightest risk, an event that the manufacturer cannot foresee and of which he cannot be held responsible. Any controversy lies within competence of the Court of
Varese.
PERSONA AUTORIZZATA A CUSTODIRE IL FASCICOLO:

PERSON AUTHORISED TO KEEP THE FILE
PIETRO VAGLIVIELLO – PRESIDENTE
LUOGO PRESSO CUI E’ CUSTODITO IL FASCICOLO:

PLACE AT WHICH THE FILE CLOSED
VIA TICINO 2/4 – 21043
CASTIGLIONE OLONA– VA
ITALIA
APPROVATO DA:
Approved by PIETRO VAGLIVIELLO – PRESIDENTE
DATA 12/10/2017
3 Rev.02
IDENTIFICATION CODE sigla di identificazione
PUMP PUMP AIR FLUID BALL VERSION
BALLS O-RING CONNECTION
MODEL BODY DIAPHRAGM DIAPHRAGM SEATS ATEX ZONE1
P07 P - PP H - HYTREL T - PTFE T - PTFE P - PP D - EPDM 1 - BSP THREATED X

A - ALUMINUM M- SANTOPRENE S-SS AISI 316 K- PVDF V - FPM 2 - FLANGED
P18 S - SS AISI 316 D - EPDM D - EPDM S - SS AISI 316 T - PTFE 3 - CLAMP
P30 O - POM N - NBR N - NBR A - ALUMINUM N - NBR 4 - TWIN CONNECTION
KC- PVDF+CF Z - PE-UHMW 5 - NPT THREATED
P50
PC - PP+CF
P65
P100
P101
P160
P250
P400
P500
P700
P1000

PF/SP18 S - AISI 316 H - HYTREL T - PTFE T - PTFE S - SS AISI 316 T - PTFE 1 - BSP THREATED X
PF: S-SS AISI 316 2 - FLANGED
PF/SP30 ELECTROPOLISCHED 3 - CLAMP
PF/SP50 SP:
MECCANICHALLYLLY
PF/SP100
POLISCHED
PF/SP160
PF/SP400
PF/SP500
PF/SP700
PF/SP1000
Each pump is supplied with the serial and model abbreviation and the serial number on the rating
plate, applied onto the support side. Check these data upon receiving the goods. Any discrepancy
between the order and the delivery must be communicated immediately. In order to be able to
trace data and information, the abbreviation, model and serial number of the pump must be
quoted in all correspondence.
Ogni pompa spedita è contrassegnata dalla sigla della serie, dal modello e dal numero di serie impressi sulla
targhetta di identificazione. Si prega di confermare i dati impressi quanto prima dal ricevimento della merce. Ogni
discrepanza tra l’ordine e le informazioni impresse sulla targhetta deve essere immediatamente comunicata. Al fine
di consentire la perfetta rintracciabilità dei dati e delle informazioni, ogni corrispondenza deve riportare la sigla, il
modello e il numero di serie della pompa in oggetto.
MODEL
modello
YEAR OF MANUFACTURE
Anno di fabbricazione
SERIAL No
Numero di serie
ATEX CERTIFICATION certificazione Atex
PHOENIX - PHOENIX FOOD - CERT. ZONE 2 II 3/3 GD c IIB T135°C
PHOENIX ATEX - PHOENIX FOOD ATEX - CERT. ZONE 2 II 2/2 GD c IIB T135°C
4 Rev.02
GENERAL NOTES
“PHOENIX” series pumps are air-operated, double-diaphragm positive-displacement pumps, designed and manufactured
for pumping fluids that are chemically compatible with the constructive materials of the pump. The characteristics of the
fluid (pressure, temperature, chemical reactivity, specific weight, viscosity, vapor pressure) and of the environment must
be compatible with the pump characteristics and are defined in the ordering phase. Fluimac is not responsible for the
pumped liquid. The customer must ensure that there is compatibility between the pumped liquids and pump materials.
“PHOENIX” series pumps are self-priming; at the start-up the pipes can be empty.
The declared dry negative suction is referred to intake of water at a temperature of 20°C/ 68°F. The priming time and
the diaphragm’s life depend on.
- the suction circuit (total length and diameter)
- specific weight of the pumped fluid
- viscosity of the pumped fluid
- negative suction: max 5.000 cps (at 18°C / 64,4°F)
- below head suction: max 50.000 cps (at 18°C / 64,4°F) “PHOENIX” series pumps may be used dry
“PHOENIX” series pumps cannot be used to generate a vacuum

Make sure that the physical-chemical characteristics of the fluid have been correctly evaluated.
The maximum temperature referred to water in continuous operation depends on the version of the materials
(indicated on the nameplate) and on the environment in which the pump will be installed:
The ambient temperature interval is related to the choice of materials

VERSION MAX TEMP. MAX TEMP.
(specified on the identification MAX ∆T (°C / °F)
VERSION
ATEX ZONE 2 ATEX ZONE 1 plate):
PP / PC 0÷40°C / 14÷104°F
PP / PC 60°C / 140°F 60°C / 140°F
PVDF+CF 0÷40°C / 14÷104°F

PVDF+CF 95°C / 203°F 80°C / 176°F
ALU 0÷40°C / 14÷104°F

ALU 95°C / 203°F 80°C / 176°F
SS 0÷40°C / 14÷104°F
SS 95°C / 203°F 80°C / 176°F
POMc 0÷40°C / 14÷104°F

POMc 95°C / 203°F 80°C / 176°F
The pump may be operated at a maximum pressure equal to 1.5 times the head value with closed delivery.
The value of the vapor pressure of the pumped fluid must be greater (of at least 3 mwc - meters of water column) than
the difference between the total absolute head value (pressure on suction level subtracted of the suction height) and
the leakages of the suction section.
The pumped fluid may contain particles suspended in different concentrations in accordance with the type of valve
assembled:
MODEL P07 P18 P30 P50/65/100/101 P160/250 P400 P500/700 P1000
MAX DIM.
mm. 10
2,5 3 3,5 3,5 7,5 8 8,5
37 Rev.02
NOTE GENERALI
Le pompe serie "PHOENIX" sono pompe pneumatiche volumetriche a doppia membrana, progettate e costruite per il
pompaggio di liquidi compatibili chimicamente con i materiali costruttivi della pompa. Le caratteristiche del liquido
(pressione, temperatura, reattività chimica, peso specifico, viscosità, tensione di vapore) e dell’ambiente devono essere
compatibili con le caratteristiche della pompa e sono definite in sede d’ordine. La Fluimac s.r.l non è responsabile dei
liquidi pompati. Il cliente deve assicurarsi che ci sia compatibilità tra i liquidi pompati e i materiali della pompa.
Le pompe serie “PHOENIX” sono autoadescanti, all’avviamento le tubazioni possono essere vuote
La capacità di aspirazione negativa a secco dichiarata è riferita al pescaggio di acqua a temperatura di 20°C/
68°F.
Il tempo di adescamento e la durata delle membrane dipende da:
- dal circuito di aspirazione (lunghezza totale e diametro)
- peso specifico del fluido pompato
- viscosità del fluido pompato:
- aspirazione negativa: max 5.000 cps (a 18°C / 64,4°F)
- aspirazione sotto battente: max 50.000 cps (a 18°C / 64,4°F)
Le pompe serie “PHOENIX” non possono essere usate per creare il vuoto
Assicurarsi che le caratteristiche fisico-chimiche del liquido siano state attentamente valutate.
La temperatura massima riferita ad acqua in funzionamento in continuo dipende dalla versione dei materiali
(riportata in targhetta) e dall’ ambiente in cui verrà installata la pompa:
VERSIONE MAX TEMP. MAX TEMP. L’intervallo di temperatura ambiente è in funzione della versione dei
ATEX ZONE 2 ATEX ZONE 1
materiali (riportata in targhetta):
PP / PC 60°C / 140°F 60°C / 140°F VERSIONE MAX ∆T (°C / °F)
PVDF+CF 95°C / 203°F 80°C / 176°F PP / PC 0÷40°C / 14÷104°F
ALU 95°C / 203°F 80°C / 176°F PVDF+CF 0÷40°C / 14÷104°F
SS 95°C / 203°F 80°C / 176°F ALU 0÷40°C / 14÷104°F
POMc 95°C / 203°F 80°C / 176°F SS 0÷40°C / 14÷104°F
POMc 0÷40°C / 14÷104°F
Il valore della tensione di vapore del liquido pompato deve essere superiore (di almeno 3 m c.a.) alla differenza tra il
battente totale assoluto (pressione sul livello in aspirazione sottratta dell’ altezza di aspirazione) e le perdite nel tratto di
aspirazione
Il liquido pompato può contenere solidi sospesi in misura diversa in relazione al tipo di valvola montata:
MODELLO P07 P18 P30 P50/65/100/101 P160/250 P400 P500/700 P1000
MAX DIM.
2,5 3 3,5 3,5 7,5 8 8,5 10
mm.
38 Rev.02
OPERATING PRINCIPLE principio di funzionamento
The pneumatic distribution system sends compressed air behind one of the two diaphragms (A), which
pushes the fluid towards the delivery circuit. Simultaneously, the opposite diaphragm (B) is in the intake
phase since it is dragged by the shaft that connects it to the other diaphragm (A) under pressure; air
present behind it is discharged into the environment through the flow rate regulator present on the
pump , while a pressure drop is created in the fluid chamber which sucks the fluid from the suction
circuit. When the diaphragm (A), under pressure, reaches the stroke limit, the distributor switches the
two inputs to the chamber on the diaphragms air side, putting diaphragm (B) under pressure and
diaphragm(A) in discharge. When the pump reaches its original starting point, each diaphragm has
carried out one air discharge stroke and one fluid delivery stroke. This sequence of movements makes
up a complete pumping cycle.
Il sistema di distribuzione pneumatico invia l’aria compressa dietro una delle due membrane(A), la quale spinge il fluido
verso il circuito di mandata. Contemporaneamente la membrana opposta(B) si trova in fase di aspirazione essendo
trascinata dall’albero che la collega all’altra membrana(A) sotto pressione; l’aria presente dietro di essa viene scaricata in
atmosfera attraverso il regolatore di prestazioni presente sulla pompa mentre nella camera del fluido si crea un
abbassamento di pressione che risucchia il fluido dal circuito di aspirazione. Quando la membrana(A), sotto pressione,
raggiunge il limite della corsa il distributore commuta i due ingressi alle camera lato aria delle membrane, mandando in
pressione la membrana(B) ed in scarico la membrana(A) Nel momento in cui la pompa raggiunge il suo punto di
partenza originale, ogni membrana ha compiuto una corsa di scarico aria e una di mandata liquido. Questa sequenza di
movimenti costituisce un ciclo di pompaggio completo.
PNEUMATIC CONNECTION connessione pneumatica
WARNING: the pneumatic supply of “PHOENIX” series pumps must be carried out with oil-free, filtered, dry and
unlubricated air Avoid pressure drops by using pipes and adjusting and controlling elements having characteristics suitable
for the pump In case of installation in atex zone, the compressor must suck air from outside the area classified as atex or
use inert gas.
ATTENZIONE: l’alimentazione pneumatica delle pompe serie “PHOENIX” deve essere eseguita con aria disoleata, filtrata, essiccata e
non lubrificata Evitare cadute di pressioni impiegando tubi ed elementi di regolazione e controllo con caratteristiche adeguate a
quelle della pompa In caso di installazione in zona ATEX il compressore deve aspirare aria esternamente alla zona classificata ATEX
ovvero utilizzare gas inerte
Minimum pressure supply 2 bar Maximum pressure supply 7 bar
1 – pressure regulator with gauge regolatore di pressione con manometro

2 - shut-off valve valvola di intercettazione
3 – way valve valvola a 3 vie
4 – flow regulator regolatore di flusso
MODEL Ø
P07 4 mm
P18/P30/P50 6 mm
P65/P100/P101 8 mm
P160/P250/400 10 mm
P500 12 mm
P700 14 mm
Maximum length between tube and pump plant: 5 m
Lunghezza massima tubo tra impianto aria e pompa: 5m
39 Rev.02
INSTALLATION AND USE INSTRUCTIONS
TRANSPORT
• cover the hydraulic connections
• lift the hydraulic plastic parts without mechanical stress
• for transport on irregular roads, cushion the bumps with suitable support plane
• blows and impacts may damage parts that are important for the machine operation and safety
STORAGE
• In case you need to get away for a period of time the pumps before installation, store in original boxes. The boxes
should be stored off the ground, in a closed, clean and dry.
• in the event that the packaging has not received any is intact, it will be necessary to free the pump from it-Checking
the integrity and restore a new packaging
• The storage place should be closed environment with a temperature not lower than -5 ° C, not more than 40 ° C
and with a moisture content not exceeding the value of 80%; any packaging must not be subjected to shocks, vibrations
and loads above you
INSTALLATION
• it is essential for the pump self-priming operation that the hydraulic system is leak-proof
• clean the system before connecting the pump
• the pump must not contain foreign bodies and all the seals on the hydraulic connections must be removed
• before starting the pump check the tightness of the screws of the pump bodies and manifolds
• the pump positioning is horizontal, the fluid delivery manifold must always be positioned in the upper part (see arrows on the pump casing)
• fastening may be on the floor or on the ceiling
• position the pump the closest possible to the point of collection
ISTRUZIONI INSTALLAZIONE E D’USO

TRASPORTO
• coprire le connessioni idrauliche
• sollevare senza sollecitare meccanicamente le parti idrauliche in plastica
• in caso di percorso accidentato, attutire i sobbalzi con piano di appoggio adeguato
• colpi ed urti possono danneggiare parti importanti per la funzionalità e la sicurezza della macchina
STOCCAGGIO
• nel caso sia necessario staccare per un periodo di tempo le pompe prima dell’installazione, conservarle nelle casse
originali. Le casse devono essere stoccate sollevate dal suolo, in un ambiente chiuso, pulito ed asciutto.
• nel caso che al ricevimento l’eventuale imballo non risulti integro, occorrerà liberare la pompa dall’imballo, verificar-
ne l’integrità e ripristinare un imballo nuovo
• il luogo di stoccaggio dev’essere un ambiente chiuso con temperatura non inferiore ai –5°C, non superiore ai 40°C
e con un tasso di umidità che non superi il valore di 80%; l’eventuale imballo non dev’essere sottoposto ad urti,
vibrazioni e carichi sovrastanti
INSTALLAZIONE
• è fondamentale per l’operazione di autoadescamento della pompa che l’impianto idraulico sia a perfetta tenuta
• pulire l’impianto prima di collegare la pompa
• la pompa non deve contenere corpi estranei e devono essere rimossi i sigilli sulle connessioni idrauliche
• prima di avviare la pompa verificare il serraggio delle viti dei corpi pompa e dei collettori
• il posizionamento della pompa è in orizzontale; il collettore di mandata del fluido deve essere posizionato sempre
nella parte superiore (vedi frecce su corpi pompa)
• il fissaggio può essere a pavimento o a soffitto
• posizionare la pompa più vicino possibile al punto di prelievo
40 Rev.02
use the plant solutions indicated in the following diagram:
1. YES: use flexible pipes reinforced with rigid spiral to connect the hydraulic circuit of the pump. Rigid piping may
cause strong vibrations and manifolds breaking. Do not use pipes with nominal diameter smaller than the
diameter of the pump connections. For negative installations and/or viscous fluids use pipes with greater
diameter related to the nominal diameter of the pump.
2. YES: pulse damper
3. YES: gate valve for delivery adjustment
4. YES: intake for gauge or protection pressure switch
5. YES: pipe anchoring
6. YES: shut-off valve
7. NO: air pockets; the circuit must be linear and short
8. YES: discharge duct around the base
9. YES: wide and rigid filtering separator in case of open tanks
11. Make it as short as possible the length of the horizontal S no vent for the air
12. Slope of the pipe to the pump
13. n the flow velocity of the fluid max. 3.5 m / s
• ensure drainage of fluids which may come out of the pump

• fix the pump using all the available locking holes, the support points must be levelled
• arrange for enough room around the pump for the movements of an operator
• arrange for free space above the pump for lifting it
• inform about the presence of aggressive fluid with suitable colored labels in accordance with the related standard
• do not install the pump (built with thermoplastic material) near heat sources
• do not install the pump in places with risk of fall of solids or fluids
• do not install the pump close to fixed workplaces or visited areas
• install additional protection shield, for the pump or for the persons as appropriate. If the diaphragm breaks the fluid
may
enter into the pneumatic circuit and come out from the pump discharge port
• install a spare equivalent pump connected in parallel
• the pump must be always electrically earthed
• if the pump is made from conductive materials and is suitable for flammable products, each pump casing must be
equipped
with a suitable ear thing cable: DANGER OF EXPLOSION AND/OR FIRE
• WARNING The pumps must always be grounded irrespective of any organ to which it is connected. Lack of
grounding or
incorrect grounding will cancel the requirements for safety and protection against the risk of explosion
• WARNING: the pump during operation is in PRESSURE, check appropriately report the hazardous conditions.
41 Rev.02
utilizzare le soluzioni impiantistiche indicate nel seguente schema:
1. SI: utilizzare tubi flessibili rinforzati con spirale rigida per collegare il circuito idraulico della pompa. Tubazioni
rigide possono provocare forti vibrazioni e la rottura dei collettori. Non utilizzare tubi con diametro nominale
inferiore a quello degli attacchi della pompa. Per installazioni negative e/o con fluidi viscosi impiegare tubi con
diametro maggiorato rispetto al diametro nominale della pompa
2. SI: smorzatore di pulsazioni
3. SI: saracinesca di regolazione sulla mandata
4. SI: presa per manometro o pressostato di protezione
5. SI: ancoraggio tubazioni
6. SI: valvola di intercettazione
7. NO: sacche d’aria; il circuito deve essere lineare e breve
8. SI: canale di scarico attorno al basamento
9. SI: ampio e rigido separatore filtrante nel caso di vasche a cielo aperto
11. Rendere il più breve possibile la lunghezza S dei tratti orizzontali senza sfogo per l’aria
12. Pendenza della tubazione verso la pompa
13. In Mandata velocità del fluido max. 3,5 m/s
garantire il drenaggio di eventuali liquidi fuoriusciti dalla pompa

• fissare la pompa utilizzando tutti i fori di bloccaggio a disposizione; i punti di appoggio devono essere livellati
• lasciare libero lo spazio attorno alla pompa per i movimenti di una persona
• lasciare libero lo spazio sopra la pompa per il suo sollevamento
• avvisare della presenza di liquido aggressivo con adeguate targhette colorate secondo normativa specifica
• non installare la pompa (costruita in materiale termoplastico) vicino a fonti di calore
• non installare la pompa in luoghi con rischio di caduta di corpi solidi o liquidi
• non installare la pompa nelle immediate vicinanze di posti di lavoro fissi o zone frequentate
• installare schermo protettivo aggiuntivo, per la pompa o per le persone secondo il caso. Nel caso di rottura delle
membrane
il fluido può entrare nel circuito pneumatico ed uscire dallo scarico della pompa
• installare una pompa equivalente di scorta collegata in parallelo
• la pompa deve essere sempre elettricamente messa a terra
• se la pompa è di materiale conduttivo ed adatta al pompaggio di fluidi infiammabili bisogna installare un adeguato
cavetto di
messa a terra su ciascun corpo pompa: PERICOLO DI ESPLOSIONE E/O INCENDIO
• ATTENZIONE: la pompa deve essere sempre messa a terra indipendentemente da altri organi ad essa collegati. La
mancata o
scorretta messa a terra fa decadere i requisiti di sicurezza e tutela dal pericolo di esplosione.
• ATTENZIONE: la pompa durante il funzionamento è in PRESSIONE, segnalare opportunamente la condizione di
pericolo
42 Rev.02
START UP
• check the correct execution of what indicated in the INSTALLATION paragraph
• check that the intake and delivery pipes of the hydraulic circuit are correctly connected
• open the intake and delivery valves of the pump hydraulic circuit
• open the 3-way valve on the air circuit
• set the operation point requested for the pump: properly adjust the air pressure and delivery that supplies the pump.
With pressure values under 2 bar the pump may stall, with pressure values above 7 bar it is possible that breakdowns and/or
yields may
occur with consequent spillage of the pumped fluid
• for pumps with split manifold the two pumped fluids must have the same viscosity value, very different viscosity values may lead to
stall
problems and/or diaphragms breaking
• do not operate at the limits of the operation curves: the maximum head or maximum delivery (total absence of leaks and intake
height in
the delivery circuit)
• check that there are no anomalous vibrations or noise due to the too elastic support structure, unsuitable fastening or cavitation
• after 2 hours of operation stop the pump correctly and check the tightening of all the bolts on the pump
AVVIAMENTO
• verificare la corretta esecuzione di quanto indicato in INSTALLAZIONE
• verificare che i tubi di aspirazione e mandata del circuito idraulico siano correttamente collegati
• aprire le valvole in aspirazione e mandata del circuito idraulico della pompa
• aprire la valvola a 3 vie sul circuito aria
• Impostare il punto di funzionamento per il quale la pompa è stata richiesta: regolare opportunamente la pressione e la portata dell’
aria che
alimenta la pompa. Con pressioni inferiori ai 2 bar la pompa può andare installo, con pressioni superiori ai 7 bar si possono
verificare
rotture e/o cedimenti con conseguente fuoriuscita del fluido pompato
• Nel caso di pompe con collettore sdoppiato i due fluidi pompati devono avere viscosità dello stesso ordine di grandezza;
viscosità sensibilmente differenti possono portare a problemi di stallo e/o rottura delle membrane
• non operare agli estremi della curva di funzionamento: massima prevalenza o massima portata (totale assenza di perdite e di
altezza di
sollevamento nel circuito di mandata)
• constatare l’assenza di anomali vibrazioni o rumorosità dovute a struttura portante troppo elastica, inadeguato fissaggio o
cavitazione
• dopo 2 ore di funzionamento arrestare correttamente la pompa e verificare il serraggio di tutti i bulloni della pompa
USE
• do not operate valves or shunts during the pump operation
• Risk of harmful water hammers in case of incorrect or sudden operations (valves must be operated only by trained personnel)
• empty and wash accurately inside the pump in case different fluids must be pumped
• insulate or empty the pump if the fluid crystallization temperature is equal to or below the ambient temperature
• stop the pump if the fluid temperature exceeds the maximum allowed temperature indicated in the GENERAL NOTES;
if the exceeding temperature is about 20% it is necessary to inspect the status of the internal parts
• stop the pump and close the valves in case of leaks
• Wash with water only if chemical compatibility allows it ; alternatively use the suitable solvent that does not generate hazardous
exothermic
reactions
• consult the fluid supplier to decide the most suitable fire-prevention method
• Empty the pump in case of long periods of disuse (particularly with fluids which are particularly tending to crystallize)
• check that there is no gas in the delivering fluid, if there is stop the pump
UTILIZZO
• non azionare valvole o derivazioni durante il funzionamento della pompa
• rischi di dannosi colpi d’ariete in caso di errate o improvvise manovre (azionamento valvole solo da personale ad- destrato)
• svuotare e lavare accuratamente l’interno pompa in caso di pompaggio di liquidi diversi
• isolare o svuotare la pompa se la temperatura di cristallizzazione del liquido risulta uguale o inferiore alla temperatura ambiente
• fermare la pompa se la temperatura del liquido supera la temperatura massima consentita indicata nelle NOTE GENERALI;
se l’aumento è dell’ordine del 20 % è necessario ispezionare lo stato delle parti interne
• arrestare la pompa e chiudere le valvole in caso di perdite
• lavare con acqua solo se la compatibilità chimica lo consente; in alternativa utilizzare il solvente appropriato che non generi
reazioni
esotermiche pericolose
• contattare il fornitore del liquido per stabilire il più appropriato metodo anti-incendio
• svuotare la pompa in caso di lunghi periodi di non utilizzo (in particolare con liquidi con forte tendenza a cristallizzare)
• controllare che nel fluido in mandata non sia presente gas, in tal caso arrestare la pompa
STOP
To stop the pump, operate exclusively on the air supply closing the 3-way valve, discharging in this way residual pressure from the
pneumatic system of the pump.
WARNING never stop the pump by totally closing the suction and/or delivery valves of the hydraulic circuit
WARNING is prohibited to stop the pump by means of the complete closure of the valves in the suction and / or discharge of the
hydraulic circuit
ARRESTO
Per arrestare la pompa agire esclusivamente sull’ alimentazione dell’aria chiudendo la valvola a 3 vie, scaricando così la pressione
residua dell’ impianto pneumatico della pompa
ATTENZIONE è vietato arrestare la pompa mediante la chiusura completa delle valvole in aspirazione e/o mandata del circuito
idraulico.
43 Rev.02
MAINTENANCE
- all the operation must be carried out by qualified personnel
- do not carry out maintenance and/or repairs with the air circuit under pressure
- carry out periodic inspections (2 ÷ 30 days in accordance with the fluid pumped) to check the filtering elements cleaning
- carry out periodic inspections (3 ÷ 5 months in accordance with the fluid pumped and with the environment conditions)
to ensure the correct operation of the system start/stop units
- the presence of fluid under the pump casing may indicate failures to the pump
- damaged parts must be replaced with complete original parts and not with repaired parts
- the replacement of damaged parts must be carried out in a clean and dry place
RECOMMENDATIONS
WARNING: before performing any maintenance or repair work on the pump, disconnect the pump from the air supply line.
Disconnect the hydraulic connections and discharge the product that is being pumped
- use gloves, goggles and acid-resistant clothing when disconnecting from the system and washing the pump
- wash the pump before carrying out maintenance operations
- do not disperse the washing waste into the environment
DISASSEMBLY
- Bolts are the type with right thread
- Clean all the pump external surfaces using a damp cloth Ball seats removal (for all models)
- Remove the delivery and intake manifolds removing the tightening bolts
- Pull off the seats, the balls and the related cages
- Check the condition of the gasket
Diaphragms removal
PHOENIX 07-18-30-50-65-100-101-160-250-500-700-1000
- Remove the deposits from the internal surfaces
- Remove the two pump casings
- Remove the plates that lock the diaphragms
- Remove the diaphragms and the related backing plates
- If it would be necessary to disassemble the shaft, remove one of the two diaphragms on air side and then pull off the shaft
Pneumatic distributor removal

- slip off the pneumatic exchanger cap and the spool (if necessary use a M6 screw for slip off the spool)
PHOENIX 07-18-30-50
- remove the manifolds, pump casing and diaphragms
- remove the bolts (pos.22) and divide the semi-central casing
PHOENIX 65-100-101-160-250-500-700-1000
- Remove the Seeger ring of the transverse sleeve of the central casing
- Overturn the pump and with the aid of a Ø6 mm punch and a press, pull off the distributor (this operation may be carried
out with pump casings assembled, check that the tightening bolts of the pump casings located on the upper area of the
distributor to not obstacle the distributor removal)
- WARNING the pneumatic distributor shall not be opened to prevent an incorrect reassembling that may cause the pump
malfunctioning
INSPECTION
Check the absence of:
• excessive abrasion of the thermoplastic parts
• clots and/or agglomerates due to the pumped fluid
• deformations and/or surface lesions of the diaphragms
• deformations and/or breakages on the valve seats
Replace the parts: broken, cracked, deformed.
Reopen all the clogged ducts and eliminate any chemical agglomerates.
Clean all the surfaces before reassembly, particularly the OR gaskets seats (risk of leaks for dripping).
CLEANING AND REPLACING THE DIAPHRAGMS

 control and internal cleaning every 500.000 cycles
 diaphragm check every 5.000.000 cycles
 diaphragm replacement every 20.000.000 cycles
44 Rev.02
MANUTENZIONE
- tutti gli interventi devono essere presidiati da personale qualificato
- non effettuare manutenzione e/o riparazioni con il circuito aria in pressione
- effettuare ispezioni periodiche (2 ÷ 30 giorni in funzione del liquido convogliato) di pulizia sugli elementi filtranti
- Effettuare ispezioni periodiche (3 ÷ 5 mesi in funzione del liquido convogliato e delle condizioni ambientali) sulla funzionalità
degli organi di consenso/arresto dell’impianto; garantirne l’efficienza
- la presenza di liquido sotto il corpo pompa può essere indizio di guasti alla pompa
- le parti danneggiate devono essere sostituite con parti originali integre e non riparate
- la sostituzione di parti danneggiate deve essere effettuata in ambiente pulito e asciutto
RACCOMANDAZIONI
ATTENZIONE: prima di intervenire sulla pompa per qualsiasi intervento di manutenzione o riparazione, scollegare dalla
pompa la linea aria di alimentazione. Staccare le connessioni idrauliche e scaricare il prodotto che si sta pompando
- utilizzare guanti, occhiali ed indumenti antiacido in fase di scollegamento dall’impianto e lavando la pompa
- lavare la pompa prima di effettuare operazioni di manutenzione
- non disperdere nell’ambiente lo scarico di lavaggio dei corpi
SMONTAGGIO
- La bulloneria è del tipo a filetto destro
- Provvedere alla pulizia esterna di tutte le superfici della pompa con un panno umido
RIMOZIONE SEDI SFERA (valido per tutti i modelli)

- Rimuovere i collettori di mandata ed aspirazione rimuovendo i bulloni di serraggio
- Estrarre le sedi, le sfere e le relative gabbie
- Verificare lo stato delle guarnizioni
Modelli 07-18-30-50-65-100-101-160-250-500-700-1000
- Rimuovere eventuali depositi dalle superfici interne
- Rimuovere i due corpi pompa
- Rimuovere i piattelli che bloccano le membrane
- rimuovere le membrane e relativi piattelli di spallamento
RIMOZIONE DEL DISTRIBUTORE PNEUMATICO

- ruotare di circa 90°il tappo del distributore (pos.36)
- sfilare il tappo e successivamente la spola (se necessario aiutarsi con una vite M6) Modelli 07-18-30-50
- per accedere al distributore occorre avere rimosso collettori, corpi pompanti e membrane
- rimuovere i bulloni di bloccaggio dei 2 semi corpi e separarli
Modelli 65-100-101-160-250-500-700-1000
- Rimuovere la vite di bloccaggio posizionata nella parte inferiore del canotto trasversale del corpo centrale
- Ribaltare la pompa ed aiutandosi con un punzone da Ø6 mm ed una pressa sfilare il distributore (l’ operazione può essere
effettuato con i corpi pompa montati, controllare che i bulloni di serraggio dei corpi pompa presenti nella zona superiore del
distributore non creino ostacolo all’ estrazione del distributore stesso
- ATTENZIONE il distributore pneumatico non deve essere aperto per evitare un non corretto RI assemblaggio che può
causare il malfunzionamento della pompa
ISPEZIONE
Verificare l’assenza di:
• eccessiva abrasione delle parti in materiale termoplastico
• grumi e/o agglomerati dovuti al liquido pompato
• deformazioni e/o lesioni superficiali delle membrane
• deformazioni e/o rotture sulle sedi valvola
Sostituire le parti: rotte, fessurate, deformate.
Riaprire tutti i condotti occlusi ed eliminare gli eventuali agglomerati chimici.
Pulire tutte le superfici prima del rimontaggio, in particolare le sedi di guarnizioni OR (rischio di perdite per gocciola- mento).
PULIZIA E SOSTITUZIONE DELLE MEMBRANE

• verifica e pulizia interna ogni 500.000 cicli
• verifica usura delle membrane ogni 5.000.000 cicli
• sostituzione delle membrane ogni 20.000.000 cicli
45 Rev.02
SAFETY RISKS
WARNING! CHEMICAL RISK. Pumps are intended for operation with different types of fluids and chemical solutions. Follow the specific internal
instructions for decontamination during the inspection or maintenance operations.
WARNING! ELECTRICAL RISK. The pump must always be earthed independently to other members connected to it. Safety requirements and
explosion risk prevention are not fulfilled if the pump is not earthed or is incorrectly earthed.
WARNING: the diaphragms (into contact with the product and external) are components extremely subject to wear. Their duration is
strongly affected by the conditions of employments and by chemical and physical stresses. By tests carried out on thousands of pumps
installed with head value from 0° to 18°C, the ordinary life exceeds
one hundred million cycles. For safety reasons, in environments with explosion risk it is necessary to disassemble and check the
diaphragms every five million cycles and to replace them every twenty million cycles.
WARNING! In the case of diaphragms total breaking, the fluid may enter in the pneumatic circuit, damage it and come out from the
discharge port. Therefore it is necessary to convey the air discharge in
a piping up to a safe area.
WARNING! In situations where the user foresees the possibility of exceeding the temperature limits indicated in this manual, it is
necessary to install a protection device on the equipment that prevents to achieve the maximum operating temperature allowed. If
exceeded, respect to the maximum marking temperature is not guaranteed.
REMEMBER! Safety risks to persons are mainly caused by improper use or accidental damage.
These risks may be of hand injury for operators working on the open pump, or caused by the nature of the fluids that are conveyed by this type of
pump. Therefore it is extremely important to diligently carry out all
the instructions contained in this manual in order to eliminate the causes of accidents that may lead to the pump failure and to the subsequent
outcome of fluid hazardous to persons and to the environment.
For installation and use in a potentially explosive environment, comply with these general precautions:
• ascertain that the pump is full and if possible, that the level is above it by 0.5 m
• ascertain that the fluid treated does not contain or cannot contain large solids or solids of a dangerous shape
• ensure that the intake or delivery ports are not obstructed nor limited to avoid cavitation or pneumatic motor strain;
• also ascertain that the connection piping is strong enough and cannot be deformed by the pump weight or by the intake. Also check that
the pump is not burdened by the weight of the piping.
• if the pump is to stay in disuse for a long period of time, clean it carefully by running a non-flammable liquid detergent through it that is
compatible with the pump’s construction materials;
• if the pump was turned off for a long period of time, circulate clean water it in for some minutes to avoid incrustations
• before starting, after long periods of disuse, clean the internal and external surfaces with a damp cloth, check the grounding ATEX ZONE ;
• always protect the pump against possible collisions caused by moving objects or by various blunt materials that may damage it or react with
its materials;
• protect the pump’s surrounding ambient from splashes caused by accidental pump failure;
WARNING: the air supply pressure must never be over 7 bar or below 2 bar.
WARNING: when using the pump with aggressive or toxic liquids or with liquids that may represent a health hazard you must install suitable
protection on the pump to contain, collect and signal any spills: DANGER OF POLLUTION, CON- TAMINATION, INJURIES AND/OR DEATH.
WARNING: the pump must not be used with fluids that are not compatible with its construction materials or in a place containing incompatible
fluids.
CAUTION: installing the pumps without on-off valves on the intake and delivery sides to intercept the product in case of spillage is forbidden: danger
of uncontrolled product spillage.
CAUTION: installing the pumps without on-off, three-way or check valves on the air supply piping to prevent the pumped liquid from entering the
pneumatic circuit if the diaphragms are broken is forbidden: danger of fluid entering the compressed air circuit and being discharged into the
environment.
WARNING: Should the user think that the temperature limits set forth in this manual may be exceeded during service, a protective device must be
installed on the system to prevent the maximum allowed process temperature from being reached. If exceeded, respect of the maximum temperature
marked cannot be guaranteed.
WARNING: The pumps must always be grounded irrespective of any organ to which they are connected. Lack of grounding or incorrect grounding
will cancel the requirements for safety and protection against the risk of
WARNING: the use of pumps made with non-conductive material, which become charged with static, and without suitable grounding for flammable
liquids is forbidden: RISK OF EXPLOSIONS DUE TO STATIC CHARGE.
CAUTION: Aggressive, toxic or dangerous liquids may cause serious injuries or damage to health, therefore it is forbidden to return a pump
containing such Products to the manufacturer or to a service center. You must empty the internal circuits from the product first and wash and treat
it.
CAUTION: Pumps containing aluminium parts or components coming into contact with the product cannot be used to pump III-trichloroethane,
methylene chloride or solvents based on other halogenated hydrocarbons: DANGER OF AN EXPLOSION CAUSED BY A CHEMICAL REACTION.
CAUTION: The pumps PHOENIX cannot pump Acetylene, Hydrogen, Carbon disulfide
CAUTION: The components of the pneumatic exchanger, including the shaft are made from materials that are not specifically resistant to chemical
products. If the diaphragm should break, replace these elements completely if they have come into contact with the product.
CAUTION: The air-driven motor of the PHOENIX pumps is self-lubricating and will not require any greasing. Therefore avoid using lubricated and
non-dried air.
WARNING: ascertain that during service no anomalous noise appears. In that case, stop the pump immediately. WARNING: ascertain that the fluid
at the delivery side does not contain gas. Otherwise stop the pump immediately.
WARNING: the diaphragms (in contact with the product or the external ones) are highly subject to wear. Their duration is strongly affected by the
conditions of use and by chemical and physical stress. Fields tests carried out on thousands of pumps with a head value from 0° to 18° C have shown
that normal service life exceeds one hundred million cycles. However, in places at risk of explosion, the diaphragm must be disassembled and checked
every 5 million cycles and replaced every 20 million cycles.
WARNING: Periodic controls must be made to ensure that there is no powder and/or deposits on the external and internal surfaces of the pump
and, if necessary, they must be cleaned with a damp cloth.
WARNING: removal of the silencer and the air supply fitting must be done when free from powder. Before restarting the pump, ensure that no
powder has entered the pneumatic distributor.
WARNING : Protect always the site and the persons from accidental failure by installing a protection guard to old and collect any
product leakage. Danger of serious injuries and damage to health and/or objects.
To replace worn parts, use only original spare parts.

Failure to comply with the above may give rise to risks for the operator, the technicians, the persons, the pump and/or
the environment that cannot be ascribed to the manufacturer.
46 Rev.02
PRESCRIZIONI PER LA SICUREZZA
ATTENZIONE! RISCHIO DI NATURA CHIMICA. Le pompe sono destinate al funzionamento con diverse tipologie di liquidi e soluzioni chimiche.
Seguire le specifiche istruzioni interne per la decontaminazione durante le operazioni di ispezione o manutenzione.
ATTENZIONE! RISCHIO DI NATURA ELETTRICO. La pompa deve essere sempre messa a terra indipendentemente da altro organo ad essa
collegato. La mancanza di messa a terra o non corretta messa a terra fa decadere i requisiti di sicurezza e tutela dal pericolo di esplosione.
ATTENZIONE: le membrane (a contatto con il prodotto ed esterne) sono componenti altamente soggetti ad usura. La loro durata è
fortemente influenzata dalle condizioni di impiego e dalle sollecitazioni chimiche e fisiche. Da test eseguiti su migliaia di pompe installate
con prevalenza pari a 0°a 18°C, la durata normale supera i cento milioni di cicli. Per motivi di sicurezza, negli ambienti con pericolo di
esplosione bisogna eseguire lo smontaggio e la verifica della membrana ogni cinque milioni di cicli e la loro sostituzione ogni venti milioni di
cicli.
ATTENZIONE! Nel caso di rottura totale delle membrane, il fluido può entrare nel circuito pneumatico, danneggiarlo ed uscire dallo
scarico. Pertanto bisogna convogliare lo scarico dell’aria in una tubazione fino ad una zona sicura.
ATTENZIONE! laddove l’utilizzatore preveda il rischio di superamento dei limiti di temperatura previsti dal presente manuale, è necessario
installare sull’impianto un dispositivo di protezione che impedisca il raggiungimento della temperatura massima ammessa di processo. In
caso di superamento non è garantito il rispetto della massima temperatura di marcatura.
RICORDA! I rischi per la sicurezza delle persone nascono principalmente per uso improprio o in caso di danni accidentali. Tali rischi
possono essere di ferimento alle mani per chi opera sulla pompa aperta, oppure sono dovuti alla natura dei liquidi che vengono convogliati
da questo genere di pompe. E’ quindi di estrema importanza eseguire diligentemente tutte le istruzioni contenute in questo manuale al fine
di eliminare le cause di incidenti che possano portare alla rottura della pompa ed alla conseguente fuoriuscita di liquido pericoloso per le
persone e per l’ambiente.
Per l’installazione e l’impiego in ambiente potenzialmente esplosivo e non, rispettare le seguenti precauzioni generali:
- controllare che la pompa sia piena e il livello sia, possibilmente, al disopra di essa di 0,5m
- controllare che nel fluido trattato non vi siano o vi possano essere parti solide di dimensioni elevate o forma dannosa non ci siano
restrizioni nell’ingresso o nell’uscita della pompa per evitare fenomeni rispettivamente di cavitazione e sforzo del motore pneumatico
- controllare che le tubazioni di collegamento siano sufficientemente resistenti e che non possano deformarsi sotto il peso della pompa e
dell’aspirazione, né che la pompa subisca il peso delle tubazioni
- se la pompa deve rimanere inattiva per lunghi periodi, pulirla accuratamente facendo circolare un fluido detergente non infiammabile
compatibile con i materiali della pompa.
- se la pompa è stata spenta per lunghi periodi è opportuno far circolare acqua pulita per alcuni minuti per evitare il rischio di incrostazioni
- prima dell’avviamento, dopo lunghi periodi di sosta, effettuare la pulizia delle superfici interne ed esterne con un panno umido, controllare
la messa a terra per ZONE ATEX .
- proteggere sempre la pompa da possibili urti provocati accidentalmente da mezzi in movimento o materiali vari contundenti che possono
danneggiarla e/o reagire al contatto.
- proteggere sempre l’ambiente circostante la pompa da spruzzi provenienti da guasti accidentali alla pompa
ATTENZIONE: l’alimentazione dell’aria non deve mai risultare superiore a 7bar o inferiore a 2 bar
ATTENZIONE: Per tutti i fluidi pompati, soprattutto fluidi aggressivi, tossici o pericolosi per la salute bisogna installare sulla pompa un’adeguata
protezione per il contenimento e la raccolta e segnalazione del prodotto in caso di fuoriuscita: PERICOLO DI INQUINAMENTO,
CONTAMINAZIONE, LESIONI E/O MORTE.
ATTENZIONE: è vietato l’uso della pompa con fluidi non compatibili con i materiali dei componenti o in ambiente con presenza di fluidi non
compatibili.
ATTENZIONE: è vietata l’installazione della pompa in assenza di valvole per l’intercettazione del prodotto sull’aspirazione e sulla mandata per
eseguire il Sezionamento in caso di perdita: pericolo di fuoriuscita incontrollata del prodotto.
ATTENZIONE: è vietata l’installazione della pompa in assenza di valvola di intercettazione, valvola a 3 vie e valvola di non ritorno sul condotto di
alimentazione dell’aria per impedire che il fluido pompato entri nel circuito pneumatico in caso di rottura delle membrane: pericolo di immissione del
fluido nel circuito dell’aria compressa e scarico in ambiente
ATTENZIONE: laddove l’utilizzatore preveda il rischio di superamento dei limiti di temperatura previsti dal presente manuale, è necessario installare
sull’impianto un dispositivo di protezione che impedisca il raggiungimento della temperatura massima ammessa di processo. In caso di superamento
non è garantito il rispetto della massima temperatura di marcatura.
ATTENZIONE: la pompa deve essere sempre messa a terra indipendentemente da altro organo ad essa collegato. La mancanza di messa a terra o
non corretta messa a terra fa decadere i requisiti di sicurezza e tutela dal pericolo di esplosione.
ATTENZIONE: è vietato l’impiego per liquidi infiammabili della pompa in materiale non conduttivo, che si carica statica- mente e senza un’adeguata
messa a terra: PERICOLO DI ESPLOSIONI A CAUSA DI CARICHE STATICHE.
ATTENZIONE: fluidi aggressivi, tossici o pericolosi possono causare gravi lesioni fisiche e/o alla salute pertanto è vieta- to restituire al produttore o
ad un centro di servizio una pompa che contenga prodotti di tale specie: Svuotare e lavare il circuito interno del prodotto e provvedere al lavaggio e
trattamento prima di rispedire la pompa.
ATTENZIONE: i modelli di pompe che contengono componenti o parti in alluminio a contatto con il prodotto non possono essere impiegate per il
pompaggio di III-tricloroetano, il cloro metilene o solventi a base di altri idrocarburi alogenati: PERICOLO DI ESPLOSIONE PER REAZIONE
CHIMICA.
ATTENZIONE: le pompe della serie PHOENIX non possono pompare acetilene, idrogeno e solfuro di carbonio
ATTENZIONE: i componenti dello scambiatore pneumatico, albero compreso, sono costruiti con materiali non specificamente resistenti ai prodotti
chimici. In caso di rottura delle membrane, se vengono a contatto con il fluido, provvedere alla loro completa sostituzione.
ATTENZIONE: il motore pneumatico delle pompe PHOENIX è autolubrificante e non necessita di ulteriore lubrificante;
pertanto evitare l’impiego di aria lubrificata e non essiccata.
ATTENZIONE: verificare che durante il funzionamento non si verifichi rumorosità anomala. In tal caso bloccare immediatamente la pompa.
ATTENZIONE: controllare che nel fluido in uscita non sia presente gas, in tal caso bloccare immediatamente la pompa.
ATTENZIONE: le membrane (a contatto con il prodotto ed esterne) sono componenti altamente soggetti ad usura. La loro durata è fortemente
influenzata dalle condizioni di impiego e dalle sollecitazioni chimiche e fisiche. Da test eseguiti su migliaia di pompe installate con prevalenza pari a 0°a
18°C, la durata normale supera i cento milioni di cicli. Per motivi di sicurezza, negli ambienti con pericolo di esplosione bisogna eseguire lo
smontaggio e la verifica della membrana ogni cinque milioni di cicli e la loro sostituzione ogni venti milioni di cicli.
ATTENZIONE: Bisogna verificare periodicamente l’assenza di polveri e/o depositi dalle superfici esterne ed interne della pompa e, se necessario,
effettuare la pulizia con un panno umido.
ATTENZIONE: lo smontaggio del silenziatore e del raccordo di alimentazione dell’aria deve essere effettuato in assenza di polvere. Prima di riavviare
la pompa assicurarsi che non sia entrata polvere all’interno del distributore pneumatico.
ATTENZIONE: Proteggere sempre l’ambiente e le persone installando una protezione, in caso di
rottura accidentale della pompa, per il contenimento e la raccolta in caso di fuoriuscita del prodotto.
Pericolo di gravi danni fisici, alla salute e/o cose
Per la sostituzione di parti usurate impiegare unicamente pezzi di ricambio originali.
L’inosservanza di quanto sopra può far insorgere pericoli per l’operatore, i tecnici, le persone, la pompa e/o l’ambiente
non imputabili al costruttore.
47 Rev.02
However five general elements are important:
A- all the operations must be carried out by skilled personnel or monitored by qualified personal as appropriate
B- implement personal protection works (when the pump is installed in places involving more than occasional visits) against splashes of fluorescent fluid for
accidental breakage and conveying works
(always) of possible fluid leakages towards collection tanks
C- wear acid-resistant clothing and protection whenever operating on the pump
D- make sure that the Intake and delivery valves are correctly closed during the disassembly
E- make sure that there is no supply to the pneumatic circuit during the disassembly
It should be noted that it is very important to realize systems with pipes well arranged, identifiable, suitably equipped with shut-off valves, with comfortable
compartments and passages for operators who must inspect their status (since the pressure developed by the pump may promote failures to the system if it is
of defective construction or worn).
In ogni caso cinque elementi generali sono importanti:

A- tutte le operazioni devono essere effettuate o da personale specializzato o supervisionate da personale qualificato secondo i casi
B- realizzare opere di protezione per le persone (quando la pompa è installata in luoghi non saltuariamente
frequentati) verso eventuali getti di liquido fuoriuscente per rotture accidentali e opere di convogliamento
(sempre) di eventuali perdite di liquido verso vasche di raccolta
C- indossare indumenti e protezioni antiacido ogniqualvolta si operi sulla pompa
D- garantire la condizione di chiusura delle valvole su Aspirazione e Mandata in fase di smontaggio
E- garantire la condizione di assenza di alimentazione al circuito pneumatico in fase di smontaggio
OPERATORS FOR INSTALLATION AND START-UP

interventions to be carried out only by skilled personnel who may delegate to others some operations in accordance with
specific evaluations (required technical skills: plumbing, pneumatic and/or electric qualification as appropriate)
OPERAZIONI PER L'INSTALLAZIONE E AVVIAMENTO
gli interventi devono essere eseguiti solo da personale specializzato che può delegare ad altri alcune operazioni in conformità
valutazioni specifiche (richieste competenze tecniche: idraulici, pneumatici e / o qualifica elettrica a seconda dei casi)
OPERATORS FOR USE AND MAINTENANCE

interventions to be carried out by generic operators (after being instructed on the correct use of the equipment):
- pump start-up/stop
- valves opening / closing with stopped pump
- casing emptying and washing by means of the prearranged valves and pipes
- filtering elements cleaning interventions to be carried out by skilled personnel (required technical skills: general knowledge of
the mechanical, electrical, chemical aspects of the equipment supplied by the pump and of the pump itself):
- environmental conditions check
- pumped fluid conditions check
- inspections of start-up/stop devices
- detection of malfunctions
OPERAZIONI PER L’UTILIZZAZlONE E LA MANUTENZIONE
interventi alla portata di operatori generici (dopo istruzione sul corretto uso dell’impianto):
- avviamento / arresto pompa
- apertura / chiusura valvole a pompa ferma
- svuotamento e lavaggio corpo tramite valvole e tubazioni predisposte
- pulizia elementi filtranti interventi da personale qualificato (capacità tecniche richieste: conoscenza generale degli aspetti meccanici, elettrici, chimici
dell’impianto alimentato dalla pompa e della pompa stessa):
- verifica condizioni ambientali
- verifica condizioni del liquido pompato
- ispezioni sulle apparecchiature di consenso/arresto
- rilevazione anomalie di funzionamento
OPERATORS FOR REPAIR

work to be carried out by generic operators supervised by skilled personnel:
- pump stop
- valves closing
- emptying of pump casing
- pipes disconnection from the connections
- unlocking of fastening screws to the base
- washing with water or suitable solvent as appropriate
- transport
Work to be carried out by skilled personnel (required technical skills: notions of mechanical processing, sensitivity with regard to damage to parts for impacts
or abrasions during handling, familiar to tighten bolts on different plastic/metal materials, use of precision measuring instruments):
- casing opening and reclosing
- removal and replacement of damaged parts
OPERAZIONI PER LA RIPARAZIONE
interventi alla portata di operatore generici con supervisione di personale qualificato:
- arresto pompa
- chiusura valvole
- svuotamento corpo pompa
- sconnessione tubazione dagli attacchi
- sbloccaggio viti di fissaggio al basamento
- lavaggio con acqua o adeguato solvente secondo il caso
- trasporto
interventi da personale qualificato (capacità tecnica richiesta: nozioni di lavorazione meccanica, sensibilità riguardo a danni alle parti per urti o abrasioni durante
la manipolazione, dimestichezza al serraggio di bulloneria su differenti materiali plastica/metallo, uso di strumenti di misura di precisione):
- apertura e richiusura corpo
- rimozione e sostituzione parti danneggiate
DISPOSAL
For type of material: separate plastic parts from metal parts and dispose of by authorized companies.
SMALTIMENTO
Per tipologia di materiale: separare le parti in plastica dalle parti in metallo e smaltire tramite imprese autorizzate.
48 Rev.02
TROUBLESHOOTING AND POSSIBLE CAUSES
DEFECT CAUSE SUGGESTION
Circuit without air Check the circuit (valves, connections, regulators, etc.)
Insufficient air pressure Adjust the air pressure
Insufficient air flow rate Check that the pipes and fittings have suitable passages
Damaged control valve Replace
Damaged pneumatic distributor Replace
Open some valves, or remove the pipes and check if the
Pump delivery or intake closed pump starts
The pump does not
1 Damaged discharge cover Replace
start
Check if air comes out of the product delivery pipe, if yes
Broken diaphragm replace the diaphragm.
Disassemble the manifolds and clean the seats or replace the
The balls do not close. balls and the seats.
Excessive intake height. Reduce the intake height.
The pump works
butit does not Install pipes with greater size especially for intake and decre-
2 Too viscous fluid. ase the pumps cycles.
pump.
Clogged intake. Check and clean.
Excessively viscous fluid. No remedy.
The pump works Clogged delivery pipe. Check and clean.
3 with slow cycles Clogged intake. Check and clean.
Internal pneumatic exchanger clogged
or defective Replace the pneumatic exchanger.
Worn shaft. Replace the pneumatic exchanger.
Ice on the discharge. Dehumidify and filter air.
The pump works Check all the air control fittings, especially the quick cou-
4 Air volume is lacking. plings.
irregularly.
Internal exchanger dirty Replace.
Intake clogs during operation. Replace the intake pipe.
Dirty air, full of condensate or oil. Check the air line.
Check the pressure with a gauge installed on thepump and
with running pump. If pressurein that point is too low related
to the mains pressure, check all the air connections, especial-
ly the quick couplings Check that all the air control devices
Insufficient air volume or pressure. have a sufficient flow rate. WARNING: In 90% of the cases
5 The pump stalls stall conditions depends on the quick couplings.
Defective distributor. Replace it.
The stop procedure was not respected. Respect the stop procedure.
The product intake pipe is not correctly
connected. Check.
Clogged pipes. Check and clean.
Install pipes with greater size especially for intake and decre-
Too viscous fluid. ase the pumps cycles.
The pump does not Check pressure with a gauge installed on the pump and with
deliver the flow rate running pump. If pressure in that point is too low related to
6 indicated on the the mains pressure, check all the air connections, especially
table. the quick couplings. Check that all the air control devices have
Insufficient air volume. a sufficient flow rate. WARNING: In 90% of the cases stall
conditions depends on the quick couplings.
49 Rev.02
ANOMALIE DI FUNZIONAMENTO E POSSIBILI CAUSE
DIFETTO CAUSA SUGGERIMENTO
Circuito senza aria Controllare il circuito(rubinetti, allacciamenti, regolatori, ecc.)
Insufficiente pressione dell’aria Regolare la pressione dell’ aria
Insufficiente portata dell’aria Controllare che tubi ed accessori abbiano passaggi adeguati
Valvola di comando danneggiata Sostituire
Distributore pneumatico danneggiato Sostituire
Mandata o aspirazione della pompa Aprire eventuali valvole, oppure rimuovere le tubazioni e
chiuse verificare se la pompa parte
La pompa non si
1 Coperchio scarico danneggiato Sostituire
avvia
Controllare se esce aria dal tubo di mandata prodotto; nel
Membrana rotta caso sostituire la membrana.
Smontare i collettori e pulire le sedi o sostituire le sfere e le
Le sfere non chiudono. sedi.
Altezza di aspirazione troppo elevata. Ridurre l’altezza di aspirazione.
La pompa funziona Installare tubi maggiorati specie in aspirazione e diminuire i
2 Fluido troppo viscoso. cicli della pompa.
ma non pompa.
Aspirazione otturata. Controllare e pulire.
Fluido troppo viscoso. Nessun rimedio.
La pompa funziona Tubo di mandata otturato. Controllare e pulire.
3 con cicli lenti Aspirazione otturata. Controllare e pulire.
Scambiatore pneumatico interno
usurato o difettoso Sostituire lo scambiatore pneumatico.
Albero usurato. Sostituire lo scambiatore pneumatico.
Ghiaccio sullo scarico. Deumidificare e filtrare l’aria.
La pompa funziona Controllare tutti gli accessori di controllo aria, in particolar
4 Manca volume d’aria. modo gli innesti rapidi.
in modo irregolare.
Scambiatore interno sporco Sostituire.
L’aspirazione si ottura durante il
funzionamento.. Sostituire il tubo di aspirazione.
Aria sporca, piena di condensa o di olio.
Verificare la linea dell’aria.
Controllare la pressione con un manometro installato sulla-
pompa ed a pompa in funzione. Se la pressione in quel punto è
troppo bassa rispetto alla pressione di rete, controllare tutti
gli attacchi dell’aria, specialmente quelli ad innesto rapido.
Volume o pressione d’aria insufficiente. Controllare che tutti i dispositivi di controllo aria abbiano
La pompa va in portata sufficiente. ATTENZIONE: Nel 90% i casi di stallo
5 stallo dipendono dagli innesti rapidi.
Distributore difettoso. Sostituirlo.
Non è stata rispettata la procedura di
arresto Rispettare la procedura di arresto.
Il tubo di aspirazione prodotto è mal
collegato. Controllare.
Tubazioni otturate. Controllare e pulire.
Installare tubi maggiorati specie in aspirazione e diminuire
Fluido troppo viscoso. I cicli della pompa.
Le sfere non chiudono. sedi..
Controllare la pressione con un manometro installato sulla
La pompa non eroga troppo bassa rispetto alla pressione di rete, controllare tutti
6 la portata di tabella. gli attacchi dell’aria, specialmente quelli ad innesto rapido.
Volume d’aria insufficiente. Controllare che tutti i dispositivi di controllo aria abbiano
portata sufficiente. ATTENZIONE: Nel 90% i casi di stallo
dipendono dagli innesti rapidi
50 Rev.02
51 Rev.02
Production head and legal office:
Via Ticino 2/4

21043 Castiglione Olona (Va)
ITALY
Tel: 0039 331.866688
Fax: 0039 331.864870
Web: www.fluimac.com
E-mail: info@fluimac.com
● The INSTRUCTION MANUAL must be delivered to the pump-user , who takes diligent note of it,
keeps the file for subsequent reference. Possible modifications
do not imply updating of the existing manuals
● MANUALE D’USO deve essere consegnato all’utilizzatore della pompa, il quale deve prenderne attenta
visione, e conservarlo per successive consultazioni. Eventuali modifiche non comportano
l’aggiornamento dei manuali preesistenti.
FLUIMAC srl Draw and text total or partial duplication is prohibited

FLUIMAC srl Vietata la duplicazione parziale o totale di testo e disegni
52 Rev.02
TSU Ex-CLX
(HF scientific)
MANUAL
Chlorine and Total Residual Oxidant Monitor
For Use in Hazardous Environments
And Extended Reagent Life
Model CLX-Ex2 28034
HF scientific
3170 Old Metro Parkway
Ft. Myers, FL 33916
Phone: 239-337-2116
Toll Free: 888-203-7248
Fax: 239-332-7643
Email:hf.info@wattswater.com
Website: www.hfscientific.com
Catalog No 28920
Rev 2 (8/2019)
Ex pxb IIC T4 Gb 0°C ≤ Ta ≤ 55°C
IECEx Certificate #IECEx LC 14.0006
To the following standards:
Explosive Atmospheres – Part 0: Equipment – General Requirements, IEC 60079-0: 2011

Explosive Atmospheres –Part 2: Equipment Protection by Pressurized Enclosure “p”, IEC 60079-2: 2014
Emissions & Immunity – Tested and passed EN61326: 2006
Manufacturer’s Name: HF scientific inc.
Manufacturer’s Address: 3170 Old Metro Parkway, Fort Myers, Florida 33916-7597
Importer’s Name:
Importer’s Address:
Type of Equipment: TRO Monitor
Model: CLX-Ex2 28034
I, the undersigned, hereby declare that the equipment specified above conforms to the above Directive and
Standard
Place: Fort Myers, Florida USA
Date: 05 August 2019

Renato Trovo,
General Manager,
HF scientific inc.
Catalog #28920 (8/2019)

Table of Contents
Section Page
Specifications ....................................................................................................1
1.0 Overview ...........................................................................................................2
1.1 Unpacking and Inspection of the Instrument and Accessories ...................2
1.2 Instrument Labels.........................................................................................3
1.3 The Display .................................................................................................3
1.4 The Touch Pad ............................................................................................4
1.5 Orientation ..................................................................................................5
2.0 Safety .................................................................................................................6

2.1 Symbols Used In CLX-Ex2 ...................................................................6
2.2 Use in Explosive Environments Safety..................................................6
3.0 Theory of Operation ........................................................................................7

3.1 The Measurement...................................................................................7
3.2 The Air Sentinel Controller ...................................................................8
3.3 Remote Standby ....................................................................................9
3.4 The Reagents .........................................................................................9
3.5 The Reagent Cooler ..............................................................................9
4.0 Installation and Commissioning ..................................................................10

4.1 Mounting & Site Selection...................................................................10
4.2 Plumbing ............................................................................................11
4.3 Air Supply ..........................................................................................11
4.4 Electrical Connections ........................................................................11
4.4.1 RS-485 ...................................................................................12
4.4.2 Relay ......................................................................................12
4.4.3 4-20 mA ..................................................................................12
4.4.4 Remote Standby Connections ..................................................13
4.4.5 RS-485/4-20 mA cable Ferrite .................................................13
4.4.6 Modbus Control .......................................................................13
4.5 Installing Reagents ..............................................................................13
5.0 Air Sentinel Controller Operation ..............................................................14

5.1 Start Up ...............................................................................................14
5.2 Indicator Lamps ...................................................................................14
5.3 Maintenance By-Pass Operation ..........................................................15
6.0 Operation .......................................................................................................16

6.1 Routine Measurement .........................................................................16
6.2 Routine Measurement with Remote Standby ......................................16
6.3 Security Access Feature .......................................................................17
6.4 The White LED ....................................................................................18
7.0 Instrument Calibration ................................................................................18

7.1 Slope (gain) Calibration Procedure .....................................................18
7.2 Zero (offset) Calibration Procedure .....................................................19
7.3 Restore Factory Settings ......................................................................20
Table of Contents (continued)
Section Page
8.0 Instrument Configuration (CONFIG mode) ...............................................20

8.1 Setting the 4-20 mA .............................................................................20
8.2 Configuring the Error Level.................................................................21
8.3 Configuring the RS-485 Port ..............................................................21
8.4 Configuring the Alarm .........................................................................21
8.4.1 Alarm1 .....................................................................................22
8.5 Enabling the Security Access...............................................................22
8.6 Extended Settings.................................................................................23
8.7 Units of Measurement ..........................................................................23
8.8 Averaging and Filtering .......................................................................23
8.9 LCD Backlight Brightness ...................................................................24
8.10 RS- 485 Parameters..............................................................................24
8.11 Cycle Time ..........................................................................................24
8.12 Water Conservation ............................................................................24
8.13 4 mA Adjustment .................................................................................25
8.14 20 mA Adjustment ...............................................................................25
9.0 Additional Features and Options ................................................................26

9.1 RS-485 Output .....................................................................................26
9.1.1 Simple Communication ...........................................................26
9.1.2 Modbus Communication..........................................................26
9.2 Remote Panel Meter .............................................................................26
10.0 Troubleshooting .............................................................................................27

10.1 CLX-Ex2 Fault Detection ....................................................................27
10.2 Setting Flow Rate .................................................................................28
10.3 Clearing Faults .....................................................................................28
10.4 Reagent Clogs .....................................................................................29
10.5 Diagnostic Chart .................................................................................29
10.6 Technical and Customer Assistance ...................................................29
11.0 Routine Maintenance .....................................................................................30

11.1 Maintenance Schedule ........................................................................30
11.2 Replacing or Installing the Reagents ...................................................33
11.3 Indicator Reagent Preparation .............................................................33
11.4 Check Valve Flushing Kit ...................................................................34
11.5 Instrument Storage ..............................................................................34
11.6 Cleaning the CLX-Ex2 ........................................................................34
12.0 Accessories and Replacement Parts List .....................................................35
13.0 Limited Warranty .........................................................................................37

Specifications
Measurement Range 0.00 – 10.00 mg/L (PPM) or 0.00 – 15.00 mg/L (PPM)
Accuracy For 0.00 – 10.00 mg/L Range: ±5% of reading or ±0.03 mg/L (PPM)
whichever is greater for range of 0-6.0 mg/L(PPM) ±10% of reading
from 6.01-10.00 mg/L (PPM)
For 0.00 – 15.00 mg/L Range: ±10% of reading or ±0.03 mg/L (PPM)
whichever is greater
Resolution 0.01 mg/L (PPM)
Cycle Time Adjustable; 60 seconds to 10 minutes (600 seconds)
Display Multi-Line Liquid Crystal Backlit Display
Alarms One NO relay contact 120-240VAC 2A
Analog Output Powered 4-20 mA, 600 Ω drive, isolated

Communications Port Bi-directional RS-485 with Modbus
Water Pressure Integral pressure regulator 0.34 bar (5.0 PSI) to 10.3 bar (150 PSI.)
Flow Rate to Waste 200 – 400 ml/min.
Operating Temperature 0°C – 55°C (32°F – 131°F)
Wetted Materials PVC, Borosilicate Glass, Reslyn (FFKM), Viton® (FKM),
Polypropylene, 316 Stainless Steel, Acetal, Noryl®, Silicone
Sample Temperature Range 0°C – 55°C (32°F – 131°F)
Power Supply 100 to 240VAC, 47-63 Hz, 250VA
Insulation Rating Double Insulated, Pollution Degree 2, Overvoltage Category II
Environmental Conditions Altitude up to 2000 meters
Up to 95 % RH (non-condensing)
IECEx Hazloc Rating Ex pxb IIC T4 Gb 0°C ≤ Ta ≤ 55°C
Compressed Air Water and oil free, -40oF (-40oC) Dew Point, Particles <5u, ISA Grade
Hydrocarbon Free. Full time clean dry air at 5.5 - 7 bar (80-101.5 PSI)
@35 SLPM (1.2 SCFM) @ 20oC (68oF) Max
Regulatory Compliance CE Approved, ETL listed to UL 61010-1 Issued May 11 2012 3rd Ed &
ETL certified to CSA 22.2 No. 61010.1 issued May 11 2012
And Certifications
EN61326:2006
Shipping Weight 27.2kg (60lbs.) Reagents are Shipped Separately
Shipping Dimensions 93 cm X 62 cm X 32 cm (36½” X 24½” X 12½”)
CLX-Ex2 (8/2019) Page 1

REV 2
1.0 Overview
The CLX-Ex2 Online Chlorine Monitor allows for the reading of chlorine levels of process
water on-line. The CLX-Ex2 has been designed to meet the design criteria specified by
Standard Methods for the Examination of Water and Wastewater (21th Edition) Method
4500-Cl G. DPD Colorimetric Method. The CLX-Ex2 uses a 515nm LED as the
measurement light source.
This instrument has been designed to operate in explosive atmospheres and meets the
IECEx rating as stated in the specifications. The instrument does this with the use of an
approved purge/pressurization controller called the Air Sentinel. Please refer to the
companion manual Cat. No. 28749 for all information on:
• Operation of the Air Sentinel.
• Electrical power connections.
• Purge Air Connection.
In addition this instrument has vortex cooling. This instrument will automatically control a
connected compressed air line to lower the temperature of one of the reagents, allowing the
reagent an operating life of up to 3 months.
Every effort has been made to ensure the accuracy of this manual. Due to the continuous
development and improvement of all instrumentation, there may be slight differences between
this manual and the instrument received. Therefore, no legal claims can be made against any
discrepancies herein.
1.1 Unpacking and Inspection of the Instrument and Accessories
The table below indicates the items in the shipment.

Item Quantity
CLX –Ex2 Monitor 1
Instruction Manual 1
Tubing/Cuvette Kit: 8 black pump tubes, 2 different Cap Assemblies, 1

1 replacement cuvette
Check Valve Flushing Kit 1
Remove the instrument from the shipping crate. Carefully inspect all items to ensure that no
visible damage has occurred during shipment. If the items received do not match the order,
please immediately contact the local distributor or the HF scientific Customer Service
Department.
CLX-Ex2 (8/2019) Page 2

REV 2
1.2 Instrument Labels
The following labels should be applied to the outside of the enclosure.
Purpose Location Label
Serial number, Front of
manufacturer, Enclosure
part number,
power rating, CE
& UL marking
Warning and Front of

informational Enclosure
Informational Front of
Enclosure
1.3 The Display

Figure 1 illustrates all the items that can appear on the display. The upper row of the
display (1) is used for reporting the chlorine levels and to provide user guidance in the
customer setting routine. The lower row of the display (2) is used to communicate error
messages (message queue) and provide user guidance. The display has two icons (3) that are
used to indicate the use of access code and offset mode. In addition, mode arrows (4) are
used to indicate the current instrument operating mode; AUTO (normal operation), CAL
(calibration) and CONFIG (configuration).
Figure 1: Display used in the instrument.
CLX-Ex2 (8/2019) Page 3

REV 2
1.4 The Touch Pad
Figure 2 illustrates the touch pad. The touch pad has six buttons: PRIME, SERVICE,
MODE/EXIT,  ,  and 
The MODE/EXIT button is used to cycle between the three operational modes of the
instrument: CAL, CONFIG, and AUTO (Measurement) mode. The  button enters the
option or mode that is highlighted or chosen. The  and  buttons are used to change
settings.
The PRIME and SERVICE buttons are dedicated controls. The PRIME will start 75 reagent
pump pulses to prime the tubing after a change or addition of reagent bottles. The SERVICE
button will drain the instrument and hold all operations until either the SERVICE button is
pushed again or the power is reset. This button should be used while changing the tubing, the
measurement cuvette or reagent bottles.
Figure 2: The CLX-Ex2 touch pad.
CLX-Ex2 (8/2019) Page 4

REV 2
1.5 Orientation
From the diagram below the major components can be located. Note that two reagents are
required the buffer and the indicator. The reagents are discussed in the Routine Maintenance
section 11.0.
Figure 3: The CLX-Ex2 with Cover Open
CLX-Ex2 (8/2019) Page 5

REV 2
2.0 Safety
This manual contains basic instructions that must be followed during the commissioning,
operation, care and maintenance of the instrument. The safety protection provided by this
equipment may be impaired if it is commissioned and/or used in a manner not described in
this manual. Consequently, all responsible personnel must read this manual prior to working
with this instrument.
In certain instances icons or symbols, have been added to give further clarification to the
instructions. Refer to the Table of Contents to easily find specific topics and to learn about
unfamiliar terms.
This manual is intended to be used in conjunction with No.28749 for more information
on the connection and operation of the Air Sentinel.
2.1 Symbols Used in this manual
This Symbol identifies hazards which, if not

avoided, will result in death or serious injury.
This symbol identifies hazards which, if not

avoided, could result in minor or moderate
injury or damage to the equipment.
This symbol identifies important information,

practices or actions.
This pictorial alert you to the need read the

manual, possibly at a different section.
This pictorial alerts you to electricity,

electrocution and shock hazards.
2.2 Use in Explosive Environments Safety

In the interests of safety the operator must ensure the atmosphere where the instrument is
located is safe from gases, vapors, dust or other flammable conditions whenever the
instrument is opened for service or maintenance. At all other times the door must be kept
closed with purge air connected the purge system operating with the all GREEN lamps lit
indicating safe operation.
CLX-Ex2 (8/2019) Page 6

REV 2
3.0 Theory of Operation
3.1 The Measurement
The CLX-Ex2 has two solenoid valves, one for sample water (FLOW) and one for draining
of the cuvette (PURGE). A third solenoid, along with four check valves forms a reagent
pump. Sample water flow is controlled by the FLOW solenoid valve. The PURGE solenoid
valve is used to empty the cuvette in the measurement chamber.
The measurement chamber consists of a sample inlet, a purge drain, and an overflow. The
reagent is added from the check valves integrated into the lower portion. A green LED
provides the 515 nm source lamp, a red LED is used for sample level and flow measurement.
A single detector is located 180º from the green LED. A replaceable glass cuvette separates
the LEDs from the detector and maintains the measurement path length. Sample water flows
in the inlet at the bottom, through the measurement cuvette and out through an overflow drain.
This flow is used to both fill the cuvette and flush the system.
The reagents are dispensed from two replaceable bottles. One bottle has a buffer to control
the pH; the second has an indicator that contains the DPD, which produces color when
chlorine is present in the sample. The degree of color is dependant on the amount of chlorine
in the sample water.
The measurement chamber is open to view operations. A white LED backlights the chamber
for a clearer view. The white LED will flash to attract attention in the case of a warning or
failure. Most warnings and failures are also displayed on the screen. To prevent interference,
the white LED is turned off during measurements.
During normal operation the CLX-Ex2 will run through a timed cycle. A simplified cycle
will consist of the following sequences:
• Flushing – continuous sample flow
• Purging – PURGE valve opens
• Zeroing – no flow with cuvette full
• Adding Reagents – one pulse of the reagent pump
• Mixing with sample – sample flow pulses in
• Reading resulting sample – no flow with cuvette full
• Purging – PURGE valve opens to remove reacted sample
The cycle above is simplified and does not describe all the actions and testing that occurs. The
CPU continuously diagnoses the entire system for correct operation and sample water flow.
If an error occurs, a message is posted to the message queue on the LCD screen.
The reagent is added by a single pulse of the reagent solenoid. When the reagents require
replacement, the PRIME button is pushed to bring new reagents into the system. During
PRIME the reagent solenoid is pulsed several times to draw fluid from the two reagent bottles
and fill the tubes with new reagent. A complete PRIME takes less than a minute.
The SERVICE button empties the cuvette, stops the flow of sample water, and clears any
errors. This provides a convenient way to replace reagents and the measurement cuvette. If
more extensive servicing is performed, all power to the CLX-Ex2 should be removed. If the
CLX-Ex2 is to be turned off, it is recommended that the instrument be placed in SERVICE
mode before removing power. This ensures that the cuvette is emptied and the flow is off.
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3.2 The Air Sentinel Controller
The Air Sentinel controller governs the power to the instrument. For normal instrument
operation air needs to passes through fitting on the base of the main enclosure and
constantly purge any vapors that could build-up. All GREEN lamps indicate a safe operating
condition. Only when this condition is reached will power be applied to the measurement
portion of the instrument.
Start-up
At start-up with the enclosure door open the Air Sentinel will display a RED PRESSURE
lamp on the visual indicator indicates that the system is not pressurized and no power is sent
to the instrument.
Closing the door with the air pressure applied, will cause the Air Sentinel to display a GREEN
PRESSURE lamp and a RED TIMER lamp. During this time the enclosure will undergo an
automatic dilution purge period of 5 minutes where at least 5 volumes of free space inside the
enclosure will be exchanged with clean purge air. No power is applied to the rest of the
instrument during this time.
After the enclosure air has gone through this purge period the Air Sentinel will display all
GREEN lamps. At this time the instrument is deemed safe and power is applied to rest of the
instrument.
WARNING: Do not apply power to the Air Sentinel controller unless the area has been
properly tested and is known not to contain explosive materials.
Bypass Key
WARNING: Use of the bypass key disables the safety features and safe operation of this
instrument. It is imperative that this operation be performed only after the area has
been tested and known to be safe.
Assuming the area has been tested and is known not to contain explosive materials; a bypass
service key is provided and can be used. In this operating mode power will be retained to the
rest of the instrument even though the door is open. It is imitative that this mode is only used
after area is known to be safe. This operation disables the safe operation of this instrument.
Upon turning the key, the indicator will display the RED BYPASS & TIMER lamps. This is
an indication of the maintenance mode. Power is retained to the instrument. The key cannot
be removed in this mode of operation.
After maintenance has been performed the door should be closed and latched. Air pressure
will once again pressurize the enclosure. The maintenance key can now be turned and
removed and the key cover replaced. The purge controller will display GREEN PRESSURE
& BYPASS lamps indicating a safe operation and power is kept applied to the instrument.
The TIMER lamp will remain RED for 5 minutes to indicate a bypass operation had taken
place.
3.3 Remote Standby

This feature will allow for remotely placing the instrument into a standby mode. This can be
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done to lower reagent usage while not performing ballasting or de- ballasting operations. The
last operation of each cycle is a flush and hold. Whenever the instrument not being used
(standby), it is stored such that the optics is clean & dry.
Dry contact are provided as feedback as to the operation of the instrument (operating or
standby). For more information on this feature refer to sections 4.4.4 Remote Standby
Connections and 6.2 Routine Measurement with Remote Standby.
3.4 The Reagents

The indicator reagent reacts with any oxidant, generally chlorine, to create a pink color which
the instrument measures and compares with a sample of water without reagents.
The buffer reagent is required to control the sample pH to bring the sample to neutral.
The reagents are provided already hydrated and require little operator preparation.
The indicator reagents are packaged a plastic box. Each 125 mL indicator will require the
addition and mixing of the DPD powder contained in the small brown bottle. This activates
the indicator reagent. The indicator reagents should be changed out on a 90 day basis even if
they are not fully used.
The 500 ml buffer does not require any preparation and is good for one year.
After one year all the reagents will have been consumed and replacement reagent set will be
required. This can be ordered through agent Catalog No.09991. This set will include a new
plastic box with four sets of Indicator reagents plus one 500 mL bottle of Buffer.
3.5 The Reagent Cooler

A reagent cooler is provided for the 125 ml indicator reagent.
For proper operation power must be applied by the Air Sentinel controller to the cooling
chamber temperature controller. Clean dry compressed air must also be provided at pressures
between 5.5 and 7 bar (80 to 101.5 PSI).
The cooling chamber temperature controller governs the solenoid which controls air flow to
the vortex cooling unit. The air flow is turned on or off as required to maintain the indicating
reagent temperature at 20-25˚C. This extends the life of the reagent up to 90 days.
To provide this extended reagent life, power to the cooling power supply and air pressure
must be supplied full time.
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4.0 Installation and Commissioning
Prior to use for the first time, one of the reagents (the indicator) will have to be mixed. Refer
to section 11.2 Replacing or Installing the Reagents.
4.1 Mounting & Site Selection

The instrument is designed for wall mounting. Choose a location that is easily accessible for
operation and service and ensure that the Purge Control lamp is about eye level. Consideration
must be made for the plumbing and electrical conduit connections. The overall mounting
dimensions of the instrument are shown in Figure 4.
Figure 4: Overall Mounting Dimensions of the Instrument
Be sure that the instrument be mounted as close as possible to the sampling point to ensure a
quick response time (within 2-3 meters (6-10 ft) of the sampling point).
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4.2 Plumbing
The instrument is designed to require very little head pressure to operate, but will need around
0.34 bar (5 PSI). The maximum pressure for proper operation should not exceed 10.3 bar
(150 PSI). The maximum allowable fluid temperature is 55°C (131°F).
The fluid waste from drain connection of this instrument contains reagents diluted with
large quantities of sample water. HF scientific recommends that in the case of ballast
installations, the waste stream is reintroduced to the bilge tanks. This waste fluid must
NEVER be reintroduced into the incoming water stream.
All plumbing connections are intended to be made through stainless steel connections.
The water sample inlet requires 6 mm OD stainless steel tubing. The fitting is a compression
fitting so the installer need only place the supplied the nut and feral over tubing and tighten.
The water drain requires 12 mm OD stainless steel tubing. This fitting is also a compression
fitting so the installer need only place the supplied the nut and feral over tubing and tighten.
Properly installed and sealed connections are required to ensure the water tightness and ratings
of the instrument.
The drain must be open to the Atmosphere for proper operation.
4.3 Air Supply

This instrument requires water and oil free air, -40oC (-40oF) Dew Point, Particles <5u, ISA
Grade Hydrocarbon free. The air needs to be provided at between 5.5 and 7 bar (80-101.5
PSI) with a volume of 4 cubic foot/min as measured at 5.5 bar (80 PSI). This air supply
must be provided continuously from a known safe area. Min flow is 35 SLPM
The air connection requires 6 mm stainless steel tubing. A compression type fitting is supplied
on the base of the main enclosure that simply requires the installer to slip the supplied nut and
feral over the tubing and then tighten the nut.
4.4 Electrical Connections

All electrical connections must pass through the three compression grommets on the left side
of the instrument. Cabling must be selected to ensure that these connections are tight. The
grommets can accept cabling from 11 to 21 mm diameter. One grommet is supplied for system
power and two are supplied for low voltage I/O connections. These grommets must be
tightened to maintain cabinet air pressure.
Most of the low voltage electrical communication connections to the instrument are made at
the termination area which is located on the left side of the instrument. Remove the access
cover by loosening the captive screw. The connections are labeled and are self-descriptive.
Please follow all government recommendations for installation of electrical connections to
and between the instrument and other peripheral devices.
All terminals are designed to accept wires in the range of 14-28 AWG. All wires should be
stripped to a length of 6 mm (¼”).
For line power connections refer to the companion manual Catalog No. 28749
4.4.1 RS-485
The RS-485 half-duplex (2-wire) digital interface operates with differential levels that
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are not susceptible to electrical interferences. This is why cable lengths up to 3000 ft
can be implemented. The last device on each bus may require terminating with a 120
ohm resistor to eliminate signal reflection on the line. Do not run RS-485 cables in the
same conduit as power. Set-up of the RS-485 is covered in 8.3 Configuring the RS–
485 Port
To prevent damage to the instrument, ensure that

power is disconnected prior to making connections.
For ease of connecting, remove the plug-in terminal
block. Connections are labeled beside this
termination on the PC board. The recommended
cable is 22 AWG shielded twisted pair. The grey
terminal block is removable to assist in making
connections.
4.4.2 Relay
One relay alarm connections labeled ALM COM &
ALM NO is provided. Please note that this is a fail-
safe so the “normal” condition is power to the CLX-
Ex2 on and no alarm condition. The relay is rated
240VAC 2A. Operation of this alarm is covered in
section 8.4 Configuring the Alarm.
4.4.3 4-20 mA
The 4-20 mA output is driven by a 15 VDC power
source and can drive recorder loads up to 600 ohms.
Transformer isolation is provided on the CLX-Ex2.
Do not run 4-20 mA cables in the same conduit as power. Operation of this output is
covered in section 8.1 Setting the 4-20 mA.
To prevent damage to the instrument, and for general safety ensure that power is
disconnected to the CLX-Ex2 prior to making any connections. Polarities of the
connections are labeled beside this termination on the PC board.
The recommended cable is 22 AWG shielded twisted pair. To prevent ground loops,
connect the shield at either the CLX-Ex2 or at its destination, but not both. The grey
terminal block is removable to assist in making connections.
The 4-20mA is factory calibrated. An adjustment is available on the 4-20mA in
sections 8.12 and 8.13. In addition to making adjustments, these menus output
continuous 4 mA or 20 mA and can be used as a signal test. Remember that the
configuration mode will timeout after 15 minutes.
4.4.4 Remote Standby Connections

The instrument operates on user control software, where an external control initiates
each cycle. This control line is called the RSI short for Remote Standby Input.
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The CLX-Ex2 will indicate the current status on another line called RSO or Remote
Standby Output. These connections are a relay contact that is closed when busy and
open during when in standby mode.
The connections are labeled RSI and RSO. The RSI has + and – polarity connection
associate with it and expects a 24VDC control signal.
The RSO is simply a relay contact and is not polarized.
4.4.5 RS-485/4-20 mA cable Ferrite

To meet IEC requirements for RF radiated immunity a clamp-on type ferrite is
supplied in the accessory kit. It should be placed on the RS-485 or 4-20 mA cable
outside, as close as possible to the CLX-Ex2. If both outputs will be used, an
additional ferrite will be needed and can be ordered from HF scientific Catalog
number 24560T.
4.4.6 Modbus Control

In addition to the above mentioned Remote Standby Connections, the same control
can be achieved using Modbus control. Two special Modbus addresses are
provided.
The reading cycle is initiated using the coil 00005 with default at False (0). Setting
this address to True (1) initiates the reading cycle.
At any time the standby status can be check at Modbus Coil Address 00005 or Modbus
Input Address 10005. False (0) indicates standby and True (1) indicates the
measurement cycle is taking place. Control is only available from the Coil Address
00005.
4.5 Installing Reagents

The CLX-Ex2 will require that two reagents be installed prior to operation. These are a
buffer and an indicator. For reagent preparation refer to section 11.2 Replacing and
Installing the Reagents.
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5.0 Air Sentinel Controller Operation
The Air Sentinel controller is mounted on the side of the main enclosure. This controller
will ensure proper safe operation of the CLX-Ex2. If of all the required conditions are met,
the controller will act as a power governor. It does this by monitoring the pressurization of
the main enclosure with clean dry air. Should this air supply pressure fail the PRESSURE
lamp on the Air Sentinel unit will turn RED and power to the rest of the instrument is
disconnected.
WARNING: Do not apply power to the Air Sentinel controller unless the area has been
properly tested and is known not to contain explosive materials.
5.1 Start Up
When power is applied to the CLX-Ex2 for the first time, ensure that the air supply is
connected as stated in section 4.3 and the cabinet is closed and locked. Once power is
applied, the Air Sentinel will go through a purge period of 5 minutes where at least five
volumes of the enclosure are pushed through the CLX-Ex2 and out the Air Sentinel vent.
During the purge period the TIMER lamp Air Sentinel will be RED indicating the purge is
in process and no power is applied to the rest of the CLX-Ex2.
At the complete of the purge, the TIMER lamp will go GREEN and power will be applied
to the rest of the system. As long as the proper air supply conditions are met the CLX-Ex2
will continue to operate.
5.2 Indicator Lamps

The indicator lamps are a very quick way to determine to operation of the controller and
thus the safety condition of the CLX-Ex2.
Lamp Color Matrix Meaning Power to rest of CLX-Ex2
All lamps GREEN Safe Operation Power ON

TIMER lamp RED Instrument purging or Bypass Power OFF
operation
PRESSURE lamp RED Unsafe Operation Power OFF
BYPASS lamp Red Bypass Key Operating Power ON
No lamps on No power applied to CLX- No power applied; everything off.
Ex2
Using the table above, you can quickly determine the operating condition of the instrument.
Under normal operation all GREEN lamps should appear.
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5.3 Maintenance Bypass Operation
Use of the bypass key disables the safety features and safe operation of this instrument.
It is imperative that this operation be performed only after the area has been tested and
known to be safe.
When shipped from the factory the bypass key is shipped on the strap securing the key
cap. Once the commissioning of the system has been done these should be moved to a
known secure location. It is not advised that they be left on the strap.
To perform some maintenance operations on the CLX-Ex2 it is necessary to have the entire
instrument powered up while the enclosure door is open. Under these conditions normally the
Air Sentinel controller would determine that the enclosure is not pressurized and power will
be removed to the measurement section of the CLX-Ex2. To allow for this situation, a special
maintenance bypass key is supplied.
Located on the right side of the Air Sentinel controller is a knurled cap. Removing this cap
reveals the key slot. Insert the key, push in slightly and turn it clockwise to engage the bypass
operation. The TIMER & BYPASS lamps will turn RED to indicate the bypass mode.
Assuming the area around the CLX-Ex2 has been tested and known to be safe, the enclosure
door can now be safely opened and power will remain on to the entire system. The key cannot
be removed while operating in the maintenance bypass mode.
Do not operate the CLX-Ex2 for long periods of time in the bypass mode. This is
intended only for maintenance operations.
Do not operate the CLX-Ex2 in the bypass mode unattended.
To return the instrument to normal, safe operation, close the enclosure door. Ensure that the
air supply is connected turn the key counter-clockwise and remove. Replace the key cover. If
the pressure in the cabinet has built up to a normal acceptable level, the Air Sentinel will show
all GREEN lamps and the instrument will continue to run.
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6.0 Operation
Under normal operation the Air Sentinel controller lamps will all be GREEN indicating safe
operation. If the lamps are not GREEN, correct this condition first. Please refer to section
5.0 Air Sentinel Controller Operation.
The CLX-Ex2 Online Chlorine Monitor allows for the measurement of the chlorine of
process water on-line. The chlorine value of the process water is usually reported in
milligrams per Liter (mg/L), these units are equivalent to Parts Per Million (PPM).
The CLX-Ex2 has two available measurement ranges, 0.00 – 10.00 or 0.00 – 15.00 mg/L
(PPM). Although the unit will display above the range, these readings will not be within the
stated accuracy. As the reagents degrade due to aging, readings above the set range may
decrease in value. .
6.1 Routine Measurement
First, ensure that all plumbing and electrical connections are complete before continuing.
The following steps describe how to measure the value of chlorine of a sample using this
instrument:
1. Apply power to the instrument and allow the unit to warm up. The instrument may
have to re-calibrate the water level sense detector. This WCAL or water calibration
will take few minutes to perform.
2. When a continuous process stream is flowing through the instrument, the instrument
will display the measured chlorine level of the sample by displaying it on the LCD
screen. In addition, the equivalent signal is provided on the analog (4-20 mA) output,
or the digital (RS-485) output, depending on the options selected.
6.2 Routine Measurement With Remote Standby

First, ensure that all plumbing and electrical connections are complete before continuing.
The following steps describe how to measure the value of chlorine of a sample using this
instrument:
1. Apply power to the instrument. The instrument will perform a water calibration
(WCAL). During this time the RSO contact will be closed, indication the system is
busy. This automatic calibration is necessary and will only be performed once on
power up.
2. When the system has completed the WCAL, the RSO contacts will open indicating
that it is in standby mode and is ready to take a measurement.
3. Application of 24VDC to the RSI+ will initiate a read cycle. The RSO contacts will
close to indicate the system is busy.
4. At the completion of the cycle, the RSO contacts will open & the measured chlorine
level of the sample will be displayed on the LCD screen. In addition, the equivalent
signal is provided on the analog (4-20 mA) output, or the digital (RS-485) output,
depending on the options selected.
The system is ready to take another measurement
As mentioned previously the same control can be performed via Modbus. Setting Coil 00005
to a 1 will start a cycle. See 4.4.6 Modbus Control.
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These screens can be seen through the window of the CLX-Ex2 with the door closed, however
to access the anything other than measurement screens requires that the instrument be placed
in bypass and the enclosure door be opened.
During normal operation, the instrument will have the

arrow beside AUTO highlighted with the current scale
displayed on the lower row of the display and the
measured reading on the upper row of the display (see
screen shown).
The screen depicted indicates that the system has just been
started or just entered AUTO mode from Service mode
and no readings have been taken yet.
Please note that calibrations will not be allowed until a reading is posted.
6.3 Security Access Feature

The instrument is equipped with a security access code feature that can be activated in the
configuration mode. If the security feature is enabled, the screen shown in the illustration
below will appear when the MODE/EXIT button is pressed.
The security code (333) must be entered to gain access to CAL or CONFIG menus. Notice
that the first number in the code is flashing. The flashing indicates that this is the number to
be changed. Use the  or  arrows to select the first of
the three numbers in the code and then press the  button
to accept the first number of the code. Now enter the
second number in the code. Proceed as with the first
number followed by  . Then repeat the process for the
third number in the access code, and finish with the 
button.
If the valid access code has been selected, the instrument will be directed to the calibration
mode. If the wrong access code is selected, the instrument will return to the AUTO mode.
Refer to section 8.4 Enabling the Security Access for more information.
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6.4 The White LED
A white LED is used to illuminate the measurement cuvette for easy viewing of the instrument
operations. During the Zeroing portion of the cycle and the Measurement portion of the cycle,
when the green LED is active, the white LED is turned off to lower interference. This is
normal operation for the instrument and does not represent an error or problem.
The white LED is also used to draw attention to a problem as described in section 10.1
CLX-Ex2 Fault Detection. In these instances the white LED blinks at a constant rate
dependant on the severity of the problem, but is still turned off as described above. Please
note that any fault is always posted to message queue on the lower portion of the LCD.
7.0 Instrument Calibration

The instrument was tested prior to leaving the factory. The instrument operates from a pre-
determined calibration curve for high accuracy of residual oxidant concentration. It is not
necessary to recalibrate to maintain accuracy specifications.
If re-calibration is required by a regulatory authority, this can easily be performed if required.
The method is by comparison against another instrument, such as a laboratory or hand held
photometer (such as HF scientific’s Chlorine Pocket Photometer).
There are two points of calibration. The slope or gain and the zero (offset). To perform the
zero calibration, the instrument must be plumbed to a sample of known chlorine free water,
such as de-ionized water for a zero adjustment.
7.1 Slope (gain) Calibration Procedure
It is important that the chlorine level be quite stable to use this method. The comparison will
be made against a trusted measurement such as a chlorine photometer, spectrophotometer, or
an amperometric titration.
1. Obtain a grab sample of the flow prior entering the instrument.
2. Measure the value of the sample with one of the methods shown above.
3. On the CLX-Ex2, press the MODE/EXIT button once. The screen is shown below.
4. Press  to enter the calibration adjustment.
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5. The screen will show the current reading on the CLX-Ex2. Using the  &  buttons
adjust the reading to agree with the laboratory method or portable photometer.
6. Press  to accept the calibration adjustment and return to AUTO measurement mode.
There is a limit to the size of the change that can be made to a current reading. The
upper limit is the current reading times 1.5. The lower limit is the current reading
divided by 1.5.
Ensure a reading is posted to the display before calibrating to avoid a nOnE error.
7.2 Zero (offset) Calibration Procedure

Generally this calibration is only required if readings are expected to be below 1 mg/L or if it
is required by a regulatory authority. To perform this calibration, the water supply to the CLX-
Ex2 must be changed to chlorine free water such as de-ionized water. This chlorine free water
must be run through the instrument for at least 5 minutes prior to using the following
procedure.
1. On the CLX-Ex2, press the MODE/EXIT button once. The screen is shown
below.
2. Press either the  or buttons to get the following screen.
3. Press  to enter the zero calibration screen.
4. The screen will show the current reading on the CLX-Ex2. Since there is no
chlorine, the only reading may be a slight offset due to the absorbance of the
reagents. There should be no pink color developed.
5. Press  to perform a Zero calibration. When the calibration has completed the
instrument will return to AUTO measurement mode automatically.
There is a limit of ±0.20 mg/L total adjustment available. A ZERO Cal. greater than this
will cause a CAL warning and no calibration will have occurred. Enter SERVICE mode
to clear this error.
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7.3 Restore Factory Settings
If the CLX-Ex2 displays a CAL error or the calibration was incorrectly performed, it may be
preferred to restore the factory calibration. All factory defaults settings including the factory
calibration can be reset by holding down the  button and then pressing and releasing the 
button then releasing the  button.
8.0 Instrument Configuration (CONFIG mode)
Please note that these operating screens can be seen except with the cabinet door closed
through the door window or with the instrument in maintenance bypass mode. See
section 5.3 for more information.
If changes to the configuration have to be performed, you will need to enter the maintenance
bypass mode see section 5.3 for more information.
The instrument has been designed to provide the ability to customize the instrument according
to needs at any time during normal operation. This mode has been split into sub-menus to
facilitate instrument configuration. This section describes how to use each of the sub-menus
to configure the instrument. While in the configuration mode, the instrument has a time-out
feature that automatically returns the system operation to the AUTO mode after a fifteen (15)
minute period of no button pushes.
Enter the CONFIG mode of the instrument by pressing the MODE/EXIT button until the
arrow beside CONFIG is illuminated, then press the ↵ button to scroll through the sub-
menus.
To exit the CONFIG mode, press the MODE/EXIT button any changes that were made
will be saved.
8.1 Setting the 4-20 mA Output

The first configuration selection is 4-20 for the 4-20 mA
output. Select the either On or OFF using the  and 
buttons. Once the desired output has been set, press the 
button to accept it. The next prompts will depend on the
output selected. Also see sections 8.12 & 8.13.
If the 4-20 mA output was turned On, prompts to set the

4mA (4MA) and 20mA (20MA) chlorine limits will be
displayed. There will also be a menu to adjust the error
level (ERLV). The first prompt will be the chlorine limit
assigned to the 4 mA output level:
Select the chlorine level to assign to the 4MA using the 
and  buttons.
Once the desired level has been set, press the  button to accept it.
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The 4MA can be set higher than 20MA level to invert the output current if required. This
may be required to control a dosing pump.
The next prompt will be the chlorine level assigned to the
20MA. Select the chlorine level using the  and 
buttons. Once the desired level has been set, press the 
button to accept it.
8.2 Configuring the Error Level
In case of an error in the CLX-Ex2, the 4-20 mA reading
can be used to indicate a problem by sending the current
to either 4.00 mA, 2.00 mA or 0 mA. The factory default
setting is OFF. Select the desired ERLV by using the 
and  buttons then press the  button to accept the
desired error response.
8.3 Configuring the RS–485 Port

The instrument is equipped with an RS 485 port which
operates in Simple bus or Modbus. Prompts will appear
for setting the baud rate, the address and the Modbus
transmission mode (RTU or ASCII).
Select the correct baud rate (1200, 2400, 4800, 9600, or

19200) for operation of the I/O port by pressing the  or  buttons to change the displayed
baud rate.
Press the  button to continue on and select the desired
instrument address using the  or  buttons. Once the
selection is satisfactory, press the  button.
To use the Modbus mode, select ASCII or RTU. See

section 9.1.2.
8.4 Configuring the Alarm

One relay is provided that are designed to operate as an independent programmable alarm or
as a system problem alarm. Please note that changes to the alarm will not be recognized until
the start of the next cycle. Two settings must be selected to fully program the alarm:
1. The alarm function (HI, LO, OFF or Error)
2. The alarm set point (level at which the alarm activates)
These items are described below:

Alarm Function: The alarm can either be turned OFF or selected to operate in one of three
different manners:
1. HI alarm: the relay changes state when the measured chlorine level is higher than the
programmed alarm level (set point).
2. LO alarm: the relay changes state when the measured chlorine level is lower than the
programmed alarm level (set point).
3. Error alarm: If there is a system fault or problem the alarm will change states.
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Alarm Set Point: The level at which the alarm activates is called the alarm set point. On the
instrument, the alarm set point is designated as “S/P”. The set point is adjustable to any valid
chlorine level over the range of the instrument in steps of 0.01 mg/L. This setting is not
available if the Error function is chosen
8.4.1 Alarm 1
Alarm 1 Function: The ALM1 is displayed and the display indicates the current
function of alarm 1 (HI, LO, OFF, or Error). Use the  or  buttons to cycle
through and select the desired function. Press the  button to accept the selection.
If the alarm was turned OFF, a prompt will appear to set up alarm 2.
Alarm 1 Set Point: This prompt is used to select the set point for this alarm; this is
indicated by “S/P” shown on the lower row of the display. Select the desired alarm
level by using the  and  buttons. Once the desired set point has been set, press
the  button to accept it.
The Remote Standby limits the relays to a single normally open connection.
Although the alarm 2 menu may display, this alarm can be used.
Due to the cyclic nature of the CLX, relay chatter is not an issue. There is no need
for alarm delays or hysteresis.
8.5 Enabling the Security Access

The instrument is equipped with a security access. If this option is turned on, the user is
required to input the access code into the instrument to get
to any mode other than AUTO. The only code is 333. This
code may not be changed. See section 6.3 for more
information on this security feature. The security key icon
will be visible and flashing on the display whenever the
access option is selected using the  or  buttons. (On
or OFF).
8.6 Extended Settings

The last settings are grouped together to prevent them
from being adjusted by accident. To gain access to the
extended settings, select On using the  or  buttons
and press the  button.
If extended settings are set to OFF, pressing the  button will save all settings and the
CLX-Ex2 will automatically return to the normal AUTO mode of the instrument.
8.7 Units of Measurement

The unit of measure can be set to either mg/L (milligrams per liter) or PPM (parts per million).
CLX-Ex2 (8/2019) Page 22
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The factory setting is mg/L. Select the desired UNIT using the  and  buttons and press
the  button to accept it.
mg/L screen PPM screen

8.8 Averaging and Filtering
The CLX-Ex2 can display and output averaged readings to help smooth out the response
and eliminate large reading variation in rapidly changing processes. There are 5 settings for
the averaging feature:
1 = No averaging, each reading is in “real time”.

2 = The current reading and previous reading are averaged.
3 = The current reading and previous 2 readings are averaged.
The factory setting is averaging of 2. Select the desired AVG using the  and  buttons and
press the  button to accept it.
In addition to averaging, the CLX-Ex2 has a software filter that limits the change between
consecutive readings to 20%. For example, the reading following a reading of 1.00 ppm
could not be displayed as higher than 1.20 ppm or lower than 0.80 ppm. This filter also
helps smooth out large changes and eliminate reading
spikes. After 3 consecutive readings, it is assumed that
the large change in the readings is "real", and the filter
will be disabled. For example, the change between
reading 1 & 2, and readings 2 & 3 will be limited to
20%, but the change between readings 3 & 4 will not be
limited.
Note: This software filter is completely disabled when the averaging (AVG) is set to 1.
8.9 LCD Backlight Brightness

The LCD backlight brightness may need to be adjusted. This is of particular interest if multiple
instruments are located in the same area and it is desired for the entire group to have the same
appearance. Ten levels are available. The factory setting
brightness is 8.
Change the brightness by pressing the  or  button.
When the desired brightness has been selected, press the
 button.
8.10 RS-485 Parameters

These menus will only appear if the RS-485 is enabled (see 8.3). The factory setting is 8 Bit,
no (nOnE) Parity, 1 Stop Bit.
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Make selections using the  and  buttons then press the  button to move to the next menu.
8.11 Cycle Time

The cycle time can be changed using this menu. Please note that changing this menu will
directly affect the volume of reagent that will be consumed.
Make selections using the  and  buttons then press the

↵ button. Allowable setting is from 60 to 600 seconds (10
minutes).
The indicator reagent has a defined life after being mixed regardless of the cycle time
setting. If the reagent is kept in the powered cooling chamber the life is 90 days.
8.12 Water Conservation

To conserve water, the flush time can be adjusted use as little water as possible.
This feature is generally not used in ballast water applications and should be set to OFF.
The instrument requires 110 seconds to complete its

normal operations, when the WCON is turned On, at the
factory cycle time the instrument sits idle for about 40
seconds. This results in about a 25% water savings. The
actual amount of water conservation is dependent on the
incoming water pressure and the cycle time setting.
The use of this option may result in some slight loss of accuracy. The factory setting for this
option is OFF.
Make selections using the  and  buttons then press the ↵ button to exit to AUTO mode
and save all configuration settings. If the 4-20 mA in section 7.1 is turned ON, there are two
additional menus that will
appear before returning to AUTO mode.
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8.13 4mA Adjustment
If the 4-20 mA setting is turned ON (8.1 Setting the 4-20 mA Output), the following two
menus will appear. The first menu outputs a constant 4
mA while allowing for a small amount of adjustment.
The adjustment can be made using the  and  buttons.
This adjustment will allow the operator to make the
CLX-Ex2 agree with a PLC or SCADA system. The
adjustment limits are ± 200 counts or about ± 0.2 mA.
This setting will be slightly different on each instrument as each CLX-Ex2 will be factory
set to 4.00mA. Press the ↵ button when adjustments are complete to save this setting and
move on to the 20mA adjustment.
8.14 20mA Adjustment

This menu operates similar to the previous menu. This menu outputs a constant 20 mA while
allowing for a small amount of adjustment. The adjustment can be made using the  and 
buttons. The adjustment limits are ± 1000 counts or about ± 1 mA.
This setting will be slightly different on each instrument

as each CLX-Ex2 will be factory set to 20.00mA.
When complete with the 20mA adjustment, press the ↵ button to exit to AUTO mode and
save all configuration settings.
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9.0 Additional Features and Options
9.1 RS-485 Outputs

The CLX-Ex2 has the capability to operate in two different RS-485 modes. Included are a
simple communication mode and Modbus communications. Both modes will automatically
configure and do not require any changes or selections
9.1.1 Simple Communication

The CLX-Ex2 can provide basic communications over simple programs such as the
Hilgraeve HyperTerminal that is included with most Microsoft Windows packages.
The user could also use Visual Basic or other programs. The factory setting
communication parameters are 8 bits, no parity and 1 stop bit. These can be changed
in the Extended CONFIG menus 8.9 RS-485 Parameters.
The master computer will send out:
• Byte #1 the attention character “:” in ASCII or 3A Hex
• Byte #2 the address of the CLX-Ex2being queried
• Byte #3 & 4 CR LF or 0D 0A in hex
The CLX-Ex2 will respond with:
The CLX-Ex2 will respond with:
• The same attention character “:” in ASCII or 3A Hex
• The address of the CLX-Ex2
• The Reading
• The Unit (mg/L)
A sample communication would look like this:
(Master computer requesting a report from address #1) :1 CRLF
(CLX-Ex2 set to address #1 Response) :001 0.0249mg/L
9.1.2 Modbus Communication

Modbus protocol communication is included with this instrument. The Modbus
address list is available from HF scientific or online at www.hfscientiifc.com.
9.2 Remote Panel Meter (Catalog # 19609)
The remote panel meter allows for remote indication of the mg/L reading using the 4-20 mA
loop of the CLX-Ex2. No external power is required, as the meter is run off of the 4-20 mA
source of the CLX-Ex2.
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10.0 Troubleshooting
10.1 CLX-Ex2 Fault Detection
Please note that these operating screens can be seen through the door window with the cabinet
door closed or in maintenance bypass mode See section 5.3 for more information on this.
The CLX-Ex2 performs continuous diagnostic monitoring. In the CLX-Ex2, there are 4
severity levels of fault detection. Level 4, 3 & 2 will allow normal operation, but warn of the
problem. Level 1 is an instrument failure and the instrument will not operate. Any faults are
displayed in a queue form in the bottom row of the LCD.
A level 4 fault is simply a screen indication that one of the alarm levels has been activated.
This fault level will not affect the 4-20 mA and will only affect the alarm activated. The
sample back light blinks at a rate of once every 4 seconds.
A level 3 fault indicates a failure or a problem that usually can be corrected by the operator.
Refer to the chart below. If any of these errors occur, the instrument will still display
readings and probably will operate correctly. These faults will self-clear when the problem
is corrected. If any of these faults occur, they may affect the 4-20mA and any alarm
dependent on the detection setting (Error). See sections 8.2 & 8.4.1 for error settings. The
sample back light blinks at a rate of once every 2.5 seconds to indicate these faults.
Level 3 (Self-Clearing) fault conditions

Message Description of Fault Corrective Action
MA 4-20 mA enabled & loop open Check 4-20 mA wiring or turn off 4-
20mA if not used
CAL Calibration invalid –not accepted Recalibrate if needed
WATR No water flowing Check water flow
FAST Intake water flow too fast Set flow rate (see section 10.2)
SLOW Sample cuvette filling too slowly Set flow rate (see section 10.2)
PURG Sample cuvette has slow purge Check drain lines
NPRG Sample cuvette not purging Check drain lines
ISOL Problem with intake solenoid Check wiring, check for clogged solenoid
PSOL Problem with purge solenoid Check wiring, check for clogged solenoid
GLAS Dirty cuvette Replace or clean cuvette
WCAL Water Level Calibration Invalid Clear fault (see section 10.3)
A level 2 fault indicates a severe problem that will usually require technical assistance from
HF scientific customer service (see section 10.6). The queued display will show POST. If this
fault occurs it will affect the 4-20mA and any alarm set for fault detection (Error). The sample
back light blinks at rate of once every 1 second.
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A level 1 fault is a system fault. This is NOT a problem that the operator can correct, and the
unit must be returned to the factory for service (see section 10.6). These failures consist of
failures in the CPU, A/D, EEPROM or other devices internal to the instrument. The queued
display will show FAIL, the upper display will show a four or five digit fault code. If this
fault occurs, it will affect the 4-20mA and any alarm set for fault detection (Error). The
instrument will not operate with this fault. The sample back light blinks at rate of once every
0.4 seconds.
If any fault condition occurs, the message indicating the fault will be shown on the lower row
of the display.
10.2 Setting Flow Rate
The flow rate on the CLX-Ex2 was factory adjusted and usually should not need adjustment.
Installation variances may affect the flow. The optimal flow rate through the CLX-Ex2may
be adjusted if needed. The flow is adjusted by removing regulator vinyl cap and turning the
adjustment screw on the pressure regulator. To assist in this adjustment follow the procedure
shown below:
1. Press the SERVICE button.
2. Wait for the display to read HOLd, then press Mode/ Exit.
3. Display will show FLOW with the number 0. Press either the  or  button.
4. CLXB will drain, and then pulse in water while a count is displayed on the screen.
5. The display will show one of three messages HI, LO or Good.
The flow test determines if the flow rate is suitable for proper operation. Loosen the locking
nut then adjust the pressure regulator using a coin or a large flat blade screwdriver. Press
either the  or  button while in the FLOW routine to display a new flow rate. Please note
that only ¼ turn incremental adjustments should be made to the regulator on each attempt.
If the message is LO, turn the regulator control clockwise. If the message is HI, turn the
regulator counterclockwise. If the message is Good, no adjustment is required. Tighten the
locking nut after adjustment and replace the regulator vinyl cap. To return to normal operation,
press the ↵ button.
10.3 Clearing Faults

Every time SERVICE mode is exited, all faults are cleared. If the original fault or a new fault
occurs, it will be posted.
In the case of WCAL, it is possible the power was enabled before a water sample was
available. Ensure a water sample is available and then press PRIME to force another Water
Calibration (WCAL).
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10.4 Reagent Clogs
If reagents fail to flow or Prime it may be due to a clog in either the tubing or at a check valve.
To alleviate this you may have to flush the system with Chlorine Free water, preferably
Deionized water. See section11.4 Check Valve Flushing Kit.
10.5 Diagnostic Chart

Symptom Cause Cure
Lower display shows MA 4-20 mA loop open Check wiring. See sections
4.4.4 and 8.1
Lower display shows FAIL Major system fault Refer to section 10.1
Readings are erratic (1) Bubbles in solution (1) See above
(2) Debris in flow (2) Install T strainer at inlet
(3) Bad or sticky check (3) Flush check valves as
valves described in section 10.4 or
replace the valves.
Readings are lower than expected (1) Condensate or leaky (1) Install desiccant cartridge
measurement cuvette kit
(2) Measurement cuvette (2) Replace or clean cuvette
dirty
(3) Reagents bad or expired (3) Replace reagents
(4) Buffer reagent not being
dispensed (4) Check buffer lines and
check valves.
Upper display flashes Sample Over-Range Check sample. Sample may be
too high to read.
Upper display shows nOnE while No current reading displayed Wait for CLX-Ex2 to post a
attempting to calibrate reading
10.6 Technical and Customer Assistance

If for any reason assistance is needed regarding this instrument please do not hesitate to
contact either the HF scientific Technical Service Department or the HF scientific Customer
Service Department:
HF scientific
Fort Myers, Florida 33916-7597
Phone: (239) 337-2116
Toll Free (888) 203-7248
Fax: (239) 332-7643
www.hfscientific.com
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11.0 Routine Maintenance
Please note that to perform these maintenance operations the cabinet door must be open
and the instrument in maintenance bypass mode. See section 5.3 for more information
on this.
Specific condition of use: Parts of the enclosure are non-conducting and exceed the maximum
permissible resistance according to the IEC 60079-0. Therefore, to avoid electrostatic charge
build-up, it must not be rubbed or cleaned with solvents or a dry cloth when installed/used
within a potentially explosive atmosphere.
11.1 Maintenance Schedule

The recommended schedule is shown below. It is important to replace the reagents to get
reliable accurate readings from the CLX-Ex2. The Buffer supplied can last for up to one year.
Each mixed indicator reagent will last for up to 90 days* when kept special cooling chamber.
The one year kit includes one buffer bottle and four sets of indicator reagents. The Buffer
reagent is mounted in a clip and is further held with a Velcro strap. The indicator reagent is
in a 125ml bottle mounts inside an insulator and also mounts in a clip with a Velcro security
strap. See section 11.2 for more information on the reagents.
The CLX-Ex2 is shipped with one CLX-Ex2 Tubing/Cuvette kit, HF part #09950EX. The kit
consists of the following:
Qty Part
1 Spare Buffer Cap Assembly
1 Spare Indicator Cap Assembly
8 Pump Tubes
1 Spare Cuvette
Two replacement sets of reagent cap/tubing assemblies are supplied with the CLX-Ex2; one
for the buffer and one for the indicator.
Additional kits can be ordered from your local HF scientific distributor or representative. It is
recommended to keep one kit on hand at all times.
Generally, both pump tubes should be replaced annually. Spare cap assemblies for both the
buffer and the indicator are supplied and can be replaced when needed.
Every 90 days
1. The indicator reagent required for operating this instrument must be changed at least
every 90 days. The buffer reagent can be used up to one year.
2. The internal strainer should be checked and cleaned if necessary.
3. The glass cuvette should be inspected. Check for excessive debris on the inside surface
of the glass. It is suggested to keep a spare cuvette to replace when required. The old
cuvette may be cleaned, if possible, for future replacement.
Flushing the System

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Press the SERVICE button to stop the water flow. Remove old reagents and discard. Place
the suction tubes in a small container of clean water. Press SERVICE to return to operation
mode, press PRIME and then  to flush the system with water. Remove the suction tubes
from the water Press PRIME and then  to remove most of the water.
After a PRIME the CLX-Ex2 will perform a water calibration (WCAL). It will take a
few minutes to complete this procedure.
*The 1 year buffer and 90 day indicator reagent life is primarily used on ballast water
applications. The assumption is based on the factory default of a 60 second cycle and up to
60 hours total operation per month.
Pump Tubing Replacement
The black pump tubes may need replacement more often due to the fact that they are subject
to wear. The inline check valves should not need to be replaced and should be saved. Please
note that the check valves are directional as shown below.
Figure 5: Inline check valve
Steps:
1 Flush the system as described above to reduce personal contact with the reagents.
2 Press SERVICE to stop the flow of sample water and drain the cuvette.
3 Remove and retain the thumb screw on top of the pump; pull the pump hammer and
spring up and out of the way. There is no need to completely remove the hammer and
spring.
4 Working on one reagent side at a time. Replace the black tubing between optics inlet and
the check valve OUTLET. Discard the old tubing.
5 Ensure the check valve is placed into its seat.
6 Repeat steps 4 & 5 for the other reagent.
7 Replace the hammer and spring back into place and secure with the thumb screw.
8 Check the drawing on the following page to ensure correct installation.
9 Return to operation as described.
Cap Assembly Replacement

When the Cap Assemblies needs to be changed follow the procedure shown below. It is
recommended that both assemblies are changed at the same time.
Steps:
1 Flush the system as described above to reduce personal contact with the reagents.
2 Press SERVICE to stop the flow of sample water and drain the cuvette.
3 Replace the buffer cap (blue or black cap) assembly.
4 Repeat step 3 above, for the indicator side (white cap).
5 Replace reagents, prime and return to service.
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Cuvette Replacement
Check the condition of cuvette and change if it appears badly soiled or discolored. Follow
the steps below.
Steps:
1. Replace the two Cap Assemblies.
2. Turn the knurled top on the optics system counterclockwise (as viewed for the top) until
the cuvette just “pops” out, but do not remove the top.
3. When the cuvette “pops” out, move the retaining o-ring & remove the cuvette. You may
need a stiff wire such as a bent paper clip to grasp the cuvette. Retain this cuvette for
future use if it can be cleaned.
4. Install the new cuvette by pushing it firmly in place and turning the knurled top clockwise
until the cuvette is held securely.
5. Check the drawing on the following page to ensure correct installation.
6. Return to operation as described.
T-Strainer Cleaning
The T-strainer is integral to the instrument and must be checked
occasionally. When necessary it must be removed and cleaned. The
strainer screen may require replacement after a period of time.
Steps:
1. Press SERVICE to stop the flow of sample water and drain the
cuvette.
2. Ensure the source water is turned off.
3. The T-strainer is clamped to the intake regulator. The removal
requires the use of a flat blade screwdriver as shown in the photo.
Once the two clamps are opened the T-strainer can be removed.
4. Disconnect the top of the T-strainer and regulator from the tubing
and clear of the enclosure.
5. Remove and clean the screen and then reassemble.
6. Be sure to tighten the bowl of the strainer.
7. Be certain the clamps are tightened fully and the tubing
connections are complete. You may require pliers to close
the clamps.
8. Turn source water back on.
9. Return to normal operation.
10. Check for any leaks.
Return to Normal Operation

Press the SERVICE button to return sample flow to the system. Check for leaks. If a leak
occurs press SERVICE again, repair leak and try again. Once the system is operating
correctly, return or replace reagents and press PRIME and then  one time to restart reagent
flow. The system will automatically return to normal operation.
Tubes may darken due to contact with the reagent. This condition does not affect the
performance of these parts.
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11.2 Replacing or Installing the Reagents
Reagent kits are available from HF scientific for Total Chlorine Refer to section 12.0
Replacement Parts and Accessories for the appropriate Catalog number. There are two
reagents required, for the instrument to operate; the buffer and the indicator.
The reagents are provided “wet” and the buffer is ready to use and will last up to one year.
The smaller indicator reagent does require the addition of the DPD power to activate it. Once
activated it starts to oxidize. This process is slowed by keeping it in the cooling chamber.
When commissioning the CLX-Ex2 it is recommended to follow the procedure in

section 11.4. This procedure only needs to be done once when the instrument first
commissioned.
11.3 Indicator Reagent Preparation

Remove the cap of the small liquid indicator reagent and add the contents of the DPD
powder bottle (small brown bottle). Cap and shake to fully dissolve the powder.
Once mixed the indicator has an expected life of 90 days if kept in the powered cooling
chamber. Write the mixing date on the reagent bottle labels in the area provided.
Dispose of expired reagents correctly.
To replace the reagents, press the SERVICE button; this will empty the cuvette and stop
any flow of water. Remove the cap on both bottles replace with the cap supplied with the
CLX-Ex2. The buffer is installed on the left and the indicator is installed in the cooling
chamber. The suction tube for both reagents will reach the bottom of the bottles.
To complete the replacement procedure, press the PRIME button and then the  button.
This will draw enough of each reagent to completely prime the tubes and replace any old
solution. The system will automatically return to normal operation after it has primed.
Use caution when changing the reagents as they are corrosive. These reagents may
stain clothing. After changing the reagents, operators should wash their hands.
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11.4 Check Valve Flushing Kit
Sometimes upon initial commissioning, the check valves stick and require manual priming.
This should not be needed after commissioning. Be careful when using this kit to use only
chlorine free water. Complete instructions are included in the kit.
Figure 6: Check Valve Flushing
11.5 Instrument Storage

If the CLX-Ex2 is relocated or will be inactive for long periods of time (several months),
remove the reagents. Flush the reagent system as describe in 11.1 Maintenance Schedule.
Place the instrument in Service mode to drain the system then remove power by
disconnecting the mains power plug. It is usually a good idea to disconnect or shut off the
source water.
11.6 Cleaning the CLX-Ex2
Flush the system as mentioned in section 11.1 Maintenance Schedule. When the flushing is
finished, press the SEVICE button wait until the display reads HOLd.
As a matter of safety, always disconnect any power source to the CLX-Ex2 prior to
attempting any cleaning. It is recommended that the source water is also shut off.
Isopropyl alcohol (rubbing alcohol) on a soft cotton cloth works very well in removing
reagent stains from plastic parts, the key pad and the display. Use care when cleaning
around electrical components. Do not use any harsh cleaning agents as these may cause
damage to the instrument components.
Ensure that the system is dry prior to applying power.
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12.0 Accessories and Replacement Parts List
The items shown below are recommended accessories and replacement parts.
Accessory Catalog Number Photo
Reagent Kit – Total Chlorine 12 09991

month supply
Purge Manual CLX-Ex (Air 28749 N/A

Sentinel)
Operating Manual CLX-Ex 28920 N/A
Tubing/Cuvette Kit 09950EX
Replacement Cuvette 25018S
Check Valve Kit 25017S
Ferrite for 4-20mA or RS-485 24560
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Check Valve Flushing Kit 25096
T-Strainer/ Pressure Regulator 25357

Assembly
Replacement T-Strainer Screen 28625
Water Intake Assembly 28411
To order any accessory or replacement part, please contact the HF scientific Customer Service
Department. If for any reason technical assistance is needed regarding this instrument, please
do not hesitate to contact the HF scientific Technical Services Department.
HF scientific
Phone: (239) 337-2116
Toll Free: (888) 203-7248
Fax: (239) 332-7643
www.hfscientific.com
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13.0 Limited Warranty
H.F. Scientific, Inc. (the "Company") warrants each product to be free from defects in material and
workmanship under normal usage for a period of twenty-four (24) months from first use or thirty-six
(36) months from shipment, whichever occurs first. In the event of defects within the warranty
period, the Company will, at its option, replace or recondition the product without charge. Parts,
which by their nature are normally required to be replaced periodically, consistent with normal
maintenance, specifically reagent, desiccant, sensors, electrodes and fuses are excluded. Also
excluded are accessories and supply type items.
Proof of purchase (invoice or paid order confirmation) and/or first use (commissioning) must be
provided when making a product warranty claim.
THE WARRANTY SET FORTH HEREIN IS GIVEN EXPRESSLY AND IS THE ONLY
WARRANTY GIVEN BY THE COMPANY WITH RESPECT TO THE PRODUCT. THE
COMPANY MAKES NO OTHER WARRANTIES, EXPRESS OR IMPLIED. THE COMPANY
HEREBY SPECIFICALLY DISCLAIMS ALL OTHER WARRANTIES, EXPRESS OR IMPLIED,
INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTIES OF
MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE.
The remedy described in the first paragraph of this warranty shall constitute the sole and exclusive
remedy for breach of warranty, and the Company shall not be responsible for any incidental, special
or consequential damages, including without limitation, lost profits or the cost of repairing or
replacing other property which is damaged if this product does not work properly, other costs
resulting from labor charges, delays, vandalism, negligence, fouling caused by foreign material,
damage from adverse water conditions, chemical, or any other circumstances over which the
Company has no control. In addition, the Company shall not be responsible for any costs incidental
to the Company’s warranty response efforts, including, without limitation, costs associated with the
removal and replacement of systems, structures or other parts of facilities, de-installation,
decontamination and re-installation of products, or transportation of products to and from the
Company. This warranty shall be invalidated by any abuse, misuse, misapplication, improper
installation or improper maintenance or alteration of the product.
Some States do not allow limitations on how long an implied warranty lasts, and some States do not
allow the exclusion or limitation of incidental or consequential damages. Therefore the above
limitations may not apply to you. This Limited Warranty gives you specific legal rights, and you may
have other rights that vary from State to State. You should consult applicable state laws to determine
your rights. SO FAR AS IS CONSISTENT WITH APPLICABLE STATE LAW, ANY IMPLIED
WARRANTIES THAT MAY NOT BE DISCLAIMED, INCLUDING THE IMPLIED
WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE,
ARE LIMITED IN DURATION TO ONE YEAR FROM THE DATE OF ORIGINAL SHIPMENT.
HF scientific, inc.
Phone: (239) 337-2116
Fax: (239) 332-7643
Toll free: 888-203-7248
Email: hf.info@wattswater.com
Website: www.hfscientific.com
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TSU Ex-APU
(FLUIMAC)
DIAPHRAGMS PUMPS
POMPEPUMPS
A MEMBRANA
USER MANUAL
MANUALE D’USO
 PHOENIX
 PHOENIX ATEX
 PHOENIX FOOD
 PHOENIX FOOD ATEX
INDEX indice
4 IDENTIFICATION CODE sigla di identificazione
5 LEGEND legenda TECHNICAL DATA dati tecnici
37 GENERAL NOTES note principali
39 OPERATING PRINCIPLE principio di funzionamento
39 PNEUMATIC CONNECTION connessioni pneumatiche
40 INSTALLATION AND USE INSTRUCTION istruzioni di installazione ed uso
TRANSPORT trasporto
STORAGE stoccaggio
INSTALLATION installazione
START UP avviamento
USE utilizzo
STOP arresto
44 MAINTENANCE manutenzione
RECOMMENDATIONS raccomandazioni
DISASSEMBLY smontaggio
INSPECTION ispezione
46 SAFETY RISKS rischi per la sicurezza

48OPERATORS FOR INSTALLATION AND START UP operazioni per installazione e avviamento
OPERATORS FOR USE AND MANTENANCE operatori per uso e manutenzione
OPERATORS FOR REPAIR operatori per la riparazione
DISPOSAL smaltimento
49 TROUBLESHOOTING AND POSSIBLE CAUSES anomalie di funzionamento e
possibili cause
2 Rev.02
DICHIARAZIONE DI CONFORMITA’
FABBRICATO DA: FLUIMAC S.r.l

VIA TICINO 2/4 - 21043
MANUFACTURED BY CASTIGLIONE OLONA (VA) –
ITALY
TIPO/SERIE POMPA PNEUMATICA A
DOPPIA
TYPE / SERIES MEMBRANA SERIE:
PHOENIX
MODELLO
MODEL P07-18-30-50-65-100-101-160-250-400-500-700-
1000
MARCATURA ATEX
MARKING ATEX II 3/3 GD c IIB T135ºC
MARCAR ATEX
PHOENIX
Questo prodotto è conforme alle seguenti direttive CE/EX e relativi standard armonizzati:
This product complies with the following European Community Directives CE/EX and relating harmonized standards:
2006/42/CE Direttiva Macchine / Machinery Directive / Maschinenrichtlinie / Directive Machines / Directiva Máquinas
2014/34/UE: Direttiva ATEX, concernente il ravvicinamento delle legislazioni degli Stati Membri relative agli apparecchi e sistemi di protezione destinati a essere utilizzati in
atmosfera potenzialmente esplosiva.
UNI EN ISO 12100:2010 – Sicurezza del macchinario. Concetti fondamentali, principi generali di progettazione. Parte 1: terminologia di base, metodologia.
UNI EN ISO 12100:2010 – Safety of the machinery. Fundamental notions, design general principles. Part 1: Basic terminology, methods.
UNI EN ISO 12100:2010 – Sicurezza del macchinario. Concetti fondamentali, principi generali di progettazione. Parte 2: principi tecnici.
UNI EN ISO 12100:2010 – Safety of the machinery. Fundamental notions, design general principles. Part 2: Technical principles.
UNI EN ISO 3746: 2011 – Acustica. Determinazione dei livelli di potenza sonora delle sorgenti di rumore mediante misurazione della pressione sonora. Metodo di controllo con una superficie
avvolgente su un piano riflettente.
UNI EN ISO 3746: 2011 – Sound. Determination of sound power levels for noise sources by measuring the sound pressure. Monitoring method with an enveloping surface on a reflecting plate.
UNI EN ISO 11200: 2014 – Acustica. Rumore emesso dalle macchine e dalle apparecchiature. Linee guida per l’uso della norme di base per la determinazione dei livelli
di pressione sonora al posto di lavoro e in altre specifiche posizioni.
UNI EN ISO 11200: 2014 – Sound. Noise done by the machines and the equipments. Guidelines for using the basic norms for determining the sound pressure levels in
the working place and in other specific positions.
UNI EN ISO 4414: 2012 - Sicurezza del macchinario. Requisiti di sicurezza relativi a sistemi e loro componenti per trasmissioni oleoidrauliche e pneumatiche. Pneumatica.
UNI EN ISO 4414: 2012 - Safety of the machinery. Safety requirements concerning the systems and their components for hydraulic and pneumatic transmissions. Pneumatic.
UNI CEI EN ISO 80079-36:2016 - Apparecchi non elettrici destinati ad essere utilizzati in atmosfere potenzialmente esplosive. Parte 1: metodo e requisiti di base.
UNI CEI EN ISO 80079-36:2016 - Non-electrical equipments to be used in potentially explosive environments. Part 1: Method and basic requirements.
UNI CEI EN ISO 80079-37:2016 - Apparecchi non elettrici per atmosfere potenzialmente esplosive. Parte 5: protezione per sicurezza costruttiva “c”.
UNI CEI EN ISO 80079-37:2016 – Non-electrical equipments for potentially explosive environments. Part 5: protection for building safety “c”.
LA SEGUENTE CONFORMITA’ E’ RIFERITA AL PROTOTIPO DELLA PHOENIX 100 MATRICOLA NR. P0001 DEL 16.01.2012.
THIS COMPLIANCE REFERS TO PHOENIX 100 PROTOTYPE, SERIAL NUMBER P0001 OF 16.01.2012.
ESTENSIONI: la presente dichiarazione si estende anche ai modelli PHOENIX 7, PHOENIX 18, PHOENIX 30, PHOENIX 50, PHOENIX 65, PHOENIX 100, PHOENIX 101, PHOENIX 160,PHOENIX
250, PHOENIX 400,PHOENIX 500, PHOENIX 700, IN PLASTICA E METALLO.
EXTENSION: this declarations is also valid for the following versions PHOENIX 7, PHOENIX 18, PHOENIX 30, PHOENIX 50, PHOENIX 65, PHOENIX 100, PHOENIX 101, PHOENIX 160,PHOENIX
250, PHOENIX 400,PHOENIX 500, PHOENIX 700, MADE OF METAL OR PLASTIC.
ATTENZIONE: data l’innumerevole varietà di prodotti e composizioni chimiche, l’utilizzatore è ritenuto il maggior conoscitore delle reazioni e compatibilità con i materiali
costruttivi della pompa. Pertanto, prima dell’impiego, eseguire con perizia tutte le verifiche e prove necessarie al fine di evitare situazioni pericolose anche se remote che
non possono essere conosciute ed imputabili al costruttore. Per ogni controversia il Foro Competente è quello di Varese.
WARNING: since there exists an endless variety of products and chemical compositions, the user is presumed to have the best knowledge of their reaction and
compatibility with the materials used to build the pump. Therefore, before using the pump, all the necessary checks and tests must be performed with great care to avoid
even the slightest risk, an event that the manufacturer cannot foresee and of which he cannot be held responsible. Any controversy lies within competence of the Court of
Varese.
PERSONA AUTORIZZATA A CUSTODIRE IL FASCICOLO:

PERSON AUTHORISED TO KEEP THE FILE
PIETRO VAGLIVIELLO – PRESIDENTE
LUOGO PRESSO CUI E’ CUSTODITO IL FASCICOLO:

PLACE AT WHICH THE FILE CLOSED
VIA TICINO 2/4 – 21043
CASTIGLIONE OLONA– VA
ITALIA
APPROVATO DA:
Approved by PIETRO VAGLIVIELLO – PRESIDENTE
DATA 12/10/2017
3 Rev.02
IDENTIFICATION CODE sigla di identificazione
P07 P - PP H - HYTREL T - PTFE T - PTFE P - PP D - EPDM 1 - BSP THREATED X

A - ALUMINUM M- SANTOPRENE S-SS AISI 316 K- PVDF V - FPM 2 - FLANGED
P18 S - SS AISI 316 D - EPDM D - EPDM S - SS AISI 316 T - PTFE 3 - CLAMP
P30 O - POM N - NBR N - NBR A - ALUMINUM N - NBR 4 - TWIN CONNECTION
KC- PVDF+CF Z - PE-UHMW 5 - NPT THREATED
P50
PC - PP+CF
P65
P100
P101
P160
P250
P400
P500
P700
P1000

PF/SP18 S - AISI 316 H - HYTREL T - PTFE T - PTFE S - SS AISI 316 T - PTFE 1 - BSP THREATED X
PF: S-SS AISI 316 2 - FLANGED
PF/SP30 ELECTROPOLISCHED 3 - CLAMP
PF/SP50 SP:
MECCANICHALLYLLY
PF/SP100
POLISCHED
PF/SP160
PF/SP400
PF/SP500
PF/SP700
PF/SP1000
Each pump is supplied with the serial and model abbreviation and the serial number on the rating
plate, applied onto the support side. Check these data upon receiving the goods. Any discrepancy
between the order and the delivery must be communicated immediately. In order to be able to
trace data and information, the abbreviation, model and serial number of the pump must be
quoted in all correspondence.
Ogni pompa spedita è contrassegnata dalla sigla della serie, dal modello e dal numero di serie impressi sulla
targhetta di identificazione. Si prega di confermare i dati impressi quanto prima dal ricevimento della merce. Ogni
discrepanza tra l’ordine e le informazioni impresse sulla targhetta deve essere immediatamente comunicata. Al fine
di consentire la perfetta rintracciabilità dei dati e delle informazioni, ogni corrispondenza deve riportare la sigla, il
modello e il numero di serie della pompa in oggetto.
MODEL
modello
YEAR OF MANUFACTURE
Anno di fabbricazione
SERIAL No
Numero di serie
ATEX CERTIFICATION certificazione Atex
PHOENIX - PHOENIX FOOD - CERT. ZONE 2 II 3/3 GD c IIB T135°C
PHOENIX ATEX - PHOENIX FOOD ATEX - CERT. ZONE 2 II 2/2 GD c IIB T135°C
4 Rev.02
GENERAL NOTES
“PHOENIX” series pumps are air-operated, double-diaphragm positive-displacement pumps, designed and manufactured
for pumping fluids that are chemically compatible with the constructive materials of the pump. The characteristics of the
fluid (pressure, temperature, chemical reactivity, specific weight, viscosity, vapor pressure) and of the environment must
be compatible with the pump characteristics and are defined in the ordering phase. Fluimac is not responsible for the
pumped liquid. The customer must ensure that there is compatibility between the pumped liquids and pump materials.
“PHOENIX” series pumps are self-priming; at the start-up the pipes can be empty.
The declared dry negative suction is referred to intake of water at a temperature of 20°C/ 68°F. The priming time and
the diaphragm’s life depend on.
- the suction circuit (total length and diameter)
- specific weight of the pumped fluid
- viscosity of the pumped fluid
- negative suction: max 5.000 cps (at 18°C / 64,4°F)
- below head suction: max 50.000 cps (at 18°C / 64,4°F) “PHOENIX” series pumps may be used dry
“PHOENIX” series pumps cannot be used to generate a vacuum

Make sure that the physical-chemical characteristics of the fluid have been correctly evaluated.
The maximum temperature referred to water in continuous operation depends on the version of the materials
(indicated on the nameplate) and on the environment in which the pump will be installed:
The ambient temperature interval is related to the choice of materials

VERSION MAX TEMP. MAX TEMP.
(specified on the identification MAX ∆T (°C / °F)
VERSION
ATEX ZONE 2 ATEX ZONE 1 plate):
PP / PC 0÷40°C / 14÷104°F
PP / PC 60°C / 140°F 60°C / 140°F
PVDF+CF 0÷40°C / 14÷104°F

PVDF+CF 95°C / 203°F 80°C / 176°F
ALU 0÷40°C / 14÷104°F

ALU 95°C / 203°F 80°C / 176°F
SS 0÷40°C / 14÷104°F
SS 95°C / 203°F 80°C / 176°F
POMc 0÷40°C / 14÷104°F

POMc 95°C / 203°F 80°C / 176°F
The pump may be operated at a maximum pressure equal to 1.5 times the head value with closed delivery.
The value of the vapor pressure of the pumped fluid must be greater (of at least 3 mwc - meters of water column) than
the difference between the total absolute head value (pressure on suction level subtracted of the suction height) and
the leakages of the suction section.
The pumped fluid may contain particles suspended in different concentrations in accordance with the type of valve
assembled:
MODEL P07 P18 P30 P50/65/100/101 P160/250 P400 P500/700 P1000
MAX DIM.
mm. 10
2,5 3 3,5 3,5 7,5 8 8,5
37 Rev.02
NOTE GENERALI
Le pompe serie "PHOENIX" sono pompe pneumatiche volumetriche a doppia membrana, progettate e costruite per il
pompaggio di liquidi compatibili chimicamente con i materiali costruttivi della pompa. Le caratteristiche del liquido
(pressione, temperatura, reattività chimica, peso specifico, viscosità, tensione di vapore) e dell’ambiente devono essere
compatibili con le caratteristiche della pompa e sono definite in sede d’ordine. La Fluimac s.r.l non è responsabile dei
liquidi pompati. Il cliente deve assicurarsi che ci sia compatibilità tra i liquidi pompati e i materiali della pompa.
Le pompe serie “PHOENIX” sono autoadescanti, all’avviamento le tubazioni possono essere vuote
La capacità di aspirazione negativa a secco dichiarata è riferita al pescaggio di acqua a temperatura di 20°C/
68°F.
Il tempo di adescamento e la durata delle membrane dipende da:
- dal circuito di aspirazione (lunghezza totale e diametro)
- peso specifico del fluido pompato
- viscosità del fluido pompato:
- aspirazione negativa: max 5.000 cps (a 18°C / 64,4°F)
- aspirazione sotto battente: max 50.000 cps (a 18°C / 64,4°F)
Le pompe serie “PHOENIX” non possono essere usate per creare il vuoto
Assicurarsi che le caratteristiche fisico-chimiche del liquido siano state attentamente valutate.
La temperatura massima riferita ad acqua in funzionamento in continuo dipende dalla versione dei materiali
(riportata in targhetta) e dall’ ambiente in cui verrà installata la pompa:
VERSIONE MAX TEMP. MAX TEMP. L’intervallo di temperatura ambiente è in funzione della versione dei
ATEX ZONE 2 ATEX ZONE 1
materiali (riportata in targhetta):
PP / PC 60°C / 140°F 60°C / 140°F VERSIONE MAX ∆T (°C / °F)
PVDF+CF 95°C / 203°F 80°C / 176°F PP / PC 0÷40°C / 14÷104°F
ALU 95°C / 203°F 80°C / 176°F PVDF+CF 0÷40°C / 14÷104°F
SS 95°C / 203°F 80°C / 176°F ALU 0÷40°C / 14÷104°F
POMc 95°C / 203°F 80°C / 176°F SS 0÷40°C / 14÷104°F
POMc 0÷40°C / 14÷104°F
Il valore della tensione di vapore del liquido pompato deve essere superiore (di almeno 3 m c.a.) alla differenza tra il
battente totale assoluto (pressione sul livello in aspirazione sottratta dell’ altezza di aspirazione) e le perdite nel tratto di
aspirazione
Il liquido pompato può contenere solidi sospesi in misura diversa in relazione al tipo di valvola montata:
MODELLO P07 P18 P30 P50/65/100/101 P160/250 P400 P500/700 P1000
MAX DIM.
2,5 3 3,5 3,5 7,5 8 8,5 10
mm.
38 Rev.02
OPERATING PRINCIPLE principio di funzionamento
The pneumatic distribution system sends compressed air behind one of the two diaphragms (A), which
pushes the fluid towards the delivery circuit. Simultaneously, the opposite diaphragm (B) is in the intake
phase since it is dragged by the shaft that connects it to the other diaphragm (A) under pressure; air
present behind it is discharged into the environment through the flow rate regulator present on the
pump , while a pressure drop is created in the fluid chamber which sucks the fluid from the suction
circuit. When the diaphragm (A), under pressure, reaches the stroke limit, the distributor switches the
two inputs to the chamber on the diaphragms air side, putting diaphragm (B) under pressure and
diaphragm(A) in discharge. When the pump reaches its original starting point, each diaphragm has
carried out one air discharge stroke and one fluid delivery stroke. This sequence of movements makes
up a complete pumping cycle.
Il sistema di distribuzione pneumatico invia l’aria compressa dietro una delle due membrane(A), la quale spinge il fluido
verso il circuito di mandata. Contemporaneamente la membrana opposta(B) si trova in fase di aspirazione essendo
trascinata dall’albero che la collega all’altra membrana(A) sotto pressione; l’aria presente dietro di essa viene scaricata in
atmosfera attraverso il regolatore di prestazioni presente sulla pompa mentre nella camera del fluido si crea un
abbassamento di pressione che risucchia il fluido dal circuito di aspirazione. Quando la membrana(A), sotto pressione,
raggiunge il limite della corsa il distributore commuta i due ingressi alle camera lato aria delle membrane, mandando in
pressione la membrana(B) ed in scarico la membrana(A) Nel momento in cui la pompa raggiunge il suo punto di
partenza originale, ogni membrana ha compiuto una corsa di scarico aria e una di mandata liquido. Questa sequenza di
movimenti costituisce un ciclo di pompaggio completo.
PNEUMATIC CONNECTION connessione pneumatica
WARNING: the pneumatic supply of “PHOENIX” series pumps must be carried out with oil-free, filtered, dry and
unlubricated air Avoid pressure drops by using pipes and adjusting and controlling elements having characteristics suitable
for the pump In case of installation in atex zone, the compressor must suck air from outside the area classified as atex or
use inert gas.
ATTENZIONE: l’alimentazione pneumatica delle pompe serie “PHOENIX” deve essere eseguita con aria disoleata, filtrata, essiccata e
non lubrificata Evitare cadute di pressioni impiegando tubi ed elementi di regolazione e controllo con caratteristiche adeguate a
quelle della pompa In caso di installazione in zona ATEX il compressore deve aspirare aria esternamente alla zona classificata ATEX
ovvero utilizzare gas inerte
Minimum pressure supply 2 bar Maximum pressure supply 7 bar
1 – pressure regulator with gauge regolatore di pressione con manometro

2 - shut-off valve valvola di intercettazione
3 – way valve valvola a 3 vie
4 – flow regulator regolatore di flusso
MODEL Ø
P07 4 mm
P18/P30/P50 6 mm
P65/P100/P101 8 mm
P160/P250/400 10 mm
P500 12 mm
P700 14 mm
Maximum length between tube and pump plant: 5 m
Lunghezza massima tubo tra impianto aria e pompa: 5m
39 Rev.02
INSTALLATION AND USE INSTRUCTIONS
TRANSPORT
• cover the hydraulic connections
• lift the hydraulic plastic parts without mechanical stress
• for transport on irregular roads, cushion the bumps with suitable support plane
• blows and impacts may damage parts that are important for the machine operation and safety
STORAGE
• In case you need to get away for a period of time the pumps before installation, store in original boxes. The boxes
should be stored off the ground, in a closed, clean and dry.
• in the event that the packaging has not received any is intact, it will be necessary to free the pump from it-Checking
the integrity and restore a new packaging
• The storage place should be closed environment with a temperature not lower than -5 ° C, not more than 40 ° C
and with a moisture content not exceeding the value of 80%; any packaging must not be subjected to shocks, vibrations
and loads above you
INSTALLATION
• it is essential for the pump self-priming operation that the hydraulic system is leak-proof
• clean the system before connecting the pump
• the pump must not contain foreign bodies and all the seals on the hydraulic connections must be removed
• before starting the pump check the tightness of the screws of the pump bodies and manifolds
• the pump positioning is horizontal, the fluid delivery manifold must always be positioned in the upper part (see arrows on the pump casing)
• fastening may be on the floor or on the ceiling
• position the pump the closest possible to the point of collection
ISTRUZIONI INSTALLAZIONE E D’USO

TRASPORTO
• coprire le connessioni idrauliche
• sollevare senza sollecitare meccanicamente le parti idrauliche in plastica
• in caso di percorso accidentato, attutire i sobbalzi con piano di appoggio adeguato
• colpi ed urti possono danneggiare parti importanti per la funzionalità e la sicurezza della macchina
STOCCAGGIO
• nel caso sia necessario staccare per un periodo di tempo le pompe prima dell’installazione, conservarle nelle casse
originali. Le casse devono essere stoccate sollevate dal suolo, in un ambiente chiuso, pulito ed asciutto.
• nel caso che al ricevimento l’eventuale imballo non risulti integro, occorrerà liberare la pompa dall’imballo, verificar-
ne l’integrità e ripristinare un imballo nuovo
• il luogo di stoccaggio dev’essere un ambiente chiuso con temperatura non inferiore ai –5°C, non superiore ai 40°C
e con un tasso di umidità che non superi il valore di 80%; l’eventuale imballo non dev’essere sottoposto ad urti,
vibrazioni e carichi sovrastanti
INSTALLAZIONE
• è fondamentale per l’operazione di autoadescamento della pompa che l’impianto idraulico sia a perfetta tenuta
• pulire l’impianto prima di collegare la pompa
• la pompa non deve contenere corpi estranei e devono essere rimossi i sigilli sulle connessioni idrauliche
• prima di avviare la pompa verificare il serraggio delle viti dei corpi pompa e dei collettori
• il posizionamento della pompa è in orizzontale; il collettore di mandata del fluido deve essere posizionato sempre
nella parte superiore (vedi frecce su corpi pompa)
• il fissaggio può essere a pavimento o a soffitto
• posizionare la pompa più vicino possibile al punto di prelievo
40 Rev.02
use the plant solutions indicated in the following diagram:
1. YES: use flexible pipes reinforced with rigid spiral to connect the hydraulic circuit of the pump. Rigid piping may
cause strong vibrations and manifolds breaking. Do not use pipes with nominal diameter smaller than the
diameter of the pump connections. For negative installations and/or viscous fluids use pipes with greater
diameter related to the nominal diameter of the pump.
2. YES: pulse damper
3. YES: gate valve for delivery adjustment
4. YES: intake for gauge or protection pressure switch
5. YES: pipe anchoring
6. YES: shut-off valve
7. NO: air pockets; the circuit must be linear and short
8. YES: discharge duct around the base
11. Make it as short as possible the length of the horizontal S no vent for the air
12. Slope of the pipe to the pump
13. n the flow velocity of the fluid max. 3.5 m / s
• ensure drainage of fluids which may come out of the pump

• fix the pump using all the available locking holes, the support points must be levelled
• arrange for enough room around the pump for the movements of an operator
• arrange for free space above the pump for lifting it
• inform about the presence of aggressive fluid with suitable colored labels in accordance with the related standard
• do not install the pump (built with thermoplastic material) near heat sources
• do not install the pump in places with risk of fall of solids or fluids
• do not install the pump close to fixed workplaces or visited areas
• install additional protection shield, for the pump or for the persons as appropriate. If the diaphragm breaks the fluid
may
enter into the pneumatic circuit and come out from the pump discharge port
• install a spare equivalent pump connected in parallel
• the pump must be always electrically earthed
• if the pump is made from conductive materials and is suitable for flammable products, each pump casing must be
equipped
with a suitable ear thing cable: DANGER OF EXPLOSION AND/OR FIRE
• WARNING The pumps must always be grounded irrespective of any organ to which it is connected. Lack of
grounding or
incorrect grounding will cancel the requirements for safety and protection against the risk of explosion
• WARNING: the pump during operation is in PRESSURE, check appropriately report the hazardous conditions.
41 Rev.02
utilizzare le soluzioni impiantistiche indicate nel seguente schema:
1. SI: utilizzare tubi flessibili rinforzati con spirale rigida per collegare il circuito idraulico della pompa. Tubazioni
rigide possono provocare forti vibrazioni e la rottura dei collettori. Non utilizzare tubi con diametro nominale
inferiore a quello degli attacchi della pompa. Per installazioni negative e/o con fluidi viscosi impiegare tubi con
diametro maggiorato rispetto al diametro nominale della pompa
2. SI: smorzatore di pulsazioni
3. SI: saracinesca di regolazione sulla mandata
4. SI: presa per manometro o pressostato di protezione
5. SI: ancoraggio tubazioni
6. SI: valvola di intercettazione
7. NO: sacche d’aria; il circuito deve essere lineare e breve
8. SI: canale di scarico attorno al basamento
11. Rendere il più breve possibile la lunghezza S dei tratti orizzontali senza sfogo per l’aria
12. Pendenza della tubazione verso la pompa
13. In Mandata velocità del fluido max. 3,5 m/s
garantire il drenaggio di eventuali liquidi fuoriusciti dalla pompa

• fissare la pompa utilizzando tutti i fori di bloccaggio a disposizione; i punti di appoggio devono essere livellati
• lasciare libero lo spazio attorno alla pompa per i movimenti di una persona
• lasciare libero lo spazio sopra la pompa per il suo sollevamento
• avvisare della presenza di liquido aggressivo con adeguate targhette colorate secondo normativa specifica
• non installare la pompa (costruita in materiale termoplastico) vicino a fonti di calore
• non installare la pompa in luoghi con rischio di caduta di corpi solidi o liquidi
• non installare la pompa nelle immediate vicinanze di posti di lavoro fissi o zone frequentate
• installare schermo protettivo aggiuntivo, per la pompa o per le persone secondo il caso. Nel caso di rottura delle
membrane
il fluido può entrare nel circuito pneumatico ed uscire dallo scarico della pompa
• installare una pompa equivalente di scorta collegata in parallelo
• la pompa deve essere sempre elettricamente messa a terra
• se la pompa è di materiale conduttivo ed adatta al pompaggio di fluidi infiammabili bisogna installare un adeguato
cavetto di
messa a terra su ciascun corpo pompa: PERICOLO DI ESPLOSIONE E/O INCENDIO
• ATTENZIONE: la pompa deve essere sempre messa a terra indipendentemente da altri organi ad essa collegati. La
mancata o
scorretta messa a terra fa decadere i requisiti di sicurezza e tutela dal pericolo di esplosione.
• ATTENZIONE: la pompa durante il funzionamento è in PRESSIONE, segnalare opportunamente la condizione di
pericolo
42 Rev.02
START UP
• check the correct execution of what indicated in the INSTALLATION paragraph
• check that the intake and delivery pipes of the hydraulic circuit are correctly connected
• open the intake and delivery valves of the pump hydraulic circuit
• open the 3-way valve on the air circuit
• set the operation point requested for the pump: properly adjust the air pressure and delivery that supplies the pump.
With pressure values under 2 bar the pump may stall, with pressure values above 7 bar it is possible that breakdowns and/or
yields may
occur with consequent spillage of the pumped fluid
• for pumps with split manifold the two pumped fluids must have the same viscosity value, very different viscosity values may lead to
stall
problems and/or diaphragms breaking
• do not operate at the limits of the operation curves: the maximum head or maximum delivery (total absence of leaks and intake
height in
the delivery circuit)
• check that there are no anomalous vibrations or noise due to the too elastic support structure, unsuitable fastening or cavitation
• after 2 hours of operation stop the pump correctly and check the tightening of all the bolts on the pump
AVVIAMENTO
• verificare la corretta esecuzione di quanto indicato in INSTALLAZIONE
• verificare che i tubi di aspirazione e mandata del circuito idraulico siano correttamente collegati
• aprire le valvole in aspirazione e mandata del circuito idraulico della pompa
• aprire la valvola a 3 vie sul circuito aria
• Impostare il punto di funzionamento per il quale la pompa è stata richiesta: regolare opportunamente la pressione e la portata dell’
aria che
alimenta la pompa. Con pressioni inferiori ai 2 bar la pompa può andare installo, con pressioni superiori ai 7 bar si possono
verificare
rotture e/o cedimenti con conseguente fuoriuscita del fluido pompato
• Nel caso di pompe con collettore sdoppiato i due fluidi pompati devono avere viscosità dello stesso ordine di grandezza;
viscosità sensibilmente differenti possono portare a problemi di stallo e/o rottura delle membrane
• non operare agli estremi della curva di funzionamento: massima prevalenza o massima portata (totale assenza di perdite e di
altezza di
sollevamento nel circuito di mandata)
• constatare l’assenza di anomali vibrazioni o rumorosità dovute a struttura portante troppo elastica, inadeguato fissaggio o
cavitazione
• dopo 2 ore di funzionamento arrestare correttamente la pompa e verificare il serraggio di tutti i bulloni della pompa
USE
• do not operate valves or shunts during the pump operation
• Risk of harmful water hammers in case of incorrect or sudden operations (valves must be operated only by trained personnel)
• empty and wash accurately inside the pump in case different fluids must be pumped
• insulate or empty the pump if the fluid crystallization temperature is equal to or below the ambient temperature
• stop the pump if the fluid temperature exceeds the maximum allowed temperature indicated in the GENERAL NOTES;
if the exceeding temperature is about 20% it is necessary to inspect the status of the internal parts
• stop the pump and close the valves in case of leaks
• Wash with water only if chemical compatibility allows it ; alternatively use the suitable solvent that does not generate hazardous
exothermic
reactions
• consult the fluid supplier to decide the most suitable fire-prevention method
• Empty the pump in case of long periods of disuse (particularly with fluids which are particularly tending to crystallize)
• check that there is no gas in the delivering fluid, if there is stop the pump
UTILIZZO
• non azionare valvole o derivazioni durante il funzionamento della pompa
• rischi di dannosi colpi d’ariete in caso di errate o improvvise manovre (azionamento valvole solo da personale ad- destrato)
• svuotare e lavare accuratamente l’interno pompa in caso di pompaggio di liquidi diversi
• isolare o svuotare la pompa se la temperatura di cristallizzazione del liquido risulta uguale o inferiore alla temperatura ambiente
• fermare la pompa se la temperatura del liquido supera la temperatura massima consentita indicata nelle NOTE GENERALI;
se l’aumento è dell’ordine del 20 % è necessario ispezionare lo stato delle parti interne
• arrestare la pompa e chiudere le valvole in caso di perdite
• lavare con acqua solo se la compatibilità chimica lo consente; in alternativa utilizzare il solvente appropriato che non generi
reazioni
esotermiche pericolose
• contattare il fornitore del liquido per stabilire il più appropriato metodo anti-incendio
• svuotare la pompa in caso di lunghi periodi di non utilizzo (in particolare con liquidi con forte tendenza a cristallizzare)
• controllare che nel fluido in mandata non sia presente gas, in tal caso arrestare la pompa
STOP
To stop the pump, operate exclusively on the air supply closing the 3-way valve, discharging in this way residual pressure from the
pneumatic system of the pump.
WARNING never stop the pump by totally closing the suction and/or delivery valves of the hydraulic circuit
WARNING is prohibited to stop the pump by means of the complete closure of the valves in the suction and / or discharge of the
hydraulic circuit
ARRESTO
Per arrestare la pompa agire esclusivamente sull’ alimentazione dell’aria chiudendo la valvola a 3 vie, scaricando così la pressione
residua dell’ impianto pneumatico della pompa
ATTENZIONE è vietato arrestare la pompa mediante la chiusura completa delle valvole in aspirazione e/o mandata del circuito
idraulico.
43 Rev.02
MAINTENANCE
- do not carry out maintenance and/or repairs with the air circuit under pressure
- carry out periodic inspections (2 ÷ 30 days in accordance with the fluid pumped) to check the filtering elements cleaning
- carry out periodic inspections (3 ÷ 5 months in accordance with the fluid pumped and with the environment conditions)
to ensure the correct operation of the system start/stop units
- the presence of fluid under the pump casing may indicate failures to the pump
- damaged parts must be replaced with complete original parts and not with repaired parts
- the replacement of damaged parts must be carried out in a clean and dry place
RECOMMENDATIONS
WARNING: before performing any maintenance or repair work on the pump, disconnect the pump from the air supply line.
Disconnect the hydraulic connections and discharge the product that is being pumped
- use gloves, goggles and acid-resistant clothing when disconnecting from the system and washing the pump
- wash the pump before carrying out maintenance operations
- do not disperse the washing waste into the environment
DISASSEMBLY
- Bolts are the type with right thread
- Clean all the pump external surfaces using a damp cloth Ball seats removal (for all models)
- Pull off the seats, the balls and the related cages
- Check the condition of the gasket
Diaphragms removal
PHOENIX 07-18-30-50-65-100-101-160-250-500-700-1000
- Remove the deposits from the internal surfaces
- Remove the two pump casings
- Remove the plates that lock the diaphragms
- Remove the diaphragms and the related backing plates
- If it would be necessary to disassemble the shaft, remove one of the two diaphragms on air side and then pull off the shaft
Pneumatic distributor removal

- slip off the pneumatic exchanger cap and the spool (if necessary use a M6 screw for slip off the spool)
PHOENIX 07-18-30-50
- remove the manifolds, pump casing and diaphragms
- remove the bolts (pos.22) and divide the semi-central casing
PHOENIX 65-100-101-160-250-500-700-1000
- Remove the Seeger ring of the transverse sleeve of the central casing
- Overturn the pump and with the aid of a Ø6 mm punch and a press, pull off the distributor (this operation may be carried
out with pump casings assembled, check that the tightening bolts of the pump casings located on the upper area of the
distributor to not obstacle the distributor removal)
- WARNING the pneumatic distributor shall not be opened to prevent an incorrect reassembling that may cause the pump
malfunctioning
INSPECTION
Check the absence of:
• excessive abrasion of the thermoplastic parts
• clots and/or agglomerates due to the pumped fluid
• deformations and/or surface lesions of the diaphragms
• deformations and/or breakages on the valve seats
Replace the parts: broken, cracked, deformed.
Reopen all the clogged ducts and eliminate any chemical agglomerates.
Clean all the surfaces before reassembly, particularly the OR gaskets seats (risk of leaks for dripping).
CLEANING AND REPLACING THE DIAPHRAGMS

 control and internal cleaning every 500.000 cycles
 diaphragm check every 5.000.000 cycles
 diaphragm replacement every 20.000.000 cycles
44 Rev.02
MANUTENZIONE
- non effettuare manutenzione e/o riparazioni con il circuito aria in pressione
- effettuare ispezioni periodiche (2 ÷ 30 giorni in funzione del liquido convogliato) di pulizia sugli elementi filtranti
- Effettuare ispezioni periodiche (3 ÷ 5 mesi in funzione del liquido convogliato e delle condizioni ambientali) sulla funzionalità
degli organi di consenso/arresto dell’impianto; garantirne l’efficienza
- la presenza di liquido sotto il corpo pompa può essere indizio di guasti alla pompa
- le parti danneggiate devono essere sostituite con parti originali integre e non riparate
- la sostituzione di parti danneggiate deve essere effettuata in ambiente pulito e asciutto
RACCOMANDAZIONI
ATTENZIONE: prima di intervenire sulla pompa per qualsiasi intervento di manutenzione o riparazione, scollegare dalla
pompa la linea aria di alimentazione. Staccare le connessioni idrauliche e scaricare il prodotto che si sta pompando
- utilizzare guanti, occhiali ed indumenti antiacido in fase di scollegamento dall’impianto e lavando la pompa
- lavare la pompa prima di effettuare operazioni di manutenzione
- non disperdere nell’ambiente lo scarico di lavaggio dei corpi
SMONTAGGIO
- La bulloneria è del tipo a filetto destro
- Provvedere alla pulizia esterna di tutte le superfici della pompa con un panno umido
RIMOZIONE SEDI SFERA (valido per tutti i modelli)

- Estrarre le sedi, le sfere e le relative gabbie
- Verificare lo stato delle guarnizioni
Modelli 07-18-30-50-65-100-101-160-250-500-700-1000
- Rimuovere eventuali depositi dalle superfici interne
- Rimuovere i due corpi pompa
- Rimuovere i piattelli che bloccano le membrane
- rimuovere le membrane e relativi piattelli di spallamento
RIMOZIONE DEL DISTRIBUTORE PNEUMATICO

- ruotare di circa 90°il tappo del distributore (pos.36)
- sfilare il tappo e successivamente la spola (se necessario aiutarsi con una vite M6) Modelli 07-18-30-50
- per accedere al distributore occorre avere rimosso collettori, corpi pompanti e membrane
- rimuovere i bulloni di bloccaggio dei 2 semi corpi e separarli
Modelli 65-100-101-160-250-500-700-1000
- Rimuovere la vite di bloccaggio posizionata nella parte inferiore del canotto trasversale del corpo centrale
- Ribaltare la pompa ed aiutandosi con un punzone da Ø6 mm ed una pressa sfilare il distributore (l’ operazione può essere
effettuato con i corpi pompa montati, controllare che i bulloni di serraggio dei corpi pompa presenti nella zona superiore del
distributore non creino ostacolo all’ estrazione del distributore stesso
- ATTENZIONE il distributore pneumatico non deve essere aperto per evitare un non corretto RI assemblaggio che può
causare il malfunzionamento della pompa
ISPEZIONE
Verificare l’assenza di:
• eccessiva abrasione delle parti in materiale termoplastico
• grumi e/o agglomerati dovuti al liquido pompato
• deformazioni e/o lesioni superficiali delle membrane
• deformazioni e/o rotture sulle sedi valvola
Sostituire le parti: rotte, fessurate, deformate.
Riaprire tutti i condotti occlusi ed eliminare gli eventuali agglomerati chimici.
Pulire tutte le superfici prima del rimontaggio, in particolare le sedi di guarnizioni OR (rischio di perdite per gocciola- mento).
PULIZIA E SOSTITUZIONE DELLE MEMBRANE

• verifica e pulizia interna ogni 500.000 cicli
• verifica usura delle membrane ogni 5.000.000 cicli
• sostituzione delle membrane ogni 20.000.000 cicli
45 Rev.02
SAFETY RISKS
WARNING! CHEMICAL RISK. Pumps are intended for operation with different types of fluids and chemical solutions. Follow the specific internal
instructions for decontamination during the inspection or maintenance operations.
WARNING! ELECTRICAL RISK. The pump must always be earthed independently to other members connected to it. Safety requirements and
explosion risk prevention are not fulfilled if the pump is not earthed or is incorrectly earthed.
WARNING: the diaphragms (into contact with the product and external) are components extremely subject to wear. Their duration is
strongly affected by the conditions of employments and by chemical and physical stresses. By tests carried out on thousands of pumps
installed with head value from 0° to 18°C, the ordinary life exceeds
one hundred million cycles. For safety reasons, in environments with explosion risk it is necessary to disassemble and check the
diaphragms every five million cycles and to replace them every twenty million cycles.
WARNING! In the case of diaphragms total breaking, the fluid may enter in the pneumatic circuit, damage it and come out from the
discharge port. Therefore it is necessary to convey the air discharge in
a piping up to a safe area.
WARNING! In situations where the user foresees the possibility of exceeding the temperature limits indicated in this manual, it is
necessary to install a protection device on the equipment that prevents to achieve the maximum operating temperature allowed. If
exceeded, respect to the maximum marking temperature is not guaranteed.
REMEMBER! Safety risks to persons are mainly caused by improper use or accidental damage.
These risks may be of hand injury for operators working on the open pump, or caused by the nature of the fluids that are conveyed by this type of
pump. Therefore it is extremely important to diligently carry out all
the instructions contained in this manual in order to eliminate the causes of accidents that may lead to the pump failure and to the subsequent
outcome of fluid hazardous to persons and to the environment.
For installation and use in a potentially explosive environment, comply with these general precautions:
• ascertain that the pump is full and if possible, that the level is above it by 0.5 m
• ascertain that the fluid treated does not contain or cannot contain large solids or solids of a dangerous shape
• ensure that the intake or delivery ports are not obstructed nor limited to avoid cavitation or pneumatic motor strain;
• also ascertain that the connection piping is strong enough and cannot be deformed by the pump weight or by the intake. Also check that
the pump is not burdened by the weight of the piping.
• if the pump is to stay in disuse for a long period of time, clean it carefully by running a non-flammable liquid detergent through it that is
compatible with the pump’s construction materials;
• if the pump was turned off for a long period of time, circulate clean water it in for some minutes to avoid incrustations
• before starting, after long periods of disuse, clean the internal and external surfaces with a damp cloth, check the grounding ATEX ZONE ;
• always protect the pump against possible collisions caused by moving objects or by various blunt materials that may damage it or react with
its materials;
• protect the pump’s surrounding ambient from splashes caused by accidental pump failure;
WARNING: the air supply pressure must never be over 7 bar or below 2 bar.
WARNING: when using the pump with aggressive or toxic liquids or with liquids that may represent a health hazard you must install suitable
protection on the pump to contain, collect and signal any spills: DANGER OF POLLUTION, CON- TAMINATION, INJURIES AND/OR DEATH.
WARNING: the pump must not be used with fluids that are not compatible with its construction materials or in a place containing incompatible
fluids.
CAUTION: installing the pumps without on-off valves on the intake and delivery sides to intercept the product in case of spillage is forbidden: danger
of uncontrolled product spillage.
CAUTION: installing the pumps without on-off, three-way or check valves on the air supply piping to prevent the pumped liquid from entering the
pneumatic circuit if the diaphragms are broken is forbidden: danger of fluid entering the compressed air circuit and being discharged into the
environment.
WARNING: Should the user think that the temperature limits set forth in this manual may be exceeded during service, a protective device must be
installed on the system to prevent the maximum allowed process temperature from being reached. If exceeded, respect of the maximum temperature
marked cannot be guaranteed.
WARNING: The pumps must always be grounded irrespective of any organ to which they are connected. Lack of grounding or incorrect grounding
will cancel the requirements for safety and protection against the risk of
WARNING: the use of pumps made with non-conductive material, which become charged with static, and without suitable grounding for flammable
liquids is forbidden: RISK OF EXPLOSIONS DUE TO STATIC CHARGE.
CAUTION: Aggressive, toxic or dangerous liquids may cause serious injuries or damage to health, therefore it is forbidden to return a pump
containing such Products to the manufacturer or to a service center. You must empty the internal circuits from the product first and wash and treat
it.
CAUTION: Pumps containing aluminium parts or components coming into contact with the product cannot be used to pump III-trichloroethane,
methylene chloride or solvents based on other halogenated hydrocarbons: DANGER OF AN EXPLOSION CAUSED BY A CHEMICAL REACTION.
CAUTION: The pumps PHOENIX cannot pump Acetylene, Hydrogen, Carbon disulfide
CAUTION: The components of the pneumatic exchanger, including the shaft are made from materials that are not specifically resistant to chemical
products. If the diaphragm should break, replace these elements completely if they have come into contact with the product.
CAUTION: The air-driven motor of the PHOENIX pumps is self-lubricating and will not require any greasing. Therefore avoid using lubricated and
non-dried air.
WARNING: ascertain that during service no anomalous noise appears. In that case, stop the pump immediately. WARNING: ascertain that the fluid
at the delivery side does not contain gas. Otherwise stop the pump immediately.
WARNING: the diaphragms (in contact with the product or the external ones) are highly subject to wear. Their duration is strongly affected by the
conditions of use and by chemical and physical stress. Fields tests carried out on thousands of pumps with a head value from 0° to 18° C have shown
that normal service life exceeds one hundred million cycles. However, in places at risk of explosion, the diaphragm must be disassembled and checked
every 5 million cycles and replaced every 20 million cycles.
WARNING: Periodic controls must be made to ensure that there is no powder and/or deposits on the external and internal surfaces of the pump
and, if necessary, they must be cleaned with a damp cloth.
WARNING: removal of the silencer and the air supply fitting must be done when free from powder. Before restarting the pump, ensure that no
powder has entered the pneumatic distributor.
WARNING : Protect always the site and the persons from accidental failure by installing a protection guard to old and collect any
product leakage. Danger of serious injuries and damage to health and/or objects.
To replace worn parts, use only original spare parts.

Failure to comply with the above may give rise to risks for the operator, the technicians, the persons, the pump and/or
the environment that cannot be ascribed to the manufacturer.
46 Rev.02
PRESCRIZIONI PER LA SICUREZZA
ATTENZIONE! RISCHIO DI NATURA CHIMICA. Le pompe sono destinate al funzionamento con diverse tipologie di liquidi e soluzioni chimiche.
Seguire le specifiche istruzioni interne per la decontaminazione durante le operazioni di ispezione o manutenzione.
ATTENZIONE! RISCHIO DI NATURA ELETTRICO. La pompa deve essere sempre messa a terra indipendentemente da altro organo ad essa
collegato. La mancanza di messa a terra o non corretta messa a terra fa decadere i requisiti di sicurezza e tutela dal pericolo di esplosione.
ATTENZIONE: le membrane (a contatto con il prodotto ed esterne) sono componenti altamente soggetti ad usura. La loro durata è
fortemente influenzata dalle condizioni di impiego e dalle sollecitazioni chimiche e fisiche. Da test eseguiti su migliaia di pompe installate
con prevalenza pari a 0°a 18°C, la durata normale supera i cento milioni di cicli. Per motivi di sicurezza, negli ambienti con pericolo di
esplosione bisogna eseguire lo smontaggio e la verifica della membrana ogni cinque milioni di cicli e la loro sostituzione ogni venti milioni di
cicli.
ATTENZIONE! Nel caso di rottura totale delle membrane, il fluido può entrare nel circuito pneumatico, danneggiarlo ed uscire dallo
scarico. Pertanto bisogna convogliare lo scarico dell’aria in una tubazione fino ad una zona sicura.
ATTENZIONE! laddove l’utilizzatore preveda il rischio di superamento dei limiti di temperatura previsti dal presente manuale, è necessario
installare sull’impianto un dispositivo di protezione che impedisca il raggiungimento della temperatura massima ammessa di processo. In
caso di superamento non è garantito il rispetto della massima temperatura di marcatura.
RICORDA! I rischi per la sicurezza delle persone nascono principalmente per uso improprio o in caso di danni accidentali. Tali rischi
possono essere di ferimento alle mani per chi opera sulla pompa aperta, oppure sono dovuti alla natura dei liquidi che vengono convogliati
da questo genere di pompe. E’ quindi di estrema importanza eseguire diligentemente tutte le istruzioni contenute in questo manuale al fine
di eliminare le cause di incidenti che possano portare alla rottura della pompa ed alla conseguente fuoriuscita di liquido pericoloso per le
persone e per l’ambiente.
Per l’installazione e l’impiego in ambiente potenzialmente esplosivo e non, rispettare le seguenti precauzioni generali:
- controllare che la pompa sia piena e il livello sia, possibilmente, al disopra di essa di 0,5m
- controllare che nel fluido trattato non vi siano o vi possano essere parti solide di dimensioni elevate o forma dannosa non ci siano
restrizioni nell’ingresso o nell’uscita della pompa per evitare fenomeni rispettivamente di cavitazione e sforzo del motore pneumatico
- controllare che le tubazioni di collegamento siano sufficientemente resistenti e che non possano deformarsi sotto il peso della pompa e
dell’aspirazione, né che la pompa subisca il peso delle tubazioni
- se la pompa deve rimanere inattiva per lunghi periodi, pulirla accuratamente facendo circolare un fluido detergente non infiammabile
compatibile con i materiali della pompa.
- se la pompa è stata spenta per lunghi periodi è opportuno far circolare acqua pulita per alcuni minuti per evitare il rischio di incrostazioni
- prima dell’avviamento, dopo lunghi periodi di sosta, effettuare la pulizia delle superfici interne ed esterne con un panno umido, controllare
la messa a terra per ZONE ATEX .
- proteggere sempre la pompa da possibili urti provocati accidentalmente da mezzi in movimento o materiali vari contundenti che possono
danneggiarla e/o reagire al contatto.
- proteggere sempre l’ambiente circostante la pompa da spruzzi provenienti da guasti accidentali alla pompa
ATTENZIONE: l’alimentazione dell’aria non deve mai risultare superiore a 7bar o inferiore a 2 bar
ATTENZIONE: Per tutti i fluidi pompati, soprattutto fluidi aggressivi, tossici o pericolosi per la salute bisogna installare sulla pompa un’adeguata
protezione per il contenimento e la raccolta e segnalazione del prodotto in caso di fuoriuscita: PERICOLO DI INQUINAMENTO,
CONTAMINAZIONE, LESIONI E/O MORTE.
ATTENZIONE: è vietato l’uso della pompa con fluidi non compatibili con i materiali dei componenti o in ambiente con presenza di fluidi non
compatibili.
ATTENZIONE: è vietata l’installazione della pompa in assenza di valvole per l’intercettazione del prodotto sull’aspirazione e sulla mandata per
eseguire il Sezionamento in caso di perdita: pericolo di fuoriuscita incontrollata del prodotto.
ATTENZIONE: è vietata l’installazione della pompa in assenza di valvola di intercettazione, valvola a 3 vie e valvola di non ritorno sul condotto di
alimentazione dell’aria per impedire che il fluido pompato entri nel circuito pneumatico in caso di rottura delle membrane: pericolo di immissione del
fluido nel circuito dell’aria compressa e scarico in ambiente
ATTENZIONE: laddove l’utilizzatore preveda il rischio di superamento dei limiti di temperatura previsti dal presente manuale, è necessario installare
sull’impianto un dispositivo di protezione che impedisca il raggiungimento della temperatura massima ammessa di processo. In caso di superamento
non è garantito il rispetto della massima temperatura di marcatura.
ATTENZIONE: la pompa deve essere sempre messa a terra indipendentemente da altro organo ad essa collegato. La mancanza di messa a terra o
non corretta messa a terra fa decadere i requisiti di sicurezza e tutela dal pericolo di esplosione.
ATTENZIONE: è vietato l’impiego per liquidi infiammabili della pompa in materiale non conduttivo, che si carica statica- mente e senza un’adeguata
messa a terra: PERICOLO DI ESPLOSIONI A CAUSA DI CARICHE STATICHE.
ATTENZIONE: fluidi aggressivi, tossici o pericolosi possono causare gravi lesioni fisiche e/o alla salute pertanto è vieta- to restituire al produttore o
ad un centro di servizio una pompa che contenga prodotti di tale specie: Svuotare e lavare il circuito interno del prodotto e provvedere al lavaggio e
trattamento prima di rispedire la pompa.
ATTENZIONE: i modelli di pompe che contengono componenti o parti in alluminio a contatto con il prodotto non possono essere impiegate per il
pompaggio di III-tricloroetano, il cloro metilene o solventi a base di altri idrocarburi alogenati: PERICOLO DI ESPLOSIONE PER REAZIONE
CHIMICA.
ATTENZIONE: le pompe della serie PHOENIX non possono pompare acetilene, idrogeno e solfuro di carbonio
ATTENZIONE: i componenti dello scambiatore pneumatico, albero compreso, sono costruiti con materiali non specificamente resistenti ai prodotti
chimici. In caso di rottura delle membrane, se vengono a contatto con il fluido, provvedere alla loro completa sostituzione.
ATTENZIONE: il motore pneumatico delle pompe PHOENIX è autolubrificante e non necessita di ulteriore lubrificante;
pertanto evitare l’impiego di aria lubrificata e non essiccata.
ATTENZIONE: verificare che durante il funzionamento non si verifichi rumorosità anomala. In tal caso bloccare immediatamente la pompa.
ATTENZIONE: controllare che nel fluido in uscita non sia presente gas, in tal caso bloccare immediatamente la pompa.
ATTENZIONE: le membrane (a contatto con il prodotto ed esterne) sono componenti altamente soggetti ad usura. La loro durata è fortemente
influenzata dalle condizioni di impiego e dalle sollecitazioni chimiche e fisiche. Da test eseguiti su migliaia di pompe installate con prevalenza pari a 0°a
18°C, la durata normale supera i cento milioni di cicli. Per motivi di sicurezza, negli ambienti con pericolo di esplosione bisogna eseguire lo
smontaggio e la verifica della membrana ogni cinque milioni di cicli e la loro sostituzione ogni venti milioni di cicli.
ATTENZIONE: Bisogna verificare periodicamente l’assenza di polveri e/o depositi dalle superfici esterne ed interne della pompa e, se necessario,
effettuare la pulizia con un panno umido.
ATTENZIONE: lo smontaggio del silenziatore e del raccordo di alimentazione dell’aria deve essere effettuato in assenza di polvere. Prima di riavviare
la pompa assicurarsi che non sia entrata polvere all’interno del distributore pneumatico.
ATTENZIONE: Proteggere sempre l’ambiente e le persone installando una protezione, in caso di
rottura accidentale della pompa, per il contenimento e la raccolta in caso di fuoriuscita del prodotto.
Pericolo di gravi danni fisici, alla salute e/o cose
Per la sostituzione di parti usurate impiegare unicamente pezzi di ricambio originali.
L’inosservanza di quanto sopra può far insorgere pericoli per l’operatore, i tecnici, le persone, la pompa e/o l’ambiente
non imputabili al costruttore.
47 Rev.02
However five general elements are important:
A- all the operations must be carried out by skilled personnel or monitored by qualified personal as appropriate
B- implement personal protection works (when the pump is installed in places involving more than occasional visits) against splashes of fluorescent fluid for
accidental breakage and conveying works
(always) of possible fluid leakages towards collection tanks
C- wear acid-resistant clothing and protection whenever operating on the pump
D- make sure that the Intake and delivery valves are correctly closed during the disassembly
E- make sure that there is no supply to the pneumatic circuit during the disassembly
It should be noted that it is very important to realize systems with pipes well arranged, identifiable, suitably equipped with shut-off valves, with comfortable
compartments and passages for operators who must inspect their status (since the pressure developed by the pump may promote failures to the system if it is
of defective construction or worn).
In ogni caso cinque elementi generali sono importanti:

A- tutte le operazioni devono essere effettuate o da personale specializzato o supervisionate da personale qualificato secondo i casi
B- realizzare opere di protezione per le persone (quando la pompa è installata in luoghi non saltuariamente
frequentati) verso eventuali getti di liquido fuoriuscente per rotture accidentali e opere di convogliamento
(sempre) di eventuali perdite di liquido verso vasche di raccolta
C- indossare indumenti e protezioni antiacido ogniqualvolta si operi sulla pompa
D- garantire la condizione di chiusura delle valvole su Aspirazione e Mandata in fase di smontaggio
E- garantire la condizione di assenza di alimentazione al circuito pneumatico in fase di smontaggio
OPERATORS FOR INSTALLATION AND START-UP

interventions to be carried out only by skilled personnel who may delegate to others some operations in accordance with
specific evaluations (required technical skills: plumbing, pneumatic and/or electric qualification as appropriate)
OPERAZIONI PER L'INSTALLAZIONE E AVVIAMENTO
gli interventi devono essere eseguiti solo da personale specializzato che può delegare ad altri alcune operazioni in conformità
valutazioni specifiche (richieste competenze tecniche: idraulici, pneumatici e / o qualifica elettrica a seconda dei casi)
OPERATORS FOR USE AND MAINTENANCE

interventions to be carried out by generic operators (after being instructed on the correct use of the equipment):
- pump start-up/stop
- valves opening / closing with stopped pump
- casing emptying and washing by means of the prearranged valves and pipes
- filtering elements cleaning interventions to be carried out by skilled personnel (required technical skills: general knowledge of
the mechanical, electrical, chemical aspects of the equipment supplied by the pump and of the pump itself):
- environmental conditions check
- pumped fluid conditions check
- inspections of start-up/stop devices
- detection of malfunctions
OPERAZIONI PER L’UTILIZZAZlONE E LA MANUTENZIONE
interventi alla portata di operatori generici (dopo istruzione sul corretto uso dell’impianto):
- avviamento / arresto pompa
- apertura / chiusura valvole a pompa ferma
- svuotamento e lavaggio corpo tramite valvole e tubazioni predisposte
- pulizia elementi filtranti interventi da personale qualificato (capacità tecniche richieste: conoscenza generale degli aspetti meccanici, elettrici, chimici
dell’impianto alimentato dalla pompa e della pompa stessa):
- verifica condizioni ambientali
- verifica condizioni del liquido pompato
- ispezioni sulle apparecchiature di consenso/arresto
- rilevazione anomalie di funzionamento
OPERATORS FOR REPAIR

work to be carried out by generic operators supervised by skilled personnel:
- pump stop
- valves closing
- emptying of pump casing
- pipes disconnection from the connections
- unlocking of fastening screws to the base
- washing with water or suitable solvent as appropriate
- transport
Work to be carried out by skilled personnel (required technical skills: notions of mechanical processing, sensitivity with regard to damage to parts for impacts
or abrasions during handling, familiar to tighten bolts on different plastic/metal materials, use of precision measuring instruments):
- casing opening and reclosing
- removal and replacement of damaged parts
OPERAZIONI PER LA RIPARAZIONE
interventi alla portata di operatore generici con supervisione di personale qualificato:
- arresto pompa
- chiusura valvole
- svuotamento corpo pompa
- sconnessione tubazione dagli attacchi
- sbloccaggio viti di fissaggio al basamento
- lavaggio con acqua o adeguato solvente secondo il caso
- trasporto
interventi da personale qualificato (capacità tecnica richiesta: nozioni di lavorazione meccanica, sensibilità riguardo a danni alle parti per urti o abrasioni durante
la manipolazione, dimestichezza al serraggio di bulloneria su differenti materiali plastica/metallo, uso di strumenti di misura di precisione):
- apertura e richiusura corpo
- rimozione e sostituzione parti danneggiate
DISPOSAL
For type of material: separate plastic parts from metal parts and dispose of by authorized companies.
SMALTIMENTO
Per tipologia di materiale: separare le parti in plastica dalle parti in metallo e smaltire tramite imprese autorizzate.
48 Rev.02
TROUBLESHOOTING AND POSSIBLE CAUSES
DEFECT CAUSE SUGGESTION
Circuit without air Check the circuit (valves, connections, regulators, etc.)
Insufficient air pressure Adjust the air pressure
Insufficient air flow rate Check that the pipes and fittings have suitable passages
Damaged control valve Replace
Damaged pneumatic distributor Replace
Open some valves, or remove the pipes and check if the
Pump delivery or intake closed pump starts
The pump does not
1 Damaged discharge cover Replace
start
Check if air comes out of the product delivery pipe, if yes
Broken diaphragm replace the diaphragm.
Excessive intake height. Reduce the intake height.
The pump works
butit does not Install pipes with greater size especially for intake and decre-
2 Too viscous fluid. ase the pumps cycles.
pump.
Clogged intake. Check and clean.
Excessively viscous fluid. No remedy.
The pump works Clogged delivery pipe. Check and clean.
3 with slow cycles Clogged intake. Check and clean.
Internal pneumatic exchanger clogged
or defective Replace the pneumatic exchanger.
Worn shaft. Replace the pneumatic exchanger.
Ice on the discharge. Dehumidify and filter air.
The pump works Check all the air control fittings, especially the quick cou-
4 Air volume is lacking. plings.
irregularly.
Internal exchanger dirty Replace.
Intake clogs during operation. Replace the intake pipe.
Dirty air, full of condensate or oil. Check the air line.
Check the pressure with a gauge installed on thepump and
with running pump. If pressurein that point is too low related
to the mains pressure, check all the air connections, especial-
ly the quick couplings Check that all the air control devices
Insufficient air volume or pressure. have a sufficient flow rate. WARNING: In 90% of the cases
5 The pump stalls stall conditions depends on the quick couplings.
Defective distributor. Replace it.
The stop procedure was not respected. Respect the stop procedure.
The product intake pipe is not correctly
connected. Check.
Clogged pipes. Check and clean.
Install pipes with greater size especially for intake and decre-
Too viscous fluid. ase the pumps cycles.
The pump does not Check pressure with a gauge installed on the pump and with
deliver the flow rate running pump. If pressure in that point is too low related to
6 indicated on the the mains pressure, check all the air connections, especially
table. the quick couplings. Check that all the air control devices have
Insufficient air volume. a sufficient flow rate. WARNING: In 90% of the cases stall
conditions depends on the quick couplings.
49 Rev.02
ANOMALIE DI FUNZIONAMENTO E POSSIBILI CAUSE
DIFETTO CAUSA SUGGERIMENTO
Circuito senza aria Controllare il circuito(rubinetti, allacciamenti, regolatori, ecc.)
Insufficiente pressione dell’aria Regolare la pressione dell’ aria
Insufficiente portata dell’aria Controllare che tubi ed accessori abbiano passaggi adeguati
Valvola di comando danneggiata Sostituire
Distributore pneumatico danneggiato Sostituire
Mandata o aspirazione della pompa Aprire eventuali valvole, oppure rimuovere le tubazioni e
chiuse verificare se la pompa parte
La pompa non si
1 Coperchio scarico danneggiato Sostituire
avvia
Controllare se esce aria dal tubo di mandata prodotto; nel
Membrana rotta caso sostituire la membrana.
Le sfere non chiudono. sedi.
Altezza di aspirazione troppo elevata. Ridurre l’altezza di aspirazione.
La pompa funziona Installare tubi maggiorati specie in aspirazione e diminuire i
2 Fluido troppo viscoso. cicli della pompa.
ma non pompa.
Aspirazione otturata. Controllare e pulire.
Fluido troppo viscoso. Nessun rimedio.
La pompa funziona Tubo di mandata otturato. Controllare e pulire.
3 con cicli lenti Aspirazione otturata. Controllare e pulire.
Scambiatore pneumatico interno
usurato o difettoso Sostituire lo scambiatore pneumatico.
Albero usurato. Sostituire lo scambiatore pneumatico.
Ghiaccio sullo scarico. Deumidificare e filtrare l’aria.
La pompa funziona Controllare tutti gli accessori di controllo aria, in particolar
4 Manca volume d’aria. modo gli innesti rapidi.
in modo irregolare.
Scambiatore interno sporco Sostituire.
L’aspirazione si ottura durante il
funzionamento.. Sostituire il tubo di aspirazione.
Aria sporca, piena di condensa o di olio.
Verificare la linea dell’aria.
Controllare la pressione con un manometro installato sulla-
troppo bassa rispetto alla pressione di rete, controllare tutti
gli attacchi dell’aria, specialmente quelli ad innesto rapido.
Volume o pressione d’aria insufficiente. Controllare che tutti i dispositivi di controllo aria abbiano
La pompa va in portata sufficiente. ATTENZIONE: Nel 90% i casi di stallo
5 stallo dipendono dagli innesti rapidi.
Distributore difettoso. Sostituirlo.
Non è stata rispettata la procedura di
arresto Rispettare la procedura di arresto.
Il tubo di aspirazione prodotto è mal
collegato. Controllare.
Tubazioni otturate. Controllare e pulire.
Installare tubi maggiorati specie in aspirazione e diminuire
Fluido troppo viscoso. I cicli della pompa.
Le sfere non chiudono. sedi..
Controllare la pressione con un manometro installato sulla
La pompa non eroga troppo bassa rispetto alla pressione di rete, controllare tutti
6 la portata di tabella. gli attacchi dell’aria, specialmente quelli ad innesto rapido.
Volume d’aria insufficiente. Controllare che tutti i dispositivi di controllo aria abbiano
portata sufficiente. ATTENZIONE: Nel 90% i casi di stallo
dipendono dagli innesti rapidi
50 Rev.02
51 Rev.02
Production head and legal office:
Via Ticino 2/4

21043 Castiglione Olona (Va)
ITALY
Tel: 0039 331.866688
Fax: 0039 331.864870
Web: www.fluimac.com
E-mail: info@fluimac.com
● The INSTRUCTION MANUAL must be delivered to the pump-user , who takes diligent note of it,
keeps the file for subsequent reference. Possible modifications
do not imply updating of the existing manuals
● MANUALE D’USO deve essere consegnato all’utilizzatore della pompa, il quale deve prenderne attenta
visione, e conservarlo per successive consultazioni. Eventuali modifiche non comportano
l’aggiornamento dei manuali preesistenti.
FLUIMAC srl Draw and text total or partial duplication is prohibited

FLUIMAC srl Vietata la duplicazione parziale o totale di testo e disegni
52 Rev.02
TSU Sol. valve Assy
(PAKER)
COILS & HOUSING
37mm Electrical Parts Availability

495905 Series - Explosion-Proof II 2 G-EEx dm IIC T4
Coil/housing assembly encapsulated in synthetic material (H class). Protection degree: IP67. Cable connection
through cable gland M20x1.5 (DIN 46320).
Voltage Power Reference Approvals Type of Protection Ambient Class of Dim.

Consumption Gas Dust Temperature insulation Drawing
24 DC 8W 495905C2 LCIE02 ATEX 6451 X II 2 G -Eex dm IIC T4 II 2D - +130°C -40 to +65 °C - 13
24/50 8W 495905A2 LCIE02 ATEX 6451 X II 2 G -Eex dm IIC T4 II 2D - +130°C -40 to +65 °C - 13
48/50 8W 495905A4 LCIE02 ATEX 6451 X II 2 G -Eex dm IIC T4 II 2D - +130°C -40 to +65 °C - 13
240/60 8W 495905B8 LCIE02 ATEX 6451 X II 2 G -Eex dm IIC T4 II 2D - +130°C -40 to +65 °C - 13
115/50 8W 495905E5 LCIE02 ATEX 6451 X II 2 G -Eex dm IIC T4 II 2D - +130°C -40 to +65 °C - 13
230/50 8W 495905F4 LCIE02 ATEX 6451 X II 2 G -Eex dm IIC T4 II 2D - +130°C -40 to +65 °C - 13
115/60 8W 495905K8 LCIE02 ATEX 6451 X II 2 G -Eex dm IIC T4 II 2D - +130°C -40 to +65 °C - 13
60
51.4
38
27
26.5 104
15
37
96.5
135
All dimensions are in mm Dimensional Drawing N° 13
39 Catalogue 8802/UK - Ed. February 2010
Subject to Change
aerospace
climate control
electromechanical
filtration
fluid and gas handling
hydraulics
pneumatic
process control
sealing & shielding
Solenoid Valves
ENGINEERING YOUR SUCCESS

Solenoide Valves
PRODUCTS OVERVIEW
General Purpose valve
121K/V/F Series 131K/V/F Series WV121S Series

122K Series 133K/V/F Series
2/2 Way valve 3/2 Way Valve 2/2 Way Valve
(Direct Operated ) (Direct Operated) (Direct Operated)
‣ Normally Closed, Normally Open ‣ Normally Closed, Universal ‣ Normally closed
‣ 7000 sleeve assembled ‣ 7000 sleeve assembled ‣ Body : Brass, StSt 303, Plastic
‣ Body : Brass, StSt 303 ‣ Body : Brass, StSt 303 ‣ Coil : S or H
‣ Coil : All of 7000 sleeve coil available ‣ Coil : All of 7000 sleeve coil available ‣ Operated on Zero MOPD
‣ Operated on Zero MOPD ‣ Operated on Zero MOPD ‣ Air, Water Inert gas, Oil, Corrosive fluid applicapable
‣ Air, Water Inert ga, Oil, Corrosive fluid and steam ‣ Air, Water Inert gas, Oil, Corrosive fluid and steam ‣ Applied Seal : FKM, NBR, Silicon
applicapable applicapable ‣ A miniature, High Performance
‣ Applied Seal : FKM, Ruby, Teflon and Factory consult ‣ Applied Seal : FKM, Ruby and Factory consult need for ‣ UL/CE approved for 'S' coil
need for NBR, EPDM NBR, EPDM
5 Page 9 Page 13 Page
WV131S Series 221G Series NKV Series
3/2 Way Valve 2/2 Way Valve 2/2 Way Valve

(Direct Operated) (Magnalift) (Magnalift)
‣ Normally Closed ‣ Normally closed ‣ Normally closed
‣ Body : Brass, StSt 303 ‣ Body : Brass ‣ Body : Brass
‣ Coil : S or WS ‣ 7000 sleeve assembled ‣ 7000 sleeve assembled
‣ Operated on Zero MOPD ‣ Coil : All of 7000 sleeve coil available ‣ Coil : All of 7000 sleeve coil available
‣ Air, Water Inert gas, Oil, Corrosive fluid applicapable ‣ Operated on nearly Zero MOPD ‣ Operated on nearly Zero MOPD
‣ Applied Seal : FKM, NBR ‣ Air, Water, Inert gas, Oil and Steam applicapable ‣ Air, Water, Inert gas, Oil and Steam applicapable
‣ A miniature, High Performance ‣ Applied Seal : FKM, NBR, EPDM ‣ Applied Seal : FKM, NBR, EPDM
‣ UL/CE approved for 'S' coil
Parker Korea Ltd.

CIC Group
www.parker.com
Catalog 0209/KOR
221S Series 321G Series 321K Series
2/2 Way Valve 2/2 Way Valve 2/2 Way Valve

(Magnalift) (Pilot Operated) (Pilot Operated)
‣ Normally closed ‣ Normally Closed ‣ Normally Closed
‣ Body : StSt 316 ‣ Body : Brass ‣ Body : Brass
‣ 7000 sleeve assembled ‣ 7000 sleeve assembled ‣ 7000 sleeve assembled
‣ Coil : All of 7000 sleeve coil available ‣ Coil : All of 7000 sleeve coil available ‣ Coil : All of 7000 sleeve coil available
‣ Operated on nearly Zero MOPD ‣ A minimum operating pressure is required ‣ A minimum operating pressure is required
‣ Oil, gase, Steam and corrosive fluid applicapable ‣ Air, Water and Steam applicapable ‣ Air, Water applicapable
‣ Applied Seal : FKM, EPDM and NBR with factory ‣ Applied Seal : NBR, EPDM and FKM with factory ‣ Anti-water hammer application
consult consult ‣ Applied Seal : FKM
E321H Series 708N Series

2/2 Way Valve 2/2 Way Valve
(Pilot Operated) (Pilot (Piston) Operated)
‣ Normally Closed ‣ Normally Closed
‣ Body : Brass ‣ Body : Brass
‣ 7000 sleeve assembled ‣ 7000 sleeve assembled
‣ Coil : All of 7000 sleeve coil available ‣ Coil : All of 7000 sleeve coil available
‣ A minimum operating pressure is required ‣ A minimum operating pressure is required
‣ Dry or Lubricated air, gases and water ‣ Steam applicapable in High pressure (8bar) and
‣ High pressure application temperature(180'c)
‣ Applied Seal : FKM, NBR ‣ Applied Seal : Teflon
27 Page 29 Page
Parker Korea Ltd.

CIC Group
www.parker.com
Blank Page
Parker Korea Ltd.

CIC Group
www.parker.com
Catalog 0209/KOR
Solenoid Valves 121K/122K Series
2/2 way Direct Operated
Model : 121K/V/F and 122K Series
121K 121V 121F
Features
● General Purpose Solenoid Valve
● 2-Way Direct lift
● Operated on Zero MOPD
● Air, Water, Inert gas, Oil, Corrosive fluid and Steam applicapable.
● Applied Seal : FKM, Ruby, Teflon and Factory consult need for NBR, EPDM
Application
● Oil burner and Boiler
● Welding machines
● Water treatment
● Fume analysers
● Gas analysers
● Distribution of light oils
● measurement and control instruments
● Lubrication system
Specifications
● Body - Brass : 121K/F, 122K
StSt 303 :121V
● Seal - FKM, Ruby, Teflon and Factory consult need for NBR, EPDM
● Sleeve - StSt 303, 7000
● Coil - Refer the Electrical part table on the last page
● Body thread type : NPT, PT available with factory consult
Parker Korea Ltd.

CIC Group
www.parker.com
Catalog 0209/KOR
Normally Cloased
PORT Body Maximum Power
VESSEL Flow Factor
Coil & Housing SIZE Orifice Operating Fluid Temp Seal Consumption
MODEL ( L/min )
(PF) Size Pre.( Kgf/cm2 ) disc (W)
NUMBER
Global Korea G Thread (mm) QN Kv DC AC Gas Liquid Oil DC AC
- I-1K 43 100 130 130 130 14 10
2995-481865 - 36 80 100 100 100 9 8
121KBG2ER00 1.2 50 0.85 RUBY
4270-481000 H-1F 43 100 130 130 130 8 8
4270-486265 H-1H 75 100 120 120 120 14 14
- I-1K 20 20 120 120 120 14 10
121KBG2GV00 2995-481865 - 1.5 80 1.5 20 20 100 100 100 FKM 9 8
4270-481000 H-1F 20 20 120 120 120 8 8
- I-1K 30 60 130 130 130 14 10
2995-481865 - 25 60 100 100 100 9 8
121KBG2GR00 1.5 80 1.5 RUBY
4270-481000 H-1F 30 75 130 130 130 8 8
4270-486265 H-1H 55 100 120 120 120 14 14
- I-1K 30 60 120 120 120 14 10
2995-481865 - 25 60 100 100 100 9 8
121KBG2GT00 1.5 80 1.5 PTFE
4270-481000 H-1F 30 70 120 120 120 8 8
4270-486265 H-1H 55 70 120 120 120 14 14
- I-1K 16 16 120 120 120 14 10
121KBG2JV00 2995-481865 2.0 140 2.5 12 16 100 100 100 FKM 9 8
- H-1F 16 16 120 120 120 8 8
- I-1K 18 40 130 130 130 14 10
2995-481865 - 15 40 100 100 100 9 8
121KBG2JR00 2.0 140 2.5 RUBY
4270-481000 H-1F 18 48 130 130 130 8 8
4270-486265 H-1H 32 70 120 120 120 14 14
- I-1K 12 28 120 120 120 14 10
2995-481865 - 10 28 100 100 100 9 8
121KBG2LT00 2.5 220 3.5 PTFE
4270-481000 H-1F 12 34 120 120 120
4270-486265 H-1H 22 50 120 120 120 8 8
- I-1K 9 14 120 120 120 14 10
2995-481865 - 7 14 100 100 100 9 8
121KBG2LV00 2.5 220 3.5 FKM
4270-481000 H-1F 9 14 120 120 120 8 8
4270-486265 H-1H 14 14 120 120 120 14 14
- I-1K 9 14 120 120 120 14 10
121KBG2LVM0 2995-481865 - 7 14 100 100 100 9 8
2.5 220 3.5 FKM
(Manual override) 4270-481000 H-1F 9 14 120 120 120 8 8
4270-486265 H-1H 14 14 120 120 120 14 14
- I-1K 12 28 130 130 130 14 10
2995-481865 - 10 28 100 100 100 9 8
121KBG2LR00 2.5 220 3.5 RUBY
4270-481000 H-1F 12 34 130 130 130 8 8
4270-486265 H-1H 22 50 120 120 120 14 14
- I-1K 8.5 10 120 120 120 14 10
2995-481865 - 7 10 100 100 100 9 8
121KBG2NV00 1/4" 3.0 315 4.5 FKM
4270-481000 H-1F 8.5 10 120 120 120 8 8
4270-486265 H-1H 10 10 120 120 120 14 14
- I-1K 8.5 10 120 120 120 14 10
121KBG2NVM0 2995-481865 - 7 10 100 100 100 9 8
3.0 315 4.5 FKM
(Manual override) 4270-481000 H-1F 8.5 10 120 120 120 8 8
4270-486265 H-1H 10 10 120 120 120 14 14
- I-1K 8.5 20 130 130 130 14 10
2995-481865 - 7 20 100 100 100 9 8
121KBG2NR00 3.0 315 4.5 RUBY
4270-481000 H-1F 8.5 25 130 130 130 8 8
4270-486265 H-1H 15 36 120 120 120 14 14
- I-1K 8.5 20 120 120 120 14 10
2995-481865 - 7 20 100 100 100 9 8
121KBG2NT00 3.0 315 4.5 PTFE
4270-481000 H-1F 8.5 25 120 120 120 8 8
4270-486265 H-1H 15 36 120 120 120 14 14
- I-1K 5 10 120 120 120 14 10
2995-481865 - 4 10 100 100 100 9 8
121KBG2QV00 4.0 480 7.5 FKM
4270-481000 H-1F 5 10 120 120 120 8 8
4270-486265 H-1H 10 10 120 120 120 14 14
- I-1K 5 10 120 120 120 14 10
121KBG2QVM0 2995-481865 - 4 10 100 100 100 9 8
4.0 480 7.5 FKM
(Manual Overide) 4270-481000 H-1F 5 10 120 120 120 8 8
4270-486265 H-1H 10 10 120 120 120 14 14
- I-1K 2.8 7 120 120 120 14 10
2995-481865 - 2 7 100 100 100 9 8
121KBG2SV00 5.0 750 11 FKM
4270-481000 H-1F 2.8 7 120 120 120 8 8
4270-486265 H-1H 5 7 120 120 120 14 14
- I-1K 2.8 7 120 120 120 14 10
121KBG2SVM0 2995-481865 - 2 7 100 100 100 9 8
5.0 750 11 FKM
(Manual Overide) 4270-481000 H-1F 2.8 7 120 120 120 8 8
4270-486265 H-1H 5 7 120 120 120 14 14
- I-1K 20 20 100 100 100 14 10
121VVG2GV00 2995-481865 - 1.5 80 1.5 20 20 120 120 120 FKM 9 8
4270-481000 H-1F 20 20 120 120 120 8 8
- I-1K 16 16 100 100 100 14 10
121VVG2JV00 2995-481865 2.0 140 2.5 12 16 100 100 100 FKM
- H-1F 16 16 120 120 120 8 8
- I-1K 9 14 120 120 120 14 10
2995-481865 - 7 14 100 100 100 9 8
121VVG2LV00 2.0 140 2.5 FKM
4270-481000 H-1F 9 14 120 120 120 8 8
4270-486265 H-1H 14 14 120 120 120 14 14
Parker Korea Ltd.

CIC Group
www.parker.com
Catalog 0209/KOR
Normally Cloased
VESSEL Flow Factor
Coil & Housing SIZE Orifice Operating Fluid Temp Seal Consumption
MODEL ( L/min )
NUMBER
- I-1K 8.5 10 120 120 120 14 10
2995-481865 - 7 10 100 100 100 9 8
121VVG2NV00 3.0 315 4.5 FKM
4270-481000 H-1F 8.5 10 120 120 120 8 8
4270-486265 H-1H 10 10 120 120 120 14 14
- I-1K 5 10 120 120 120 14 10
2995-481865 - 4 10 100 100 100 9 8
121VVG2QV00 1/4" 4.0 480 7.5 FKM
4270-481000 H-1F 5 10 120 120 120 8 8
4270-486265 H-1H 10 10 120 120 120 14 14
- I-1K 2.8 7 120 120 120 14 10
2995-481865 - 2 7 100 100 100 9 8
121VVG2SV00 5.0 750 11 FKM
4270-481000 H-1F 2.8 7 120 120 120 8 8
4270-486265 H-1H 5 7 120 120 120 14 14
- I-1K 20 20 120 120 120 14 10
121FBF4GV00 2995-481865 - 1.5 80 1.5 20 20 100 100 100 FKM 9 8
4270-481000 H-1F 20 20 120 120 120 8 8
- I-1K 30 60 130 130 130 14 10
2995-481865 - 25 60 100 100 100 9 8
121FBF4GR00 1.5 80 1.5 RUBY
4270-481000 H-1F 30 75 130 130 130 8 8
4270-486265 H-1H 55 100 120 120 120 14 14
- I-1K 30 60 120 120 120 14 10
2995-481865 - 25 60 100 100 100 9 8
121FBF4GT00 1.5 80 1.5 PTFE
4270-481000 H-1F 30 70 120 120 120 8 8
4270-486265 H-1H 55 70 120 120 120 14 14
- I-1K 16 16 120 120 120 14 10
121FBF4JV00 2995-481865 2.0 140 2.5 12 16 100 100 100 FKM
- H-1F 16 16 120 120 120 8 8
- I-1K 18 40 130 130 130 14 10
2995-481865 - 15 40 100 100 100 9 8
121FBF4JR00 2.0 140 2.5 RUBY
4270-481000 H-1F 18 48 130 130 130 8 8
4270-486265 H-1H 32 70 120 120 120 14 14
- I-1K 18 40 120 120 120 14 10
2995-481865 - 15 40 100 100 100 9 8
121FBF4JT00 2.0 140 2.5 PTFE
4270-481000 H-1F 18 48 120 120 120 8 8
4270-486265 H-1H 32 70 120 120 120 14 14
- I-1K 9 14 120 120 120 14 10
2995-481865 - 7 14 100 100 100 9 8
121FBF4LV00 2.5 220 3.5 FKM
4270-481000 H-1F 9 14 120 120 120 8 8
SB
4270-486265 H-1H 14 14 120 120 120 14 14
- I-1K 12 28 130 130 130 14 10
2995-481865 - 10 28 100 100 100 9 8
121FBF4LR00 2.5 220 3.5 RUBY
4270-481000 H-1F 12 34 130 130 130 8 8
4270-486265 H-1H 22 50 120 120 120 14 14
- I-1K 12 28 120 120 120 14 10
2995-481865 - 10 28 100 100 100 9 8
121FBF4LT00 2.5 220 3.5 PTFE
4270-481000 H-1F 12 34 120 120 120 8 8
4270-486265 H-1H 22 50 120 120 120 14 14
- I-1K 8.5 10 120 120 120 14 10
2995-481865 - 7 10 100 100 100 9 8
121FBF4NV00 3.0 315 4.5 FKM
4270-481000 H-1F 8.5 10 120 120 120 8 8
4270-486265 H-1H 10 10 120 120 120 14 14
- I-1K 8.5 20 130 130 130 14 10
121FBF4NR00 2995-481865 - 7 20 100 100 100 9 8
3.0 315 4.5 RUBY
4270-481000 H-1F 8.5 25 130 130 130 8 8
4270-486265 H-1H 15 36 120 120 120 14 14
- I-1K 8.5 20 120 120 120 14 10
2995-481865 - 7 20 100 100 100 9 8
121FBF4NT00 3.0 315 4.5 PTFE
4270-481000 H-1F 8.5 25 120 120 120 8 8
4270-486265 H-1H 15 36 120 120 120 14 14
- I-1K 8.5 10 120 120 120 14 10
2995-481865 - 7 10 100 100 100 9 8
121FBF4QV00 4.0 315 4.5 FKM
4270-481000 H-1F 8.5 10 120 120 120 8 8
4270-486265 H-1H 10 10 120 120 120 14 14
- I-1K 7 10 70 70 70 14 10
121KBR3QVWV(*) 2995-481865 - 4.0 480 7.5 4 10 70 70 70 FKM 9 8
- H-1H 10 10 100 100 100 8 8
PT3/8"
- I-1K 5 7 70 70 70 14 10
121KBR3SVWV(*) 2995-481865 - 5.0 750 11 2 7 70 70 70 FKM 9 8
- H-1H 5 7 100 100 100 8 8
Parker Korea Ltd.

CIC Group
www.parker.com
Catalog 0209/KOR
Normally Open
Pipe Body Maximum Power
VESSEL Flow Factor Fluid
Coil & Housing Size Orifice Operating Seal Consumption
MODEL ( L/min ) Temp
NUMBER (°C)
Global Korea G Thread (mm) QN Kv DC AC DC AC
122K63 4270-486265 H-1H 1/4" 3.2 220 4 - 30 120 RUBY 14 14
Note : (*) are for korean market only.
* Connection Thread type : Available NPT, PT. Need consultation
* Pipe size : 1/8" available, need consulation
All K/V/F series numbering system

2 3 4 5 6 7 8 9 10 11&12
Functional Flow Family Body Pipe Orifice Seal
Actuation Connection Options
Type Pattern (Series) Material Size code Material
1 Direct 2 2-way 2-way 1 A Al A SAE 0 Sub-base A C CR 00 No Option
1 Normally Closed 2 B Brass E NPT Male 1 1/8" B E EPDM A2 Silver shading
2 Direct Lift 3 3-way 2 Normally Open 4 L Noryl F Flange 2 1/4" C F PCTFE Ring
3 Multi purpose 5 R 316SS G BSP 3 3/8" D (Kel F) J1 Exhaust
3 Pilot operated 4 4-way 9 Normally Open 6 S 430SS parallel 4 1/2" E 1.0mm K PFPM Adaptor Nut
Internal supply Pressure in body 8 T Teflon R BSP 5 3/4" F (Kalrez) M0 Manual override
Pressure out
9 V 303SS Taper 6 1" G 1.5mm L Nylon W0 Anti-water
sleeve
4 Pilot operated F J Fitting 7 1-1/4" J 2.0mm M Metal Hammer
External supply 3-way G N NPT Female 8 1-1/2" L 2.5mm N NBR RF For refrigeration
1 Normally Closed H (National 9 2" N 3.0mm R Ruby SO STEAM
5 Remote 2 Normally Open K Pipe thread) C 2-1/2" Q 4.0mm T PTFE WV Replaced WV
Pressure 3 Multi purpose R D 3" S 5.0mm (Teflon)
operated 8 Diverting V U 6.0mm V FKM
9 Normally Open 1~9 (Viton)
6 Manual Pressure out body
operated Pressure in sleeve
4-way
1 2-position
2 3-position
EX)
VESSEL HOUSING NUT & WASHER COIL VOLTAGE REMARK
121KBG2LV00 - 4270 - 481000C2 STD / ALL
131VVG2LV00 - H - 1F - 4K KOR ONLY
- I - 1K - C2 ALL
Parker Korea Ltd.

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Catalog 0209/KOR
3/2 Way Direct Operated
Model : 131K/V/F, 133K/F Series
131/133K 131/133V 131F 131/133K. WV
Features
● General Purpose Solenoid Valve
● 3-Way Direct lift
● Operated on Zero MOPD
● Air, Water, Inert gas, Oil, Corrosive fluid and Steam applicapable.
● Applied Seal : FKM, Ruby and Factory consult need for NBR, EPDM
Application
● Air Compressores
● Diesel oil burners
● Water treatment plants
● Vending machine
● Packing machine
Specifications
● Body - Brass : 131K/F, 133K
303 StSt : 131V
● Seal - FKM, Ruby, PTFE and NBR with factory consult
● Sleeve - StSt 303,7000
● Coil - Refer the Electrical part table on the last page
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Catalog 0209/KOR
NORMALLY CLOSED
VESSEL Flow Factor Min
Coil & Housing SIZE Orifice Operating Seal Fluid Temp(°C) Consumption
MODEL ( L/min ) Operating
(PF) Size 2 Pre.( Kgf/cm2 ) disc (W)
NUMBER Pre.(Kgf/Cm )
131KBG2BT00 4270-481000 H-1F 0.8 - 0.3 0 40 40 PTFE - 75 75 8 8
4270-481000 H-1F - 75 - 130 - 8 8
131KBG2BR00 0.8 - 0.3 0 RUBY
4270-486265 H-1F 75 - - 140 - 14 14
- I-1K 15 15 100 100 100 14 10
131KBG2GV00 4270-481000 H-1F 1.5 80 1.5 0 15 15 FKM 120 120 120 8 8
2995-481865 15 15 100 100 100 9 8
131KBG2GVM0 - I-1K 15 15 100 100 100 14 10
(Manual 4270-481000 H-1F 1.5 80 1.5 0 15 15 FKM 120 120 120 8 8
override) 2995-481865 15 15 100 100 100 9 8
- I-1K 10 10 100 100 100 14 10
131KBG2JV00 4270-481000 H-1F 2.0 140 2.5 0 10 10 FKM 120 120 120 8 8
2995-481865 10 10 100 100 100 9 8
131KBG2JVM0 - I-1K 10 10 100 100 100 14 10
(Manual 4270-481000 H-1F 2.0 140 2.5 0 10 10 FKM 120 120 120 8 8
override) 2995-481865 10 10 100 100 100 9 8
1/4"
- I-1K 7 7 100 100 100 14 10
131KBG2LV00 4270-481000 H-1F 2.5 220 3.5 0 7 7 FKM 120 120 120 8 8
2995-481865 7 7 100 100 100 9 8
131KBG2LVM0 - I-1K 7 7 100 100 100 14 10
(Manual 4270-481000 H-1F 2.5 220 3.5 0 7 7 FKM 120 120 120 8 8
override) 2995-481865 7 7 100 100 100 9 8
- I-1K 15 15 100 100 100 14 10
131VVG2GV00 4270-481000 H-1F 1.5 80 1.5 0 15 15 FKM 120 120 120 8 8
2995-481865 15 15 100 100 100 9 8
- I-1K 10 10 100 100 100 14 10
131VVG2JV00 4270-481000 H-1F 2.0 140 2.5 0 10 10 FKM 120 120 120 8 8
2995-481865 10 10 100 100 100 9 8
- I-1K 7 7 100 100 100 14 10
131VVG2LV00 4270-481000 H-1F 2.5 220 3.5 0 7 7 FKM 120 120 120 8 8
2995-481865 7 7 100 100 100 9 8
I-1K 15 15 100 100 100 14 10
131FBG4GV00 4270-481000 H-1F 1.5 80 1.5 0 15 15 FKM 120 120 120 8 8
2995-481865 15 15 100 100 100 9 8
131FBG4GVM0 I-1K 15 15 100 100 100 14 10
(Manual H-1F 1.5 80 1.5 0 15 15 FKM 120 120 120 8 8
override) 2995-481865 15 15 100 100 100 9 8
I-1K 10 10 100 100 100 14 10
131FBG4JV00 4270-481000 H-1F 2.0 140 2.5 0 10 10 FKM 120 120 120 8 8
2995-481865 10 10 100 100 100 9 8
SB
131FBG4JVM0 I-1K 10 10 100 100 100 14 10
(Manual 4270-481000 H-1F 2.0 140 2.5 0 10 10 FKM 120 120 120 8 8
override) 2995-481865 10 10 100 100 100 9 8
I-1K 7 7 100 100 100 14 10
131FBG4LV00 4270-481000 H-1F 2.5 220 3.5 0 7 7 FKM 120 120 120 8 8
2995-481865 7 7 100 100 100 9 8
131FBG4LVM0 I-1K 7 7 100 100 100 14 10
(Manual 4270-481000 H-1F 2.5 220 3.5 0 7 7 FKM 120 120 120 8 8
override) 2995-481865 7 7 100 100 100 9 8
Parker Korea Ltd.

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Catalog 0209/KOR
UNIVERSAL
PORT Body Min Maximum Power
VESSEL Flow Factor
Coil & Housing SIZE Orifice Operating Operating Seal Fluid Temp(°C) Consumption
MODEL ( L/min )
(PF) Size Pre.(Kgf/ Pre.( Kgf/cm2 ) disc (W)
NUMBER
Global Korea G Thread (mm) QN Kv Cm2) DC AC Gas Liquid Oil DC AC
I-1K 10 10 100 100 100 14 10
133KBG2GV00 4270-481000 H-1F 1.5 80 1.5 0 10 10 FKM 120 120 120 8 8
2995-481865 10 10 100 100 100 9 8
133KBG2GVM0 I-1K 10 10 100 100 100 14 10
(Manual 4270-481000 H-1F 1.5 80 1.5 0 10 10 FKM 120 120 120 8 8
override) 2995-481865 10 10 100 100 100 9 8
I-1K 7 7 100 100 100 14 10
133KBG2JV00 4270-481000 H-1F 2.0 140 2.5 0 7 7 FKM 120 120 120 8 8
2995-481865 7 7 100 100 100 9 8
133KBG2JVM0 I-1K 7 7 100 100 100 14 10
(Manual 4270-481000 H-1F 2.0 140 2.5 0 7 7 FKM 120 120 120 8 8
override) 2995-481865 7 7 100 100 100 9 8
I-1K 4 4 100 100 100 14 10
133KBG2LV00 4270-481000 H-1F 1/4" 2.5 220 3.5 0 4 4 FKM 120 120 120 8 8
2995-481865 4 4 100 100 100 9 8
133KBG2LVM0 I-1K 4 4 100 100 100 14 10
(Manual 4270-481000 H-1F 2.5 220 3.5 0 4 4 FKM 120 120 120 8 8
override) 2995-481865 4 4 100 100 100 9 8
I-1K 10 10 100 100 100 14 10
133VVG2GV00 4270-481000 H-1F 1.5 80 1.5 0 10 10 FKM 120 120 120 8 8
2995-481865 10 10 100 100 100 9 8
I-1K 7 7 100 100 100 14 10
133VVG2JV00 4270-481000 H-1F 2.0 140 2.5 0 7 7 FKM 120 120 120 8 8
2995-481865 7 7 100 100 100 9 8
I-1K 4 4 100 100 100 14 10
133VVG2LV00 4270-481000 H-1F 2.5 220 3.5 0 4 4 FKM 120 120 120 8 8
2995-481865 4 4 100 100 100 9 8
I-1K 10 10 100 100 100 14 10
133FBG4GV00 4270-481000 H-1F 1.5 80 1.5 0 10 10 FKM 120 120 120 8 8
2995-481865 10 10 100 100 100 9 8
133FBG4GVM0 I-1K 10 10 100 100 100 14 10
(Manual 4270-481000 H-1F 1.5 80 1.5 0 10 10 FKM 120 120 120 8 8
override) 2995-481865 10 10 100 100 100 9 8
I-1K 7 7 100 100 100 14 10
133FBG4JV00 4270-481000 H-1F 2.0 140 2.5 0 7 7 FKM 120 120 120 8 8
2995-481865 7 7 100 100 100 9 8
SB
133FBG4JVM0 I-1K 7 7 100 100 100 14 10
(Manual 4270-481000 H-1F 2.0 140 2.5 0 7 7 FKM 120 120 120 8 8
override) 2995-481865 7 7 100 100 100 9 8
I-1K 4 4 100 100 100 14 10
133FBG4LV00 4270-481000 H-1F 2.5 220 3.5 0 4 4 FKM 120 120 120 8 8
2995-481865 4 4 100 100 100 9 8
133FBG4LVM0 I-1K 4 4 100 100 100 14 10
(Manual 4270-481000 H-1F 2.5 220 3.5 0 4 4 FKM 120 120 120 8 8
override) 2995-481865 4 4 100 100 100 9 8
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Catalog 0209/KOR
Dimensions
131K, 133K Series
Valve Code Reference
Normal Close Normal Open
Universal
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Catalog 0209/KOR
Solenoid Valves WV121S Series
2/2 Way Valve, Direct Operated
Model : WV121S Series
Brass body with S coil StSt body with Scoil Brass body with H coil StSt body with H coil Plastic body with S coil
Features Specifications
● Normally closed ● Body - Brass, StSt 303
● Body : Brass, StSt 303, Plastic ● Seal - FKM and NBR with factory consult
● Coil : S or H ● Sleeve - StSt 303, 7000
● Operated on Zero MOPD ● Coil - Refer the Electrical part table on the last page
● Long life cycle ( I Million )
● Air, Water Inert gas, Oil, Corrosive fluid applicapable
● Manifold confiqurations
● Applied Seal : FKM, NBR, Silicon
● Standard FKM seal
● A miniature, High Performance
● UL & CE components recognized
● UL/CE approved for 'S' coil
● Body thread type : NPT, PF available with factory consult
Valve body numbering Coil numbering

Maximun Operating You can add following coil umber to valve body part
Orifice Flow number
Valve Body Port & Body Size Factor Pressure(kgf/cm2) Fluid Temp
˚C
(mm) (Kv) DC AC 1) I-1S Coil : 5 different voltage available
WV121S221GV 1.6 1.3 10 15 75 I-1S-PO : AC24/50~60 ( 5W )
I-1S-P3 : AC110/50,AC120/60 ( 5W )
WV121S221JV 2.0 1.9 7 10 75 I-1S-Q3 : AC220/50,AC240/60 ( 5.5W )
WV121S221LV 1/8 inch, PT, Brass 2.5 2.8 5 7 75 I-1S-C1 : DC12V ( 6W )
I-1S-C2 : DC24V ( 6W )
WV121S221NV 3.0 3.2 4 5 75
WV121S221QV 4.0 3.5 2 4 75 2) H-WS Coil : 4 different voltage available
H-WS-B5 : AC110/60 ( 8W )
WV121S222GV 1.6 1.3 10 15 75 H-WS-B7 : AC220/60 ( 8W )
WV121S222JV 2.0 1.9 7 10 75 H-WS-C1 : DC12V ( 9W )
H-WS-C2 : DC24V ( 9W )
WV121S222LV 1/4 inch, PT, Brass 2.5 2.8 5 7 75
WV121S222NV 3.0 3.2 4 5 75
Ordering example
WV121S222QV 4.0 3.5 2 4 75
If you want brass body, 1/8 inch pipe size with PT
WV121S121GV 1.6 1.3 10 15 75 connection, I coil with AC240V/50Hz, then, you can
order as followes.
WV121S121JV 2.0 1.9 7 10 75
1/8 inch, PT, St Factory consult need for NPT, PF thread
WV121S121LV 2.5 2.8 5 7 75
steel
WV121S121NV 3.0 3.2 4 5 75 "WV121S221LV I-1S-Q3"
WV121S121QV 4.0 3.5 2 4 75
WV121S122GV 1.6 1.3 10 15 75
WV121S122JV 2.0 1.9 7 10 75
1/4 inch, PT, St
WV121S122LV 2.5 2.8 5 7 75
Steel
WV121S122NV 3.0 3.2 4 5 75
WV121S122QV 4.0 3.5 2 4 75
1/4 Inch, NPT,
121S432KS 2.5 2.8 5 7 75
Plastic
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Catalog 0209/KOR
Drawing (Unit : mm)
H-WS Coil Assembly I-1S Coil Assembly
St. steel 303 Body Assembly Brass Body Assembly Plastic Body Assembly
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Catalog 0209/KOR
3/2 Way Direct Operated
Model : WV131S Series
Brass body with S coil StSt body with S coil
Features Specifications
● Normally Closed ● Body -Brass, StSt 303 Response Time
● Body : Brass, StSt 303 ● Seal -FKM and NBR with factory ● 25 to 40 milliseconds
● Coil : S or H consult
● Operated on Zero MOPD ● Sleeve -StSt 303, 7000 Duty Cycle
● Air, Water Inert gas, Oil, Corrosive ● Coil -Refer the Electrical part table ● Continuous Duty
fluid applicapable on the last page
Mounting
● Applied Seal : FKM, NBR
● For direct pipe mounting
● A miniature, High Performance or 2-M 5 * 0.8 mm screws
● UL/CE approved for 'S' coil
● Body thread type : NPT, PF available
with factory consult
Normally Closed
Sleeve Body Maximum
VESSEL Body Operating
COIL Pipe Orifice Orifice Seal Fluid
MODEL Kv Pressure( Kgf/cm2 )
& HOUSING Size Size Size disc Temp.
NUMBER Factor
(mm) (mm) DC AC
I-1S-XX
WV131S222GV 1.3 1.6 1.6 6 6 FKM 75
H-WS-XX
I-1S-XX
WV131S222JV PT 1/4 1.9 1.6 2.0 4.5 4.5 FKM 75
H-WS-XX
I-1S-XX
WV131S222LV 2.8 1.6 2.5 3 3 FKM 75
H-WS-XX
* Connection Thread type : Available NPT, PT. Need consultation
* Pipe size : 1/8" available, need consulation
* StSt 303 body available with factory counsult
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Catalog 0209/KOR
Drawing
(Unit : mm) (Unit : mm)
H-WS Coil I-1S Coil
(Unit : mm)
Brass Body
WV121/131 Series Numbering system

1 2 3 4 5 6 7 8 9 10 11
Functional Flow Family Body Seal Coil
Actuation Connection Pipe Size Orifice code Voltage/Hz
Type Pattern (Series) Material Material type
1 Direct 2 2-way 1 N.C S 1 SUS303 1 PF 1 1/8" G 1.6mm N NBR I-1S PO AC24/50~60
3 3-way 2 N.O 2 Brass 2 PT 2 1/4" J 2.0mm E EPDM P3 AC110/50,AC120/60
3 MULTI 3 NPT L 2.5mm V VITON Q3 AC220/50,AC240/60
9 Pressure N 3.0mm (FKM) C1 DC12V
out the Q 4.0mm C CR C2 DC24V
sleeve H-WS P0 AC24/50~60
B5 AC110/60
B7 AC220/60
C1 DC12V
C2 DC24V
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Catalog 0209/KOR
Solenoid Valves 221G Series
2/2Way Magnalift
Model : 221G Series

Features
● Normally closed
● Body : Brass
● 7000 sleeve assembled
● Coil : All of 7000 sleeve coil available
● Operated on nearly Zero MOPD
● Air, Water, Inert gas, Oil and Steam applicapable
● Applied Seal : FKM, NBR, EPDM
Application
● Thermohydraulic system ● Autoclaves
● Oil burner, Bolier ● Molding machines
● Steam generators ● Sterilisation system
● Industrial washing machines
● Washing system ● Boiling system
● Cooling of machine tools ● Hospital equipment
Normally Closed,Water, Air, Gas, light oil

PORT ADMISSIBLE MAX.
FLOW Power
REFERENCE NO. SIZE ORIFICE DIFF. PRESSURE FLUID
( L / min ) SEAL (W)
(PF) (mm) (BAR) TEMP.(˚C)
COIL Liquids Gases Max
VESSEL N0. HOUSING G Thread Min Gas Liquids Oil DC AC
Gobal Korea kv Qmax Qn DC AC
I - 1K - 16 100 75 100 14 10
2995 481865 - - 16 100 75 100 9 8
4270 481000 - - 16 100 75 100 8 8
221G13 15 65 65 4500 0 NBR
4270 486265 - 7 - 100 75 100 14 14
H - 1F - 16 100 75 100 8 8
H - 1H 3/8" 7 - 100 75 100 14 14
I - 1K - 16 100 - 100 14 10
2995 481865 - - 16 100 - 100 9 8
4270 481000 - - 16 120 - 120 8 8
221G23 15 65 65 4500 0 FKM
4270 486265 - 7 20 120 - 140 14 10
H - 1F - 16 120 - 120 8 8
H - 1H 7 20 120 - 140 14 10
I - 1K - 16 100 75 100 14 10
2995 481865 - - 16 100 75 100 9 8
4270 481000 - - 16 100 75 100 8 8
221G15 15 65 65 4500 0 NBR
4270 486265 - 7 - 100 75 100 14 14
H - 1F - 16 100 75 100 8 8
H - 1H 7 - 100 75 100 14 14
1/2"
I - 1K - 16 100 - 100 14 10
2995 481865 - - 16 100 - 100 9 8
4270 481000 - - 16 120 - 120 8 8
221G25 15 65 65 4500 0 FKM
4270 486265 - 7 20 120 - 140 14 10
H - 1F - 16 120 - 120 8 8
H - 1H 7 20 120 - 140 14 10
I - 1K - 16 100 75 100 14 10
2995 481865 - - 16 100 75 100 9 8
4270 481000 - - 16 100 75 100 8 8
221G16 15 80 80 6000 0 NBR
4270 486265 - 7 - 100 75 100 14 14
H - 1F - 16 100 75 100 8 8
H - 1H 7 - 100 75 100 14 14
3/4"
I - 1K - 16 100 - 100 14 10
2995 481865 - - 16 100 - 100 9 8
4270 481000 - - 16 120 - 120 8 8
221G26 15 80 80 6000 0 FKM
4270 486265 - 7 20 120 - 140 14 10
H - 1F - 16 120 - 120 8 8
H - 1H 7 20 120 - 140 14 10
I - 1K - 16 100 75 100 14 10
2995 481865 - - 16 100 75 100 9 8
4270 481000 - - 16 100 75 100 8 8
221G17 15 80 80 6000 0 NBR
4270 486265 - 7 - 100 75 100 14 14
H - 1F - 16 100 75 100 8 8
H - 1H 7 - 100 75 100 14 14
1"
I - 1K - 16 100 - 100 14 10
2995 481865 - - 16 100 - 100 9 8
4270 481000 - - 16 120 - 120 8 8
221G27 15 80 80 6000 0 FKM
4270 486265 - 7 20 120 - 140 14 10
H - 1F - 16 120 - 120 8 8
H - 1H 7 20 120 - 140 14 10
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Catalog 0209/KOR
Normally Cloased, Steam application

ADMISSIBLE MAX.
PORT FLOW Power
REFERENCE NO. DIFF. PRESSURE FLUID
SIZE ORIFICE ( L / min ) (W)
(BAR) TEMP.(˚C) SEAL
(PF) (mm)
COIL Liquids Gases Max
VESSEL N0. HOUSING G Thread Min WATER STEAM DC AC
Gobal Korea kv Qmax Qn DC AC
I - 1K - 10 100 - 14 10
2995 481865 481865 - 10 100 - 9 8
4270 481000 1F - 10 120 - 8 8
221G1303 4270 486265 - 3/8" 15 65 65 4500 0 7 10 120 - EPDM 14 14
4270 486265 - 4 4 - 140 14 14
H - 1H 7 10 120 - 14 14
H - 1H 4 4 - 140 14 14
I - 1K - 10 100 - 14 10
2995 481865 481865 - 10 100 - 9 8
4270 481000 1F - 10 120 - 8 8
221G1503 4270 486265 - 1/2" 15 65 65 4500 0 7 10 120 - EPDM 14 14
4270 486265 - 4 4 - 140 14 14
H - 1H 7 10 120 - 14 14
H - 1H 4 4 - 140 14 14
I - 1K - 10 100 - 14 10
2995 481865 481865 - 10 100 - 9 8
4270 481000 1F - 10 120 - 8 8
221G1603 4270 486265 - 3/4" 15 80 80 6000 0 7 10 120 - EPDM 14 14
4270 486265 - 4 4 - 140 14 14
H - 1H 7 10 120 - 14 14
H - 1H 4 4 - 140 14 14
I - 1K - 10 100 - 14 10
2995 481865 481865 - 10 100 - 9 8
4270 481000 1F - 10 120 - 8 8
221G1703 4270 486265 - 1" 15 80 80 6000 0 7 10 120 - EPDM 14 14
4270 486265 - 4 4 - 140 14 14
H - 1H 7 10 120 - 14 14
H - 1H 4 4 - 140 14 14
*Port type : Available NPT, PT . Need consultation
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Catalog 0209/KOR
VALVE SECTION
Class F coil or Class H coil for all

voltage
High performed plunger to remain low

magnetism and rise the life cycle.
Exhaust orifice of pilot chamfer
Operating in condition of zero differential

pressure by mechanical connection of
diaphragm and plunger
Inflow orifice of pilot chamfer

(221G TYPE)
Diaphragm is seperated from pliot chamfer
Seal
Valve connection hole
Dimension
Modle
A B C D E F G H
221G 3/8” 75 93 37.5 15 34 27 10 -
221G 1/2” 75 93 37.5 15 34 27 15 -
221G 3/4” 80 95.5 40 17.5 34 32 20 53
221G 1” 85 102.5 42.5 22.5 46 41 25 53
Dimensions
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Catalog 0209/KOR
Solenoid Valves NKV Series
Blank Page
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Catalog 0209/KOR
2/2 Way Valve (Magnalift)
Model : NKV Series
Features
● Normally closed
● Body : Brass
● Air, Water, Inert gas, Oil and Steam applicapable
● Applied Seal : FKM, NBR, EPDM
● Body thread type : NPT, PF available with factory consult
Specification
Major material features Respons time
● Body -Brass ● Open / Close time : 80 ~ 100 ms
● Seal -FKM,EPDM ,NBR
Ambient temperature
● Sleeve - StSt 303 ,7000
● 0 ~ 50˚C
Rated Voltage & Power Consumption
Fluid temperature
● Please refer to table #1
on the back side ● 60˚C Water & Air (NBR)
● 100˚C Oil (FKM)
● 140˚C Steam (EPDM)
Port size Rc (PT)

● 1/2", 3/4", 1"
(PF/NPT, Factory Consulting)
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Catalog 0209/KOR
Normally closed ,Air,Water, Oil ,Steam
FLOW ADMISSIBLE MAX.

PORT Power
REFERENCE NO. (L/MIN) DIFF. PRESSURE FLUID
SIZE ORIFICE (W)
( L / min ) (BAR) TEMP.( ˚C ) SEAL
(PT) (mm)
COIL Liquids Max
VESSEL N0. HOUSING Thread Min Water Oil DC AC
Gobal Korea KV DC AC
I - 1K - 10 60 - 14 10
2995 481865 - - 10 60 - 9 8
4270 481000 - - 10 60 - 8 8
NKV10N 15 40 0 NBR
4270 486265 - 7 10 60 - 14 14
H - 1F - 10 60 - 8 8
H - 1H 3/8” 7 10 60 - 14 14
2995 481865 - - 10 60 100 9 8
4270 481000 - - 10 60 100 8 8
NKV10F 4270 486265 - 15 40 0 7 10 60 100 FKM 14 14
H - 1F - 10 60 100 8 8
H - 1H 7 10 60 100 14 14
I - 1K - 10 60 - 14 10
2995 481865 - - 10 60 - 9 8
4270 481000 - - 10 60 - 8 8
NKV15N 15 50 0 NBR
4270 486265 - 7 10 60 - 14 14
H - 1F - 10 60 - 8 8
H - 1H 1/2” 7 10 60 - 14 14
2995 481865 - - 10 60 100 9 8
4270 481000 - - 10 60 100 8 8
NKV15F 4270 486265 - 15 50 0 7 10 60 100 FKM 14 14
H - 1F - 10 60 100 8 8
H - 1H 7 10 60 100 14 14
I - 1K - 10 60 - 14 10
2995 481865 - - 10 60 - 9 8
4270 481000 - - 10 60 - 8 8
NKV20N 24 90 0 NBR
4270 486265 - 7 10 60 - 14 14
H - 1F - 10 60 - 8 8
H - 1H 3/4” 7 10 60 - 14 14
2995 481865 - - 10 60 100 9 8
4270 481000 - - 10 60 100 8 8
NKV20F 4270 486265 - 24 90 0 7 10 60 100 FKM 14 14
H - 1F - 10 60 100 8 8
H - 1H 7 10 60 100 14 14
I - 1K - 10 60 - 14 10
2995 481865 - - 10 60 - 9 8
4270 481000 - - 10 60 - 8 8
NKV25N 27 120 0 NBR
4270 486265 - 7 10 60 - 14 14
H - 1F - 10 60 - 8 8
H - 1H 1” 7 10 60 - 14 14
2995 481865 - - 10 60 100 9 8
4270 481000 - - 10 60 100 8 8
NKV25F 4270 486265 - 27 120 0 7 10 60 100 FKM 14 14
H - 1F - 10 60 100 8 8
H - 1H 7 10 60 100 14 14
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Catalog 0209/KOR

REFERENCE NO. PORT DIFF. PRESSURE FLUID Power
(L/MIN)
SIZE ORIFICE (BAR) TEMP.( ˚C ) (W)
( L / min ) SEAL
(PT) (mm)
VESSEL COIL Liquids Max WATER STEAM
HOUSING Thread Min
N0. Gobal Korea kv DC AC DC AC
I - 1K - 10 80 - 14 10
2995 481865 481865 - 10 80 - 9 8
4270 481000 1F - 10 80 - 8 8
NKV10E 4270 486265 - 3/8” 15 40 0 7 10 80 - EPDM 14 14
4270 486265 - 4 4 80 140 14 14
H - 1H 7 10 80 - 14 14
H - 1H 4 4 80 140 14 14
I - 1K - 10 80 - 14 10
2995 481865 481865 - 10 80 - 9 8
4270 481000 1F - 10 80 - 8 8
NKV15E 4270 486265 - 1/2” 15 50 0 7 10 80 - EPDM 14 14
4270 486265 - 4 4 80 140 14 14
H - 1H 7 10 80 - 14 14
H - 1H 4 4 80 140 14 14
I - 1K - 10 80 - 14 10
2995 481865 481865 - 10 80 - 9 8
4270 481000 1F - 10 80 - 8 8
NKV20E 4270 486265 - 3/4” 24 90 0 7 10 80 - EPDM 14 14
4270 486265 - 4 4 80 140 14 14
H - 1H 7 10 80 - 14 14
H - 1H 4 4 80 140 14 14
I - 1K - 10 80 - 14 10
2995 481865 481865 - 10 80 - 9 8
4270 481000 1F - 10 80 - 8 8
NKV25E 4270 486265 - 1” 27 120 0 7 10 80 - EPDM 14 14
4270 486265 - 4 4 80 140 14 14
H - 1H 7 10 80 - 14 14
H - 1H 4 4 80 140 14 14
Dimensions
NKV Series
(Unit : mm)
Dimension
Series(Fitting size)
A B C
NKV 3/8" 72 100 85
NKV 1/2" 72 100 85
NKV 3/4" 84 108 90
NKV 1" 95 118 95
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Catalog 0209/KOR
H-1F / H-1H Rated Voltage & Power Consumption
Coil G-200146("F" Class) Enclosure (Unit : mm)

G-200148("H" Class) Housing(G-200140) (Table #1)
Code Volts / Hz Watt Coil
C1 DC12
14 H-1H
PF1/2"
C2 DC24
A2 24/50
B2 24/50
6J 110/60, 115/60
320±10 Plate(G-200142) 8 H-1F
0A 110/50, 115/50
4K 220/60, 240/60
14.8
40.0
3A 220/50, 230/50
45.5
A2 24/50
OP 100/50, 115/60
41.3 A5 110/50
14 H-1H
B7 220/60
S2 200/50, 230/60
A7 220/50
How to Order
NKV 15 N-H-1F-C1
❶ ❷ ❸ ❹ ❺
❶ Valve series ❹E
nclosure & Coil
❷ Port size H-1F 1/2" PF Conduit
10 PT3/8" 8 Watt, "F" Class
15 PT1/2" H-1H 1/2" PF Conduit
20 PT 3/4" 14 Watt, "H" Class
25 PT1" ❺ Rated voltage code
❸ Seal material See Table #1
N NBR
F FKM
E EPDM
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Catalog 0209/KOR
Solenoid Valves 221S Series
2/2 Way Valve (Magnalift)
Model : 221S Series
Features
● Normally closed
● Body : StSt 316
● Oil, gase, Steam and corrosive fluid applicapable
● Applied Seal : FKM, EPDM and NBR with factory consult
Application
● Chiller (Semiconductor)
● Food and fluid Press process
● Oil and gase applied equipment
● Printing machine
● Testing equipment
Normally Cloased
REFERENCE NO. PORT DIFF. PRESSURE FLUID
(L/MIN) Power
SIZE ORIFICE SEAL
( L / min ) (BAR) TEMP.(ºC) (W)
(PF) (mm)
VESSEL N0. COIL Liquids Max
HOUSING G Thread Min Water Steam
Lucifer Gobal Korea KV DC AC DC AC
I - 1K - 10 85 14 10
2995 481865 - - 10 85 9 8
4270 481000 - 0 - 10 85 8 8
221S10F 15 40 FKM
4270 486265 - 7 10 85 14 14
H - 1F - 10 85 8 8
H - 1H 3/8" 7 10 85 14 14
2995 481865 - - 10 85 - 9 8
4270 481000 - - 10 85 - 8 8
221S10E 4270 486265 - 15 40 0 4 4 - 140 EPDM 14 14
H - 1F - 10 85 8 8
H - 1H 4 4 - 140 14 14
I - 1K - 10 85 14 10
2995 481865 - - 10 85 9 8
4270 481000 - - 10 85 8 8
221S15F 15 50 0 FKM
4270 486265 - 7 10 85 14 14
H - 1F - 10 85 8 8
H - 1H 1/2" 7 10 85 14 14
2995 481865 - - 10 85 9 8
4270 481000 - - 10 85 8 8
221S15E 4270 486265 - 15 50 0 4 4 - 140 EPDM 14 14
H - 1F - 10 85 8 8
H - 1H 4 4 - 140 14 14
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Catalog 0209/KOR
Solenoid Valves 221S Series
Normally Cloased
REFERENCE NO. PORT DIFF. PRESSURE FLUID
(L/MIN) Power
SIZE ORIFICE SEAL
( L / min ) (BAR) TEMP.(ºC) (W)
(PF) (mm)
VESSEL N0. COIL Liquids Max
HOUSING G Thread Min Water Steam
Lucifer Gobal Korea KV DC AC DC AC
I - 1K - 10 85 14 10
2995 481865 - - 10 85 9 8
4270 481000 - - 10 85 8 8
221S20F 24 95 0 FKM
4270 486265 - 7 10 85 14 14
H - 1F - 10 85 8 8
H - 1H 3/4" 7 10 85 14 14
2995 481865 - - 10 85 9 8
4270 481000 - - 10 85 8 8
221S20E 4270 486265 - 24 95 0 4 10 - 140 FKM 14 14
H - 1F - 10 85 8 8
H - 1H 4 10 - 140 14 14
I - 1K - 10 85 14 10
2995 481865 - - 10 85 9 8
4270 481000 - - 10 85 8 8
221S25F 24 105 0 FKM
4270 486265 - 7 10 85 14 14
H - 1F - 10 85 8 8
H - 1H 1' 7 10 85 14 14
2995 481865 - - 10 85 9 8
4270 481000 - - 10 85 8 8
221S25E 4270 486265 - 24 105 0 4 4 85 140 EPDM 14 14
H - 1F - 10 85 8 8
H - 1H 4 4 85 140 14 14
Dimension
unit: mm
Model
Size
221S10F 221S15F 221S20F 221S25F
A 72 72 72 83
B 100 100 117 117
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Catalog 0209/KOR
2/2Way Pilot Operated

Features
Model : 321G Series ● General Purpose Solenoid Valve
● 2-Way Pilot Operated
● Air, Water, and Steam applicapable.
● Applied Seal : NBR, EPDM
Application
● Water treatment plants
● Industrial washing plants
● Irrigation Systems
● HVAC
● Cooling System
● Fire-fighting system
Normally Cloased, Water, Air application

PORT Power
REFERENCE NO. (L/MIN) DIFF. PRESSURE FLUID
SIZE ORIFICE (W)
( L / min ) (BAR) (ºC) SEAL
COIL (PF) (mm) Max
Liquids
VESSEL N0. HOUSING G Thread Min Water DC AC
Gobal Korea KV DC AC
I - 1K 16 16 75 14 10
2995 481865 - 16 16 75 9 8
E321G3610 3/4" 20 135 0.3 NBR
4270 481000 - 16 16 75 8 8
H - 1F 16 16 75 8 8
I - 1K 16 16 75 14 10
2995 481865 - 16 16 75 9 8
E321G3710 1" 25 180 0.3 NBR
4270 481000 - 16 16 75 8 8
H - 1F 16 16 75 8 8
I - 1K 16 16 75 14 10
2995 481865 - 16 16 75 9 8
4270 481000 - 16 16 75 8 8
E321G3810 1-1/4" 28 280 0.3 NBR
H - 1F 16 16 75 8 8
4270 486265 - 16 20 75 14 14
H - 1H 16 20 75 14 14
I - 1K 8.5 16 75 14 10
2995 481865 - 10 16 75 9 8
4270 481000 - 8.5 16 75 8 8
E321G3910 1-1/2" 40 420 0.3 NBR
4270 486265 - 16 20 75 14 14
H - 1F 8.5 16 75 8 8
H - 1H 16 20 75 14 14
I - 1K 8.5 16 75 14 10
2995 481865 - 10 16 75 9 8
4270 481000 - 8.5 16 75 8 8
E321G4010 2" 40 560 0.3 NBR
4270 486265 - 16 20 75 14 14
H - 1F 8.5 16 75 8 8
H - 1H 16 20 75 14 14

FLOW ADMISSIBLE
PORT MAX. Power
REFERENCE NO. ORIFICE ( L / min ) DIFF. PRESSURE
SIZE(PF) FLUI(ºC) SEAL (W)
(mm) Liquids (BAR)
COIL G Thread Max
VESSEL N0. HOUSING kv Min WATER Steam DC AC
Gobal Korea DC AC
I - 1K 16 16 100 - 14 10
2995 481865 481865 16 16 100 - 9 8
321G3803 4270 481000 1F 1-1/4" 28 280 0.3 16 16 120 - EPDM 8 8
4270 486265 - 4 4 - 145 14 14
H - 1H 4 4 - 145 14 14
I - 1K 14 16 100 - 14 10
2995 481865 481865 10 16 100 - 9 8
321G3903 4270 481000 1F 1-1/2" 40 420 0.3 8.5 16 120 - EPDM 8 8
4270 486265 - 4 4 - 145 14 14
H - 1H 4 4 - 145 14 14
I - 1K 14 16 100 100 14 10
2995 481865 481865 10 16 100 100 9 8
321G4003 4270 481000 1F 1" 40 560 0.3 8.5 16 120 120 EPDM 8 8
4270 486265 - 4 4 - 145 14 14
H - 1H 4 4 - 145 14 14
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Catalog 0209/KOR
Fluid Temp.
• Min. : -10℃ Class F Coil or Class H Coil
• Max. : Prefer Table
Ambient Temp. High performed plunger to remain low

• -10℃ +50℃ magnetism and rise the life cycle.
Coil Class
• Class F (Coil 481865, 481000) Seal Assembly for prevent the impact to rise the life
• Class H (High Temp Coil 486265) cycle and reduce the impact when it closed
Power Consumption
• 8~9W Pilot Orifice
Diaphragm
Manual Operator
Flow control device
Valve Port
Dimensions
Model
A B C D E F G H
E321G38 110 137.5 55 33 60.5 60 32 70
E321G39 140 144 75 33 67 60 40 99
E321G40 150 158.5 80 41.5 73 75 50 99
Dimensions(mm)
* 321G All type
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Catalog 0209/KOR
Solenoid Valves 321K Series
2/2 Way Pilot Operated
Model : 321K Series Features

● Normally Closed , Universal
● 7000 Sleeve
● Body : Brass
● Coil : All of 7000 sleeve suitable coil available
● A minimum operating pressure is required
● Air, Water ,Inert gas, Oil applicapable
● Shunt-off applications of liquids with high flow and
pressure
● Applied Seal : FKM , EPDM with Factory consult
Application
● Fire system
● Air dryer
● Water treatment system
Normally Cloased, Water, Air application

ADMISSIBLE
PORT FLOW MAX.
REFERENCE NO. DIFF. PRESSURE Power
SIZE (L/MIN) FLUID
ORIFICE (BAR) (W)
(PF) ( L / min ) TEMP.(˚C ) SEAL
Valve COIL (mm) Max
G Liquids
Reference HOUSING Min
Gobal Korea Thread KV DC AC Water DC AC
no
I - 1K 12 12 100 14 10
2995 481865 - 12 12 100 9 8
321K4106 12 30 0.3 FKM
4270 481000 - 12 12 100 8 8
H - 1F 12 12 100 8 8
1/4”
I - 1K 12 12 100 14 10
2995 481865 - 12 12 100 9 8
321K4156 12 30 0.3 FKM
4270 481000 - 12 12 100 8 8
H - 1F 12 12 100 8 8
I - 1K 12 12 100 14 10
2995 481865 - 12 12 100 9 8
321K4306 12 45 0.3 FKM
4270 481000 - 12 12 100 8 8
H - 1F 12 12 100 8 8
3/8”
I - 1K 12 12 100 14 10
2995 481865 - 12 12 100 9 8
321K4356 12 45 0.3 FKM
4270 481000 - 12 12 100 8 8
H - 1F 12 12 100 8 8
I - 1K 12 12 100 14 10
2995 481865 - 12 12 100 9 8
321K4506 12 50 0.3 FKM
4270 481000 - 12 12 100 8 8
H - 1F 12 12 100 8 8
1/2”
I - 1K 12 12 100 14 10
2995 481865 - 12 12 100 9 8
321K4556 12 50 0.3 FKM
4270 481000 - 12 12 100 8 8
H - 1F 12 12 100 8 8
I - 1K 12 12 100 14 10
2995 481865 - 12 12 100 9 8
321K4606 18 100 0.3 FKM
4270 481000 - 12 12 100 8 8
H - 1F 12 12 100 8 8
3/4”
I - 1K 12 12 100 14 10
2995 481865 - 12 12 100 9 8
321K4656 18 100 0.3 FKM
4270 481000 - 12 12 100 8 8
H - 1F 12 12 100 8 8
I - 1K 12 12 100 14 10
2995 481865 - 12 12 100 9 8
321K4706 18 110 0.3 FKM
4270 481000 - 12 12 100 8 8
H - 1F 12 12 100 8 8
1”
I - 1K 12 12 100 14 10
2995 481865 - 12 12 100 9 8
321K4756 18 110 0.3 FKM
4270 481000 - 12 12 100 8 8
H - 1F 12 12 100 8 8
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Catalog 0209/KOR
Solenoid Valves E321H Series
2/2Way Pilot Operated
Model : E321H Series

Features
● Normally Closed
● 7000 Sleeve
● Body : Brass
● Coil : All of 7000 sleeve suitable coil available
● A minimum operating pressure is required
● Air, Water ,Inert gas, Oil applicapable
● Shunt-off applications of liquids with high flow and pressure
● Applied Seal : FKM , EPDM with Factory consult
Application
● Oil Burner
● Blow former
● Compressor
● Industrial machine
Normally Cloased
REFERENCE NO. PORT FLOW ADMISSIBLE MAX. Power
SIZE (L/MIN) DIFF. PRESSURE FLUID Consumption
ORIFICE (BAR) TEMP.(˚C ) (W)
Valve Reference COIL (PF) ( L / min ) SEAL
HOUSING (mm)
no G Liquids Max
Min Gas Liquid Oil DC AC
Gobal Korea (Inch) KV DC AC
I - 1K 30 40 - 100 100 14 10
2995 481865 - 25 40 - 100 100 9 8
4270 481000 - 30 40 - 100 100 8 8
E321H21 8 36 0.3 FKM
4270 486265 40 40 - 100 100 14 14
H - 1F 30 40 - 100 100 8 8
1/4"
H - 1H 40 40 - 100 100 14 14
I - 1K 30 40 100 75 100 14 10
2995 481865 - 25 40 100 75 100 9 8
E321H11 8 36 0.3 NBR
4270 481000 - 30 40 100 75 100 8 8
H - 1F 30 40 100 75 100 8 8
I - 1K 30 40 - 100 100 14 10
2995 481865 - 25 40 - 100 100 9 8
4270 481000 - 30 40 - 100 120 8 8
E321H23 11 50 0.3 FKM
4270 486265 40 40 - 100 140 14 14
H - 1F 30 40 - 100 120 8 8
3/8"
H - 1H 40 40 - 100 140 14 14
I - 1K 30 40 100 75 100 14 10
2995 481865 - 25 40 100 75 100 9 8
E321H13 11 50 0.3 NBR
4270 481000 - 30 40 100 75 100 8 8
H - 1F 30 40 100 75 100 8 8
I - 1K 30 40 - 100 100 14 10
2995 481865 - 25 40 - 100 100 9 8
4270 481000 - 30 40 - 100 120 8 8
E321H25 14.5 60 0.3 FKM
4270 486265 40 40 - 100 140 14 14
H - 1F 30 40 - 100 120 8 8
1/2"
H - 1H 40 40 - 100 140 14 14
I - 1K 30 40 100 75 100 14 10
2995 481865 - 25 40 100 75 100 9 8
E321H15 15 60 0.3 NBR
4270 481000 - 30 40 100 75 100 8 8
H - 1F 30 40 100 75 100 8 8
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Catalog 0209/KOR
Solenoid Valves 708N Series
2/2Way Pilot (Piston) Operated
Model : 708N Series

Features
● Normally Closed
● Body : Brass
● Steam applicapable in High pressure (8bar) and
temperature(180˚c)
● Applied Seal : Teflon
Applications
● Ironing machines
● Tanning plants
● A Sterilizer
● Food and fluid steam Press process
● A dyeing machine
● Hospital equipment
● Tobacco plants
Normally Closed
ADMISSIBLE MAX.
PORT SIZE FLOW Power
REFERENCE NO. DIFF. PRESSURE FLUID
(PF) ORIFICE ( L / min ) (W)
(BAR) TEMP.(ºC) SEAL
G (mm) Liquids
COIL Max
VESSEL N0. HOUSING (INCH) kv Min Steam AC DC
Gobal Korea DC AC
4270 486265 - - 8 180 14 -
708N2 1/2 15 62 0.3
H - 1H-XX - 8 180 14 -
4270 486265 - - 8 180 14 -
708N3 3/4 19 79 0.3 TEFLON
H - 1H-XX - 8 180 14 -
4270 486265 - - 8 180 14 -
708N4 1 28 195 0.3
H - 1H-XX - 8 180 14 -
Cross Section Drawing Dimensions
① Brass Forging Body

⑨
② Orifice Seat(Teflon)
③ Piston Guide ⑦
④ Piston Seal ⑥
⑤ Spring Piston ⑧ ④
⑥ Piston Spring(SUS)
②
(708N2, 708N3) (708N4)
⑤ ①
⑦ Plunger Assembly
③ Dimension
Model
⑧ Float Buttom Seal OUT IN H P L F G S D W
708N2 129 115 68 36 - - - -
⑨ Coil (High Temp., Class H) 708N3 134.5 118 70 36 - - - -
708N4 - 100.5 98 54 41 59.5 93 115
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Coil Reference
Power
24/50
24/60
24/50~60
42/50, 48/60
48/50
100/50, 110/60
110/50
110/50, 115/50
110/60
100/50, 115/60
110/60, 115/60
Consumption(Watt)
WV Coil
Housing & Coil Part 7000
Series Insulation Certification USED ON
No. Sleeve
Sleeve Class
DC AC
4270-481000 - 8 8 F NA A2 B2 S7 A4 OA 6J
OK
4270-486265 - 14 14 H NA A2 A5 OP
GP All
2995-481865 OK - 9 8 F CE A2 B2 A5
I-1K OK - 14 10 F UL, CE 8P
I-1S OK 6 5.5 F UL, CE PO 8P

WV121S
-
WV131S
H-WS OK 9 8 F NA PO B5
H-1F - 8 8 F NA A2 B2 OA 6J
GP All
OK
(KOR Markt)
H-1H - 14 14 H NA A2 A5 OP
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Coil Reference
110/50, 120/60
115/60
200/50, 220/60
220/50
220/60
220/50, 230/50
200/50, 230/60
220/50, 240/60
220/60, 240/60
230/50
230/60
380/50
380/50, 440/60
12/DC
24/DC
48/DC
110/DC
220/DC
Housing & Coil
Housing type
Part No.
4270-481000 3D 4K 5P C1 C2 C4 C5 C7 Coil Housing with screw terminals
4270-486265 A7 B7 S2 F4 A9 C1 C2 C4 Coil Housing with screw terminals
Coils for din plug connection IP67

2995-481865 K8 J3 C1 C2 C4 C5
Lucifer coil
I-1K P3 9P Q3 F4 C1 C2 Molded lead wire
I-1S P3 9P Q3 C1 C2 Molded lead wire
H-WS B7 C1 C2 Coil Housing
H-1F 4K C1 C2 Coil Housing with screw terminals
H-1H A7 B7 S2 C1 C2 Coil Housing with screw terminals
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Memo
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34 CIC Group
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Memo
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Parker Korea Ltd.
CIC Group
777 Jung-ri, Dongtan-myeon, Hwaseong-city Gyeonggi-do, 445-813, Korea
Tel. 031-379-2200
Fax. 031-377-9710
TSU Water seperator
(MISUMI)
OPERATION MANUAL ②Do not use under following conditions.
Fluid except compressed air Air pressure more than 1.0MPa** and
WATER SEPARATOR 0.05MPa* or less
Series AMG Min. 0.05MPa

Max. 1.0 MPa
To get the best performance from your purchase, be Air only !
sure to read this manual carefully before use.

*Type N.C. auto drain: 0.15MPa,
Refer drawings or catalogue for construction and Type N.O. auto drain: 0.1MPa
specifications.
！ WARNING **Option H: 1.6 MPa
Please understand the contents of this operation manual Following conditions lead to cause breakage.
may be revised without notification. Place where more than 0.1MPa Place where air may flow backwards
pressure pulsation
FEATURES No back flow
・Water drop contained in compressed air is effectively removed just by

Over rated flow
installing this.
・You hardly need to replace the element of this product due to unique
structure.
CAUTIONS ON USE
！ WARNING
Keep following items to operate water separator properly. Following conditions
①Do not use under following environment. cause element breakage.
Chemicals Corrosive gas + ③Precautions for installation.
Atmosphere containing organic solvent ・Install vertically.
・Ensure no leakage.
！ WARNING ・Flush inside of pipings with air.
・Do not pipe upwardly.
Following environments
Environment ・Keep sight glass in front.
lead to cause breakage.
lower than ・Drain while liquid level is visible.
Broken pieces injuring
・Drain piping: 5m or less
Environment 5℃ if broken. N.C. auto drain: φ 4 or more (I.D.), φ 10 (O.D.)
Higher than 60℃ N.O. auto drain: φ 6.5 or more (I.D.), φ 10 (O.D.)
Vibration, impact AMG850: φ9 or more (I.D.), 2.8 m or less (overall length)
・Install it in where pressure is higher and temperature is lower.
-1- -2-
Application and line arrangement of water separator ２）Prevention for solid obstruction entering into the water separator
１．General applications and arrangement If large amount of solid obstruction (sand, rust) is intruded into
Please refer to the applications and arrangement the air flowing into the water separator, the obstruction may stack
on the bowl and cause the operating failure of the auto drain and
which are used normally as Figure 1.
the drain cock, and air leakage. However, the intrusion of the
Cleaning obstruction into the water separator can be prevented by setting the
(Air gun) air filter of the main line filter to the inlet side of the water
Air filter separator.
Regulator
MAINTENANCE
General
industrial Although element replacement is basically unnecessary, extremely dirty air
valve and might cause clogging due to deteriorated oil or rust. Replacement is
Compressor sylinder necessary in that case. (When pressure drop reach 0.1MPa)
Water Air filter Lubricator
separator Regulator Element (gasket, o-ring accessory) model number: AMG-EL***
※ *** is AMG size symbol. (Ex: AMG-EL150)
Painting Hexagon socket head bolt
Main line Mist

filter Regulator separator
O-ring(New) O-ring(Used)
Figure１．Application and circuit
２． How to use water separator Gasket(New) Gasket(Used)

１）To maximize the performance of the water separator
Liquidize the moisture (vapor) in the air as much as possible and Element(New) Element(Used)
lower air pressure and relative humidity after removing the
liquidized moisture. To make the condition mentioned above, when the Case
water separator is mounted, keep following points. 【How to replace element】
①Mount the water separator to the place with the highest pressure First, discharge the pressure in the body. (Make pressure 0 MPa)
①Remove four hexagon socket head bolt.
in used pneumatic circuit. (High pressure helps liquidize the
②Replace element, gasket, o-ring. ③Tighten hexagon socket head bolt.
moisture.) Mount the regulator to the outlet side of the water
Reference table production no. showing production month and year of a filter.
separator(just after secondary side). （LX→2007.10）
②Mount the water separator to the place with lowest temperature in
SYMBOL J K L M N o P Q R S T U
used pneumatic circuit.
Year 2005 2006 2007 2008 2009 2010 2011 2012 2013 2014 2015 2016
(Lower temperature helps liquidize the moisture.)
SYMBOL o P Q R S T U V W X y Z
One of ways to lower the temperature is to make the piping at
the inlet side of the water separator longer. Month Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec
Long inlet side piping helps the release of the heat. ＳＭＣＣＯＲＰＯＲＡＴＩＯＮＡＭＸ−ＯＭ−Ｆ００５−Ｃ
-3- -4-
BA01149C/07/EN/08.20
71491465
Products Solutions Services
2020-07-31
Operating Instructions
Smartec CLD18
Conductivity measuring system
Smartec CLD18 Table of contents
Table of contents
1 About this document . . . . . . . . . . . 4 9 Diagnostics and
1.1 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 troubleshooting . . . . . . . . . . . . . . . 34
1.2 Symbols used . . . . . . . . . . . . . . . . . . . . . . . . 4 9.1 General troubleshooting . . . . . . . . . . . . . 34
1.3 Symbols on device . . . . . . . . . . . . . . . . . . . . 5 9.2 Troubleshooting instructions . . . . . . . . . 34
9.3 Queued diagnostic messages . . . . . . . . . . 35
2 Basic safety instructions . . . . . . . 5
2.1 Requirements for personnel . . . . . . . . . . . 5 10 Maintenance . . . . . . . . . . . . . . . . . . 38
2.2 Designated use . . . . . . . . . . . . . . . . . . . . . . 5 10.1 Maintenance tasks . . . . . . . . . . . . . . . . . . 38
2.3 Workplace safety . . . . . . . . . . . . . . . . . . . . 5
2.4 Operational safety . . . . . . . . . . . . . . . . . . . 7
2.5 Product safety . . . . . . . . . . . . . . . . . . . . . . . 7
11 Repair . . . . . . . . . . . . . . . . . . . . . . . . . . 39
11.1 General notes . . . . . . . . . . . . . . . . . . . . . . 39
2.6 IT security . . . . . . . . . . . . . . . . . . . . . . . . . . 7
11.2 Return . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
11.3 Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
3 Product description . . . . . . . . . . . . . 8
3.1 Product design . . . . . . . . . . . . . . . . . . . . . . . 8
12 Accessories . . . . . . . . . . . . . . . . . . . . 40
12.1 Calibration solutions . . . . . . . . . . . . . . . . 40
4 Incoming acceptance and
product identification . . . . . . . . . . 9 13 Technical data . . . . . . . . . . . . . . . . . 40
4.1 Incoming acceptance . . . . . . . . . . . . . . . . . 9 13.1 Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
4.2 Product identification . . . . . . . . . . . . . . . . . 9 13.2 Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
4.3 Scope of delivery . . . . . . . . . . . . . . . . . . . . 10 13.3 Power supply . . . . . . . . . . . . . . . . . . . . . . . 41
4.4 Certificates and approvals . . . . . . . . . . . . 11 13.4 Performance characteristics . . . . . . . . . . 42
13.5 Environment . . . . . . . . . . . . . . . . . . . . . . . 42
5 Installation . . . . . . . . . . . . . . . . . . . . 11 13.6 Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
5.1 Installation conditions . . . . . . . . . . . . . . . 11 13.7 Mechanical construction . . . . . . . . . . . . . 44
5.2 Mounting the compact device . . . . . . . . . 17
5.3 Post-installation check . . . . . . . . . . . . . . . 17 Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
6 Electrical connection . . . . . . . . . . 17
6.1 Connecting the transmitter . . . . . . . . . . . 17
6.2 Ensuring the degree of protection . . . . . 21
6.3 Post-connection check . . . . . . . . . . . . . . . 21
7 Operation options . . . . . . . . . . . . . 22
7.1 Overview of operating options . . . . . . . . 23
7.2 Structure and function of the operating
menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
8 Commissioning . . . . . . . . . . . . . . . . 25
8.1 Switching on the measuring device . . . . 25
8.2 Display settings (Display menu) . . . . . . . 25
8.3 Configuring the measuring device . . . . . 26
8.4 Advanced settings . . . . . . . . . . . . . . . . . . 26
8.5 Calibration (Calibration menu) . . . . . . . . 31
Endress+Hauser 3
About this document Smartec CLD18
1 About this document

1.1 Warnings
Structure of information Meaning
LDANGER This symbol alerts you to a dangerous situation.

Causes (/consequences) Failure to avoid the dangerous situation will result in a fatal or serious injury.
If necessary, Consequences of non-
compliance (if applicable)
‣ Corrective action
LWARNING This symbol alerts you to a dangerous situation.

Causes (/consequences) Failure to avoid the dangerous situation can result in a fatal or serious injury.
LCAUTION This symbol alerts you to a dangerous situation.

Causes (/consequences) Failure to avoid this situation can result in minor or more serious injuries.
NOTICE This symbol alerts you to situations which may result in damage to property.
Cause/situation
‣ Action/note
1.2 Symbols used
Symbol Meaning
Additional information, tips
Permitted or recommended
Not permitted or not recommended
Reference to device documentation
Reference to page
Reference to graphic
 Result of a step
4 Endress+Hauser
Smartec CLD18 Basic safety instructions
1.3 Symbols on device
Symbol Meaning
Reference to device documentation
2 Basic safety instructions

2.1 Requirements for personnel
• Installation, commissioning, operation and maintenance of the measuring system may be
carried out only by specially trained technical personnel.
• The technical personnel must be authorized by the plant operator to carry out the specified
activities.
• The electrical connection may be performed only by an electrical technician.
• The technical personnel must have read and understood these Operating Instructions and
must follow the instructions contained therein.
• Faults at the measuring point may only be rectified by authorized and specially trained
personnel.
Repairs not described in the Operating Instructions provided must be carried out only
directly at the manufacturer's site or by the service organization.
2.2 Designated use

The compact measuring system is used for inductive conductivity measurement in liquids with
medium to high conductivity.
Use of the device for any purpose other than that described, poses a threat to the safety of
people and of the entire measuring system and is therefore not permitted.
The manufacturer is not liable for damage caused by improper or non-designated use.
NOTICE
Applications outside specifications!
Incorrect measurements, malfunctions and even measuring point failure could result
‣ Use the product only in accordance with the specifications.
‣ Pay attention to the technical data on the nameplate.
2.3 Workplace safety

As the user, you are responsible for complying with the following safety conditions:
• Installation guidelines
• Local standards and regulations
Endress+Hauser 5
Basic safety instructions Smartec CLD18
Electromagnetic compatibility
• The product has been tested for electromagnetic compatibility in accordance with the
applicable international standards for industrial applications.
• The electromagnetic compatibility indicated applies only to a product that has been
connected in accordance with these Operating Instructions.
6 Endress+Hauser
Smartec CLD18 Basic safety instructions
2.4 Operational safety

Before commissioning the entire measuring point:
1. Verify that all connections are correct.
2. Ensure that electrical cables and hose connections are undamaged.
3. Do not operate damaged products, and protect them against unintentional operation.
4. Label damaged products as defective.
During operation:
‣ If faults cannot be rectified:
products must be taken out of service and protected against unintentional operation.
2.5 Product safety

The product is designed to meet state-of-the-art safety requirements, has been tested, and
left the factory in a condition in which it is safe to operate. The relevant regulations and
international standards have been observed.
2.6 IT security
We only provide a warranty if the device is installed and used as described in the Operating
Instructions. The device is equipped with security mechanisms to protect it against any
inadvertent changes to the device settings.
IT security measures in line with operators' security standards and designed to provide
additional protection for the device and device data transfer must be implemented by the
operators themselves.
Endress+Hauser 7
Product description Smartec CLD18
3 Product description
3.1 Product design
5
4
3
2
A0019184
1 Elements
1 Temperature sensor
2 Process connection
3 Leakage bore (offset by 90° in relation to the flow direction)
4 Removable housing cover
5 Window for display
6 Cable glands (M16)
7 Flow opening of sensor
8 Endress+Hauser
Smartec CLD18 Incoming acceptance and product identification
4 Incoming acceptance and product identification

4.1 Incoming acceptance
1. Verify that the packaging is undamaged.
 Notify the supplier of any damage to the packaging.
Keep the damaged packaging until the issue has been resolved.
2. Verify that the contents are undamaged.
 Notify the supplier of any damage to the delivery contents.
Keep the damaged goods until the issue has been resolved.
3. Check that the delivery is complete and nothing is missing.
 Compare the shipping documents with your order.
4. Pack the product for storage and transportation in such a way that it is protected
against impact and moisture.
 The original packaging offers the best protection.
Make sure to comply with the permitted ambient conditions.
If you have any questions, please contact your supplier or your local Sales Center.
Technical data→  40
4.2 Product identification

4.2.1 Nameplate
The nameplate provides you with the following information on your device:
• Manufacturer identification
• Order code
• Extended order code
• Serial number
• Firmware version
• Ambient and process conditions
• Input and output values
• Measuring range
• Safety information and warnings
• Protection class
‣ Compare the information on the nameplate with the order.
Endress+Hauser 9
Incoming acceptance and product identification Smartec CLD18
4.2.2 Product identification
Product page
www.endress.com/CLD18
Interpreting the order code

The order code and serial number of your product can be found in the following locations:
• On the nameplate
• In the delivery papers
Obtaining information on the product

1. Go to www.endress.com.
2. Call up the site search (magnifying glass).
3. Enter a valid serial number.
4. Search.
 The product structure is displayed in a popup window.
5. Click on the product image in the popup window.
 A new window (Device Viewer) opens. All of the information relating to your
device is displayed in this window as well as the product documentation.
Manufacturer's address
Endress+Hauser Conducta GmbH+Co. KG
Dieselstraße 24
D-70839 Gerlingen
4.3 Scope of delivery

The delivery comprises:
• A Smartec CLD18 measuring system in the version ordered
• Operating Instructions BA01149C/07/EN
10 Endress+Hauser
Smartec CLD18 Installation
4.4 Certificates and approvals

4.4.1 Declaration of Conformity
The product meets the requirements of the harmonized European standards. As such, it
complies with the legal specifications of the EU directives. The manufacturer confirms
successful testing of the product by affixing to it the  mark.
4.4.2 Hygiene
FDA
All materials in contact with the product are FDA-listed materials (apart from the PVC process
connections).
EHEDG
Certified cleanability according to EHEDG Type EL Class I.
When using the sensor in hygienic applications, please note that the cleanability of the
sensor also depends on the way the sensor is installed. To install the sensor in a pipe, use
the appropriate and EHEDG-certified flow vessels for the particular process connection.
3-A
Certified according to 3-A Standard 74- ("3-A Sanitary Standards for Sensor and Sensor
Fittings and Connections Used on Milk and Milk Products Equipment").
EC Regulation No. 1935/2004
The sensor meets the requirements of EC Regulation No. 1935/2004 on materials and articles
intended to come into contact with food.
4.4.3 Pressure approval

Canadian pressure approval for pipes according to ASME B31.3
5 Installation
5.1 Installation conditions
5.1.1 Installation instructions
Hygienic requirements
‣ Easily cleanable installation of equipment according to the criteria of the EHEDG must be
free of dead legs.
‣ If a dead leg is unavoidable, it shall be kept as short as possible. Under no circumstances
shall the length of a dead leg L exceed the pipe’s inner diameter D minus the equipment’s
enveloping diameter d. The condition L ≤ D – d applies.
‣ Furthermore, the dead leg must be self-draining, so neither product nor process fluids are
retained therein.
Endress+Hauser 11
Installation Smartec CLD18
‣ Within tank installations, the cleaning device must be located so that it directly flushes the
dead leg.
‣ For further reference, see the recommendations concerning hygienic seals and installations
in EHEDG Doc. 10 and the Position Paper: “Easy cleanable Pipe couplings and Process
connections”.
For 3-A-compliant installation, please observe the following:
‣ After the device has been mounted, hygienic integrity must be guaranteed.
‣ The leakage hole must be located at the lowest point on the device.
‣ 3-A-compliant process connections must be used.
Orientations
The sensor must be completely immersed in the medium. Avoid air bubbles in the area of the
sensor.
> 1 (3.3)
A0037970
2 Orientation of conductivity sensors. Engineering unit: m (ft)
If the flow direction changes (after pipe bends), turbulence in the medium can result.
‣ Install the sensor at a distance of at least 1 m (3.3 ft) downstream from a pipe bend.
12 Endress+Hauser
The product should flow along the hole of the sensor (see the arrows on the housing). The
symmetrical measuring channel allows flow in both directions.
In confined installation conditions, the walls affect the ionic

current in the liquid. This effect is offset by what is referred to
as the installation factor. The installation factor can be entered
in the transmitter for the measurement or the cell constant is
corrected by multiplying by the installation factor.
The value of the installation factor depends on the diameter
and the conductivity of the pipe nozzle as well as the distance a
between the sensor and the wall.
The installation factor can be disregarded (f = 1.00) if the
distance to the wall is sufficient (a > 20 mm, from DN 60).
If the distance to the wall is smaller, the installation factor
a
increases for electrically insulating pipes (f > 1) and decreases
for electrically conductive pipes (f < 1). A0037972
It can be measured using calibration solutions, or a close 3 Installation of CLD18

approximation can be determined from the following diagram.
a Wall distance
1.05
2
1.00
1
0.95
0 10 20 30 40 a [mm]
0.39 0.79 1.18 1.57 a [inch]

A0020517
4 Relationship between installation factor f and wall distance a

1 Electrically conductive pipe wall
2 Electrically insulating pipe wall
Install the measuring system in such a way that the housing is not exposed to direct
sunlight.
Endress+Hauser 13
28 (1.10) 85 (3.35)
78 (3.07)
127 (5.00)
A 23 A
(0.91)
69 (2.72)
(2.10)
(0.24)
53.3
6
112 (4.41)
28 (1.10) 85 (3.35)
(2.89)
123 (4.84)
73.5
5.2
(0.20)
B B
(2.10)
53.3
(2.72)
69
20.5
(0.81)
114.5 (4.51)
12.3 (0.49)
136.5 (5.37)
123 (4.84)
32.8 (1.29)
17.1 (0.67)
C D
101.7 (4.00)
86 (3.39)
A0018942
5 Dimensions and versions (examples). Dimensions: mm (in)

A Plastic housing with thread G 1½
B Stainless steel housing with ISO 2852 clamp 2"
C Stainless steel housing with Varivent DN 40 to 125
D Plastic housing with coupling nut 2¼" PVC
14 Endress+Hauser
5.1.2 Installation examples
51 (2.01)
Ø 48.3
(1.90)
Ø 44.3
(1.74)
A0019302
6 Installation in DN 40 pipe with Tri-Clamp 2" process connection. Dimensions: mm (in)
Endress+Hauser 15
(1.22)
31
(1.50)
(1.61)
Ø 41
Ø 38
A0022166
7 Installation in DN 40 pipe with Varivent process connection. Dimensions: mm (in)
(2.26)
57.5
Ø 40 (1.58)
Ø 50 (1.97)
A0024073
8 Installation in DN 40 pipe with 2¼" PVC coupling nut process connection. Dimensions: mm (in)
16 Endress+Hauser
Smartec CLD18 Electrical connection
5.2 Mounting the compact device

‣ Choose the installation depth of the sensor in the medium such that the coil body is
completely immersed in the medium.
Pay attention to the information on wall clearance →  11
1. Mount the compact device directly on a pipe nozzle or tank nozzle via the process
connection.
2. For the 1½" threaded connection, use a Teflon tape to seal the connection and an
adjustable pin wrench (DIN 1810, flat face, size 45 to 50 mm (1.77 to 1.97 in)) to
tighten it.
3. When installing, align the compact device in such a way that the medium flows through
the flow opening of the sensor in the direction of medium flow. Use the arrow on the
nameplate to help you align the device.
4. Tighten the flange.
5.3 Post-installation check

1. Following installation, check the compact device for damage.
2. Ensure that the compact device is protected against direct sunlight.
6 Electrical connection
LWARNING
Device is live!
Incorrect connection may result in injury or death!
‣ The electrical connection may be performed only by an electrical technician.
‣ The electrical technician must have read and understood these Operating Instructions and
must follow the instructions contained therein.
‣ Prior to commencing connection work, ensure that no voltage is present on any cable.
6.1 Connecting the transmitter

LWARNING
Risk of electric shock!
‣ At the supply point, the power supply must be isolated from dangerous live cables by
double or reinforced insulation in the case of devices with a 24 V power supply.
Endress+Hauser 17
Electrical connection Smartec CLD18
6.1.1 Direct connection of the cables
mA
IOut1 MRS
Lf
mA
IOut2 L
X
Alarm Out
A0033106
9 Electrical connection
18 Endress+Hauser
L+
Out+
MRS+
IOut2+
+
IOut1+
L-
L-
Out-
MRS-
IOut2-
IOut1-
L
2
A0029684
 10 Terminal assignment
IOut1 Current output conductivity (active)

IOut2 Current output temperature (active)
Out Alarm output (open-collector)
MRS Binary input (measuring range switch)
L+/L- Power supply
X Grounding pin (flat male tab 4.8 mm)
1 Cover on electronics box
2 Electronics box
NOTICE
Removing the electronics box will destroy the sensor connection!
‣ The electronics box must not be removed under any circumstances.
‣ Do not open the cover on the electronics box.
The recommended cable cross-section for the connecting cables is 0.5 mm2. The
maximum cable cross-section is 1.0 mm2.
Connect the transmitter of the compact device as follows:

1. Unscrew the housing cover.
Endress+Hauser 19
Electrical connection Smartec CLD18
2. Guide the connecting cables through the cable glands.

3. Connect the cables as per the terminal assignment diagram.
4. Connect the protective ground to the terminal pin for the housing ground.
6.1.2 Connection via M12 connector
4 3
1 2
A0033108
 11 View of connector, 4-pin, data cable (at device)

1 IOUT1+ Conductivity 3 IOUT2- Temperature
2 IOUT2+ Temperature 4 IOUT1- Conductivity
5
4
6
7 3
8
1 2
A0033109
 12 View of connector, 8-pin, power supply/controller (at device)

1 L+ Power supply 5 Out+ Alarm output+
2 L- Power supply 6 Out- Alarm output-
3 MRS+ Binary input 7 GND Functional ground
4 MRS- Binary input 8 GND Functional ground
20 Endress+Hauser
6.2 Ensuring the degree of protection

Guarantee the degree of protection as follows:
1. Verify that the O-ring is seated correctly in the housing cover.
2. Screw the housing cover tight until the stop.
3. Screw the cable glands tight.
6.3 Post-connection check

Once you have performed the electrical connections, carry out the following checks :
Instrument status and specifications Notes
Are the transmitter and cables free from damage on the outside? Visual inspection
Electrical connection Notes
Are the installed cables strain-relieved and not twisted?
Is the cable run correct, without loops and cross-overs?
Are the signal cables correctly connected as per the wiring diagram?
Are all the cable entries fitted, tightened and leak-proof?
Are the PE distributor blocks grounded (if present)? Grounding is carried out at the point
of installation.
Endress+Hauser 21
Operation options Smartec CLD18
7 Operation options
1
3
Main µS/cm
- ESC -
_
+ E
4
A0018963
 13 Display and keys of the CLD18

1 Parameters
2 Measured value
3 Unit
4 Operating keys
The ASTN display (Advanced Super Twisted Nematic) is split into two sections. The segment
section displays the measured value. The dot-matrix section displays the parameter and unit.
The operating texts are displayed in English.
In the event of an error the device automatically alternates between displaying the error and
the measured value.
22 Endress+Hauser
Smartec CLD18 Operation options
7.1 Overview of operating options
• Open the Configuration menu

• Confirm the entry
E • Select a parameter or submenu
A0029236
Within the Configuration menu:

• Gradually select the specified menu items / characters for the
parameter
A0029235
• Change the selected parameter
Outside the Configuration menu:
Display enabled and calculated channels, as well as minimum and
maximum values, for all the active channels.
Press both keys simultaneously (< 3 s) to quit the setup without
saving any changes.
Always quit menu items / submenus at the end of the menu via "x Back".
Symbols in the editing mode:
Accept entry.
A0020597 If this symbol is selected, the entry is applied at the position specified by the user, and you quit editing mode.
Reject entry.
If this symbol is selected, the entry is rejected and you quit editing mode. The previously set text remains.
A0020598
Jump one position to the left.

A0020599 If this symbol is selected, the cursor jumps one position to the left.
Delete backwards.
A0020600
If this symbol is selected, the character to the left of the cursor position is deleted.
Delete all.
if this symbol is selected, the entire entry is deleted.
A0020601
Endress+Hauser 23
Operation options Smartec CLD18
7.2 Structure and function of the operating menu

The operating functions of the compact measuring device are divided into the following
menus:
Display Settings for the device display: contrast, brightness, time for alternating measured values on the display
Setup Device settings
Calibration Perform sensor calibration*
Diagnostics Device information, diagnostics logbook, sensor information, simulation
* The air set and the correct cell constant have already been configured at the factory for the
Smartec CLD18. A sensor calibration is not necessary during commissioning.
24 Endress+Hauser
Smartec CLD18 Commissioning
8 Commissioning
8.1 Switching on the measuring device
1. Familiarize yourself with the operation of the transmitter before it is first switched on.
 After power-up, the device performs a self-test and then goes to the measuring
mode.
2. If you are commissioning the device for the first time, Setup program the as described in
the following sections of the Operating Instructions.
8.2 Display settings (Display menu)

1. Use the 'E' key to call up the main menu.
 The menu appears on the display Display.
2. Press the 'E' key again to open the menu.
3. Use the option, Back which can be found at the bottom of each menu, to move up a
level in the menu structure.
Parameter Possible settings Description
Contrast 1 to 7 Setting for the contrast

Default: 5
Brightness 1 to 7 Setting for the brightness of the display

Default: 5
Alternating time 0, 3, 5, 10 s Alternating time between the two measured values

Default: 5 0 means that the values do not alternate on the display
Endress+Hauser 25
Commissioning Smartec CLD18
8.3 Configuring the measuring device

2. Navigate through the available menus with the '+' and '–' keys.
3. Press the 'E' key to open the desired menu.
Default settings are in bold.
Current range 4-20 mA ‣ Select the current range.

0-20 mA
Out1 0/4 mA 0 to 2000000 μS/cm ‣ Enter the measured value at which the min. current value (0/4 mA) is
0 μS/cm present at the transmitter output.
Out1 20 mA 0 to 2000000 μS/cm ‣ Enter the measured value at which the max. current value (20 mA) is
0 μS/cm present at the transmitter output.
Out2 0/4 mA -50 to 250 °C ‣ Enter the measured value at which the min. current value (0/4 mA) is
0.0 °C present at the transmitter output.
Out2 20 mA -50 to 250 °C ‣ Enter the measured value at which the max. current value (20 mA) is
100.0 °C present at the transmitter output.
Damping main 0 ... 60 s Damping value for the conductivity measured value
0s
Extended setup
 Advanced settings→  26
Manual hold Off, On Function for freezing the current and alarm outputs
8.4 Advanced settings

Default settings are in bold.
System General settings
Device tag Customized text Enter the device designation

Max. 16 characters
26 Endress+Hauser
Temp. unit °C Setting for the temperature unit

°F
Hold release 0 to 600 s Prolongs the device hold when the hold condition no longer
0s applies
Alarm delay 0 to 600 s Time delay after which an alarm is output

0s This suppresses alarm conditions that are present for a period
that is shorter than the alarm delay time.
Input Setting for the inputs
Cell const. Read only Displays the cell constant
Inst. factor 0.1 to 5.0

1.0  The effects of the distance from the wall can be corrected
with the installation factor →  29
Unit Auto, μS/cm, mS/cm Unit of conductivity

"auto" automatically switches between μS/cm and mS/cm.
Damping main 0 ... 60 s Setting for the damping

0s
Temp. comp. Off, Linear Setting for temperature compensation
Alpha coeff. 1.0 to 20.0 %/K Coefficient for linear temperature compensation
2.1 %/K
Ref. temp. +10 to +50 °C Enter the reference temperature

25 °C
Process check The process check checks the measuring signal for stagnation. An
alarm is triggered if the measuring signal does not change over a
specific period (several measured values).
Function On, Off ‣ Switch the process check on or off.

Duration 1 to 240 min The measured value must change within this time as otherwise
60 min an error message is triggered.
Observation width 1 to 20 % Bandwidth for the process check

0.0 %
Analog output Setting for analog outputs
Current range 4-20 mA Current range for analog output

0-20 mA
Out1 0/4 mA 0 to 2000000 μS/cm ‣ Enter the measured value at which the min. current value
0 μS/cm (0/4 mA) is present at the transmitter output.
Out1 20 mA 0 to 2000000 μS/cm ‣ Enter the measured value at which the max. current value
0 μS/cm (20 mA) is present at the transmitter output.
Out2 0/4 mA -50 to 250 °C ‣ Enter the measured value at which the min. current value
0.0 °C (0/4 mA) is present at the transmitter output.
Out2 20 mA -50 to 250 °C ‣ Enter the measured value at which the max. current value
100.0 °C (20 mA) is present at the transmitter output.
Endress+Hauser 27
MRS
 Setting for measuring range switching →  31
Out1 0/4 mA 0 to 2000000 μS/cm ‣ Enter the measured value at which the min. current value
0 μS/cm (0/4 mA) is present at the transmitter output.
Out1 20 mA 0 to 2000000 μS/cm ‣ Enter the measured value at which the max. current value
0 μS/cm (20 mA) is present at the transmitter output.
Out2 0/4 mA -50 to 250 °C ‣ Enter the measured value at which the min. current value
0.0 °C (0/4 mA) is present at the transmitter output.
Out2 20 mA -50 to 250 °C ‣ Enter the measured value at which the max. current value
100.0 °C (20 mA) is present at the transmitter output.
Damping main 0 ... 60 s Setting for the damping

0s
Alpha coeff. 1.0 to 20 %/K Coefficient for linear temperature compensation

2.1 %/K
Factory default Factory settings
Please confirm No
No, Yes
28 Endress+Hauser
8.4.1 Installation factor

In confined installation conditions, the conductivity measurement in the liquid is affected by
the pipe walls. This effect is offset by the installation factor. The cell constant is corrected by
multiplying by the installation factor.
The value of the installation factor depends on the diameter and the conductivity of the pipe
nozzle as well as the sensor's distance to the wall.
The installation factor f (f = 1.00) can be disregarded if the distance to the wall is sufficient
(a>20 mm (0.79 in), from DN60).
If the distance to the wall is small, the installation factor increases for electrically insulating
pipes (f > 1), and decreases for electrically conductive pipes (f < 1).
It can be measured using calibration solutions, or a close approximation determined from the
following diagram.
1.05
2
1.00
1
0.95
0 10 20 30 40 a [mm]
0.39 0.79 1.18 1.57 a [inch]

A0020517
 14 Relationship between the installation factor (f) and the distance from wall (a)
1 Electrically conductive pipe wall
2 Electrically insulating pipe wall
Endress+Hauser 29
8.4.2 Temperature compensation

The conductivity of a liquid depends heavily on the temperature, as the mobility of the ions
and the number of dissociated molecules are temperature-dependent. In order to compare
measured values, they must be referenced to a defined temperature. The reference
temperature is 25 °C (77 °F).
The temperature is always specified when the conductivity is specified. k(T0) represents the
conductivity measured at 25 °C (77 °F) or referenced back to 25 °C (77 °F).
The temperature coefficient α represents the percentage change in the conductivity per degree
of temperature change. The conductivity k at the process temperature is calculated as follows:
k(T) = k(T0) . (1+ a . (T - T0))

A0009163
Where
k(T) = conductivity at process temperature T
k(T0) = conductivity at process temperature T0
The temperature coefficient depends on both the chemical composition of the solution and on
the temperature, and is between 1 and 5 % per °C. The electrical conductivity of the majority
of diluted saline solutions and natural waters changes in a close-to-linear fashion.
Typical values for the temperature coefficient α:
Natural waters Approx. 2 %/K

Salts (e.g. NaCl) Approx. 2.1 %/K
Alkali (e.g. NaOH) Approx. 1.9 %/K
Acids (e.g. HNO3) Approx. 1.3 %/K
30 Endress+Hauser
8.4.3 Measuring range switch (MRS)

Measuring range switching involves a parameter set changeover for two substances:
• in order to cover a large measuring range
• in order to adjust temperature compensation in the event of a product change
The two analog outputs can each be configured with two parameter sets.
• Parameter set 1:
• The parameters for the current outputs and the damping can be set Setup in the menu.
• The alpha coefficient for temperature compensation can be set Setup/Extended setup/
Input in the menu.
• Parameter set 1 is active if the "MRS" binary input is Low .
• Parameter set 2:
• The parameters for the current outputs, the damping and the alpha coefficient for
temperature compensation can be configured Setup/Extended setup/Remote switch in
the menu.
• Parameter set 2 is active if the "MRS" binary input High is .
The settings for parameter set 1 are also listed in Extended setup/Analog output the
menu.
Technical data→  41
8.5 Calibration (Calibration menu)

In the case of the Smartec CLD 18, the air set and the correct cell constant have already been
configured at the factory. A sensor calibration is not necessary during commissioning.
8.5.1 Types of calibration

The following types of calibration are possible:
• Cell constant with calibration solution
• Air set (residual coupling)
8.5.2 Cell constant
General
The calibration of a conductivity measuring system is always performed in such a way that the
suitable calibration solutions determine or verify the exact cell constant. This process is
described in the standards EN 7888 and ASTM D 1125, for example, and the method for
producing a number of calibration solutions is explained.
Endress+Hauser 31
Calibrating the cell constant

‣ With this type of calibration, enter a reference value for the conductivity.
 In the result, the device calculates a new cell constant for the sensor.
First switch off the temperature compensation:

1. Select the menu Setup/Extended setup/Input/Temp. comp. .
2. Off Select .
3. Return to the menu Setup .
Perform the calculation of the cell constant as follows:

1. Select the menu Calibration/Cell const. .
2. Cond. ref. Select and enter the value of the standard solution.
3. Place the sensor in the medium.
4. Start the calibration.
 "Wait calib." - wait for calibration to end. The new value is displayed after the
calibration.
5. Press the Plus key.
 "Save calib data?"
6. Yes Select .
 "Calib successful"
7. Switch the temperature compensation back on.
32 Endress+Hauser
8.5.3 Air set (residual coupling)

For physical reasons, the calibration line goes through zero in the case of conductive sensors
(a current flow of 0 corresponds to a conductivity of 0). When working with inductive sensors,
the residual coupling between the primary coil (transmitter coil) and secondary coil (receiver
coil) must be taken into account or compensated for. The residual coupling is not only caused
by the direct magnetic coupling of the coils but also by crosstalk in the supply cables.
As is the case with the sensors, the cell constant is then determined using a precise calibration
solution.
To perform an airset, the sensor must be dry.
Perform an airset as follows:

1. Calibration/Airset Select .
 The current value is displayed.
 "Keep sensor in air"
3. Keep the dried sensor in air and press the Plus key.
 "Wait calib." - wait for calibration to end. The new value is displayed after the
calibration.
 "Save calib data?"
5. Yes Select .
 "Calib successful"
 The device switches back to the measuring mode.
Endress+Hauser 33
Diagnostics and troubleshooting Smartec CLD18
9 Diagnostics and troubleshooting

9.1 General troubleshooting
User interface Cause Solution
No measured value displayed No power supply connected Check the device's power supply.
Power is supplied, device is defective The device must be replaced.
Diagnostic message is displayed

 Diagnostic messages →  35
9.2 Troubleshooting instructions

Current diag. Read only Displays the current diagnostic message
Last diag. Read only Displays the last diagnostic message
Diag. logbook Read only Displays the last diagnostic messages
Device info Read only Displays device information
Sensor info Read only Displays sensor information
Simulation
Analog out 1 Off Outputs a corresponding value at the "Analog out 1"
0 mA, 3.6 mA, 4 mA, 10 mA, 12 mA, output.
20 mA, 21 mA
Analog out 2 Off Outputs a corresponding value at the "Analog out 2"
0 mA, 3.6 mA, 4 mA, 10 mA, 12 mA, output.
20 mA, 21 mA
Alarm out Off

Active
Inactive
Reset device
34 Endress+Hauser
Smartec CLD18 Diagnostics and troubleshooting
9.3 Queued diagnostic messages

The diagnostic message consists of a diagnostic code and a message text. The diagnostic code
consists of the error category as per Namur NE 107 and the message number.
Error category (letter in front of the message number):
• F = Failure, a malfunction has been detected
The measured value of the affected channel is no longer reliable. Look for the cause in the
measuring point. If a control system is connected, it must be switched to manual mode.
• M = Maintenance required, action should be taken as soon as possible
The device still measures correctly. Immediate measures are not necessary. Proper
maintenance efforts may prevent a possible malfunction in the future.
• C = Function check, waiting (no error)
Maintenance work is being performed on the device. Wait until the work has been
completed.
• S = Out of specification, the measuring point is being operated outside your specification
Operation is still possible. However, you run the risk of increased wear, shorter operating
life or reduced measurement accuracy. Look for the cause in the measuring point.
Diagnostic code Message text Description
F61 Sensor elec. Sensor electronics defective

Remedy:
Contact the Service Department
F62 Sens. Connect Sensor connection

Remedy:
F100 Sensor comm. Sensor not communicating

Possible reasons:
No sensor connection
Remedy:
F130 Sensor supply Sensor check

No conductivity displayed
Possible reasons:
• Sensor in air
• Sensor defective
Remedy:
• Check sensor installation
• Contact the Service Department
F143 Selftest Sensor self-test error

Remedy:
F152 No airset Sensor data

No calibration data available
Remedy:
Perform an air set
Endress+Hauser 35
Diagnostics and troubleshooting Smartec CLD18
F523 Cell constant Sensor calibration warning

Invalid cell constant, max. range reached
Remedy:
• Enter cell constant as per factory specifications
F524 Cell constant Sensor calibration warning

Min. possible cell constant is undershot
Remedy:
F845 Device id Incorrect hardware configuration
F847 Couldn’t save param Incorrect parameters
F848 Calib AO1 Incorrect calibration values for analog output 1
F849 Calib AO2 Incorrect calibration values for analog output 2
F904 Process check Process check system alarm

Measuring signal has not changed for a long time
Possible reasons:
• Contaminated sensor, or sensor in air
• No flow to sensor
• Software error
Remedy:
• Check electrode system
• Check sensor
• Restart device
C107 Calib. active Sensor calibration is active

Remedy:
Wait for calibration to be finished
C154 No calib. data Sensor data

No calibration data available, factory settings are used
Remedy:
• Check the calibration information of the sensor
C850 Simu AO1 Simulation of analog output 1 is active
C851 Simu AO2 Simulation of analog output 2 is active
36 Endress+Hauser
Smartec CLD18 Diagnostics and troubleshooting
S844 Process value Measured value outside the specified range

Possible reasons:
• Sensor in air
• Incorrect flow to sensor
Remedy:
• Increase process value
• Check electrode system
M500 Not stable Sensor calibration aborted

Main measured value fluctuating
Possible reasons:
• Sensor in air
• Sensor fouled
• Incorrect flow to sensor
Remedy:
• Check sensor
• Check installation
M526 Cell constant Sensor calibration warning

Invalid cell constant, max. range reached
Remedy:
• Repeat the calibration
M528 Cell constant Sensor calibration warning

Min. possible cell constant is undershot
Remedy:
• Repeat the calibration
Endress+Hauser 37
Maintenance Smartec CLD18
10 Maintenance
LWARNING
Risk of injury if medium escapes!
‣ Before each maintenance task, ensure that the process pipe is unpressurized, empty and
rinsed.
The electronics box does not contain any parts that the user must maintain.
• The cover on the electronics box may be opened only by the Endress+Hauser Service
Department.
• The electronics box may only be removed by the Endress+Hauser Service Department.
10.1 Maintenance tasks

10.1.1 Cleaning the housing
‣ Clean the front of the housing using commercially available cleaning agents only.
The front of the housing is resistant to the following in accordance with DIN 42 115:
• Ethanol (for a short time)
• Diluted acids (max. 2% HCl)
• Diluted bases (max. 3% NaOH)
• Soap-based household cleaning agents
‣ When performing any work on the device, bear in mind any potential impact this may have
on the process control system or on the process itself.
NOTICE
Prohibited cleaning agents!
Damage to the housing surface or housing seal
‣ Never use concentrated mineral acids or alkaline solutions for cleaning.
‣ Never use organic cleaners such as benzyl alcohol, methanol, methylene chloride, xylene or
concentrated glycerol cleaner.
‣ Never use high-pressure steam for cleaning.
38 Endress+Hauser
Smartec CLD18 Repair
11 Repair
The O-ring is defective if medium escapes from the leakage hole.
‣ Contact the E+H Service Department to replace the O-ring.
11.1 General notes

‣ Only use spare parts from Endress + Hauser to guarantee the safe and stable functioning of
the device.
Detailed information on the spare parts is available at:

www.endress.com/device-viewer
11.2 Return
The product must be returned if repairs or a factory calibration are required, or if the wrong
product was ordered or delivered. As an ISO-certified company and also due to legal
regulations, Endress+Hauser is obliged to follow certain procedures when handling any
returned products that have been in contact with medium.
To ensure the swift, safe and professional return of the device:

‣ Refer to the website www.endress.com/support/return-material for information on the
procedure and conditions for returning devices.
11.3 Disposal
If required by the Directive 2012/19/EU on waste electrical and electronic equipment

(WEEE), the product is marked with the depicted symbol in order to minimize the disposal
of WEEE as unsorted municipal waste. Do not dispose of products bearing this marking as
unsorted municipal waste. Instead, return them to Endress+Hauser for disposal under the
applicable conditions.
Endress+Hauser 39
Accessories Smartec CLD18
12 Accessories
The following are the most important accessories available at the time this documentation
was issued.
‣ For accessories not listed here, please contact your Service or Sales Center.
12.1 Calibration solutions

Conductivity calibration solutions CLY11
Precision solutions referenced to SRM (Standard Reference Material) by NIST for qualified
calibration of conductivity measuring systems in accordance with ISO 9000:
• CLY11-C, 1.406 mS/cm (reference temperature 25 °C (77 °F)), 500 ml (16.9 fl.oz)
Order No. 50081904
• CLY11-D, 12.64 mS/cm (reference temperature 25 °C (77 °F)), 500 ml (16.9 fl.oz)
Order No. 50081905
• CLY11-E, 107.00 mS/cm (reference temperature 25 °C (77 °F)), 500 ml (16.9 fl.oz)
Order No. 50081906
For further information on "Calibration solutions", see the Technical Information
13 Technical data
13.1 Input
13.1.1 Measured variable
Conductivity
Temperature
13.1.2 Measuring range
Conductivity: Recommended range: 200 μS/cm to 1000 mS/cm

(uncompensated)
Temperature: –10 to 130 °C (14 to 266 °F)
40 Endress+Hauser
Smartec CLD18 Technical data
13.1.3 Binary input

The binary input is used for measuring range switching.
Voltage range 0 V to 30 V
Voltage High Min. 12 V
Voltage Low max. 9.0 V
Current consumption at 24 V 30 mA
Undefined voltage range 9.0 to 12 V
13.2 Output
13.2.1 Output signal
Conductivity: 0 / 4 to 20 mA, galvanically isolated

Temperature: 0 / 4 to 20 mA, galvanically isolated
13.2.2 Load
Max. 500 Ω
13.2.3 Characteristic
Linear
13.2.4 Signal resolution
Resolution: > 13 bit

Accuracy: ± 20 μA
13.2.5 Alarm output

The alarm output is implemented as an "open collector".
Max. current 200 mA

Max. voltage 30 V DC
Error or device without supply voltage Alarm output blocked (0 mA)

No error Alarm output open (up to 200 mA)
13.3 Power supply

13.3.1 Supply voltage
24 V DC ± 20 %, protected against reverse polarity
13.3.2 Power consumption

3W
Endress+Hauser 41
Technical data Smartec CLD18
13.3.3 Cable specification
Recommendation 0.5 mm2

max. 1.0 mm2
13.3.4 Overvoltage protection

Overvoltage category I
13.4 Performance characteristics

13.4.1 Response time
Conductivity: t95 < 1.5 s

Temperature: t90 < 20 s
13.4.2 Maximum measured error
Conductivity: ± (2.0 % of measured value + 20 µS/cm)

Temperature: ± 1.5 K
Signal outputs ± 50 μA
13.4.3 Repeatability
Conductivity: max. 0.5 % of measured value ± 5 µS/cm ± 2 digits
13.4.4 Cell constant

11.0 cm-1
13.4.5 Temperature compensation
Range –10 to 130 °C (14 to 266 °F)

Types of compensation • None
• Linear with user-configurable temperature
coefficient
13.4.6 Reference temperature

25 °C (77 °F)
13.5 Environment
13.5.1 Ambient temperature range
Stainless steel process connection: –20 to 60 °C (–4 to 140 °F)

PVC process connection: –10 to 60 °C (14 to 60 °F)
42 Endress+Hauser
13.5.2 Storage temperature
Stainless steel process connection: –25 to 80 °C (–13 to 176 °F)

PVC process connection: –10 to 60 °C (14 to 140 °F)
13.5.3 Humidity
≤ 100 %, condensating
13.5.4 Climate class

Climate class 4K4H as per EN 60721-3-4
13.5.5 Degree of protection

IP 69k as per EN 40050:1993
Degree of protection NEMA TYPE 6P as per NEMA 250-2008
13.5.6 Shock resistance

Complies with IEC 61298-3, certified up to 5 g
13.5.7 Vibration resistance

Complies with IEC 61298-3, certified up to 5 g
13.5.8 Electromagnetic compatibility

Interference emission as per EN 61000-6-3:2007 + A1:2011 and EN 55011:2009 + A1:2010
Interference immunity as per EN 61326-1:2013
13.5.9 Degree of contamination

Pollution level 2
13.5.10 Altitude
<2000 m (6500 ft)
13.6 Process
13.6.1 Process temperature
Stainless steel process connection:
–10 to 110 °C (14 to 230 °F)
Max.130 °C (266 °F) up to 60 minutes
PVC process connection:

–10 to 60 °C (14 to 140 °F)
13.6.2 Absolute process pressure

Stainless steel process connection:
13 bar (188.5 psi), abs to up to 50 °C (122 °F)
Endress+Hauser 43
7.75 bar (112 psi), abs at 110 °C (230 °F)

6.0 bar (87 psi), abs at 130 °C (266 °F) max. 60 minutes
1 to 6 bar (14.5 to 87 psi), abs in CRN environment tested with 50 bar (725 psi)
PVC process connection:

9 bar (130.5 psi), abs to up to 50 °C (122 °F)
6.0 bar (87 psi), abs at 60 °C (140 °F)
1 to 6 bar (14.5 to 87 psi), abs in CRN environment tested with 50 bar (725 psi)
13.6.3 Pressure-temperature ratings
p (abs.)
[psi] [bar]
188.5 13
1
130.5 9
2
87 6
14.5 1
50 60 110 130 T [°C]
122 140 230 266 T [°F]

A0030822-EN
 15 Pressure-temperature ratings
1 Stainless steel process connection
2 PVC process connection
A Process temperature increased briefly (max. 60 minutes)
13.6.4 Flow velocity

max. 10 m/s (32.8 ft/s) for low-viscosity media in pipe DN 50
13.7 Mechanical construction

13.7.1 Dimensions
→  12
44 Endress+Hauser
13.7.2 Weight
Stainless steel housing: up to 1.870 kg (4.12 lbs)
Plastic housing: up to 1.070 kg (2.36 lbs)
13.7.3 Materials
In contact with medium

Sensor: PEEK (polyetheretherketone)
Process connection: Stainless steel 1.4435 (AISI 316 L), PVC-U
Seal: EPDM
Not in contact with medium
Stainless steel housing: Stainless steel 1.4308 (ASTM CF-8, AISI 304)
Plastic housing: PBT GF20, PBT GF10
Seals: EPDM
Window: PC
Cable glands: PA, TPE
Endress+Hauser 45
13.7.4 Process connections
GGE / GCP MDK MEK

Ø 48.5(1.90) Ø 92 (3.62) Ø 78 (3.07)
(2.10)
53.3
(2.72)
69
MOK MQK MXK

Ø 92 (3.62) Ø 78 (3.07) Ø 82 (3.23)
(2.10)
53.3
(2.72)
69
MYK TXJ TDK

Ø 94 (3.70) Ø 84 (3.31) Ø 64 (2.52)
(2.10)
53.3
(2.72)
69
LQP
7 (0.28)
Ø 83 (3.27)
TSK
Ø 84 (3.31)
(0.67)
17.1
(1.29)
32.7
86 (3.39)
101.7 (4.00)
(1.29)
Ø 39.7
32.8
(1.56)
A0018955
 16 Process connections, dimensions in mm (inch)
46 Endress+Hauser
GGE Thread G1½

GCP Thread G1½ PVC
MDK Aseptic DIN 11864-1-A DN 50
MEK Aseptic DIN 11864-1-A DN 40
MOK Dairy fitting DIN 11851 DN 50
MQK Dairy fitting DIN 11851 DN 40
MXK Dairy fitting DIN 11853 -2 DN 40
MYK Dairy fitting DIN 11853 -2 DN 50
TXJ SMS 2"
TDK Tri-Clamp ISO 2852 2"
TSK Varivent N DN 40 to 125
LQP Coupling nut 2¼" PVC
13.7.5 Temperature sensor

Pt1000
Endress+Hauser 47
Index Smartec CLD18
Index
A Menus . . . . . . . . . . . . . . . . . . . . . . . . 24
Accessories . . . . . . . . . . . . . . . . . . . . . 40 MRS . . . . . . . . . . . . . . . . . . . . . . . . . 31
Advanced Setup . . . . . . . . . . . . . . . . . . 26
Air set . . . . . . . . . . . . . . . . . . . . . . . . 33
N
Application examples . . . . . . . . . . . . . . . 15 Nameplate . . . . . . . . . . . . . . . . . . . . . . 9
C O
Calibration . . . . . . . . . . . . . . . . . . . . . 31 Operating keys . . . . . . . . . . . . . . . . . . . 23
Cell constant . . . . . . . . . . . . . . . . . . . . 31 Operation . . . . . . . . . . . . . . . . . . . . . . 22
Certificates and approvals . . . . . . . . . . . . . 11 Operational safety . . . . . . . . . . . . . . . . . . 7
Cleaning the housing . . . . . . . . . . . . . . . 38 Orientations . . . . . . . . . . . . . . . . . . . . . 12
Commissioning . . . . . . . . . . . . . . . . . . . 25
P
D Post-connection check . . . . . . . . . . . . . . . 21
Declaration of Conformity . . . . . . . . . . . . . 11 Post-installation check . . . . . . . . . . . . . . 17
Designated use . . . . . . . . . . . . . . . . . . . . 5 Power up . . . . . . . . . . . . . . . . . . . . . . 25
Device configuration . . . . . . . . . . . . . . . . 26 Product description . . . . . . . . . . . . . . . . . 8
Device diagnostics . . . . . . . . . . . . . . . . . 34 Product identification . . . . . . . . . . . . . . . . 9
Diagnostic messages . . . . . . . . . . . . . . . . 35 Product page . . . . . . . . . . . . . . . . . . . . 10
Diagnostics . . . . . . . . . . . . . . . . . . . . . 34 Product safety . . . . . . . . . . . . . . . . . . . . 7
Display settings . . . . . . . . . . . . . . . . . . . 25
R
Disposal . . . . . . . . . . . . . . . . . . . . . . . 39
Repair . . . . . . . . . . . . . . . . . . . . . . . . 39
E Residual coupling . . . . . . . . . . . . . . . . . . 33
Electrical connection . . . . . . . . . . . . . . . . 17 Return . . . . . . . . . . . . . . . . . . . . . . . . 39
Ensuring the degree of protection . . . . . . . . 21
S
I Safety instructions . . . . . . . . . . . . . . . . . . 5
Incoming acceptance . . . . . . . . . . . . . . . . 9 Scope of delivery . . . . . . . . . . . . . . . . . . 10
Installation . . . . . . . . . . . . . . . . . . . 11, 17 Symbols . . . . . . . . . . . . . . . . . . . . . . . . 4
Installation conditions . . . . . . . . . . . . . . . 11
T
Installation examples . . . . . . . . . . . . . . . 15
Technical data . . . . . . . . . . . . . . . . . . . 40
Installation factor . . . . . . . . . . . . . . . . . 29
Temperature compensation . . . . . . . . . . . . 30
Interpreting the order code . . . . . . . . . . . . 10
Troubleshooting . . . . . . . . . . . . . . . . . . 34
IT security measures . . . . . . . . . . . . . . . . . 7
Troubleshooting instructions . . . . . . . . . . . 34
M W
Maintenance . . . . . . . . . . . . . . . . . . . . 38
Warnings . . . . . . . . . . . . . . . . . . . . . . . 4
Manufacturer's address . . . . . . . . . . . . . . 10
Wiring . . . . . . . . . . . . . . . . . . . . . . . . 17
Measuring range switch . . . . . . . . . . . . . . 31
Workplace safety . . . . . . . . . . . . . . . . . . 5
Menu . . . . . . . . . . . . . . . . . . . . . . . . . 26
Calibration . . . . . . . . . . . . . . . . . . 31
Diagnostics . . . . . . . . . . . . . . . . . . 34
Display . . . . . . . . . . . . . . . . . . . . . 25
Setup . . . . . . . . . . . . . . . . . . . . . . 26
48 Endress+Hauser
*71491465*
71491465
www.addresses.endress.com
GDS
(HONEYWELL)
Sensepoint XCD Technical Manual SPXCDHMANEN Issue 2
1 Safety
Ensure that this Operating Manual is read and understood BEFORE installing / operating /
maintaining the equipment. Pay particular attention to Warnings and Cautions. All document
Warnings are listed here and repeated where appropriate at the start of the relevant chapter(s) of
this Operating Manual. Cautions appear in the sections/sub-sections of the document where they
apply.
WARNINGS
Sensepoint XCD is designed for installation and use in Zone 1 or 2 hazardous areas in
many countries including Europe and for Class 1 Division 1 or 2 area applications in North
America.
Installation must be in accordance with the recognized standards of the appropriate
authority in the country concerned.
Access to the interior of the detector, when carrying out any work, must only be conducted
by trained personnel.
Before carrying out any work ensure local regulations and site procedures are followed.
Appropriate standards must be followed to maintain the overall certification of the detector.
For installations where conduit is used, and the sensor is mounted directly to the
Sensepoint XCD, there must be a “Seal Fitting” installed for each of the cable gland entries
within 18 inches of the Sensepoint XCD. The total distance of the location of these Seal
Fittings is 18 inches. (e.g. If all 3 gland entries are to be used, 3 Seal Fittings should be
located, each within 6 inches of the wiring entrance).
If using an anti-seize compound, the threads should be thinly coated with an approved
silicone free compound e.g. petroleum jelly
To reduce the risk of ignition of hazardous atmosphere, de-classify the area or disconnect
the equipment from the supply circuit before opening the detector enclosure. Keep
assembly tightly closed during operation.
Never attempt to open a junction box/enclosure or replace/refit the sensor in potentially
hazardous atmospheres while power is still applied to the transmitter.
The detector must be earthed/grounded for electrical safety and to limit the effects of radio
frequency interference. Earth/ground points are provided inside and outside the unit. The
internal grounding shall be used as the primary equipment ground. The external terminal is
only a supplemental bonding connection where local authorities permit or require such a
connection.
Ensure that all screens/instrument earth/clean earth wiring is earthed/grounded at a single
point (either at the controller or detector - BUT NOT BOTH) to prevent false readings or
alarms that may occur due to potential earth/ground loops.
Take care when handling sensors as they may contain corrosive solutions.
Do not tamper with or in any way disassemble the sensor.
Do not expose to temperatures outside the recommended ranges.
Do not expose sensors under storage conditions to organic solvents or flammable liquids.
At the end of their working life, replacement electrochemical sensors for oxygen and toxic
gas must be disposed of in an environmentally safe manner. Disposal should be according
to local waste management requirements and environmental legislation.
Alternatively, old replaceable sensors may be securely packaged and returned to Honeywell
Analytics clearly marked for environmental disposal.
Electrochemical sensors should NOT be incinerated as this action may cause the cell to
emit toxic fumes.
Refer to the local or national regulations relative to the installation at the site. For Europe
see EN60079-29-2, EN60079-14 and EN61241-14.
Only assessed for ATEX for ignition hazards.
This equipment is designed and constructed as to prevent ignition sources arising, even in
the event of frequent disturbances or equipment operating faults.
The sensor head must be fitted with the supplied weather protection, and mounted so that
the sinter is pointing downward to provide ingress protection IPX6.
The weather protection is a potential electrostatic charging hazard. The manufacturer’s
instructions should be observed.
NOTE: The control card must have a suitably rated fuse.
2
2 Information
This manual is for use with the Sensepoint XCD range transmitters only.
The Start-up/Surge/In rush current is dependant on the type of power supply used. The
typical start-up current for Sensepoint XCD is less than 800mA. Measure the start-up
current using the specific power supply before installation to ensure suitability for your
application.
Honeywell Analytics can take no responsibility for installation and/or use of its equipment if
not done so in accordance with the appropriate issue and/or amendment of the Operating
Manual.
The reader of this Operating Manual should ensure that it is appropriate in all details
for the exact equipment to be installed and/or operated. If in doubt, contact Honeywell
Analytics for advice.
The following types of notices are used throughout this Operating Manual:
WARNING
Identifies a hazardous or unsafe practice which could result in severe injury or
death to personnel.
Caution: Identifies a hazardous or unsafe practice which could result in minor injury
to personnel, or product or property damage.
Note: Identifies useful/additional information.
Every effort has been made to ensure the accuracy of this document, however, Honeywell
Analytics can assume no responsibility for any errors or omissions in this document or
their consequences.
Honeywell Analytics would greatly appreciate being informed of any errors or omissions
that may be found in the content of this document.
For information not covered in this document, or if there is a requirement to send

comments/corrections about this document, please contact Honeywell Analytics using the
contact details given on the back page.
Honeywell Analytics reserve the right to change or revise the information supplied
in this document without notice and without obligation to notify any person or
organization of such revision or change. If information is required that does not
appear in this document, contact the local distributor/agent or Honeywell Analytics.
3
3 Table of contents
1 Safety 2
2 Information 3
3 Table of contents 4
4 Introduction 6
4.1 Transmitter 7
4.2 Flammable, Toxic Oxygen Gas sensors 7
4.3 Accessories 8
5 Installation 10
5.1 Mounting and location 11
5.2 Mounting the transmitter 11
5.3 Installing the sensor 13
6 Electrical connections 14
6.1 Transmitter Wiring 15
6.2 Terminal connections 16
6.3 Power 17
6.4 Cabling 18
6.5 Cable and Earth/Ground regimes 18
6.6 Ground Terminal Wiring 19
7 Default configuration 20
8 Normal Operation 21
8.1 Display Screen 21
8.2 System Status 22
8.3 Magnetic Wand Activation 23
8.4 Operation Mode Structure 23
9 First time switch on (Commissioning) 24
10 Response Check and Calibration 26
10.1 Zeroing and span calibration 26
10.2 Zeroing and span calibration of Hydrogen Sulfide sensors 29
11 General Maintenance 30
11.1 Operational Life 30
12 Servicing 31
12.1 Sensor replacement 31
12.2 Replacing Modules within the Transmitter 33
12.3 Faults and Warnings 34
13 Menu’s and Advanced Configuration 35
13.1 Abort Function 35
13.2 Configuration Mode 35
13.2.1 Configuration mode operation table 38
13.3 Sensor / Gas Selection 40
13.3.1 Sensor Selection 40
13.3.2 Gas Selection 40
13.4 Review Mode 42
4
14 General specification 45
15 Ordering information 46
16 Warranty statement 48
17 Installation Drawing 49
17.1 Mechanical Installation Drawing 49
17.2 Electronic Connection Drawing 50
17.3 Duct Mounting Drawing 51
17.4 Collecting Cone Drawing 52
17.5 Mounting Bolt Assy Drawing 53
17.6 Mounting Bracket Drawing 54
18 Certification 55
18.1 China GB Ex and PA 55
18.2 Korea KTL 58
18.3 European ATEX 59
18.4 International IEC 61
18.5 ATEX Name Plate 63
18.6 UL Name Plate 64
18.7 Sensor Cartridges Label 65
19 Cross Interference and Cross Calibration 66
19.1 Cross Interference Table for Toxic and Oxygen 66
19.2 Cross Calibration Flammable Gas Detector 67
5
4 Introduction
The Sensepoint XCD (“Exceed”) comprises a gas detector transmitter and a choice
of sensors for detecting flammable gas, toxic gas and oxygen. The construction of
Sensepoint XCD allows it to be used in hazardous area locations; it may also be used in
other areas not classified as hazardous.
As well as a comprehensive range of Sensepoint XCD sensors, a wide range of existing

Honeywell Analytics sensors may be used with the Sensepoint XCD transmitter to detect a
broader range of target gases (please contact Honeywell Analytics for further details).
The transmitter features a display and three programmable relays for controlling external
equipment e.g. alarms, sirens, valves or switches. The transmitter provides an industry
standard 3-wire, 4-20mA source or sink output for connection to a dedicated gas detection
control system or PLC.
Calibration and maintenance is carried out using a Magnetic Wand, this allows a single
user to undertake routine maintenance without needing to access internal components.
Sensepoint XCD is suitable for use in Zone 1 or 2 hazardous areas (International) or Class
I Division 1 or 2 area applications (North America).
Sensepoint XCD comprises of the main parts as shown below.
Field Cable/Conduit Entries

EExd Plug (x2) Certification Label
Display Module Integral
mounting plate
Cover
Internal Earth
Point
External Earth
Terminal Module Point (x2)
Locking Seal
Grub
screw Sensor Socket
Enclosure
Plug-In Sensor Cartridge
Sensor Retainer
Locking Grub screw
Diagram 1. – Exploded View
6
4.1 Transmitter
The transmitter enclosure has three threaded entries. The two cable/conduit entries either
side of the upper part of the transmitter housing are for connecting the power source,
signal output and relay contacts to associated signalling equipment. The bottom entry
allows direct connection of the sensor socket. There is a mounting plate incorporated into
the transmitter housing allowing for various mounting configuration options.
A local LCD provides gas type, concentration, alarm and operating status. The display
provides numerical, bar graph and icon information.
Diagnostic information may also be displayed when the transmitter is interrogated using
a magnet. The transmitter cover has a glass window which allows use of the Magnetic
Wand to activate the three user interface magnetic switches that are located on the front
of the display module. The magnet also enables a non intrusive, one-man calibration and
configuration facility for the Sensepoint XCD.
Magnetic Magnetic Wand

MENU/ENTER activation Icon
Switch Calibration Icon
Full Scale Test Pass Icon

Warning/
Bar Graph
Fault Icon
Gas Type
Inhibit Icon
Gas Reading Alarm Icon
Measuring
Units
Magnetic
DOWN Magnetic
Switch UP Switch
Diagram 2: Sensepoint XCD Display and Magnetic Switches
4.2 Flammable, Toxic Oxygen Gas sensors

The Sensepoint XCD transmitter is designed to work with a variety of gas sensors for
detecting flammable gases. Sensepoint XCD sensors use NDIR infrared and electro-
catalytic technologies.
In addition, the Sensepoint XCD transmitter is designed to work with a wide range of
toxic gas sensors. Sensepoint XCD sensors for monitoring toxic gas oxygen use electro-
chemical cell (ECC) technology.
7
Diagram 3: Sensepoint XCD Flammable, Toxic and Oxygen Sensor Cartridge
4.3 Accessories
A range of accessories are available to allow use of Sensepoint XCD in a wide variety of
applications. These including mounting brackets, maintenance tools, weather housings,
flow housing, collecting cone, duct mounting kit and sensor junction boxes.
Standard Weather Protection Magnetic wand

The Standard Weather Protection (P/N: The magnetic wand (P/N: SPXCDMAG) is used
SPXCDWP) is designed to protect the sensor as a tool to allow the user to communicate with
from changes in environmental conditions. This is the Sensepoint XCD transmitter for the purpose
recommended to be fitted to a Sensepoint XCD of configuration, calibration and interrogating
sensor for outdoor exposed applications, system status, (supplied with XCD kit).
(supplied with XCD kit).
Pipe mounting bracket Gassing Cap
The Pipe Mounting Bracket (P/N: SPXCDMTMB) The Gassing Cap (P/N: S3KCAL) is an optional
is an optional accessory and may be used to accessory that may be temporarily fitted to the
allow the Sensepoint XCD to be installed onto a sensor in place of the Weather Protection for Gas
dedicated mounting post or existing structure at Response checking during commissioning and
the desired location. routine maintenance.
8
Collecting cone Duct mounting kit
The Collecting Cone (P/N: SPXCDCC) is an The Duct Mounting Kit (P/N: SPXCDDMK)
optional accessory that may be fitted to the is an optional accessory that is designed for
Weather Protection. The collecting cone is applications to allow the monitoring for the
designed for use with lighter than air. presence of gas inside a Heating, Ventilation or
Air Conditioning (HVAC) duct is required.
Sunshade Deluge Cover Typical Mounting Arrangement
The XCD Sunshade Deluge Cover (P/N:

SPXCDSDP) is an optional accessory that may
be fitted to the integral mounting plate. This
accessory is designed to protect XCD from
overheating in exposed hot and arid climates,
particularly offering additional protection from
thermal shock in Tropical Environments
9
5 Installation
WARNINGS
Sensepoint XCD is designed for installation and use in Zone 1 or 2 hazardous areas in
many countries including Europe and for Class 1 Division 1 or 2 area applications in North
America.
Care should be taken when removing and refitting the Sensepoint XCD plug-in Sensor to
the Sensor Socket so that damage to the connection pins can be avoided.
within 18 inches of the Sensepoint XCD. For installations where the sensor will be mounted
remotely from Sensepoint XCD, an additional “Seal Fittings” will be required: One at each of
the conduit entries for the power/signal/relay contact outputs and one at the sensor wiring
entrance. The total distance of the location of these Seal Fittings is 18 inches. (e.g. If all 3
gland entries are to be used, 3 Seal Fittings should be located, each within 6 inches of the
wiring entrance).
The detector must be earthed/grounded for electrical safety and to limit the effects of
radio frequency interference. Earth/ground points are provided inside and outside the unit.
point (either at the controller or detector - BUT NOT BOTH) to prevent false alarms due to
earth/ground loops.
emit toxic fumes.
see EN60079-29-2, EN60079-14 and EN61241-14.
This equipment is designed and constructed as to prevent ignition sources arising, even in
NOTE: The control card must have a suitably rated fuse.
10
5.1 Mounting and location
Caution: The location of gas detectors should be made in accordance with any relevant
local and national legislation, standards or codes of practice. Always replace sensors
with a sensor of the same type.
Gas detectors should be mounted where a potential hazard of gas is most likely to be
present. The following points should be noted when locating gas sensors.
• When locating detectors consider the possible damage caused by natural events e.g.
rain or flooding.
• Consider ease of access to the gas detector for functional testing and servicing.
• Consider how escaping gas may behave due to natural or forced air currents.
Note: The placement of gas detectors should be determined following the advice of
experts having specialist knowledge of gas dispersion, experts having knowledge of the
process plant system and equipment involved, safety and engineering personnel. The
agreement reached on the location of detectors should be recorded.
5.2 Mounting the transmitter
The Sensepoint XCD transmitter has an integral mounting plate consisting of four
mounting holes on the transmitter body. The transmitter may be fixed directly to a surface
mounting, or to a horizontal or vertical pipe/structure, 40.0-80.0mm (1.6 to 3.1 inches) in
diameter/cross section. The Pipe Mounting Bracket accessory (optional accessory) may
be used for this purpose.
M20 entries for

ATEX/IECEx/AP
Versions and 3/4"NPT
cable/conduit entries
on UL/CSA versions
All dimensions are

shown in mm.
Diagram 4: Outline and mounting dimensions
11
Diagram 5: Mounting arrangements
To mount the Sensepoint XCD transmitter to a Vertical or Horizontal pipe/structure, use

the optional XCD Mounting Kit and following procedure:
1. Fit the four spring washers, then the plain washers to the M8 x 80mm SS316 bolts.
2. Pass the four bolts through the four mounting holes of the transmitter housing.
3. Note: If the XCD sunshade is to be used then fit the sunshade and the two locking
bolts and washers to the M8 x 80 bolts.
4. Place the transmitter housing against the mounting position and fit the two “U”
channel mounting bars the other side of the Pipe/Structure.
5. Secure bolts to the threaded holes of the “U” channel mounting bars.
6. Tighten the four bolts securely, (but do not over-tighten) until the transmitter housing
cannot be moved by hand on its mounting position.
Note: For further details of installation please see section 17.
12
5.3 Installing the sensor
The XCD gas sensor cartridge plugs into the XCD Sensor Socket.
Sensor Socket
Weather Protection
Plug-In Sensor Cartridge
Sensor Retainer
Locking Grub Screw
Diagram 6: Installing the Sensor
WARNINGS
Care should be taken when removing and refitting the Sensepoint XCD plug-in Sensor to
Take care when handling old sensors as they may contain corrosive solutions.
Take care when removing or replacing the Sensor Retainer as there may be sharp edges
present on the adjoining threads.
The equipment is designed and constructed as to prevent ignition sources arising, even in
To install the XCD Sensor Cartridge to the XCD Sensor Socket:
1. Remove the weather protection (if fitted) from the sensor.
2. Use a 1.5mm Allen key (hexagonal wrench-included) to loosen the Locking Grub
Screw on the Sensor Retainer.
3. Unscrew and remove the Sensor Retainer.
4. Remove the XCD Sensor Cartridge from its packaging and plug it into the XCD
Sensor Socket, taking care to align the sensor pins with the connector.
5. Refit the Sensor Retainer and tighten the Locking Grub Screw.
6. Refit the weather protection (as required) to the XCD sensor.
13
6 Electrical connections
WARNINGS
Sensepoint XCD is designed for installation and use in Zone 1 or 2 hazardous areas in many
countries including Europe and Class 1 Division 1 or 2 area applications in North America.
Care should be taken when removing and refitting the Sensepoint XCD Sensor Cartridge to
within 18 inches of the Sensepoint XCD. The total distance of the location of these Seal
Fittings is 18 inches. (e.g. If all 3 gland entries are to be used, 3 Seal Fittings should be
located, each within 6 inches of the wiring entrance).

The detector must be earthed/grounded for electrical safety and to limit the effects of
radio frequency interference. Earth/ground points are provided inside and outside the unit.
point (either at the controller or detector - BUT NOT BOTH) to prevent false alarms due to
earth/ground loops.
emit toxic fumes.
see EN60079-29-2, EN60079-14 and EN61241-14.
14
6.1 Transmitter Wiring
Caution: All electrical connections should be made in accordance with any relevant
local or national legislation, standards or codes of practice.
The Sensepoint XCD transmitter may be wired in either Current SOURCE or Current
SINK configuration. These two options are offered to allow greater flexibility in the type of
control system that it can be used with. SOURCE/SINK is selectable via the switch located
on the back side of the display module; accessible by removing the display module during
installation / commissioning (see section 9).
Controller Detector
+VE +VE
1 1
Signal Signal
2 3
RL
-VE -VE
3 2
XCD Source 3 Wire 4-20mA (Source)
Controller Detector
+VE +VE
1 1
RL
Signal Signal
2 3
-VE -VE
3 2
XCD Sink 3 Wire 4-20mA (Sink)
Note: Terminate cable screen at detector or controller, not both.

250ohm load resistor (RL) is installed in the factory, In case of connection with controller,
this resistor should be removed because controller has load resistor internally.
15
6.2 Terminal connections
Note: Ensure that none of the wires in the terminal area cause an obstruction when
refitting the Display Module. Ensure that the socket on the Display Module is fully engaged
in the Display Module Connector on the Terminal Module.
Ground/Earth
Point
Terminal Block
Terminal Block
Power & Signal
7 for Relays
1
2 8
3 9
4 10
11 Display Module
5 Alignment Pin
Display Module 6 12
13 Locator
Connector
14
15 Note: Terminal
Sensor Blocks are
Connector plug/socket type
and may be
removed to ease
wiring.
Diagram 7: Terminal module
Terminal Module Connections

Terminal Number Marking Connection Description
1 24V +VE Supply(16-32VDC)
2 0V -VE Supply(0VDC)
Controller Connections
3 4~20mA Current Output Signal
4 COM Drain
MODBUS RTU.
5 TxD MODBUS B (+)
RS485 (Pending)
6 RxD MODBUS A (-)
7 RLY1/NC Normally Closed
Programmable Relay 1
8 RLY1/COM Common
(Default A1)
9 RLY1/NO Normally Open
11 RLY2/COM Common
(Default A2)
14 RLY3/COM Common
(Default Fault)
Table 1: Transmitter terminal connections
16
6.3 Power
The Sensepoint XCD transmitter requires a power supply from the controller of between
16Vdc and 32Vdc. Ensure that a minimum supply of 16Vdc is measured at the sensor,
taking into account the voltage drop due to cable resistance.
The maximum loop resistance in the field cable is calculated as follows:
R loop = (V controller – V detector min) / I detector
Example;
The controller is supplying a nominal 24Vdc (V controller), the detector minimum allowable
voltage is 16Vdc (V detector min), therefore the maximum allowable voltage drop between the
controller and detector is 8Vdc; this means a voltage drop of 4V in each core (+ve core
and -ve core).
+20V
(wrt Controller 0V) +24V
4-20mA Signal
16V (min) XCD Controller
Field Cable (L)
+4V 0V
(wrt Controller 0V) Diagram 8: Power Connection
Power consumption of the detector is 5.0W. The current required to drive the detector at
the minimum voltage is (I = P / V), 5.0 / 16 = 312.5mA (I detector).
So, the maximum field cable loop resistance (R loop) = 8 / 0.31 = 26 Ohms, or 13 Ohms
per core, (allowing for component variations, losses, etc.).
The following tables show the maximum cable distances between the controller and
transmitter assuming a voltage drop of 4V in each core and for different cable parameters.
The tables are examples only and actual cable parameters and source power supply
voltage for the application should be used to calculate the maximum cable distance
allowed at the installation site.
Typical cable data Maximum Cable length (L)

Cable size Cable resistance Meters Feet
(cross sectional area) Ω/km (Ω/mi)
0.5mm2 (20AWG*) 36.8 (59.2) 353 1158
1.0mm2 (17AWG*) 19.5 (31.4) 666 2185
1.5mm2 (16AWG*) 12.7 (20.4) 1023 3356
2.0mm2 (14AWG*) 10.1 (16.3) 1287 4222
2.5mm2 (13AWG*) 8.0 (12.9) 1621 5318
*nearest equivalent
Table 2: Maximum cable distances

17
6.4 Cabling
The use of industrial grade, suitably armoured field cable is recommended.
For example, screened 3 cores (plus screen 90% coverage), suitably mechanically
protected copper cable with a suitable M20 explosion-proof gland, or ¾” NPT steel
conduit, with 0.5 to 2.5 mm2 (20 to 13 AWG) conductors. Ensure the cable gland is
installed correctly and fully tightened. All unused cable/conduit entries must be sealed with
a suitable certified sealing plug (one plug is supplied).
6.5 Cable and Earth/Ground regimes
Effective Earth/Ground bonding is important to ensure good EMC and RFI immunity.
The following diagrams show examples of how to earth/ground bond the cable at
enclosures. The same principles apply to conduit installations. These bonding techniques
provide good RFI/EMC performance. Earth/ground loops must be avoided to prevent the
risk of false signal variation.
Controller
Clean / Instrument
Earth Screen
Cable to Transmitter
Cable outer sheath Cable inner sheath
Diagram 9: Controller Grounding
Transmitter Controller
Power & Signal
Earth Screen
Diagram 10: System grounding
18
The Earth Screen of the field cable should be “tied to Earth” or connected to Ground at
one point only. It is common practise to adopt a STAR EARTH connection regime where
all instrumentation Screens are connected at one common point.
The Screen at the other end of the cable should be “parked” or terminated into a blank
terminal.
The following diagrams show how to install the wire into the ground screw of the
enclosure.
Loosen the bolt Insert cable Fasten the bolt
6.6 Ground Terminal Wiring

Internal Ground connection: Utilize the shield of the wiring cable recommended in the
wiring instructions. For connection to this terminal. Twist the shield wire to avoid stray
shield wires, Loosen the screw sufficiently and wrap the wire around the screw in a “U”
shape. Raise the clamp and place the wire between the clamp and ground base, lower the
clamp and tighten the screw to 6.9lb-in torque.
External Ground Connection: If required by local authority, Utilize a No 14 AWG copper,

(Stranded or Solid), wire. Loosen the screw sufficiently to enable ‘wrapping the wire
around the screw in a “U” shape. Raise the clamp and place the wire between the clamp
and ground base, lower the clamp and tighten the screw to10.4lb-in torque.
19
7 Default configuration
The Sensepoint XCD transmitter is supplied with the following default configuration.
Function Value/Setting Meaning

XCD recognizes the XCD sensor cartridge according
Automatic according to Sensor type
Sensor Type to the gas type within its own sensor family i.e. mV,
connected
EC or O2 .
≥0.0<1.0 mA Fault (refer to table 5 section 12.3 for details)
Inhibit (during configuration/user settings)
2.0 mA or 4.0 mA (17.4mA)
Signal output For Oxygen, 2.0 mA or 17.4 mA
4.0 mA to 20.0 mA Normal gas measurement
22.0 mA Maximum over range
Value is sensor dependant Lower alarm level
Alarm Relay 1* De-energized Energizes on alarm
Contact Normally Open (NO) Closes on alarm
Value is sensor dependant Higher alarm level
Alarm Relay 2* De-energized Energizes on alarm
<1mA Detector Fault
Fault Relay Energized De-energizes on alarm
2.0 mA (default) or 4.0 mA for Toxic
Signal output inhibited during menu use.
and Flammable
Inhibit If any relay is set to inhibit relay, then inhibit relay will
2.0 mA (default) or 17.4 mA
be activated.
For Oxygen
No inhibit timeout. The detector waits for a button
press before returning to the previous state/setting.
Timeout Disabled
Timeout period can be set in ‘Configure Inhibit’ menu
in Configuration Mode.
0000 (Password disabled). If changed then password
Password 0000 (Disabled)
is activated.
Location Optional feature to identify the location or User’s “Tag”
0000
(Tag Number) number of the XCD
o
Temperature C Option to have oC or oF
* Alarm relays automatically reset when reading falls within alarm thresholds. If relay configured to LATCH, then relays must be reset using
the Magnetic Wand.
Table 3: Default configuration
Gas Name Default Range Lower Alarm Lower Alarm Higher Alarm Higher Alarm
Type Type
Oxygen 25.0%VOL 19.5%Vol Falling 23.5%Vol Rising
Hydrogen Sulfide 50.0ppm 10.0ppm Rising 20.0ppm Rising
Carbon Monoxide 300ppm 100ppm Rising 200ppm Rising
Hydrogen 1,000ppm 200ppm Rising 400ppm Rising
Flammable IR 100%LEL 20%LEL Rising 40%LEL Rising
Flammable CAT 100%LEL 20%LEL Rising 40%LEL Rising
Carbon Dioxide IR 2.00%Vol 0.40%Vol Rising 0.80%Vol Rising
For details of how to change the configuration of the Sensepoint XCD please refer
to section 13.
20
8 Normal Operation
Sensepoint XCD is supplied configured and ready for use according to the “Default
Settings” table shown above. However these setting may be tailored to a specific
application requirement using the Sensepoint XCD configuration menu system.
Access to the Sensepoint XCD transmitter’s configuration menus system is via the
Magnetic Activation Tool.
8.1 Display Screen

The Sensepoint XCD display features an LCD with Numeric and bar-graph gas
concentration data, alpha-numeric warning and status indication, a target for magnetic
switch activation and the UP/DOWN/ESC/ENTER zones for remote configuration. The
LCD is also backlit with hi-intensity multi-colour LED indicator to show NORMAL, ALARM
and FAULT status.
During normal operation the instrument display shows a steady GREEN backlight.
During Low and High Gas Alarm it displays a flashing RED backlight
During Fault condition the instrument display shows a flashing YELLOW backlight.
The screen is visible through the window of the transmitter’s cover. The display shows the
gas concentration (both graphically and numerically), range, units, alarm/
fault status, etc.
Note: The detector display may become sluggish in sub-zero temperatures and possibly
unclear at temperatures below -40 °C, but the detector continues its gas monitoring
function. The display is not damaged and recovers when the temperature increases.
Full Scale
Bar Graph
(Proportional Test Pass Icon
to gas reading)
Gas Type
Measuring
Unit
Gas Reading
Diagram 11: Example of a O2 Transmitter Display screen – Normal Operation
21
8.2 System Status

Display indications, current output and relay states for various operational conditions
are shown in the following table. For further details of error messages and trouble shooting
see section 12.3.
System Status
Relay Back
Status Display Current Output
A1 A2 Fault Light
F-XX
Fault:
fault number
Circuit or sensor 0-1.0 mA Yellow,
with fault icon
error flashing
blinking
System Fault N/A 0-0.15mA
Note: In the event of processor failure the watchdog will automatically reset the system for
recovery.
W-XX
Green
warning number Dependent on
Warning Steady
with fault icon system status
blinking
0.0
Green
Normal Gas 4-20 mA
Steady
concentration
Gas
concentration. Red,
Alarm 1 4-20 mA
1st alarm icon flashing
blinking
Gas
concentration. Red,

1
Alarm 2 4-20 mA
2nd alarm icon flashing
blinking
Full scale icon
Red,

2
Over-range and reading 22mA
flashing
blinking
Inhibit icon
dependent 2 or 4mA
on Menu depending on
command. If configuration. Green
Inhibit
any relay is set Note: Steady
to inhibit relay, 2 or 17.4mA for
then inhibit relay Oxygen version
will be activated.
Table 4: System status
Note:
1. For Oxygen, A1 relay will not be activated because AL1 is configured to activate above
23.5 %Vol (in Rising Alarm configuration).
2. For Oxygen, A2 relay will not be activated because AL2 is configured to activate below
19.5 %Vol (in Falling Alarm configuration).
22
8.3 Magnetic Wand Activation
The magnetic wand is used as a tool to allow the user

to communicate with the Sensepoint XCD transmitter.
Communication with the XCD is achieved by positioning
the Magnetic Wand at one of three different positions on
the front glass window of the Sensepoint XCD transmitter.
Activation of the switches is verified by observing
the Magnetic Wand Activation Icon on the LCD display
Hold the Magnetic Wand in position for up to 2 seconds =
Hold the Magnetic Wand in position for 3 seconds or more =
8.4 Mode Structure

Sensepoint XCD has 3 operating modes.
1. Monitoring mode, is the normal operating status while XCD measures and displays
gas concentration. The fault/warning status is periodically checked, relay contacts
are activated according to the configuration.
2. Configuration mode, this mode allows parameters relating to the configuration of

the Transmitter functions to be changed according to specific needs. This mode can
be protected by a password mechanism to prevent unauthorised changes being
made.
3. Review mode, allows the user to view the current configuration settings.
Start - Up
Configuration Monitoring Review

Mode Mode Mode
Diagram 12: Mode Structure
Further details of the information available and configuration options for the Sensepoint
XCD can be found in Section 13. of this manual.
23
9 First time switch on (Commissioning)
WARNING
The following procedure requires the Transmitter Cover to be removed while carrying out
supply voltage checks. Therefore the appropriate permits to work should be sought in
preparation.
Prior to carrying out any HOT WORK ensure local and site procedures are followed.
Ensure that the associated control panel output actuation is inhibited so as to prevent false
alarms.
Caution: The following procedure should be followed carefully and only performed by
suitably trained personnel
Note: Calibration is mandatory before the detector can be used for gas monitoring. Refer
to Section 10.1 Calibration for the proper procedure.
1. Remove the transmitter housing cover and detach the display unit by lifting the semi-
circular handle and pulling the assembly directly away from the termination module
(without twisting it)
2. Configure the detector's analogue output signal configuration for Current SINK or
Current SOURCE operation using the selector switch located on the back of the
display module. The default setting is Current SOURCE.
3. Check that all electrical connections are terminated correctly as per section 6.
4. Switch On the external power supply to the transmitter at the safe area gas detection
controller (or PLC).
5. Using a Digital Multi Meter (DMM), check the Supply Voltage at the terminals 1 (24V)
and 2 (0V), this should be a minimum supply voltage of 16Vdc (Maximum supply
voltage is 32V DC)
6. Switch Off the external power to the detector.
7. Refit the Display Module and Cover.
Note: Ensure that none of the wires in the terminal area cause an obstruction when
refitting the Display Module. Ensure that the socket on the Display Module is fully engaged
in the Display Module Connector on the Terminal Module.
8. Switch On external power to the detector.

9. All the display icons/text/numbers are displayed for 3 seconds.
10. A start up sequence will then be displayed, similar to the one shown in Diagram 15.
24
Note:
For a full description of each screen shown in Diagram 15., please refer to Section 13.3
“Review Mode” of this Manual.
Diagram 15: Normal Start up procedure (For the CO sensor version)
11.The warm up countdown of 60 seconds (depending on the gas type) is then

displayed.
12. Normal Monitoring Mode is then resumed.
25
10 Response Check and Calibration

It is recommended to periodically carry out a gas response check on the Sensepoint XCD
to ensure correct operation. This may be done in two ways;
1. A simple Response Check often referred to as a “BUMP TEST” is a test using calibration
gas applied to the sensor via the nozzle of the Weather Protection or using the Sensepoint
XCD Gassing Cap.
If a BUMP TEST is done via the Weather Protection nozzle it may be necessary in windy
conditions to increase the flow rate of the test gas by a further 1 LPM, OR, to shelter the
weather protection from the wind.
2. A full gas calibration of the sensor as described in the following section, using ONLY the
Sensepoint XCD Gassing Cap (Part No.: S3KCAL).
10.1 Zeroing and span calibration
Caution: Before initial calibration allow the detector to stabilize for 30 minutes after applying
power.
When in zeroing and span calibration mode the current output from the detector is inhibited
(default 2mA) to avoid false alarms.
For Flammable gas calibration use a calibration gas concentration of between 25%LEL and
75%LEL to ensure that the required accuracy can be attained.
For Hydrogen Sulfide type sensors refer to section 10.1.2 before conducting zero and span
calibration.
To calibrate the detector, use an appropriate span gas cylinder, constant flow regulator
AND the Sensepoint XCD Gassing Cap (see section 4.7). The flow rates used for
calibration gas are as follows:
Gas Type Flow rate (L / Min)
Air or N2 for Zero 0.5 to 1.0
Flammable CAT 1 to 1.5
O2 0.5 to 1.0
H2S 0.5 to 1.0
CO 0.5 to 1.0
H2 0.5 to 1.0
Flammable IR 0.4 to 0.6
CO2 IR 0.4 to 0.6
A compressed air cylinder (20.9%Vol oxygen) should be used to perform the zero
calibration if the area where the detector is located contains any residual amount of the
target gas. If no residual gas is present then the background air can be used to perform
the zero calibration. Contact your Honeywell Analytics representative for details of suitable
calibration kits.
To calibrate the detector follow the procedure below.
Note: the Oxygen sensor does not require a zeroing procedure. Background air (20.9%Vol
oxygen) can be used to span the oxygen sensor in place of a compressed air cylinder
(20.9%Vol oxygen). For oxygen sensors only do parts 1-4, 12, 13 (if compressed air
cylinder is used), 14-17 and 22 of the procedure below.
26
(ZERO CALIBRATION)
1. If the ambient air is NOT considered reliable to use to set the ZERO, then remove
the weather protection and fit the Gassing Cap accessory (see Section 4.3) onto the
sensor and apply a clean source of zero gas or compressed air.
2. To access the calibration menu, hold the end of the magnet over the switch located
at the top center of the detector display () for at least 3 seconds and then remove.
3. The display will indicate the first configuration mode menu ‘SEt CAL’.
4. Put the magnet over the ‘’ switch again and move to enter the Calibration menu.
5. The display will show the current gas reading, and the ‘ ’ icon flashes.
6. When the zero gas reading is stable use ‘’ to confirm zero calibration.
7. If successful the display shows ‘ZEro PASS’ (if not successful, the display shows ‘ZEro
FAIL’ and returns to configuration mode).
8. If using zero-air, turn it off. Zeroing is complete and saved.
9. The display shows ‘SPAn’ with ‘YES’ flashing.
10. If span calibration is required use ‘’ proceed to the next step. If span calibration
is not required, use ‘’ to select ‘No’ and ‘’ to return to configuration mode.
27
(SPAN CALIBRATION)
11. The display shows the current calibration span gas concentration while flashing the
‘ ’ icon. Use ‘’ to change the calibration span gas concentration, and ‘’ when
required span calibration level is set.
12. The display will show the current gas reading, and the ‘ ’ icon flashes.
13. Connect the regulator to the span gas cylinder.
14. Apply the span gas to the sensor using the Sensepoint XCD Gassing Cap (see
section 4.7 for description). The live gas reading is displayed. When the reading is
stable, use ‘’ to confirm span calibration.
15. If the sensor has been replaced the following display may be shown.
16. Use ‘’ to select ‘YES’ if the sensor has been replaced or ‘No’ if it has not been
replaced.
17. If the span calibration is successful the instrument will briefly display ‘SPAn PASS’ (if
fails ‘SPAN FAIL’ displayed and returns to configuration mode).
Note: the calibration due warning counter is reset after a successful calibration. See
section 12.3 for further details of setting a calibration due warning.
18. The display alternates between “Purg gAS” and the gas reading to indicate that the
unit is expecting the span gas to be removed from the sensor.
28
19. Promptly switch off the calibration span gas and remove the Sensepoint XCD
Gassing Cap from the sensor to allow the gas to disperse.
20. When the reading falls below 50% of the calibration gas level the display indicates a
countdown (up to 180 seconds dependant on gas type).
21. When the countdown is finished, the calibration procedure is complete.
22. The instrument returns to the ‘Set CAL’ menu. Activate the ‘’ or ‘’ switch to select
another menu or select ‘QuIT’ to return to normal monitoring mode.
Note: Remember to always replace the Weather Protection and other accessories.
10.2 Zeroing and span calibration of Hydrogen Sulfide sensors
Hydrogen Sulphide sensors can be affected by extreme humidity changes. A sudden

increase in ambient humidity can result in a short-term positive drift in the instrument’s
reading. A sudden decrease in ambient humidity can result in a short-term negative drift in
the instrument’s reading. These are most likely to be noticed during calibration with dry or
cylinder gas.
When calibrating Hydrogen Sulphide cartridges the following should be taken into account
while following the procedure in 10.1:
1. To zero the sensor, use a compressed air cylinder of 20.9%Vol oxygen (not Nitrogen).
Do not use background air.
2. Apply the gas to the sensor for three minutes before using ‘’ to confirm the zero
calibration.
3. If a span calibration is to be performed, the span calibration gas should be applied to

the sensor immediately after the zeroing procedure. Do not allow the sensor to return
to ambient air conditions between steps 2 and 3.
4. Apply the span gas for two minutes before using ‘’ to confirm the span calibration.
29
11 General Maintenance
WARNINGS
Access to the interior of the transmitter, when carrying out any work, must only be
conducted by trained personnel.
Care should be taken when removing and refitting the Sensepoint XCD plug-in Sensor
Cartridge to the Sensor Socket so that damage to the connection pins can be avoided.
Appropriate standards must be followed to maintain the overall certification of the sensor
and transmitter.
the equipment from the supply circuit before opening the transmitter enclosure. Keep

hazardous atmospheres.
emit toxic fumes.
Honeywell Analytics recommends that gas detectors are tested and re-calibrated on a six-
monthly basis, or according to site practice. For remote Flammable or Toxic sensors are
used with the XCD Transmitter, please refer to the individual sensor manuals for specific
recommended calibration periods.
11.1 Operational Life
The pellistors used in the Catalytic flammable gas sensor can suffer from a loss of
sensitivity when in the presence of poisons or inhibitors, e.g. silicones, sulphides, chlorine,
lead or halogenated hydrocarbons. The pellistors are poison resistant to maximize the
operational life of the Catalytic flammable sensor. A typical operating life, subject to the
presence of poisons/inhibitors is 36 months.
The NDIR (infrared) flammable gas sensor is not affected by the above-mentioned poisons
and therefore has a longer life span. A typical operating life is 5 years.
Typical life of a toxic gas sensor is dependant on the application, frequency and amount of
gas exposure. Under normal conditions (3 monthly visual inspection and 6 monthly test/re-
calibration), the XCD Oxygen and other toxic sensors have an expected life equal to or
greater than 24 months.
Refer to section 12 for sensor replacement procedures.

30
Caution: Oxygen deficient atmospheres (less than 6%V/V) may result in inaccuracy of
reading and performance.
12 Servicing
WARNINGS
Take care when handling sensors as they may contain corrosive solutions. Do not tamper
or in any way dis-assemble the sensor. Do not expose to temperatures outside the
recommended range. Do not expose sensor to organic solvents or flammable liquids.
emit toxic fumes.
Caution: The following procedure should be followed carefully and only performed by
suitably trained personnel.
A fault condition will be signalled by the detector if the sensor is removed with the unit
under power.
12.1 Sensor replacement
The Flammable Catalytic and Toxic ECC sensor cartridge that are used with the
Sensepoint XCD Sensor Socket have no serviceable parts. When they have reached the
end of their operational life, simply replace the cells.
31
Sensor Socket
Sensor Cartridge
Weather Protection
Sensor Retainer
Locking Grub Screw
Diagram 13: Sensor Replacement
To replace the plug-in sensor of a Sensepoint XCD Sensor Socket use the following
procedure:
1. Important: Remove the Power from the Sensepoint XCD Transmitter
2. Remove the Weather Protection or other accessories from the sensor socket
thread.
3. Loosen the Locking Grub Screw and unscrew the Sensor Retainer
4. Carefully pull the old Sensor from the sensor socket without twisting.
5. Fit the new Sensor in its place
6. Calibrate sensor
WARNING
Ensure that the same Gas Type and Range of Sensor is fitted in place of the old Sensor.

32
12.2 Replacing Modules within the Transmitter
Two replaceable module assemblies are located within the transmitter housing. The
Display Module and the Terminal Module.
The Display Module is simply removed by unplugging it from the Terminal Module (this
procedure is done during normal installation).
To replace the Terminal Module, use the following procedure:
1. Unscrew and remove the Transmitter Cover
2. Lift the handle and un-plug and remove the Display

Module.
3. Unplug the connection terminals and lift them clear of the

Terminal Module.
4. Unplug the connector for the XCD sensor.
5. Loosen and remove the three “cross-headed” screws that

secure the Terminal Module to the Transmitter housing.
6. Carefully lift the Terminal Module from the transmitter

housing.
7. Fit the new Terminal Module using the above procedure in

reverse order.
33
12.3 Faults and Warnings

The table below provides details of possible error.
Message Description Action
The unit has not been calibrated for the
configured calibration interval
W-01 Calibration needed
Calibration is necessary due to change
of sensor/gas type
Transmitter Temperature
W-02 Use ‘’ to clear when within limits
limits exceeded
Re-configure alarm settings such that
Alarm setting needs to be
W-03 upper alarm should not exceed user
configured
configured scale
W-04* Over-range warning Use ‘’ to clear when within limits
The sensor is switched off Make sure that there is no flammable
W-05* to prevent it from being gas in the air and use ‘’ to clear when
deteriorated within limits
Cycle power to detector. Replace
F-01 Internal I2C failure
detector
For Toxic, replace sensor
F-02 Cell failure For Flammable/IR, cycle power to
detector. Replace sensor
F-03 Significant zero drift Re zero/calibrate
F-04 Unexpected sensor fitted Replace sensor

Reset transmitter. If fault still appear,
F-05 EEPROM is corrupted
replace transmitter
F-06 Low supply voltage
replace transmitter
F-07 SRS processor failure
replace transmitter
F-08 RAM read/write fault
replace transmitter
F-09 Info. memory corrupted
replace transmitter
F-10 Code Memory corrupted
replace transmitter
Check load resistor or sink/source mode
F-11 DAC output failure
switch was configured properly
F-12 Heater failure
replace transmitter
F-13 Supplied voltage failure Check supply voltage. Replace detector
*Note : W-04 and W-05 are only for flammable catalytic bead sensors. For other gases, gas reading will blink on the LCD
instead of the over-range warning.
Table 5: Fault and Warning List
34
13 Menu’s and Advanced Configuration
13.1 Abort Function
In Review Mode or Configuration Mode the user can escape one step back from the
current position using the Abort Function. To do this the user must activate the Enter
switch for more than 3 seconds with the Magnetic Wand. Switching between each pair of
modes or between menus and sub menus are shown in the following table.
From To Example
Activate Enter switch for more than 3 seconds

Review Mode Monitoring Mode
while in Review Mode
Activate Enter switch for more than 3 seconds

Configuration Mode Monitoring Mode while navigating menus in the Configuration
Mode
Configuration Mode Configuration Activate Enter switch for more than 3 seconds
sub menu Mode main menu while in a sub menu
Table 6: Transmitter menu switching
13.2 Configuration Mode
The table below shows the functions available via the configuration menu that can be
displayed on the transmitter and accessed using the Magnetic Wand.
The instrument will show the main Menu when the “Enter” switch is activated with the
Magnetic Wand and held for at least 3 seconds.
The Menu is password protected to prevent any unauthorized changes. The password is
initially disabled and the default password is ‘0000’. If the default password is changed
to other than ‘0000’, then the password is enabled automatically and requested when
entering Configuration Mode.
With the Menu showing, the following functions can be performed: calibration, bump test,
sensor selection and configuration of parameters such as measuring range, calibration
gas level, calibration interval, inhibit current, inhibit timeout, alarm setting, relay setting,
password change, location setting, temperature unit reading, force analogue output and
alarm function checks.
While in Configuration mode, the output current of the transmitter is inhibited to prevent
false alarms.
Names, displays and descriptions for each menu item in Configuration Mode are shown in
the following table.
35
Menu Display Description

Execute zero/span calibration
Set calibration gas level
Set Calibration After zero, the option exists to proceed with
span calibration, or return to the Menu.
Select the type of sensor from the sensor

Select Sensor list. This menu is only available for
flammable / IR sensor.
Select the type of gas from the list. This

menu is only available for flammable / IR
Select Gas
sensor.
Set Range Set measuring range
Select inhibit current

Configure Inhibit
Set timeout option (5 minute increments)
Enable/disable password
Set Password Set password
Default – no password (Select ‘0000’)
Set Calibration Interval Set calibration interval, 30 to 365 days

User configurable option to display warning
Execute a ‘bump’ test to check gas

Bump Test response of the sensor.
Force analogue output to test functionality

Force Current of GD control system during system
commissioning.
Set alarm 1, alarm 2 levels, functionality

Set Alarms and operation (none/falling/rising)
Set relay 1,2,3 type (alarm 1, alarm 2,

Set Relays fault and inhibit) and action (energized/de-
energized)
36
Relay Operation Configure relay on delay time, relay off delay

time and latch/non-latch
Set location (or TAG number)

Set Location
Set Temperature Unit Change temperature display unit.

°C (Celcius) or °F (Fahrenheit)
Simulate alarm situation to check the alarm

Check Alarm functions system without gas present at the sensor
Quit Return to Monitoring mode
Table 7: Transmitter menu descriptions
Monitoring
Mode
Menu Switch
( > 3 Seconds)
Quit/ESC command
Auto quit after no activity of timeout
No
Access permitted?
Abort
Inhibit mA O/P Yes Release mA O/P

Set Calibration Force Current
Select Sensor* Set Alarms
Select Gas* Set Relays
Configuration Mode
Set Range Relay Operation
(Inhibited)
Configure Set Location
Inhibit
Set Password Set Temperature

Unit
Set Cal. Interval Test Alarms
Bump Test
* Note : “Select Sensor” and “Select Gas” menus are only available for flammable/IR sensors.
Diagram 14: Configuration Mode
37
13.2.1 Configuration mode operation table
Configuration mode allows the user to perform calibration and configure parameters such as full scale range, calibration gas level,
calibration interval, inhibit current & timeout, alarm settings, relay settings, set a password, etc. To activate Configuration mode hold
the magnet over the ENTER switch for at least 3 seconds and then remove. Configuration mode can be password protected to prevent
unauthorized personnel from changing parameters. Initially the password is set to ‘0000’ meaning it is disabled. While in Configuration
mode, the output current of the detector is inhibited to prevent false alarms.
Use the table below to help navigate the menus and make configuration changes. The menus are shown in the left hand column. Use
to select the required menu and ‘’ to enter. Follow the information and instructions in the table from left to right from the required
menu.
OK OK OK OK
GAS NAME, CURRENT CONCENTRATION AND
‘SPAN’ DISPLAYED AND ‘YES’ FLASHING ‘ ’ ICON DISPLAYED. APPLY SPAN GAS
Sensepoint XCD Technical Manual
GAS NAME, ZERO CONCENTRATION AND ‘GAS’ TARGET CONCENTRATION

FLASHING TO ASK IF YOU NOW AND USE ‘ ’ WHEN READING STABLE. IF OK ‘PASS’
SEt FLASHING ‘ ’ ICON DISPLAYED. APPLY FLASHING AND ‘ ’ ICON DISPLAYED.
WANT TO PERFORM SPAN & ‘PurG’ DISPLAYED (IF FAIL ‘SPAN FAIL’ DISPLAYED
ZERO GAS AND USE ‘ ’ WHEN READING IS USE TO CHANGE GAS
CAL1 CALIBRATION. USE ‘ ’ TO PROCEED AND RETURNS TO MENU). REMOVE SPAN GAS.
STABLE. ‘ZEro PASS’ DISPLAYED IF OK, CONCENTRATION AND ‘ ’ TO START
OR USE TO SELECT ‘No’ AND WHEN READING <50% OF SPAN POINT,
‘ZEro FAIL’ IF NOT. SPAN CALIBRATION.
RETURN TO MENU MODE. COUNTDOWN BEGINS & UNIT RETURNS TO MENU
MODE.
IF SENSOR TYPE IS CHANGED,
38
‘SEnS’ DISPLAYED WITH SENSOR TYPE ‘CAL YES’ DISPLAYED TO ASK
SEL2 DISPLAYED. USE TO SELECT IF YOU NOW WANT TO PERFORM
CALIBRATION. USE ‘ ’ TO PROCEED
SENS DIFFERENT SESNOR. OR USE TO SELECT ‘No’ AND
RETURN TO MENU MODE.
IF GAS TYPE IS CHANGED,
‘9AS’ DISPLAYED WITH GAS TYPE ‘CAL YES’ DISPLAYED TO ASK IF
SEL YOU NOW WANT TO PERFORM
DISPLAYED. USE TO SELECT CALIBRATION. USE ‘ ’ TO
9AS2 DIFFERENT GAS. PROCEED OR USE TO SELECT
‘No’ AND RETURN TO MENU MODE.
IF RANGE IS CHANGED, ‘CAL’ IF RANGE IS CHANGED, ‘ALrm’
BAR GRAPH INDICATING CURRENT RANGE, DISPLAYED AND ‘YES’ FLASHING TO DISPLAYED AND ‘YES’ FLASHING TO
SEt ‘rAn9’ DISPLAYED & CURRENT RANGE ASK IF YOU NOW WANT TO ASK IF YOU NOW WANT TO MODIFY
UNIT RETURNS TO MENU MODE
rAn9 FLASHES. USE TO SELECT DIFFERENT PERFORM CALIBRATION. USE ‘ ’ TO ALARM SETTINGS. USE ‘ ’ TO
RANGE PROCEED OR USE TO SELECT PROCEED OR USE TO SELECT
‘No’. ‘No’ AND RETURN TO MENU MODE.
‘tImE’ DISPLAYED WITH ‘ ’ ICON.
‘Inhb’ DISPLAYED WITH ‘ ’ ICON
FLASHING CURRENT INHIBIT
ConF FLASHING. CURRENT INHIBIT mA VALUE
TIMEOUT PERIOD (MINUTES)
FLASHES. USE TO SELECT NEW UNIT RETURNS TO MENU MODE
Inhb FLASHES. USE TO SET NEW
VALUE (2 OR 4mA TOXICS, OR 2 OR 17.4mA
TIMEOUT. (IF SET TO 0 OUTPUT IS
OXYGEN VERSION).
PERMANENTLY INHIBITED)
‘PASS’ DISPLAYED WITH FIRST DIGIT
SEt PLACE ICON OF THE PASSCODE FLASHING.
USE TO SELECT 1ST DIGIT OF CURRENT UNIT RETURNS TO MENU MODE
PASS PASSWORD. USE TO MOVE TO NEXT
DIGIT AND SET REST OF PASSCODE.
SPXCDHMANEN Issue 2
Forc ‘Forc’ DISPLAYED WITH ‘ ’ ICON. DEFAULT UNIT TRANSMITS THE CURRENT
FORCE CURRENT ‘4.00’ FLASHES. USE IF YOU WANT TO EXIT FROM THIS
Curr TO CHANGE TO REQUIRED mA LEVEL. MENU, USE ABORT FUNCTION
‘duE’ DISPLAYED AND ‘No’, ‘LCd’ OR

CAL ‘Int’ DISPLAYED WITH CURRENT
‘ALL’ FLASHING. USE TO
CALIBRATION INTERVAL FLASHING. USE UNIT RETURNS TO MENU MODE
Int33 SELECT REQUIRED CAL DUE
TO CHANGE INTERVAL.
WARNING OUTPUT.
UNIT RETURNS TO MENU MODE
PEAK READING DISPLAYED WITH OUTPUT WARNING: DO NOT RETURN TO
CURRENT GAS CONCENTRATION
bumP INHIBITED ‘ ’ ICON AND PEAK STRING NORMAL MODE UNTIL CURRENT GAS
DISPLAYED WITH OUTPUT CONCENTRATION HAS FALLEN
tESt FLASHING. APPLY BUMP TEST GAS AND
INHIBITED ‘ ’ ICON FLASHING. BELOW A1 LIMIT OR THE DETECTOR
CHECK PEAK READING ON DISPLAY.
WILL GIVE AN ALARM
‘AL2’, ICON DISPLAYED AND
‘AL1’, ICON DISPLAYED AND CURRENT
‘AL1’ DISPLAYED WITH ‘NonE’, ‘rISE’ CURRENT ALARM LEVEL 2 ‘AL2’ DISPLAYED WITH ‘NonE’, ‘rISE’ OR ‘FALL’
SEt ALARM LEVEL 1 CONCENTRATION
OR ‘FALL’ FLASHING. USE TO CONCENTRATION FLASHES. USE FLASHING. USE TO SELECT REQUIRED ALARM
ALrm FLASHES. USE TO CHANGE TO
SELECT REQUIRED ALARM ACTION. TO CHANGE TO REQUIRED ACTION AND USE ‘ ’ TO RETURN TO MENU MODE.
REQUIRED CONCENTRATION LEVEL.
CONCENTRATION LEVEL.
‘Rl2’ DISPLAYED AND ‘AL1’, ‘AL2’, ‘Inht’
‘rL1’ DISPLAYED AND ‘AL1’, ‘AL2’, ‘Inht’ or ‘rL1’ DISPLAYED AND ‘dEEn’ or ‘Enr9’
Set or ‘FLt’ FLASHES. USE TO ‘rL2’ DISPLAYED AND ‘dEEn’ or ‘Enr9’ FLASHES. USE
‘FLt’ FLASHES. USE TO CHANGE TO FLASHES. USE TO CHANGE TO
rLY CHANGE TO REQUIRED RELAY TO CHANGE TO REQUIRED RELAY ACTION.

REQUIRED RELAY TARGET. REQUIRED RELAY ACTION.
TARGET.
‘rL3’ DISPLAYED AND ‘AL1’, ‘AL2’, ‘Inht’ or ‘rL3’ DISPLAYED AND ‘dEEn’ or ‘Enr9’
‘FLt’ FLASHES. USE TO CHANGE TO FLASHES. USE TO CHANGE TO UNIT RETURNS TO MENU MODE
REQUIRED RELAY TARGET. REQUIRED RELAY ACTION.
‘rLY’, ‘OFF’ DISPLAYED AND
rlY ‘rLY’, ‘ON’ DISPLAYED AND CURRENT ‘Ltch’ DISPLAYED AND ‘YES’ or ‘No’
CURRENT RELAY-OFF TIME
RELAY-ON TIME FLASHES. USE TO FLASHES. USE TO CHANGE TO UNIT RETURNS TO MENU MODE
39
OPr FLASHES. USE TO CHANGE TO
CHANGE TO REQUIRED RELAY-ON DELAY. REQUIRED LATCH OPTION.
REQUIRED RELAY-OFF DELAY.
‘Loc’ DISPLAYED WITH FIRST 4
CHARACTERS OF THE LOCATION STRING. ‘Loc’ DISPLAYED NEW LOCATION
USE TO CHANGE THE 1ST CHARACTER STRING. THE STRING MOVES
Set OF CURRENT LOCATION STRING. USE RIGHT-TO-LEFT TO SHOW WHOLE
Loc TO MOVE TO NEXT CHARACTER AND SET CHARACTERS TWICE. THEN UNIT
REST OF STRING. MAXIMUM 12 AUTOMATICALLY RETURNS TO
CHARACTERS CAN BE SET. MENU MODE.
tEmP ‘tEmP’ DISPLAYED WITH ‘ C’ OR ‘ F’

FLASHING. USE TO CHANGE TO UNIT RETURNS TO MENU MODE
UnIt REQUIRED TEMPERATURE UNIT.
tESt ‘Forc’ DISPLAYED and ’AL1’ FLASHING TO GAS NAME, CURRENT GAS
SELECT TEST-REQURED ALARM. USE ‘ ’ CONCENTRATION DISPLAYED AND UNIT RETURNS TO MENU MODE
ALrm TO FORCE ALARM1. ‘ ’ ICON AND AL ICON FLASHE.
QUITS MENU MODE AND RETURNS TO

9uIt MONITORING MODE
OK OK OK OK
1
Refer to section 10.1 for detailed zero and span calibration procedures. A detector fitted with an oxygen sensor will skip the zeroing
procedure. Re-calibrate the detector if left un-powered for periods in excess of 24 hours.
2
This menu is only available and visible when the unit is fitted with flammable/IR sensor.
SPXCDHMANEN Issue 2
3
The calibration due warning counter is automatically reset after a successful calibration.
13.3 Sensor / Gas Selection
NOTE:
This Configuration option is not available for XCD units with EC sensors
13.3.1 Sensor Selection

“Select Sensor” sets the identity of the type of mV sensor attached to the XCD when XCD
does not detect the sensor type automatically. when sensor type is detected by XCD
automatically, the current sensor type can be confirmed in this menu.
The available mV sensors:
Ir-1 NDIR Infrared CO2 0-2%Vol

Ir-3 NDIR Infrared Methane 0-100%LEL
Cb-1 Catalytic 0-100%LEL
Selecting ‘’ will move the operator to the Select Sensor screen. The first screen displays
the currently configured sensor. To select a new mV sensor, use ‘’ to move through
the list, then use ‘’ to make the selection or discard the selection and return to menu
mode by using abort function. If type of sensor is changed, calibration prompt will appear
to ask if you want to perform calibration. If the sensor type is not changed, it means that
XCD has detected the sensor type automatically and a user does not need to configure
the sensor type manually.
Diagram 15: Sensor Selection
13.3.2 Gas Selection
Use “SEL gAS” to set the target gas for sensors capable of detecting multiple gases. The
available gases:
40
Sensor type Gas type Gas Name displayed
Ir-1 CO2 CO2

Ir-3 mEt mEt
Cb-1 Str1 to Str8 FLM
Gas selection is dependent on the type of sensor attached to the XCD. If Ir-1/Ir-3 sensor
is attached, then a user can only select CO2/mEt gas respectively. But when Cb-1 sensor
is attached to the XCD, a user can select the gas from Str1 (1*) to Str8 (8*). For more
information on star rating, please refer to section 19.2.
The current configuration of the XCD is displayed and by using the ‘’ switch to enter “SEL
gAS” menu. To select a flammable gas, use ‘’ to move through the list, then use ‘’ to
make the selection or abort function to discard the selection and return to menu mode.
If type of gas is changed, calibration prompt will appear to ask if you want to perform
calibration.
...
Diagram 16: Gas Selection
41
13.4 Review Mode
The instrument will enter Review mode when the “Enter” switch is activated with the
Magnetic Wand and held for around one second.
Names, displays and descriptions for each review item in Review Mode are shown in the
following table.
Item name Display Description
Software version S/W version of transmitter
SRS version S/W version of SRS (watch dog)
EEP version EEPROM parameter version
Gas Gas type
Measuring range A user selected measuring range
Calibration level Calibration gas level
Calibration due Estimated time to next calibration
Alarm 1 Alarm settings for Alarm 1
Alarm 2 Alarm settings for Alarm 2
42
Location Location in which the transmitter is installed
Power Power voltage*
Temperature Internal Transmitter temperature*
Peak conc. Maximum concentration detected up to now
Test Result There is no fault detected.
Table 8: Transmitter menu descriptions
Note:
*Power voltage and internal transmitter temperature may be different from actual value
due to measuring accuracy and internal heating components.
43
Menu Switch
(1s to 3s)
Review Monitoring
Mode Abort Mode
Auto end to cycle

S/W Version
Test Result
2 second delay
2 second delay
SRS Version
Peak Reading
2 second delay
2 second delay
EEPROM Version
Temperature
2 second delay
2 second delay
Gas Type Supplied input voltage
2 second delay
2 second delay
Measuring Range Location
2 second delay 2 second delay
Calibration Gas Level Alarm Setting
2 second delay
2 second delay
Calibration Due
Diagram 17: Review Mode
44
14 General specification
Sensepoint XCD Transmitter
Use 3-wire, 4-20mA, gas detector transmitter for use with directly installed flammable and toxic gas
sensors. For the protection of personnel and plant from flammable and toxic gas hazards.
Electrical
Input Voltage Range: 16 to 32Vdc (24Vdc nominal)
Max Power Consumption: Max 5 Watts. at 24Vdc (see section 2 regarding maximum in
rush current)
Current output 4-20mA (Source or Sink)
≥0.0<1.0 mA Fault (refer to table 5 section 12.3 for further details).
4.0 mA to 20.0 mA Normal gas measurement
2.0 mA or 4.0 mA (17.4 mA) Inhibit (during configuration/user settings)
22.0 mA Maximum over range
Terminals 15 x screw terminals suitable for wire diameter 0.5mm 2 to
2
2.5mm (20AWG to 13AWG).
Relays 3 x 5A@250VAC. Selectable normally open or normally closed
(switch) and energized/de-energized (programmable).
Communication RS485, Modbus RTU (Pending)
Construction
Material Epoxy painted aluminium alloy or 316 Stainless Steel
Weight Aluminium alloy: 1.7kg, 316 Stainless Steel: 3.7kg
Mounting Pole or wall mounting
Entries 2 x M20 (for ATEX/IECEx/AP Approval) or 2x3/4NPT (for UL Approval)
Detectable Gases & Performance (See notes below)
Response
User Selectable Full Default User Selectable Default Cal Operating Temperature* Default alarm points
Gas Steps Time (T90) Accuracy
Scale Range Range Cal Gas Range Point
secs Min Max A1 A2
Electrochemical Sensors
O xyg e n 2 5 .0 % V /V o n ly 2 5 .0 % V /V n /a 2 0 .9 % V /V (F ixe d ) 2 0 .9 % V /V <30 < + /-0 .5 % V o l. -2 0 °C / -4 °F 5 5 °C / 1 3 1 °F 1 9 .5 V /V▼ 2 3 .5 V /V▲
H yd ro g e n S u lfid e 1 0 .0 to 1 0 0 .0 p p m 5 0 .0 p p m 1 .0p p m 2 5 .0p p m <50 < + /-1 p p m -2 0 °C / -4 °F 5 5 °C / 1 3 1 °F 1 0 .0p p m▲ 2 0 .0p p m▲
C a rb o n M o n o xid e 1 0 0 to 1 ,0 0 0 p p m 300ppm 1 0 0p p m 100ppm <30 < + /-6 p p m -2 0 °C / -4 °F 5 5 °C / 1 3 1 °F 100 p p m▲ 20 0 p p m▲
H yd ro g e n 1 ,0 0 0 p p m o n ly 1 ,0 0 0 p p m n /a 500ppm <65 < + /-2 5 p p m -2 0 °C / -4 °F 5 5 °C / 1 3 1 °F 2 0 0 p p m▲ 4 0 0 p p m▲
Catalytic Bead Sensors 3 0 to 7 0 % o f
F la m m a b le 1 to 8 * 2 0 to 1 0 0 % L E L 100% LEL 1 0 % L E L se le cte d fu ll sca le 50% LEL <25 < + /-1 .5 % L E L -2 0 °C / -4 °F 5 5 °C / 1 3 1 °F 2 0 % L E L▲ 4 0 % L E L▲
Infrared Sensors ra n g e
M e th a n e 2 0 to 1 0 0 % L E L 100% LEL 10% LEL 50% LEL <40 < + /-1 .5 % L E L -2 0 °C / -4 °F 5 0 °C / 1 2 2 °F 2 0 % L E L▲ 4 0 % L E L▲

C a rb o n D io xid e 2 .00% V o l o n ly 2 .00% V /V n /a 1 .00% V /V <40 < + /-0 .0 4 % V o l. -2 0 °C / -4 °F 5 0 °C / 1 2 2 °F 0 .4 0% V /V▲ 0 .8 0% V /V▲
▲ - Rising Alarm ▼ - Falling Alarm
NOTES
Performance figures are taken at 20~25୅;
1. measured using a sample humidity of 50%RH, applicable between 10 and 90% of full scale,
2. measured using test units calibrated at 50% of full scale,
3. measured at 1000cc/min for Methane CAT, 500cc/min for O2, Toxic and Methane/Carbon Dioxide IR with calibration cup (S3KCAL).
Response time (T90) may increase when operating in lower temperature conditions or when gas is introduced with the Weather
Protection accessory (SPXCDWP) fitted. Methane IR sensor is calibrated and linearised only for Methane. Should it be exposed to other
HC then non linear response is expected. For linearised operation other than Methane contact HA for alternate parts. Flammable CAT
and Methane IR is calibrated at the factory 50%LEL Methane (2.5%Vol). This calibration enables 100% functional test prior to dispatch.
This calibration does not remove need for calibration & test as part of commissioning at site. For gases other than Methane the unit has
to be calibrated at site using target gas.Data represents typical values, and system conditioning may be required to achieve stated
result. Contact HA for details.
* Extended operating temperature range of -40°C to +65°C (-40°F to +149°F) for all sensor except for IR and H2 EC sensors, with an
accuracy of +/- 30% of applied gas from -20°C to -40°C (-4°F to -40°F) and +55°C to +65°C (+131°F to +149°F). Long term operation
at this range may cause decline in sensor performance.
Contact Honeywell Analytics for any additional data or details.
Certification
China GB Ex d IIC T4 GB3836.1&2 -2000, PA, (CCCF – Pending)
Korea KTL Ex d IIC T6 (-40ºC to +65ºC)
US UL - Class I, Division 1, Groups B, C and D, Class I, Division 2, Groups B, C & D, Class II,
Division, Groups E, F & G, Class II, Division 2, Groups F & G. -40ºC to+65ºC
European ATEX Ex II 2 GD Ex d IIC Gb T6(Ta -40ºC to +65ºC) Ex tb IIIC T85ºC Db IP66
International IEC Ex II 2 GD Ex d IIC Gb T6(Ta -40ºC to +65ºC) Ex tb IIIC T85ºC Db IP66
CE EN50270:2006 EN6100-6-4:2007
Environmental
IP Rating IP66 in accordance with EN60529:1992
Operating -40ºC to +65ºC/ -40ºF to +149ºF, (IR: -20ºC to +50ºC/ -4ºF to +122ºF).
Note: The detector display may become illegible at temperatures below -40°C, but the detector continues its gas monitoring
Temperature function. The display is not damaged and recovers when the temperature rises back above -20 °C.
Operating
Continuous 20-90%RH (non condensing), Intermittent 10-99%RH (non condensing)
Humidity
Operating
90-110kPa
Pressure
Storage
-25°C to +65°C (-13°F to +149°F)
Conditions
45
15 Ordering information
Part Number Description
Sensepoint XCD transmitter and sensor KIT (ATEX/IECEx/AP*, ADC12 and M20 Entry)
SPXCDAAMFX ATEX/IECEx/AP* approved Methane CAT 0-100%LEL (20 to 100%LEL, 10%LEL) with ADC12, M20 Entry
SPXCDAAMRX ATEX/IECEx/AP* approved Methane IR 0-100%LEL (20 to 100%LEL, 10%LEL) with ADC12, M20 Entry
SPXCDAAMO1 ATEX/IECEx/AP* approved Oxygen 25.0%/Vol with ADC12, M20 Entry
SPXCDAAMHX ATEX/IECEx/AP* approved Hydrogen Sulfide 0-50ppm (10.0 to 100.0ppm, 1ppm) with ADC12, M20 Entry
SPXCDAAMCX ATEX/IECEx/AP* approved Carbon Monoxide 0-300ppm (100 to 1000ppm, 100ppm) with ADC12, M20 Entry
SPXCDAAMG1 ATEX/IECEx/AP* approved Hydrogen 0-1000ppm with ADC12, M20 Entry
SPXCDAAMB1 ATEX/IECEx/AP* approved Carbon Dioxide IR 0-2.00%VOL with ADC12, M20 Entry
Sensepoint XCD transmitter and sensor KIT (ATEX/IECEx/AP*, LM25 and M20 Entry)
SPXCDALMFX ATEX/IECEx/AP* approved Methane CAT 0-100%LEL (20 to 100%LEL, 10%LEL) with LM25, M20 Entry
SPXCDALMRX ATEX/IECEx/AP* approved Methane IR 0-100%LEL (20 to 100%LEL, 10%LEL) with LM25, M20 Entry
SPXCDALMO1 ATEX/IECEx/AP* approved Oxygen 25.0%/Vol with LM25, M20 Entry
SPXCDALMHX ATEX/IECEx/AP* approved Hydrogen Sulfide 0-50ppm (10.0 to 100.0ppm, 1ppm) with LM25, M20 Entry
SPXCDALMCX ATEX/IECEx/AP* approved Carbon Monoxide 0-300ppm (100 to 1000ppm, 100ppm) with LM25, M20 Entry
SPXCDALMG1 ATEX/IECEx/AP* approved Hydrogen 0-1000ppm with LM25, M20 Entry
SPXCDALMB1 ATEX/IECEx/AP* approved Carbon Dioxide IR 0-2.00%VOL with LM25, M20 Entry
Sensepoint XCD transmitter and sensor KIT (ATEX/IECEx/AP*, 316SS and M20 Entry)
SPXCDASMFX ATEX/IECEx/AP* approved Methane CAT 0-100%LEL (20 to 100%LEL, 10%LEL) with 316SS, M20 Entry
SPXCDASMRX ATEX/IECEx/AP* approved Methane IR 0-100%LEL (20 to 100%LEL, 10%LEL) with 316SS, M20 Entry
SPXCDASMO1 ATEX/IECEx/AP* approved Oxygen 25.0%/Vol with 316SS, M20 Entry
SPXCDASMHX ATEX/IECEx/AP* approved Hydrogen Sulfide 0-50ppm (10.0 to 100.0ppm, 1ppm) with 316SS, M20 Entry
SPXCDASMCX ATEX/IECEx/AP* approved Carbon Monoxide 0-300ppm (100 to 1000ppm, 100ppm) with 316SS, M20 Entry
SPXCDASMG1 ATEX/IECEx/AP* approved Hydrogen 0-1000ppm with 316SS, M20 Entry
SPXCDASMB1 ATEX/IECEx/AP* approved Carbon Dioxide IR 0-2.00%VOL with 316SS, M20 Entry
Sensepoint XCD transmitter and sensor KIT (UL, ADC12 and 3/4”NPT Entry)
SPXCDUANFX UL approved Methane CAT 0-100%LEL (20 to 100%LEL, 10%LEL) with ADC12, 3/4"NPT Entry
SPXCDUANRX UL approved Methane IR 0-100%LEL (20 to 100%LEL, 10%LEL) with ADC12, 3/4"NPT Entry
SPXCDUANO1 UL approved Oxygen 25.0%/Vol with ADC12, 3/4"NPT Entry
SPXCDUANHX UL approved Hydrogen Sulfide 0-50ppm (10.0 to 100.0ppm, 1ppm) with ADC12, 3/4"NPT Entry
SPXCDUANCX UL approved Carbon Monoxide 0-300ppm (100 to 1000ppm, 100ppm) with ADC12, 3/4"NPT Entry
SPXCDUANG1 UL approved Hydrogen 0-1000ppm with ADC12, 3/4"NPT Entry
SPXCDUANB1 UL approved Carbon Dioxide IR 0-2.00%VOL with ADC12, 3/4"NPT Entry
Sensepoint XCD transmitter and sensor KIT (UL, 316SS and 3/4”NPT Entry)
SPXCDUSNFX UL approved Methane CAT 0-100%LEL (20 to 100%LEL, 10%LEL) with 316SS, 3/4"NPT Entry
SPXCDUSNRX UL approved Methane IR 0-100%LEL (20 to 100%LEL, 10%LEL) with 316SS, 3/4"NPT Entry
46
SPXCDUSNO1 UL approved Oxygen 25.0%/Vol with 316SS, 3/4"NPT Entry
SPXCDUSNHX UL approved Hydrogen Sulfide 0-50ppm (10.0 to 100.0ppm, 1ppm) with 316SS, 3/4"NPT Entry
SPXCDUSNCX UL approved Carbon Monoxide 0-300ppm (100 to 1000ppm, 100ppm) with 316SS, 3/4"NPT Entry
SPXCDUSNG1 UL approved Hydrogen 0-1000ppm with 316SS, 3/4"NPT Entry
SPXCDUSNB1 UL approved Carbon Dioxide IR 0-2.00%VOL with 316SS, 3/4"NPT Entry
Replacement sensor cartridge
SPXCDXSFXSS Methane CAT 0-100%LEL (20 to 100%LEL, 10%LEL)
SPXCDXSRXSS Methane IR 0-100%LEL (20 to 100%LEL, 10%LEL)
SPXCDXSO1SS Oxygen 25.0%/Vol only
SPXCDXSHXSS Hydrogen Sulphide 0-50ppm (10.0 to 100.0ppm, 1ppm)
SPXCDXSCXSS Carbon Monoxide 0-300ppm (100 to 1000ppm, 100ppm)
SPXCDXSG1SS Hydrogen 0-1000ppm only
SPXCDXSB1SS Carbon Dioxide IR 0-2.00%VOL only
Accessories
S3KCAL Calibration cap
SPXCDCC Collecting cone for use with lighter than air gases
SPXCDDMK Duct mounting kit
SPXCDHMANEN Hard Copy Manual in English
SPXCDMTBR Pipe Mounting bracket (inc. fixings and hex wrench set)
SPXCDSDP Sunshade / Deluge Protection
Spares
SPXCDDMT Replacement display module (O2 & Toxic)
SPXCDDMF Replacement display module (FL & IR)
SPXCDTMO Replacement terminal module (O2)
SPXCDTMT Replacement terminal module (Toxic)
SPXCDTMF Replacement terminal module (FL & IR)
SPXCDNPTP 3/4”NPT Plug
SPXCDM20P M20 Plug
SPXCDMANCD Instruction manual CD
SPXCDNADP 3/4”NPT to M20 Adaptor
SPXCDWP Weather Protection
SPXCDMAG Magnet
SPXCDSRLS Sensor Retainer with locking screw
SPXCDAKS Allen key for stopper
SPXCDHWES Hex wrench for earth screw
SPXCDEBS Earth Bracket and Screws
* AP approvals include GB & PA for China and KTL for Korea.
47
16 Warranty statement
All products are designed and manufactured to the latest internationally recognized
standards by Honeywell Analytics under a Quality Management system that is certified to
ISO 9001. As such Honeywell Analytics warrants its products against defective parts and
workmanship and will repair or (at its option) replace any instruments which are or may
become defective under proper use within 12 months from date of commissioning by an
approved Honeywell Analytics representative
or 18 months from date of shipment from Honeywell Analytics, whichever is the sooner.
This warranty does not cover disposable batteries or damage caused by accident, abuse,
abnormal operating conditions or poisoning of sensor.
Defective goods must be returned to Honeywell Analytics premises accompanied by a

detailed description of any issue. Where return of goods is not practicable Honeywell
Analytics reserves the right to charge for any site attendance where any fault is not found
with he the equipment. Honeywell Analytics shall not be liable for any loss or damage
whatsoever or howsoever occasioned which may be a direct or indirect result of the use or
operation of the Contract Goods by the Buyer or any Party.
This warranty covers instrument and parts sold to the Buyer only by authorized distributors,
dealers and representatives as appointed by Honeywell Analytics. The warranties set out
in this clause are not pro rata, i.e. the initial warranty period is not extended by virtue of
any works carried out there under.
In no event will Honeywell Analytics be liable for any incidental damages, consequential
damages, special damages, punitive damages, statutory damages, indirect damages,
loss of profits, loss of revenues, or loss of use, even if informed of the possibility of such
damages. Honeywell Analytic's liability for any claims arising out of or related to this
product will in no case exceed the order value. To the extent permitted by applicable
law, these limitations and exclusions will apply regardless of whether liability arises from
breach of contract, warranty, tort (including but not limited to negligence), by operation of
law, or otherwise.
48
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SPXCDHMANEN Issue 2
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18 Certification
18.1 China GB Ex and PA
China GB Ex (Chinese Version):
55
China GB Ex (English Version):
56
China PA Certification:
57
18.2 Korea KTL
58
18.3 European ATEX

ATEX For Transmitter:
59
ATEX for Sensor
60
18.4 International IEC

IEC Ex for Transmitter
61
IEC Ex for Sensor
62
THIS DOCUMENT HAS BEEN GENERATED USDING
3001EA041 SHT. ADOBE ILLUSTRATOR AND MUST ONLY BE UPDATED BY A.I.
Honeywell Sensepoint XCD

Honeywell Analytics Inc. Lincolnshire, IL, USA 60069
Read Sensepoint XCD Manual prior to use and install as per
Control Drawing No.3001EA041. Temp. Code T4 32Volts DC
MAX. Class 2, Pmax=5W
P/N : S/N :
II 2 GD
Ex d IIC Gb T6(Ta -40୅ to +65୅P

Ex tb IIIC T85୅GDb IP66
0344 Baseefa08ATEX0222
IECEx BAS 08.0072
WARNING : DO NOT OPEN WHEN ENERGISED OR

WHEN AN EXPLOSIVE GAS ATMOSPHERE IS NOTES
PRESENT
1. This is an ATEX schedule drawing and can only
18.5 Sensepoint XCD ATEX Name Plate
be changed after approval is given by the
63
certifiying body
2. Serial no. format
S/N: SIIPPPYYWWNNN
Sequence number
Week of MFG
Year of MFG
Part Code
Issue State
SUPPLIER CODE
3. Etching Depth : 0.1 mm
THIS ITEM FORMS PART OF A CERTIFIED PRODUCT

NO MODIFICATION PERMITTED WITHOUT
REFERENCE TO CERTIFICATION DEPARTMENT
FINISH MATERIAL SCALE DRAWING BEN HUR 16 MAY 08
THIS DRAWING IS CONFIDEN- JIS G4304: SUS 316 TITILE
TIAL. IT IS THE PROPERTY OF Minimum Thickness: 0.5mm NONE
HONEYWELL ANALYTICS LTD
1 E D C B A ISSUE Sensepoint XCD
AND MUST NOT BE REPRO-
DUCED EITHER WHOOLY OR 30/SEP/08 16/SEP/08 08/SEP/08 14/JUL/08 17/JUN/08 16/MAY/08 DATE ATEX Name Plate
PARTLY. ALL RIGHTS IN RESPECT ADD Certi. ADD Certi. CHANGED CHANGED MARKING NEW
IP66 Numbers NOTES NOTES REVISED DRAWING CHANGE
OF PATENTS, DESIGNS AND SHT.
COPYRIGHT ARE RESERVED. APPROVED
J.Y.JIN J.Y.JIN J.Y.JIN J.Y.JIN J.Y.JIN J.Y.JIN BY
3001EA041 OF
SPXCDHMANEN Issue 2
3001EU041 ADOBE ILLUSTRATOR AND MUST ONLY BE UPDATED BY A.I.
Honeywell Sensepoint XCD

Honeywell Analytics Inc. Lincolnshire, IL, USA 60069
Gas Detector for use in Hazardous Locations
as to fire, Electrical Shock, Explosion Hazards Only.
Class I Division 1&2, Groups B,C,D;
Class II Division 1, Groups E,F,G; Honeywell Sensepoint XCD
Class II Division 2, Groups F+G; Honeywell Analytics Inc. Lincolnshire, IL, USA 60069
35YL Gas Detector for use in Hazardous Locations
Class I, Zone 1,Group IIB+H2 Hazardous Locations. as to fire, Electrical Shock, Explosion Hazards Only.
Class I Division 1&2, Groups B,C,D;
Read Sensepoint XCD Manual Prior to Use. Class II Division 1, Groups E,F,G;
Class II Division 2, Groups F+G;

Class I, Zone 1,Group IIB+H2 Hazardous Locations. 35YL
Temp. Code T4, 16~32Volts DC, Pmax=3W, Read Sensepoint XCD Manual Prior to Use.
Relay Ratings 3x5A@250VAC, Tamb.-40୅ To +65୅ Temp. Code T4, 16~32Volts DC, Pmax=3W,
Relay Ratings 3x5A@250VAC, Tamb.-40୅ To +65୅
P/N : ______________________________
P/N : ______________________________ S/N : ________________________________

18.6 Sensepoint XCD UL Name Plate
WARNING :To reduce the risk of Hazardous Atmos-

pheres, Disconnect the equipment from supply circuit
S/N : ________________________________ before opening. Keep tightly closed when in opera
-tion. Conduit runs must have a seal fitting within
18 inches of the enclosure.
64
WARNING :To reduce the risk of Hazardous Atmos-
pheres, Disconnect the equipment from supply circuit
before opening. Keep tightly closed when in opera
-tion. Conduit runs must have a seal fitting within
18 inches of the enclosure.
SCALE 2/1
BEN 16 MAY 08
NONE
5 4 3 2 1 B A Sensepoint XCD
27/JAN/09 24/JAN/09 15/JAN/09 06/JAN/09 09/DEC/08 23/JUL/08 16/MAY/08 UL Name Plate
CHANGE REMOVE CHANGE CHANGE CHANGE CHANGE NEW
SENTENCE “CLASS2” SENTENCE SENTENCE REVISION RATING DRAWING
J.Y.JIN J.Y.JIN J.Y.JIN J.Y.JIN J.Y.JIN J.Y.JIN J.Y.JIN 3001EU041

SPXCDHMANEN Issue 2
3001EA053 SHT. ADOBE ILLUSTRATOR AND MUST ONLY BE UPDATED BY A.I.
Gas Type
II 2 GD
Honeywell Analytics Inc. Ex d IIC T6(Ta -40 to +65 ) Gb
0344 Lincolnshire, IL, USA 60069 Ex tb IIIC T85 Db IP66 A21
Baseefa08ATEX0316X
Sensepoint XCD IECEx BAS 08.0104X
Disposable Sensor P/N :
WARNING : DO NOT SEPARATE
Rev. S/N : SIIPPPYYWWNNNN WHEN ENERGISED
18.7 Sensor Cartridges Label
Revision Number
65
N
THIS ITEM FORMS PART OF A CERTIFIED PRODUCT

NO MODIFICATION PERMITTED WITHOUT
REFERENCE TO CERTIFICATION DEPARTMENT
FINISH REFERENCE PARTNUMBER SCALE DRAWING BEN HUR 12 SEP 08
THIS DRAWING IS CONFIDEN- TITILE
TIAL. IT IS THE PROPERTY OF NTS
HONEYWELL ANALYTICS LTD Sensor Cartridge Label
1 A ISSUE
AND MUST NOT BE REPRO-
DUCED EITHER WHOOLY OR 10/NOV/08 12/SEP/08 DATE Artwork Drawing
PARTLY. ALL RIGHTS IN RESPECT NEW
REVISED DRAWING CHANGE
OF PATENTS, DESIGNS AND SHT.
COPYRIGHT ARE RESERVED. J.Y.JIN J.Y.JIN APPROVED 3001EA053 OF
BY
SPXCDHMANEN Issue 2
19 Cross Interference and Cross Calibration

19.1 Cross Interference Table for Toxic and Oxygen
This below table shows the relative cross sensitivity of the Sensepoint XCD to other
gases. “Gas Type” indicated the XCD sensor type fitted to the XCD. “Gas Type Applied”
indicates the gas that may be applied to that sensor and the resulting Reading.
Gas
Gas Type Applied Concentration Unit Reading Unit
type
%vol (change O2
O2 Carbon Dioxide 5 %vol 0.1
reading) per %vol CO2
Ammonia 50 ppm 0 ppm H2S
Carbon Monoxide 100 ppm <2 ppm H2S
Carbon Dioxide 5000 ppm 0 ppm H2S
Chlorine 0.5 ppm 0 ppm H2S
Ethylene 100 ppm 0 ppm H2S
H 2S
Hydrogen 100 ppm 0 ppm H2S
Hydrogen Sulfide 10 ppm 10 ppm H2S
Nitrogen Monoxide 25 ppm 0 ppm H2S
Nitrogen Dioxide 3 ppm 0 ppm H2S
Sulfur Dioxide 2 ppm 0 ppm H2S
Acetone 1000 ppm 0 ppm CO
Acetylene 40 ppm 80 ppm CO
Ammonia 100 ppm 0 ppm CO
Carbon Monoxide 100 ppm 100 ppm CO
Chlorine 2 ppm 0 ppm CO
Ethanol 2000 ppm 3 ppm CO
CO Ethylene 100 ppm 85 ppm CO
Hydrogen 100 ppm 20 ppm CO
Hydrogen 25 ppm 0 ppm CO
Iso-Propanol 200 ppm 0 ppm CO
Nitrogen Monoxide 50 ppm 8 ppm CO
Nitrogen Dioxide 800 ppm 20 ppm CO
Sulfur Dioxide 50 ppm 0.5 ppm CO
Carbon Monoxide 300 ppm ≤60 ppm H2
Hydrogen Sulfide 15 ppm <3 ppm H2
Sulfur Dioxide 5 ppm 0 ppm H2
Nitrogen Monoxide 35 ppm »10 ppm H2
H2 Nitrogen Dioxide 5 ppm 0 ppm H2
Chlorine 1 ppm 0 ppm H2
Hydrogen Cyanide 10 ppm »3 ppm H2
Hydrogen Chloride 5 ppm 0 ppm H2
Ethylene 100 ppm »80 ppm H2
66
19.2 Cross Calibration Flammable Gas Detector

For greater accuracy, a catalytic gas detector should be calibrated using a certified
gas/air mixture equal to 50% LEL of the actual target gas intended to be monitored.
However, it is not always practical to obtain every detectable type of hydrocarbon gas in
a calibration-ready, certified and verifiable form. Therefore, it is possible to carry out a
“cross calibration” using another hydrocarbon gas/air mixture.
When the Sensepoint XCD Combustible LEL sensor is to be calibrated with a gas which is
different to the gas or vapour to be detected, the following cross calibration procedure may
be followed:
Caution: Where the user calibrates any sensor using a different gas, responsibility for
identifying and recording calibration rests with the user. Refer to the local regulations where
appropriate.
Notes:
1. Table 11 lists a selection of hydrocarbon compounds and states a reference figure or
“Star Rating” according to the reaction they produce in relation to other hydrocarbons.
2. An eight star (8*) gas produces the highest output, while a one star (1*) gas produces
the lowest output.
No. Gas Star Rating

1 Acetone 4*
2 Ammonia 7*
3 Benzene 3*
4 Butanone 3*
5 Butane 4*
6 Butyl acetate 1*
7 Butyl acrylate 1*
8 Cyclohexane 3*
9 Cyclohexanone <1*
10 Diethyl ether 4*
11 Ethane 6*
12 Ethanol 5*
13 Ethyl acetate 3*
14 Ethylene 5*
15 Heptane 3*
16 Hexane 3*
17 Hydrogen 6*
18 Methane 6*
19 Methanol 5*
20 MIBK 3*
21 Octane 3*
22 Pentane 3*
23 Propane 5*
24 Propan-2-ol 4*
67
25 Styrene 2*
26 Tetra hydrafuran 4*
27 Toluene 3*
28 Triethylamine 3*
29 Xylene 2*
Table 11 . Star Rating of Gases
To cross calibrate the SG16B flammable gas detector catalytic bead:

(1) Obtain the star rating for both the calibration test gas and the gas to be detected from
Table 11
(2) These values may then be used in Table 12 to obtain the required calibration span
setting when a 50% LEL test gas is applied to the detector.
*Rating of *Rating of Gas to be Detected

Calibration Gas 8* 7* 6* 5* 4* 3* 2* 1*
8* 50 62 76 95 - - - -
7* 40 50 61 76 96 - - -
6* 33 41 50 62 78 98 - -
5* 26 33 40 50 63 79 100 -
4* 21 26 32 40 50 63 80 -
3* - 21 26 32 40 50 64 81
2* - - - 25 31 39 50 64
1* - - - - 25 31 39 50
Note: These settings must only be used with a calibration gas concentration of 50% LEL.
Table 12. Calibration span setting
(3) If a sensor is to be used to detect a gas other than that for which it was calibrated and
there is no intention to use an equivalent calibration gas to re-calibrate the sensor, then
the required correction factor may be obtained from Table 13.
The reading shown on the gas detector controller or transmitter display should be
multiplied by this number in order to obtain a more accurate gas concentration result.
Sensor calibrated to Sensor used to detect

detect 8* 7* 6* 5* 4* 3* 2* 1*
8* 1.00 1.24 1.52 1.89 2.37 2.98 3.78 4.83
7* 0.81 1.00 1.23 1.53 1.92 2.40 3.05 3.90
6* 0.66 0.81 1.00 1.24 1.56 1.96 2.49 3.17
5* 0.53 0.66 0.80 1.00 1.25 1.58 2.00 2.55
4* 0.42 0.52 0.54 0.80 1.00 1.26 1.60 2.03
3* 0.34 0.42 0.51 0.64 0.80 1.00 1.27 1.62
2* 0.26 0.33 0.40 0.50 0.63 0.79 1.00 1.28
1* 0.21 0.26 0.32 0.39 0.49 0.62 0.78 1.00
Table 13. Correction factors
68
Notes:
1. Since catalytic sensors require oxygen for correct operation, a mixture of gas in air
should always be used for calibration purposes.
2. Assuming average performance of the sensor, the sensitivity information in Tables 11 To
13 is normally accurate to + or - 20%.
Working Example:
If the target gas to be detected is 0-100%LEL Ethylene and the only calibration gas
available to re-calibrate the sensor is Methane (at 50% LEL concentration), the procedure
is as follows:
(1) Look up the star rating for each gas in Table 11:
Gas No. 14, Ethylene = 5*

Gas no. 18, Methane = 6*
(2) Then, look up the span settings for a 50% LEL calibration gas in Table 12 by selecting
the row of figures next to the 6* in the “calibration gas” column. Select the figure in the 5*
column of the “gas to be detected” section. The figure is 62.
(3) This means that during re-calibration, the span gas setting on the gas detector
transmitter or controller should be set to 62% LEL to give an accurate measuring scale for
0-100%LEL Ethylene, when using 50% LEL Methane as the calibration gas.
Please contact your local Honeywell Analytics sales or service distributor, or regional office
should further clarification or additional information be required.
69
D aejeon T el : 042)824-9872 Fax : 042)824-9873
E -mail: sdd@sd-d.co.kr
Web site: http//www.sd-d.co.kr
FTS
(DANFOSS)
Data sheet
Temperature sensor with integrated transmitter for

maritime applications
MBT 5560
With MBT 5560 we have combined the
technology of our standard temperature sensors
and the electrical connections from our MBS
pressure transmitters with a new developed
electronics which has resulted in a compact
temperature sensor with a built-in transmitter.
The MBT 5560 is designed for use in harsh
industrial environments where reliable, robust
and accurate equipment is required.
Available with a wide selection of process and
electrical connections. Can be delivered with a
33 mm extension length which makes it possible
to measure temperatures up to 200 °C without
damaging the built-in electronics.
Features • Designed for use in harsh industrial • Ultra compact design

environments where reliable, robust • Temperature range -50 – 200 °C
and accurate equipment is required • Sensor pockets available for applications
• All metal enclosure parts made where emptying the system is not an option
of stainless steel (AISI 316) • Based on Pt 1000 technology
• Output signals: 4 – 20 mA
or Ratiometric 10 – 90%
• A wide selection of process and electrical
connections
Approvals Lloyds Register of Shipping, LR Nippon Kaiji Kyokai, NKK

Germanischer Lloyd, GL (not ratiometric) American Bureau of Shipping, ABS
Det Norske Veritas, DNV (not ratiometric) Korean Register of Shipping, KRS
Registro Italiano Navale, RINA
Bureau Veritas, BV
© Danfoss | DCS (im) | 2019.04 AI202286432128en-000801| IC.PD.P30.F8.02 | 1

Data sheet | Temperature sensor with integrated transmitter for maritime applications, MBT 5560
Technical data Main specifications

Process connections See page 3
Measuring ranges Any combinations between -50 – 200 °C
Minimum span 25 °C
Output signals 4 – 20 mA or Ratiometric 10 – 90%
Electrical connections See page 4
Performance
Indicative response times
Water 0.2 m/s Air 1 m/s
t0.5 t0.9 t0.5 t0.9
ø8 mm
10 s 35 s 95 s 310 s
Accuracy < ± 0.5% FS (typ.)
< ± 1.0% FS (max.)
Max. load protection tube 100 bar
Electrical specifications
Nom. Output signal (short-circuit protected)

ratiometric 10 – 90%
4 – 20 mA
of supply voltage
Supply voltage [US] polarity 4.75 – 8 V DC
10 – 30 V DC
protected 5 V DC (Nom.)
Supply – current consumption – < 4 mA at 5 V DC
> 100 Mohm at > 100 Mohm at
Insulation resistance
100 V DC 100 V DC
Supply voltage dependency < ± 0.05% FS/10 V –
Current limitation 30 mA –
Output impedance – < 25 ohm
Load [RL] RL<(US-10) / (0.02 A) ohm RL> 5 kohm at 5 V DC
Environmental conditions
Media temperature (max. 120 °C without extension length) -50 – 200 °C
Temperature on electronics 1
)
-40 – 85 °C
Transport temperature range -50 – 85 °C
EMC – Emmision EN 61000-6-3
EMC – Immunity EN 61000-6-2
Sinusoidal 15.9 mm-pp, 5 Hz – 25 Hz –
Vibration stability 4 g, 25 Hz – 2 kHz IEC 60068-2-6
Random 7.5 gms, 5 Hz – 1 kHz IEC 600868-2-34, IEC 60068-2-36
Shock 500 g/1 ms IEC 60068-2-27
Shock resistance
Free fall IEC 60068-2-32
Enclosure (depending on electrical connections) See page 4
1
) Temperature of the electronics depends on the media temperature, extension length, ambient temperature and air velocity.
Mechanical characteristics
Wetted parts W.no. 1.4571 (AISI 316 Ti)
Materials:
Enclosure W.no. 1.4404 (AISI 316 L)
Measuring insert fixed
Net weight
0.1 – 0.15 kg
(Depending on design)
2 | AI202286432128en-000801| IC.PD.P30.F8.02 © Danfoss | DCS (im) | 2019.04

Data sheet | Temperature sensor with integrated transmitter for maritime applications, MBT 5560
Ordering standard
Sensor
Type MBT 5560
Measuring range Transmitter setting

-50 – 200 °C 0 1 1 0 0 – 100 °C
1 1 5 0 – 150 °C
Output signal 1 2 0 0 – 200 °C
4 – 20 mA 0 4 1 5 -50 – 150 °C
Ratiometric...10 – 90% 1 4 2 0 -50 – 200 °C
9 9 9 Other
Protection tube, W.no. 1.4571 (AISI 316 TI)

Acid-proof steel, ø8 mm (-50 – 200 °C) 0 Process connection
0 G 1/4 A
Extension length 1 G 3/8 A
None 0 2 G½A
33 mm 1 7 ½ – 14 NPT
9 Other
Insertion length
0050 mm 0050 Electrical connection
0080 mm 0080 1 Plug, EN 175301-803, Pg 9
0100 mm 0100 4 Plug, AMP Econoseal, J series, Male, excl. female plug
0120 mm 0120 5 Screened cable, 2 m
0150 mm 0150 6 Plug, IEC 947-5-2, M12 × 1, male, excl. female plug
0200 mm 0200 A Flying leads
0250 mm 0250 9 Other
Preferred versions
Non-standard build up combinations

may be selected. However, minimum
order quantities may apply,
please contact your local Danfoss
office for more information
Electrical connections AMP Econoseal IEC 947-5-2

EN 175301-803 Flying leads 2 m screened cable
J series (male) M12 × 1
Enclosure
IP65 IP67 IP67 IP67 IP67
Materials
Glass filled Glass filled Glass filled Glass filled
PUR
polyamid, PA 6.6 polyamid, PA 6.6 polyamid, PA 6.6 polyamid, PA 6.6

Electrical connection, 4 – 20 mA output (2 wire)
Pin 1: +supply
Red wire: +supply
Pin 2: ÷supply Pin 1: +supply
Pin 1: +supply Red wire: +supply White wire: ÷supply
Pin 3: Not used Pin 2: Not used
Pin 2: ÷supply Black wire: ÷supply Red/black wire: Not used
Earth: Not Pin 3: Not used
Pin 3: Not used Screen: Not connected to
connected to MBT Pin 4: ÷supply
MBT housing
housing
Electrical connection, Ratio metric (3-wire) 10 – 90%

Pin 1: +supply
Red wire: +supply
Pin 2: ÷supply Pin 1: +supply
Pin 1: +supply Red wire: +supply White wire: ÷supply
Pin 3: Output Pin 2: not used
Pin 2: ÷supply Black wire: ÷supply Red/ Black wire: Output
Earth: Not Pin 3: Output
Pin 3: Output Blue wire: Output Screen: Not connected
connected Pin 4: ÷supply
to MBT housing
to MBT housing
Dimensions AMP Econoseal IEC 947-5-2 EN 175301-803, 2 m Screened

Flying leads
J series (male) M12 × 1, 4-pin Pg 9 cable
Ø30.5
E
Ø8
8
Ø
E = Extension length = 33 mm
L = Insertion length
H = 9 mm

FMU
(ABB)
—
A B B M E A S U R E M E N T & A N A LY T I C S | O P E R AT I N G I N S T R U C T I O N
ProcessMaster FEP300, FEP500

HygienicMaster FEH300, FEH500
Electromagnetic flowmeter
Measurement made easy
ProcessMaster
Valid as of software version Further information
FEP300, FEP500
HygienicMaster
• 01/01/00 with HART Additional documentation on ProcessMaster
FEP300, FEP500/HygienicMaster FEH300, FEH500
FEH300, FEH500
• 01/00/00 with PROFIBUS PA or is available for download free of charge at
FOUNDATION fieldbus www.abb.com/flow.
Alternatively simply scan this code:

Manufacturer
ABB Automation Products GmbH ABB Inc. ABB Engineering (Shanghai) Ltd.
Measurement & Analytics Measurement & Analytics Measurement & Analytics
Dransfelder Str. 2 125 E. County Line Road No. 4528, Kangxin Highway,
37079 Göttingen Warminster Pudong New District
Deutschland PA 18974 Shanghai, 201319,
Tel: 0800 1114411 USA P.R. China
Fax: 0800 1114422 Tel: +1 215 674 6000 Tel: +86(0) 21 6105 6666
Email: vertrieb.messtechnikprodukte@ Fax: +1 215 674 7183 Fax: +86(0) 21 6105 6677
de.abb.com Email: china.instrumentation@cn.abb.com
Customer Service ABB Limited

Tel: +49 0180 5 222 580 Measurement & Analytics
Email: automation.service@de.abb.com Oldends Lane, Stonehouse
Gloucestershire, GL10 3TA
Tel: +44 (0)1453 826 661
Fax: +44 (0)1453 829 671
Email: instrumentation@gb.abb.com
Contents
1 Safety .............................................................................................................................................................8
1.1 General information and notes for the reader ................................................................................................8
1.2 Intended use ...................................................................................................................................................9
1.3 Improper use ..................................................................................................................................................9
1.4 Target groups and qualifications ....................................................................................................................9
1.5 Warranty provisions........................................................................................................................................9
1.6 Plates and symbols ......................................................................................................................................10
1.6.1 Safety- / warning symbols, note symbols..............................................................................................10
1.6.2 Name plate ............................................................................................................................................11
1.7 Transport safety information.........................................................................................................................14
1.8 Installation safety information .......................................................................................................................14
1.9 Safety instructions for electrical installation .................................................................................................14
1.10 Safety instructions for operation ...................................................................................................................15
1.11 Technical limit values ...................................................................................................................................15
1.12 Allowed measuring media ............................................................................................................................15
1.13 Maintenance and inspection safety information ...........................................................................................16
1.14 Returning devices.........................................................................................................................................16
1.15 Integrated management system ...................................................................................................................17
1.16 Disposal ........................................................................................................................................................17
1.16.1 Information on WEEE Directive 2012/19/EU (Waste Electrical and Electronic Equipment).................17
2 Design and function ...................................................................................................................................18
2.1 Measuring principle ......................................................................................................................................18
2.2 Device designs .............................................................................................................................................19
2.2.1 Design ...................................................................................................................................................20
2.2.2 Integral mount design............................................................................................................................20
2.2.3 Remote mount design ...........................................................................................................................21
3 Transport and storage ...............................................................................................................................22
3.1 Inspection .....................................................................................................................................................22
3.2 Transport of flanged units smaller than DN 450...........................................................................................22
3.3 Transport of flanged units larger than DN 400 .............................................................................................23
3.4 Storage conditions........................................................................................................................................23
4 Mounting .....................................................................................................................................................24
4.1 General information on installation ...............................................................................................................24
4.1.1 Supports for meter sizes larger than DN 400 .......................................................................................24
4.1.2 Selecting gaskets ..................................................................................................................................25
4.1.3 Devices with a wafer-type design .........................................................................................................25
4.1.4 Installing the meter tube ........................................................................................................................26
4.2 Torque information .......................................................................................................................................27
4.3 Information on 3A conformity .......................................................................................................................31
4.4 Installation Requirements .............................................................................................................................32
4.4.1 Flow direction ........................................................................................................................................32
4.4.2 Electrode axis........................................................................................................................................32
4.4.3 In- and outlet pipe sections ...................................................................................................................32
4.4.4 Vertical connections ..............................................................................................................................32
4.4.5 Horizontal connections ..........................................................................................................................32
4.4.6 Free inlet or outlet .................................................................................................................................32
4.4.7 Strongly contaminated measuring media..............................................................................................32
4.4.8 Installation in the vicinity of pumps .......................................................................................................33
OI/FEX300/FEX500-EN FEX300, FEX500 3

Contents
4.4.9 Installation of the high temperature design ...........................................................................................33
4.4.10 Devices with extended diagnostic functions .........................................................................................33
4.4.11 Minimum distance .................................................................................................................................33
4.4.12 Installation in pipelines with larger nominal diameters..........................................................................33
4.5 Rotating the LCD display / Rotating the housing .........................................................................................34
4.5.1 Rotating the LCD display ......................................................................................................................35
4.5.2 Rotating the housing .............................................................................................................................35
4.6 Ground..........................................................................................................................................................35
4.6.1 General information on ground connections .........................................................................................35
4.6.2 Metal pipe with fixed flanges .................................................................................................................36
4.6.3 Metal pipe with loose flanges ................................................................................................................37
4.6.4 Plastic pipes, non-metallic pipes or pipes with insulating liner .............................................................38
4.6.5 Sensor type HygienicMaster .................................................................................................................39
4.6.6 Ground for devices with protective plates .............................................................................................39
4.6.7 Ground with conductive PTFE grounding plate ....................................................................................39
4.6.8 Devices with extended diagnostic functions .........................................................................................39
4.6.9 Installation and grounding in pipelines with cathodic corrosion protection (CCP) ................................40
5 Electrical connections ...............................................................................................................................42
5.1 Routing the signal and magnet coil cable ....................................................................................................42
5.2 Preparing the signal and magnet coil cable in the case of transmitters with dual-compartment housing ...43
5.2.1 Cable with part number D173D027U01 ................................................................................................43
5.3 Preparing the signal and magnet coil cable in the case of transmitters with single-compartment housing . 45
5.4 Connecting the flowmeter sensor .................................................................................................................47
5.4.1 Metal terminal box for ProcessMaster and HygienicMaster .................................................................47
5.4.2 Connection via cable conduit ................................................................................................................48
5.4.3 IP rating IP 68 .......................................................................................................................................49
5.5 Connecting the transmitter ...........................................................................................................................51
5.5.1 Connecting the power supply................................................................................................................51
5.5.2 Transmitter with dual-compartment housing .........................................................................................52
5.5.3 Transmitter with single-compartment housing ......................................................................................52
5.5.4 Connecting the signal and magnet coil cables .....................................................................................53
5.6 Terminal connection diagrams .....................................................................................................................54
5.6.1 HART, PROFIBUS PA and FOUNDATION fieldbus protocol ...............................................................54
5.7 Electrical data ...............................................................................................................................................55
5.7.1 Current / HART output ..........................................................................................................................55
5.7.2 Digital output DO1 .................................................................................................................................55
5.7.4 Digital input DI .......................................................................................................................................55
5.7.5 Digital communication ...........................................................................................................................56
5.8 Connection examples ...................................................................................................................................56
5.8.2 Digital outputs DO1 and DO2 ...............................................................................................................56
5.8.3 PROFIBUS PA - Connection via M12 plug ...........................................................................................56
6 Digital communication ...............................................................................................................................57
6.1 HART protocol ..............................................................................................................................................57
4 FEX300, FEX500 OI/FEX300/FEX500-EN

Contents
6.1.1 System integration ................................................................................................................................57
6.2 PROFIBUS PA .............................................................................................................................................57
6.2.1 Bus topology .........................................................................................................................................57
6.2.2 Voltage / current consumption ..............................................................................................................57
6.3 FOUNDATION fieldbus (FF) ........................................................................................................................58
6.3.1 Bus topology .........................................................................................................................................58
6.3.3 Bus address ..........................................................................................................................................58
7 Commissioning ..........................................................................................................................................59
7.1 Preliminary checks prior to start-up ..............................................................................................................59
7.2 Configuring the current output ......................................................................................................................59
7.2.1 Transmitter with dual-compartment housing .........................................................................................60
7.2.2 Transmitter with single-compartment housing ......................................................................................61
7.3 Start-up of PROFIBUS PA units ...................................................................................................................62
7.3.1 Local address setting in the case of transmitters with dual-compartment housing ..............................63
7.3.2 Configuration in the case of transmitters with single-compartment housing ........................................64
7.4 Start-up of FOUNDATION FIELDBUS devices ............................................................................................66
7.4.1 Configuration of transmitters with dual-compartment housing .............................................................67
7.4.2 Configuration of transmitters with single-compartment housing ...........................................................68
7.4.3 Bus address settings .............................................................................................................................69
7.5 Commissioning the unit ................................................................................................................................70
7.5.1 Downloading the system data ...............................................................................................................70
7.5.2 Parameterization via the "Commissioning" menu function ...................................................................72
7.6 Flowmeter sizes, flow range .........................................................................................................................78
8 Parameterization ........................................................................................................................................79
8.1 Operation ......................................................................................................................................................79
8.1.1 Menu navigation ....................................................................................................................................79
8.2 Menu levels ..................................................................................................................................................80
8.2.1 Process display .....................................................................................................................................81
8.2.2 Switching to the information level (operator menu) ..............................................................................82
8.2.3 Switching to the configuration level (parameterization) ........................................................................85
8.2.4 Hardware write protection .....................................................................................................................86
8.2.5 Selecting and changing parameters .....................................................................................................87
8.3 Overview of parameters on the configuration level ......................................................................................89
8.4 Description of parameters ............................................................................................................................97
8.4.1 Menu: Easy Setup .................................................................................................................................97
8.4.2 Menu: Device Info ...............................................................................................................................100
8.4.3 Menu: Device Setup ............................................................................................................................104
8.4.4 Menu: Display .....................................................................................................................................108
8.4.5 Menu: Input/Output .............................................................................................................................110
8.4.6 Menu: Process Alarm ..........................................................................................................................116
8.4.7 Menu: Communication ........................................................................................................................117
8.4.8 Menu: Diagnostics...............................................................................................................................122
8.4.9 Menu: Totalizer ...................................................................................................................................131

Contents
8.5 Alarm Simulation ........................................................................................................................................133
8.6 FEP500 and FEH500 during fill operation..................................................................................................134
8.6.1 Configuration .......................................................................................................................................134
8.7 Software – history.......................................................................................................................................137
8.7.1 Devices with HART protocol ...............................................................................................................137
8.7.2 Devices with PROFIBUS PA or FOUNDATION fieldbus ....................................................................137
9 Extended diagnostic functions ...............................................................................................................138
9.1 General remarks .........................................................................................................................................138
9.1.1 Detection of partial filling .....................................................................................................................138
9.1.2 Detection of gas bubbles ....................................................................................................................138
9.1.3 Electrode coating detection .................................................................................................................139
9.1.4 Conductivity monitoring .......................................................................................................................139
9.1.5 Electrode impedance monitoring ........................................................................................................139
9.1.6 Sensor measurements ........................................................................................................................140
9.1.7 Trend ...................................................................................................................................................140
9.1.8 Fingerprint ...........................................................................................................................................140
9.1.9 Checking the grounding ......................................................................................................................140
9.2 Performing the earthing check ...................................................................................................................141
9.3 Recommended settings for diagnostic limit values ....................................................................................142
9.3.1 Limit values for the coil resistance ......................................................................................................142
9.3.2 Limit values for the electrode deposits................................................................................................143
9.3.3 Limit values for the electrode impedance ...........................................................................................143
9.3.4 Recommended settings for the Trend Logger ....................................................................................143
10 Error messages ........................................................................................................................................144
10.1 Invoking the error description .....................................................................................................................144
10.2 Error states and alarms ..............................................................................................................................145
10.2.1 Errors ..................................................................................................................................................145
10.2.2 Function check ....................................................................................................................................146
10.2.3 Operation outside of specifications (Off Spec) ...................................................................................148
10.2.4 Maintenance........................................................................................................................................149
10.3 Overview of error states and alarms ..........................................................................................................150
10.3.1 Error messages during commissioning ...............................................................................................154
11 Maintenance ..............................................................................................................................................156
11.1 Flowmeter sensor .......................................................................................................................................156
11.2 Gaskets ......................................................................................................................................................156
11.3 Replacing the transmitter or the sensor .....................................................................................................157
11.3.1 Transmitter ..........................................................................................................................................157
11.3.2 Sensor .................................................................................................................................................158
11.3.3 Downloading the system data .............................................................................................................159
12 Spare parts list .........................................................................................................................................160
12.1 Fuses for transmitter electronics ................................................................................................................160
12.2 Spare parts for devices with integral mount design ...................................................................................160
12.3 Spare parts for devices with remote mount design ....................................................................................161
12.3.1 field-mount housing .............................................................................................................................161
12.3.2 Round field-mount housing .................................................................................................................161
12.3.3 Flowmeter sensor (Zone 2 / Div. 2).....................................................................................................162
12.3.4 Flowmeter sensor (Zone 1 / Div. 1).....................................................................................................162
13 Performance specifications ....................................................................................................................163

Contents
13.1 General .......................................................................................................................................................163
13.1.1 Reference conditions ..........................................................................................................................163
13.1.2 Maximum measuring error ..................................................................................................................163
13.1.3 Reproducibility, response time ............................................................................................................163
13.1.4 Power supply.......................................................................................................................................163
13.2 Mechanical properties ................................................................................................................................164
13.3 IP rating ......................................................................................................................................................164
13.4 Vibration .....................................................................................................................................................164
13.5 Temperature data .......................................................................................................................................164
14 Functional and technical properties - ProcessMaster .........................................................................165
14.1 IP rating ......................................................................................................................................................165
14.2 Pipeline vibration ........................................................................................................................................165
14.3 Installation length .......................................................................................................................................165
14.4 Signal cable ................................................................................................................................................165
14.5 Temperature data .......................................................................................................................................165
14.5.1 Storage temperature ...........................................................................................................................165
14.5.2 Minimum permissible pressure as a function of measuring medium temperature .............................165
14.5.3 Maximum permissible cleaning temperature ......................................................................................165
14.5.4 Maximum ambient temperature depending on measuring medium temperature ...............................166
14.5.5 ProcessMaster with remote mount design (standard sensor design) .................................................167
14.5.6 Overview sensor design level "C" .......................................................................................................168
14.6 Material load ...............................................................................................................................................168
14.6.1 Flowmeter sensor design level “B” ......................................................................................................168
14.6.2 Flowmeter sensor design level “C” .....................................................................................................169
14.7 Materials for flowmeter sensors .................................................................................................................170
14.7.1 Wetted parts ........................................................................................................................................170
14.7.2 Non-wetted parts (process connection) ..............................................................................................170
14.7.3 Flowmeter sensor housing ..................................................................................................................170
15 Functional and technical properties - HygienicMaster ........................................................................171
15.1 Flowmeter sensor .......................................................................................................................................171
15.1.1 IP rating according to EN 60529 .........................................................................................................171
15.1.2 Pipeline vibration according to EN 60068-2-6 ....................................................................................171
15.1.3 Installation length ................................................................................................................................171
15.1.4 Signal cable (for external transmitters only) .......................................................................................171
15.1.5 Temperature range .............................................................................................................................171
15.1.6 Material load........................................................................................................................................173
15.1.7 Mechanical properties .........................................................................................................................174
16 Appendix ...................................................................................................................................................175
16.1 Return form ................................................................................................................................................175
16.2 Overview of parameter settings (factory settings) ......................................................................................176
16.2.1 For Profibus PA version ......................................................................................................................176
16.3 Declaration of conformity............................................................................................................................177

Safety
1 Safety
1.1 General information and notes for the reader
You must read these instructions carefully prior to installing and commissioning the device.
These instructions are an important part of the product and must be kept for future reference.
These instructions are intended as an overview and do not contain detailed information on all
designs for this product or every possible aspect of installation, operation and maintenance.
For additional information or if specific problems occur that are not discussed in these
instructions, contact the manufacturer.
The content of these instructions is neither part of any previous or existing agreement, promise
or legal relationship nor is it intended to change the same.
This product is built based on state-of-the-art technology and is operationally safe. It has been
tested and left the factory in perfect working order from a safety perspective. The information in
the manual must be observed and followed in order to maintain this state throughout the period
of operation.
Modifications and repairs to the product may only be performed if expressly permitted by these
instructions.
Only by observing all of the safety instructions and all safety/warning symbols in these
instructions can optimum protection of both personnel and the environment, as well as safe and
fault-free operation of the device, be ensured.
Information and symbols directly on the product must be observed. They may not be removed
and must be fully legible at all times.
IMPORTANT (NOTE)
• An additional document with Ex safety instructions is available for measuring systems that
are used in explosion hazardous areas.
• Ex safety information is an integral part of this manual. As a result, it is crucial that the
installation guidelines and connection values it lists are also observed.
The icon on the name plate indicates the following:

Safety
1.2 Intended use
This device is intended for the following uses:

• To transmit fluid, pulpy or pasty measurement media with electrical conductivity.
• To measure the flowrate of the operating volume or mass flow units (at constant pressure /
temperature), if a mass engeineering unit is selected.
The following items are included in the intended use:

• Read and follow the instructions in this manual.
• Observe the technical ratings; refer to the section 1.11 „Technical limit values“.
• Use only allowed measurement media; refer to the section 1.12 „Allowed measuring media“.
1.3 Improper use
The following are considered to be instances of improper use of the device:

• Operation as a flexible adapter in piping, e.g., to compensate for pipe offsets, pipe vibrations,
pipe expansions, etc.
• As a climbing aid, e. g., for mounting purposes
• As a support for external loads, e. g., as a support for piping, etc.
• Adding material, e. g., by painting over the name plate or welding/soldering on parts
• Removing material, e. g., by spot drilling the housing
1.4 Target groups and qualifications
Installation, commissioning, and maintenance of the product may only be performed by trained
specialist personnel who have been authorized by the plant operator to do so. The specialist
personnel must have read and understood the manual and comply with its instructions.
Prior to using corrosive and abrasive measurement media, the operator must check the level of
resistance of all parts coming into contact with the wetted parts. ABB Automation Products
GmbH will gladly support you in selecting the materials, but cannot accept any liability in doing
so.
The operators must strictly observe the applicable national regulations with regards to
installation, function tests, repairs, and maintenance of electrical products.
1.5 Warranty provisions
Using the device in a manner that does not fall within the scope of its intended use, disregarding
this instruction, using underqualified personnel, or making unauthorized alterations releases the
manufacturer from liability for any resulting damage. This renders the manufacturer's warranty
null and void.

Safety
1.6 Plates and symbols
1.6.1 Safety- / warning symbols, note symbols
DANGER – <Serious damage to health / risk to life>

This symbol in conjunction with the signal word "Danger" indicates an imminent danger.
Failure to observe this safety information will result in death or severe injury.

This symbol in conjunction with the signal word "Danger" indicates an imminent electrical
hazard. Failure to observe this safety information will result in death or severe injury.
WARNING – <Bodily injury>

This symbol in conjunction with the signal word “Warning“ indicates a possibly dangerous
situation. Failure to observe this safety information may result in death or severe injury.
This symbol in conjunction with the signal word "Warning" indicates a potential electrical
hazard. Failure to observe this safety information may result in death or severe injury.
CAUTION – <Minor injury>

This symbol in conjunction with the signal word “Caution“ indicates a possibly dangerous
situation. Failure to observe this safety information may result in minor or moderate injury.
This may also be used for property damage warnings.
NOTICE – <Property damage>!

The symbol indicates a potentially damaging situation.
Failure to observe this safety information may result in damage to or destruction of the product
and/or other system components.
IMPORTANT (NOTE)
This symbol indicates operator tips, particularly useful information, or important information
about the product or its further uses. It does not indicate a dangerous or damaging situation.

Safety
1.6.2 Name plate
IMPORTANT (NOTE)
An additional document with Ex safety instructions is available for measuring systems that are
used in explosion hazardous areas. As a result, it is crucial that the specifications and data it
lists are also observed.
1.6.2.1 Name plate for integral mount design
3
300
13
4
14
5
15
6
7
16
8
17
9
18
10
19
11
12 G00629
Fig. 1: Integral mount design (e.g., transmitter with dual-compartment housing)

1 Model number (for more detailed information about 15Supplementary information: EE = earthing electrodes,
the technical design, refer to the data sheet or the TFE = partial filling electrode
order confirmation) 16Accuracy to which the unit was calibrated (e.g., 0.2%
2 Project number of rate)
3 Meter size and nominal pressure rating 17Excitation frequency of sensor coils
4 Material: Flange / lining / electrode 18Version level (xx.xx.xx)
5 Client-specific TAG number (if specified) 19 Label indicating whether the unit is subject to the
6 Tmed = maximum permissible fluid temperature Pressure Equipment Directive (PED).
Tamb = maximum permissible ambient temperature Information on the relevant fluid group.
Fluid group 1 = hazardous fluids, liquid, gaseous.
7 Protection type according to EN 60529
(Pressure Equipment Directive = PED).
8 Calibration value QmaxDN
If the pressure equipment is not subject to the
9 Calibration value Ss (span) Pressure Equipment Directive 2014/68/EU, it is
Calibration value Sz (zero point) classified in accordance with SEP (= sound
10 Communications protocol of transmitter engineering practice) as per Art. 3 Para. 3 of the PED.
11 Software version If no such information is present, it means that the
12Year of manufacture device does not claim to comply with the requirements
13CE mark of the Pressure Equipment Directive 2014/68/EU.
14Serial number for identification by the manufacturer Water supplies and connected equipment accessories
are classed as an exception in accordance with
guideline 1/16 of Art. 1, Para. 3.2 of the Pressure
Equipment Directive.
IMPORTANT (NOTE)
Meters with 3A approval are labeled with an additional plate.

Safety
1.6.2.2 Name plate for the remote mount design
Fig. 2: Remote mount design

1 Model number (for more detailed information about 13Supplementary information: EE = earthing electrodes,
the technical design, refer to the data sheet or the TFE = partial filling electrode
order confirmation) 14Accuracy to which the unit was calibrated (e.g., 0.2%
2 Project number of rate)
3 Meter size and nominal pressure rating 15Excitation frequency of sensor coils
4 Material: Flange / lining / electrode 16Label indicating whether the unit is subject to the
5 Client-specific TAG number (if specified) Pressure Equipment Directive (PED).
6 Tmed = maximum permissible fluid temperature Information on the relevant fluid group.
Tamb = maximum permissible ambient temperature Fluid group 1 = hazardous fluids, liquid, gaseous.
(Pressure Equipment Directive = PED).
8 Calibration value QmaxDN
Pressure Equipment Directive 2014/68/EU, it is
9 Calibration value Ss (span) classified in accordance with SEP (= sound
Calibration value Sz (zero point) engineering practice) as per Art. 3 Para. 3 of the PED.
10 Year of manufacture If no such information is present, it means that the
11CE mark device does not claim to comply with the requirements
12Serial number for identification by the manufacturer of the Pressure Equipment Directive 2014/68/EU.
Water supplies and connected equipment accessories
are classed as an exception in accordance with
guideline 1/16 of Art. 1, Para. 3.2 of the Pressure
Equipment Directive.
IMPORTANT (NOTE)

Safety
1.6.2.3 Name plate for remote transmitter
5
9
6
G00632-01
Fig. 3: Remote transmitter (e.g., transmitter with dual-compartment housing)

1 Model number (for more detailed information about 5 Protection type according to EN 60529
the technical design, refer to the data sheet or the 6 Supply voltage
order confirmation) 7 Communications protocol of transmitter
2 Project number 8 Software version
3 Client-specific TAG number (if specified) 9 Version level (xx.xx.xx)
4 Tamb = maximum permissible ambient temperature

Safety
1.7 Transport safety information
• Depending on the device, the center of gravity may not be in the center of the equipment.
• The protection plates or protective caps installed on the process connections of devices lined
with PTFE / PFA must not be removed until just before installation; to prevent possible
leakage, make sure that the liner on the flange is not cut or damaged.
1.8 Installation safety information
Observe the following instructions:

• The flow direction must correspond to the direction indicated on the device, if labeled.
• Comply with the maximum torque for all flange bolts.
• Install the devices without mechanical tension (torsion, bending).
• Install flange and wafer type units with coplanar counter flanges.
• Only install devices for the intended operating conditions and with suitable seals.
• Secure the flange bolts and nuts against pipeline vibrations.
1.9 Safety instructions for electrical installation
Electrical connections may only be established by authorized specialist personnel in

accordance with the electrical circuit diagrams.
The electrical connection information in the manual must be observed; otherwise, the type of
electrical protection may be adversely affected.
Ground the flowmeter and the sensor housing.
The line for the supply power must be installed according to the relevant national and
international standards. A separate fuse must be connected upstream and in close proximity to
each unit. The fuses must be identified accordingly. The rated current of the circuit breaker must
not exceed 16 A.
The unit has a protection class of I and overvoltage class II (IEC664).
The power supply and the electrical circuit for the coils of the flowmeter sensor are dangerous
and pose a contact risk.
The coil and signal circuit may be connected with the corresponding ABB flowmeter sensors
only. Use the supplied cable.
Only electrical circuits that do not pose a contact risk can be connected to the remaining signal
inputs and outputs.

Safety
1.10 Safety instructions for operation
During operation with hot fluids, contact with the surface may result in burns.
Aggressive fluids may result in corrosion or abrasion of the parts that come into contact with the
medium. As a result, pressurized fluids may escape prematurely.
Wear to the flange gasket or process connection gaskets (e.g., aseptic threaded pipe
connections, Tri-Clamp, etc.) may enable a pressurized medium to escape.
When using internal flat gaskets, these can become embrittled through CIP/SIP processes.
If pressure shocks exceeding the device's permissible nominal pressure occur continuously
during operation, this can have a detrimental effect on the device's service life.
1.11 Technical limit values
The device is designed for use exclusively within the stated values on the name plate and within
the technical limit values specified in the data sheets.
The following technical limit values must be observed:
• The permissible operating pressure (PS) in the permissible temperature (TS) may not
exceed the pressure-temperature ratings.
• The maximum operating temperature may not be exceeded.
• The permitted operating temperature may not be exceeded.
• The housing protection system must be observed.
• The flowmeter sensor may not be operated in the vicinity of powerful electromagnetic fields,
e.g., motors, pumps, transformers, etc. A minimum spacing of approx. 1 m (3.28 ft) should
be maintained. For installation on or to steel parts (e.g., steel brackets), a minimum spacing
of approx. 100 mm (3.94 inch) should be maintained (based on IEC801-2 and IECTC77B).
1.12 Allowed measuring media
When using measuring media, the following points must be observed:

• Measuring media (fluids) may only be used if it can be ensured that the chemical and
physical properties—which are required for operational security—of the components coming
into contact with the media are not affected during the operating life. This can be achieved
through the use of state-of-the-art technology or the operating experience of the operator.
Components coming into contact with the media include measuring electrodes, lining, and, if
applicable, earth electrodes, mating parts, protective washers or protective flanges
• Measuring media with unknown properties or abrasive measuring media may only be used if
the operator is able to perform regular and suitable tests to ensure the safe condition of the
device
• The information on the name plate must be observed

Safety
1.13 Maintenance and inspection safety information
WARNING – Risk to persons!

When the housing cover is open, EMC and protection against contact are suspended. There
are electric circuits within the housing which pose a contact risk.
The auxiliary power must be switched off before opening the housing cover.
WARNING – Risk to persons!

The inspection screw (for draining condensate fluid) for devices ≥ DN 450 can be under
pressure. The fluid which spurts out can cause severe injuries.
Depressurize pipes before opening the inspection screw.
Corrective maintenance work may only be performed by trained personnel.

• Depressurize the device and adjoining lines or containers before removing the device.
• Check whether hazardous materials are used as materials to be measured before opening
the device. Residual amounts of hazardous material may still be present in the device and
could escape when the device is opened.
• As far as provided in the scope of the operational responsibility, check the following items
through a regular inspection:
 the pressure-carrying walls / lining of the pressure device
 the measurement-related function
 the leak tightness
 the wear (corrosion)
1.14 Returning devices
Use the original packaging or suitably secure shipping containers if you need to return the
device for repair or recalibration purposes. Fill out the return form (see the Appendix) and
include this with the device.
According to EC guidelines for hazardous materials, the owner of hazardous waste is
responsible for its disposal or must observe the following regulations for shipping purposes:
All devices delivered to ABB Automation Products GmbH must be free from any hazardous
materials (acids, alkalis, solvents, etc.).
Rinse out and neutralize hazardous materials from all hollow spaces such as between meter
tube and housing. For flowmeters larger than DN 400, the service screw (for draining
condensate fluid) at the lower point of the housing must be opened to dispose of hazardous
substances and to neutralize the coil and electrode chamber. These activities must be
confirmed in writing using the return form.
Please
Please contact Customer Center Service acc. to page 2 for nearest service location.

Safety
1.15 Integrated management system
ABB Automation Products GmbH operates an integrated management system, consisting of:
• Quality management system to ISO 9001
• Environmental management system to ISO 14001
• Occupational health and safety management system to BS OHSAS 18001 and
• Data and information protection management system
Environmental awareness is an important part of our company policy.

Our products and solutions are intended to have a minimal impact on the environment and on
people during manufacturing, storage, transport, use, and disposal.
This includes the environmentally-friendly use of natural resources. We conducts an open
dialog with the public through our publications.
1.16 Disposal
This product is manufactured from materials that can be reused by specialist recycling
companies.
1.16.1 Information on WEEE Directive 2012/19/EU (Waste Electrical and Electronic Equipment)
This product is not subject to WEEE Directive 2012/19/EU or relevant national laws
(e.g., ElektroG in Germany).
The product must be disposed of at a specialist recycling facility. Do not use municipal garbage
collection points. According to the WEEE Directive 2012/19/EU, only products used in private
applications may be disposed of at municipal garbage facilities. Proper disposal prevents
negative effects on people and the environment, and supports the reuse of valuable raw
materials.
If it is not possible to dispose of old equipment properly, ABB Service can accept and dispose of
returns for a fee.

Design and function
2 Design and function
2.1 Measuring principle
Measurements performed by the electromagnetic flowmeter are based on Faraday’s law of

induction. A voltage is generated in a conductor when it moves through a magnetic field.
This principle is applied to a conductive fluid in the measuring tube through which a magnetic
field is generated perpendicular to the flow direction (see schematic).
The voltage induced in the fluid is measured by two electrodes located diametrically opposite
each other. This signal voltage UE is proportional to the magnetic induction B, the electrode
spacing D and the average flow velocity v.
Considering that the magnetic induction B and the electrode spacing D are constant values, a
proportionality exists between the signal voltage UE and the average flow velocity v. From the
equation for calculating the volume flowrate, it follows that the signal voltage is linearly
proportional to the volume flowrate: UE ~ qv.
The induced voltage is converted by the transmitter to standardized, analog and digital signals.
G00005
Fig. 4: Electromagnetic flowmeter schematic

1 Magnet coil
2 Measuring tube in electrode plane
3 Signal electrode
UE Signal voltage
UE ~ B Dv
B Magnetic induction
D Electrode spacing D 2
v
v Average flow velocity
qv = 4
qv Volume flow
U E ~ qv

Design and function
2.2 Device designs
IMPORTANT (NOTE)
ProcessMaster / HygienicMaster is available in two series.

ProcessMaster / HygienicMaster 300 with basic functionality and ProcessMaster /
HygienicMaster 500 with extended functions and options. The following table gives an overview.
ProcessMaster HygienicMaster
FEP300 FEP500 FEH300 FEH500
Measuring accuracy X - X -
0.4 % (optional 0.2 %) of rate
Measuring accuracy - X - X
0,3 % (optional 0.2 %) of rate
Batch functions - X - X
Presetting counter, overrun correction,
external start/stop, batch end contact
Other software functions X X X X
Mass units, editable totalizers,
Two measuring ranges - X - X
Graphic display X X X X
Line recorder function
Diagnostic functions - X - X
Detection of gas bubbles or deposits on
electrodes, conductivity monitoring,
temperature monitoring, finger print, trend
Partially filled X X - -
Recognition through partial filling
electrode (TFE)
Hardware options - X - -
• Ceramic carbide lining
• Wolfram carbide electrodes
• Double layer electrodes
Hardware options - - - X
DN 1 ... 2
Startup functions - X - X
Grounding check
Fieldbus X X X X
PROFIBUS PA, FOUNDATION fieldbus
Verifications / Diagnostic tool X X X X
ScanMaster

Design and function
2.2.1 Design
An electromagnetic flowmeter system consists of a sensor and a transmitter. The sensor is

installed in the specified pipeline while the transmitter is mounted locally or at a central location.
2.2.2 Integral mount design
For devices with an integral mount design, the transmitter and the sensor form a single
mechanical unit.
The transmitter is available in two housing designs:
• Single-compartment housing:
On the single-compartment housing, the electronics area and the connection area in the
transmitter are not separated from each other.
• Dual-compartment housing:
On the dual-compartment housing, the electronics area and the connection area in the
transmitter are separated from each other.
ProcessMaster
The ProcessMaster sensor is available in two designs, which are distinguished by the design
level.
FEP311 (without explosion protection) FEP315 Zone 2, Div. 2 FEP315
Zone 1, Div. 1
1), 3) 2), 3) 2), 4) 2), 5) 1), 3) 2), 3) 2), 4) 2), 3) 2), 4)
G01082-02 G00487-02 G00886-02
Fig. 5: ProcessMaster versions (example)

1) Single-compartment housing.
2) Dual-compartment housing.
3) Design level "B" sensor.
4) Design level "B" sensor, versions made from stainless steel
5) Design level "C" sensor, nominal diameter: DN 25 ... 600
HygienicMaster
FEH311 (without explosion FEH315 Zone 2, Div. 2 FEH315 Zone 1, Div. 1
protection)
1) 2) 1) 2) 2)
G01346 G01346 G01347
Fig. 6: HygienicMaster versions (example)


Design and function
2.2.3 Remote mount design
For devices with a remote mount design, the transmitter and sensor are mounted in separate locations. The
electrical connection between the transmitter and the sensor is provided by a signal cable.
When the minimum conductivity of the measuring medium is 5 µS/cm, a maximum signal cable length of 50 m
(164 ft) is possible without fitting an additional preamplifier to the sensor. With a pre-amplifier, the maximum
permissible signal cable length is 200 m (656 ft).
The transmitter is available in two housing designs:
• Single-compartment housing:
On the single-compartment housing, the electronics area and the connection area in the transmitter are not
separated from each other.
• Dual-compartment housing:
On the dual-compartment housing, the electronics area and the connection area in the transmitter are separated
from each other.
ProcessMaster
The ProcessMaster sensor is available in two designs, which are distinguished by the design level.
Sensor
FEP321 / FEP521 FEP325 / FEP525 FEP325 / FEP525
(without explosion Zone 2, Div. 2 Zone 1, Div. 1
protection)
1) 2) 1) 1)
G01083-02 G00489-01 G00489-01
Transmitter
FET321 / FET521 FET325 / FET525 FET321 / FET521 FET325 / FET525 FET325 / FET525 FET321 / FET521
(without explosion (Zone 2, Div. 2) (without explosion (Zone 1, Div. 1) (Zone 2, Div. 2) (without explosion
protection) protection) protection)
3) 4) 3) 4) 3) 4) 4) 3) 4) 3) 4)
G01084-02 G01084-02 G01084-02 G00863-02 G01084-02 G01084-02
HygienicMaster
Sensor
FEH321 / FEH521 (without FEH325 / FEH525 (Zone 2, Div. 2)
explosion protection)
Transmitter
FET321 / FET521 (without FET325 / FET525 (Zone 2, Div. 2) FET321 / FET521 (without explosion
explosion protection) protection)
3) 4) 3) 4) 3) 4)
G01084-02 G01084-02 G01084-02
1) Design level "B" sensor.

2) Design level "C" sensor, DN 25 … 600.

Transport and storage
3 Transport and storage
3.1 Inspection
Check the devices for possible damage that may have occurred during transport. Damages in
transit must be recorded on the transport documents. All claims for damages must be claimed
without delay against the shipper and before the installation.
3.2 Transport of flanged units smaller than DN 450
WARNING – Danger of injuries due to slipping meter.

The center of gravity for the complete device may be higher than the lifting straps.
Make sure the device has not rotated or slipped unintentionally during transport. Support the
meter laterally.
For transport of flanged units smaller than DN 450 use a lifting strap. Wrap the straps around
both process connections when lifting the device. Avoid chains since these may damage the
housing.
Fig. 7: Transport of flanged units smaller than DN 450

Transport and storage
3.3 Transport of flanged units larger than DN 400
NOTICE - Potential damage to device!

Use of a forklift to transport the device can bend the housing and damage the internal magnet
coils.
Flanged units may not be lifted at the middle of the housing when transporting via forklift.
Flanged units may not be lifted by the terminal box or at the middle of the housing. Use only the
eye bolts on the device to lift and install it in the pipeline.
Fig. 8: Transport of flanged units larger than DN 400
3.4 Storage conditions
When storing the unit, please note the following points.

• Store the unit in its original packaging in a dry and dust-free location.
• Avoid storing the unit in direct sunlight.

Mounting
4 Mounting
IMPORTANT (NOTE)
4.1 General information on installation
The following points must be observed during installation:

• The flow direction must correspond to the marking, if present
• The maximum torque for all flange screws must be complied with
• The devices must be installed without mechanical tension (torsion, bending)
• Install flange devices / wafer-type devices with plane parallel counterflanges and use
appropriate gaskets only
• Only gaskets made from a material that is compatible with the measuring medium and
measuring medium temperature may be used
• Gaskets must not extend into the flow area, since possible turbulence could influence the
accuracy of the device
• The piping may not exert any inadmissible forces or torques on the device
• Do not remove the sealing plugs in the cable glands until you are ready to install the
electrical cable
• Make sure the gaskets for the housing cover are seated correctly. Carefully gasket the
cover. Tighten the cover fittings
• The transmitter with a remote mount design must be installed at a largely vibration-free
location
• Do not expose the transmitter and sensor to direct sunlight. Provide appropriate sun
protection as necessary
• When installing the transmitter in a control cabinet, make sure adequate cooling is provided
• For devices with a remote mount design and a measuring accuracy of 0.2 % of the
measured value, make sure that the sensor and the transmitter have been correctly
assigned. Compatible devices have the same end numbers on the name plate, e.g. X001
and Y001 or X002 and Y002
4.1.1 Supports for meter sizes larger than DN 400
NOTICE - Potential damage to device!

Improper support for the device may result in deformed housing and damage to internal
magnet coils.
Place the supports at the edge of the housing (see arrows in the figure).
Devices with meter sizes larger than DN 400 must be mounted with support on a sufficiently
strong foundation.
Fig. 9: Support for meter sizes larger than DN 400

Mounting
4.1.2 Selecting gaskets
The following points must be observed when installing gaskets:

Devices with a hard rubber, soft rubber or ceramic carbide liner
• Devices with a hard / soft rubber liner always require additional gaskets
• ABB recommends using gaskets made from rubber or rubber-like sealing materials
• When selecting the gaskets, ensure that the tightening torques specified in chapter „Torque
information“ on page 27 are not exceeded
Devices with a PTFE, PFA or ETFE liner

• In principle, devices with a PTFE, PFA or ETFE liner do not require additional gaskets
4.1.3 Devices with a wafer-type design
For devices with a wafer-type design, ABB offers an installation set as an accessory that
comprises threaded rods, nuts, washers and centering sleeves for installation.
1 2 3 3 G01348
Fig. 10: Installation set for wafer-type installation

1 Threaded rod 3 Centering sleeves
2 Nut with washer

Mounting
4.1.4 Installing the meter tube
Notice – potential damage to device!

The use of graphite with the flange or process connection gaskets is prohibited. This is
because, in some instances, an electrically conductive coating may form on the inside of the
meter tube. Vacuum shocks in the piping should be avoided to prevent damage to the liners
(PTFE). Vacuum shocks can destroy the device.
The meter tube can be installed at any location in the piping while taking the installation
conditions into account.
1. Remove protective plates, if present, to the right and left of the meter tube. To prevent
possible leakage, make sure that the liner on the flange is not cut or damaged.
2. Position the meter tube coplanar and centered between the piping.
3. Install gaskets between the surfaces; see chapter „Torque information“ on page 27.
IMPORTANT (NOTE)
For achieve the best results, ensure the gaskets fit concentrically with the meter tube
4. Use the appropriate screws for the holes in accordance with chapter „Torque information“ on
page 27.
5. Slightly grease the threaded nuts.
6. Tighten the nuts in a crosswise manner as shown in the figure. Observe the tightening
torques in accordance with chapter „Selecting gaskets“ on page 25!
First tighten the nuts to approx. 50 % of the maximum torque, then to 80 %, and finally a
third time to the maximum torque. Do not exceed the max. torque.
1 5
1 3
8 3
4 7
4 2
6 2 G00034
Fig. 11

Mounting
4.2 Torque information
IMPORTANT (NOTE)
The specified torques are valid only for greased threads and piping that is not subject to tensile stress.
ProcessMaster in flange design and HygienicMaster in flange or wafer-type design
Nominal diameter Nominal pressure Maximum tightening torque [Nm]

[mm (inch)] rating Hard / soft rubber PTFE, PFA, ETFE Ceramic carbide
2) 3) 2) 3) 2) 3)
PN40 – – 12,43 12,43 – –
PN63/100 – – 12,43 12,43 – –
DN 3 ... 101)
CL150 – – 12,98 12,98 – –
(1/10 ... 3/8“1))
CL300 – – 4,94 17,38 – –
JIS 10K – – 12,43 12,43 – –
PN40 6,74 4,29 14,68 14,68 – –
PN63/100 13,19 11,2 22,75 22,75 – –
CL150 3,65 3,65 12,98 12,98 – –
DN 15 (1/2“)
CL300 4,94 3,86 4,94 17,38 – –
CL600 9,73 9,73 – – – –
JIS 10K 2,84 1,37 14,68 14,68 – –
PN40 9,78 7,27 20,75 20,75 – –
PN63/100 24,57 20,42 42,15 42,15 – –
CL150 5,29 5,29 18,49 18,49 – –
DN 20 (3/4“)
CL300 9,77 9,77 33,28 33,28 – –
CL600 15,99 15,99 – – – –
JIS 10K 4,1 1,88 20,75 20,75 – –
PN40 13,32 8,6 13,32 8,6 13,32 8,6
PN63/100 32,09 31,42 53,85 53,85 53,85 53,85
CL150 5,04 2,84 23,98 23,98 23,98 23,98
DN 25 (1“)
CL300 17,31 16,42 65,98 38,91 65,98 38,91
CL600 22,11 22,11 – – – –
JIS 10K 8,46 5,56 26,94 26,94 26,94 26,94
PN40 27,5 15,01 45,08 45,08 45,08 45,08
PN63/100 42,85 41,45 74,19 70,07 74,19 70,07
CL150 4,59 1,98 29,44 29,44 29,44 29,44
DN 32 (1 1/4“)
CL300 25,61 14,22 45,52 45,52 45,52 45,52
CL600 34,09 34,09 – – – –
JIS 10K 9,62 4,9 45,08 45,08 45,08 45,08
PN40 30,44 23,71 56,06 56,06 56,06 56,06
PN63/100 62,04 51,45 97,08 97,08 97,08 97,08
CL150 5,82 2,88 36,12 36,12 36,12 36,12
DN 40 (1 1/2“)
CL300 33,3 18,41 73,99 73,99 73,99 73,99
CL600 23,08 23,08 – – – –
JIS 10K 12,49 6,85 56,06 56,06 56,06 56,06
PN40 41,26 27,24 71,45 71,45 71,45 71,45
PN63 71,62 60,09 109,9 112,6 109,9 112,6
CL150 22,33 22,33 66,22 66,22 66,22 66,22
DN 50 (1 1/2“)
CL300 17,4 22,33 38,46 38,46 38,46 38,46
CL600 35,03 35,03 – – – –
JIS 10K 17,27 10,47 71,45 71,45 71,45 71,45
Continued on next page
1) Connection flange DIN / EN1092-1 = DN 10 (3/8"), connection flange ASME = DN 15 (1/2").

2) Flange material: steel.
3) Flange material: stainless steel.

Mounting

2) 3) 2) 3) 2) 3)
PN16 14,94 8 37,02 39,1 37,02 39,1
PN40 30,88 21,11 43,03 44,62 43,03 44,62
PN63 57,89 51,5 81,66 75,72 81,66 75,72
DN 65 (2 1/2“) CL150 30,96 30,96 89,93 89,93 89,93 89,93
CL300 38,38 27,04 61,21 61,21 61,21 61,21
CL600 53,91 53,91 – – – –
JIS 10K 14,94 8 37,02 39,1 37,02 39,1
PN40 38,3 26,04 51,9 53,59 51,9 53,59
PN63 63,15 55,22 64,47 80,57 64,47 80,57
CL150 19,46 19,46 104,6 104,6 104,6 104,6
DN 80 (3“)
CL300 75,54 26,91 75,54 75,54 75,54 75,54
CL600 84,63 84,63 – – – –
JIS 10K 16,26 9,65 45,07 47,16 45,07 47,16
PN16 20,7 12,22 49,68 78,19 49,68 78,19
PN40 67,77 47,12 78,24 78,19 78,24 78,19
PN63 107,4 95,79 148,5 119,2 148,5 119,2
DN 100 (4“) CL150 17,41 7,82 76,2 76,2 76,2 76,2
CL300 74,9 102,6 102,6 102,6 102,6 102,6
CL600 147,1 147,1 – – – –
JIS 10K 20,7 12,22 49,68 78,19 49,68 78,19
PN16 29,12 18,39 61,4 64,14 61,4 64,14
PN40 108,5 75,81 123,7 109,6 123,7 109,6
PN63 180,3 164,7 242,6 178,2 242,6 178,2
DN 125 (5“)
CL150 24,96 11,05 98,05 98,05 98,05 98,05
CL300 81,64 139,4 139,4 139,4 139,4 139,4
CL600 244,1 244,1 – – – –
PN16 46,99 23,7 81,23 85,08 81,23 85,08
PN40 143,5 100,5 162,5 133,5 162,5 133,5
PN63 288,7 269,3 371,3 243,4 371,3 243,4
DN 150 (6“)
CL150 30,67 13,65 111,4 111,4 111,4 111,4
CL300 101,4 58,4 123,6 123,6 123,6 123,6
CL600 218,4 218,4 – – – –
PN10 45,57 27,4 113 116,9 113 116,9
PN16 49,38 33,82 70,42 73 70,42 73
PN25 100,6 69,17 109,9 112,5 109,9 112,5
PN40 196,6 144,4 208,6 136,8 208,6 136,8
DN 200 (8“)
PN63 350,4 331,8 425,5 282,5 425,5 282,5
CL150 49,84 23,98 158,1 158,1 158,1 158,1
CL300 133,9 78,35 224,3 224,3 224,3 224,3
CL600 391,8 391,8 – – – –
PN10 23,54 27,31 86,06 89,17 86,06 89,17
PN16 88,48 61,71 99,42 103,1 99,42 103,1
PN25 137,4 117,6 166,5 133,9 166,5 133,9
DN 250 (10“)
PN40 359,6 275,9 279,9 241 279,9 241
CL150 55,18 27,31 146,1 148,3 146,1 148,3
CL300 202,7 113,2 246,4 246,4 246,4 246,4


Mounting

2) 3) 2) 3) 2) 3)
PN10 58,79 38,45 91,29 94,65 91,29 94,65
PN16 122,4 85,64 113,9 114,8 113,9 114,8
PN25 180,6 130,2 151,1 106,9 151,1 106,9
DN 300 (12“)
PN40 233,4 237,4 254,6 252,7 254,6 252,7
CL150 90,13 50,37 203,5 198 203,5 198
CL300 333,3 216,4 421,7 259,1 421,7 259,1
PN10 69,62 47,56 72,49 75,22 72,49 75,22
PN16 133,6 93,61 124,9 104,4 124,9 104,4
DN 350 (14“) PN25 282,3 204,3 226,9 167,9 226,9 167,9
CL150 144,8 83,9 270,5 263 270,5 263
CL300 424,1 252,7 463,9 259,4 463,9 259,4
PN10 108,2 75,61 120,1 113,9 120,1 113,9
PN16 189 137,2 191,4 153,8 191,4 153,8
DN 400 (16“) PN25 399,4 366 404 246,7 404 246,7
CL150 177,6 100 229,3 222,8 229,3 222,8
CL300 539,5 318,8 635,8 328,1 635,8 328,1
CL150 218,6 120,5 267,3 192,3 267,3 192,3
DN 450 (18“)
CL300 553,8 327,2 660,9 300 660,9 300
PN10 141,6 101,4 153,9 103,5 153,9 103,5
PN16 319,7 245,4 312,1 224,8 312,1 224,8
DN 500 (20“) PN25 481,9 350,5 477,1 286 477,1 286
CL150 212,5 116 237,3 230,4 237,3 230,4
CL300 686,3 411,8 786,8 363,1 786,8 363,1
PN10 224,7 164,8 238,7 149,1 238,7 149,1
PN16 515,1 399,9 496,7 365,3 496,7 365,3
DN 600 (24“) PN25 826,2 600,3 750,7 539,2 750,7 539,2
CL150 356,6 202,8 451,6 305,8 451,6 305,8
CL300 1188 719 1376 587,4 1376 587,4
PN10 267,7 204,9 On request On request 267,7 204,9
DN 700 (28“) PN25 905,9 709,2 On request On request 905,9 709,2
CL150 364,1 326,2 449,2 432,8 364,1 326,2
CL300 1241 On request On request On request 1241 On request
CL150 423,8 380,9 493,3 442 423,8 380,9
DN 750 (30“)
DN 800 (32“) PN25 1358 1087 On request On request 1358 1087
CL150 410,8 380,9 493,3 380,9 410,8 380,9
CL150 336,2 394,6 511 458,5 336,2 394,6


Mounting

2) 3) 2) 3) 2) 3)
CL150 654,2 598,8 650,6 385,1 654,2 598,8
CL150 749,1 682,6 741,3 345,9 – –
DN 1100 (44“)
CL300 2607 On request On request On request – –
PN 6 363,5 On request – – – –
PN10 705,9 On request – – – –
DN 1200 (48“) PN16 1464 On request – – – –
CL150 815,3 731,6 – – – –
CL300 3300 On request – – – –
CL150 1036 983,7 – – – –
DN 1350 (54“)
CL300 5624 On request – – – –
PN 6 515 On request – – – –
DN 1400 (56“) PN10 956,3 On request – – – –
PN16 1558 On request – – – –
CL150 1284 1166 – – – –
DN 1500 (60“)
CL300 6139 On request – – – –
PN 6 570,7 On request – – – –
DN 1600 (64“) PN10 1215 On request – – – –
PN16 2171 On request – – – –
PN 6 708,2 On request – – – –
DN 1800 (72“) PN10 1492 On request – – – –
PN16 2398 On request – – – –
PN 6 857,9 On request – – – –
DN 2000 (80“) PN10 1840 On request – – – –
PN16 2860 On request – – – –

Variable process connections HygienicMaster
Nominal diameter Max. tightening torque

[mm] [inch] [Nm]
DN 1 ... 2 1/25 ... 3/32“ PVC / POM: 0.2 brass / 1.4571: 3
DN 3 ... 10 3/8“ 8
DN 15 1/2“ 10
DN 20 3/4“ 21
DN 25 1 31
DN 32 1 1/4“ 60
DN 40 1 1/2“ 80
DN 50 2 5
DN 65 2 1/2“ 5
DN 80 3 15
DN 100 4 14

Mounting
4.3 Information on 3A conformity
IMPORTANT (NOTE)
If concentric reducers are installed on the device, it must be mounted in a vertical position.
G01319
Fig. 12
1 Bracket 2 Leakage hole
Please observe the following points:

• Do not install the device vertically with the terminal box or transmitter housing pointing
downward.
• The "angle bracket" option no longer applies.
• Please ensure that the leakage hole of the process connection is located at the deepest
point of the installed device.
• Only devices with a transmitter with dual-compartment housing are 3A-compliant.

Mounting
Change from one to two columns
4.4 Installation Requirements 4.4.4 Vertical connections

Vertical installation for measuring abrasive fluids, preferably with flow
4.4.1 Flow direction in upward direction.
The device measures the flowrate in both directions. Forward flow is
the factory setting, as shown in Fig. 13.
G00657-01 G00039-01
Fig. 13 Fig. 16
4.4.2 Electrode axis 4.4.5 Horizontal connections

Electrode axis (1) should be horizontal if at all possible or no more • Meter tube must always be completely full.
that 45° from horizontal. • Provide for a slight incline of the connection for degassing.
max. 45° 3°
G00038
1
G00041
Fig. 17
Fig. 14
4.4.6 Free inlet or outlet
• Do not install the flowmeter at the highest point or in the draining-
4.4.3 In- and outlet pipe sections off side of the pipeline, flowmeter runs empty, air bubbles can
form (1).
The metering principle is independent of the flow profile as long as • Provide for a siphon fluid intake for free inlets or outlets so that
standing eddies do not extend into the metering section, such as may the pipeline is always full (2).
occur after double elbows (1), in the event of tangential inflow, or
where half-open gate valves are located upstream of the flowmeter
sensor. 2
In such cases, measures must be put in place to normalize the flow
profile.
1
• Do not install fittings, manifolds, valves, etc., directly in front of the
flowmeter sensor (1).
• Butterfly valves must be installed so that the valve plate does not G00040
extend into the flowmeter sensor.

Fig. 18
• Valves or other turn-off components should be installed in the
outlet pipe section (2).
4.4.7 Strongly contaminated measuring media
Experience has shown that, in most installations, straight inlet
For strongly contaminated measuring media, a bypass connection
sections 3 x DN long and straight outlet sections 2 x DN long are
according to the figure is recommended so that operation of the
sufficient (DN = nominal diameter of the sensor Fig. 15 ).
system can continue to run without interruption the during the
For test stands, the reference conditions of 10 x DN straight inlet and
mechanical cleaning.
5 x DN straight outlet must be provided, in accordance with EN 29104
/ ISO 9104.
1 2
3xDN 2xDN G00983
Fig. 15 G00042
Fig. 19

Mounting
4.4.8 Installation in the vicinity of pumps 4.4.12 Installation in pipelines with larger nominal
diameters
For flowmeter primaries which are to be installed in the vicinity of
pumps or other vibration generating equipment, the utilization of Determine the resulting pressure loss when using reduction
mechanical snubbers is advantageous. pieces (1):
1. Calculate the diameter ratio d/D.
2. Determine the flow velocity based on the flow range nomograph
(Fig. 24).
3. Read the pressure drop on the Y-axis in Fig. 24.
G00561
Fig. 20
4.4.9 Installation of the high temperature design

The high temperature design allows for complete thermal insulation of
the sensor. The pipeline and sensor must be insulated after installing Fig. 23
the unit according to the following illustration. 1 Flange transition piece p pressure loss [mbar]
d Inside diameter of the D Inside diameter of the
flowmeter pipeline
1 V flow velocity [m/s]
Nomograph for pressure drop calculations

For flange transition piece with /2 = 8°
G00654
Fig. 21
1 Insulation
4.4.10 Devices with extended diagnostic functions

For devices with extended diagnostic functions different installation
conditions may be valid.
For further information read and observe chapter 9 "Extended
diagnostic functions" on page 138.
4.4.11 Minimum distance

In order to prevent the devices from interfering with each other, a
minimum distance of 0.7 m (2.3 ft) must be maintained between the
devices.
xx m (xx ft)
G01349
Fig. 24
Fig. 22

Mounting
4.5 Rotating the LCD display / Rotating the housing
Depending on the mounting position, the LCD display or transmitter housing can be rotated to
enable horizontal readings.
Transmitter with dual-compartment housing

1
G00659-01
Transmitter with single-compartment housing

Fig. 25

Mounting
4.5.1 Rotating the LCD display
WARNING – Electrical dangers!

When the housing is open, EMC protection is impaired and there is no longer any protection
against accidental contact.
Switch off the power supply before opening the housing.
1. Switch off the power supply.

2. Unscrew housing cover (1).
3. Pull back the anti-rotation lock (2) and turn the LCD display 90° to the left or right until the
lock (2) catches again.
4. Screw on housing cover (1) again.
NOTICE - Potentially adverse effect on housing ingress protection

If the gasket (o-ring) is seated incorrectly or damaged, this may have an adverse effect on the
housing ingress protection.
Before closing the housing cover, check the gasket (o-ring) for any damage and replace if
necessary. Check that the gasket is properly seated when closing the housing cover.
4.5.2 Rotating the housing
1. Loosen screws (3) and rotate housing 90° to the left or right.
2. Retighten screws (3).
4.6 Ground
IMPORTANT (NOTE)
4.6.1 General information on ground connections
Observe the following items when grounding the device:

• For plastic pipes or pipes with insulating lining, the ground is provided by the grounding plate
or grounding electrodes.
• When stray potentials are present, install a grounding plate upstream and downstream of the
flowmeter sensor.
• For measurement-related reasons, the potentials in the station ground and in the pipeline
should be identical.
• An additional ground on the terminals is not required.
IMPORTANT (NOTE)
If the flowmeter sensor is installed in plastic or earthenware pipelines, or in pipelines with an
insulating lining, transient current may flow through the grounding electrode in special cases.
In the long term, this may destroy the sensor, since the ground electrode will in turn degrade
electrochemically. In these special cases, the connection to the ground must be performed
using grounding plates. Install a grounding plate upstream and downstream of the device in
this case.

Mounting
4.6.2 Metal pipe with fixed flanges
Use a copper wire (at least 2.5 mm² (14 AWG)) to establish the ground connection between the
sensor (1), the pipeline flanges and an appropriate grounding point.
Flange design Wafer-type design

Fig. 26: Metal pipe, without liner (example)
IMPORTANT (NOTE)
• Earthing is illustrated using the example of the dual-compartment transmitter housing; in
the case of transmitters with single-compartment housing, earthing is to be performed as
shown

Mounting
4.6.3 Metal pipe with loose flanges
1. Solder the threaded nuts M6 (1) to the pipeline and connect the ground as shown in the
illustration.
2. Use a copper wire (at least 2.5 mm² (14 AWG)) to establish the ground connection between
the sensor (2) and an appropriate grounding point.

Fig. 27: Metal pipe, without liner (example)
IMPORTANT (NOTE)
shown

Mounting
4.6.4 Plastic pipes, non-metallic pipes or pipes with insulating liner
For plastic pipes or pipes with insulating lining, the earthing for the measuring medium is
provided by the grounding plate as shown in the figure below or via grounding electrodes that
must be installed in the device (option). If grounding electrodes are used, the grounding plate is
not necessary.
1. Install the flowmeter sensor with grounding plate (3) in the pipeline.
2. Connect the terminal lug (2) for the grounding plate (3) and ground connection (1) on the
flowmeter sensor with the grounding strap.
3. Use a copper wire (min. 2.5 mm² (14 AWG)) to link the earthing terminal (1) to a suitable
earthing point.

Fig. 28: Plastic pipes, non-metallic pipes or pipes with insulating liner
IMPORTANT (NOTE)
shown

Mounting
4.6.5 Sensor type HygienicMaster
Ground the stainless steel model as shown in the figure. The measuring fluid is grounded via
the adapter (1) and an additional ground is not required.
Fig. 29
4.6.6 Ground for devices with protective plates

The protective plates are used to protect the edges of the liner in the measuring tube, e.g., for
abrasive fluids. In addition, they function as a grounding plate.
• For plastic or pipes with insulating lining, electrically connect the protective plate in the same
manner as a grounding plate.
4.6.7 Ground with conductive PTFE grounding plate
For devices with a meter size between DN 10 … 250, grounding plates made of conductive
PTFE are available. These are installed in a similar way to conventional grounding plates.
4.6.8 Devices with extended diagnostic functions
For devices with extended diagnostic functions different grounding conditions may be valid.
For further information read and observe chapter 9 “Extended diagnostic functions”.

Mounting
4.6.9 Installation and grounding in pipelines with cathodic corrosion protection (CCP)
The installation of electromagnetic flowmeters in systems with cathodic corrosion protection

must be made in compliance with the corresponding system conditions. The following factors
are especially important:
a) Pipelines inside electrically conductive or insulating.
b) Pipelines completely or for the most part with cathodic corrosion protection (CCP) or mixed
systems with CCP areas and PE areas.
• When installing an EMF in pipes with insulating inner lining and free from foreign matter, it
should be insulated with grounding plates on the upstream and downstream side. The CCP
potential is diverted. The grounding plates upstream and downstream of the EMF are
connected to functional ground (Fig. 30 / Fig. 31).
• If the occurrence of external stray currents is to be expected in pipelines with internal
insulation (e.g. in the case of long pipe sections in the vicinity of power supply units), an
uninsulated pipe of approx. 1/4 DN of length should be provided upstream and downstream
of the flowmeter sensor in order to deviate these currents away from the measuring system
(Fig. 32).
4.6.9.1 Internally insulated pipelines with cathodic corrosion protection potential
Fig. 30: Bolt screw view

1 Pipe flange 6 Insulating plate
2 Insulating plate 7 Flange
3 Gasket / insulating ring 8 Lining
4 Grounding plate 9 Insulation
5 Insulating pipe 10Flowmeter sensor
Install grounding plates on each side of the flowmeter sensor. Insulate the grounding plates
from the pipe flanges and connect them to the flowmeter sensor and to functional ground.
Insulate the screw bolts for the flange connections when mounting. The insulation plates and
the insulation pipe are not included in the delivery. They must be provided onsite by the
customer.

Mounting
The CCP potential must be diverted through a connecting line "A" away from the insulated
flowmeter sensor.
Fig. 31: Flowmeter sensor with grounding plate and functional ground
1 Insulated pipe A Connecting line for CCP potential
2 Functional ground ≥ 4 mm2 Cu, not included in the delivery,
3 Grounding plate to be provided onsite
B Insulated screw bolts without grounding
plates
4.6.9.2 Mixed system pipeline with CCP and functional ground potentials
This mixed system has an insulated pipeline with CCP potential and an uninsulated bar metal
pipe (L = 1/4 x flowmeter sensor size) with functional ground potential upstream and
downstream of the flowmeter sensor.
The Fig. 32 shows the preferred installation for cathodic corrosion protection systems.
Fig. 32: Flowmeter sensor with functional ground

1 Insulated pipe A Connecting line for CCP potential
2 Bare metal pipe ≥ 4 mm2 Cu, not included in the delivery,
3 Functional ground to be provided onsite
B Insulated screw bolts without grounding
plates

Electrical connections
5 Electrical connections
5.1 Routing the signal and magnet coil cable
Observe the following points when routing cables:

• A magnet coil cable (red and brown) is run parallel to the signal lines (violet and blue). As a
result, only one cable is required between the flowmeter sensor and the transmitter. Do not
run the cable over junction boxes or terminal strips.
• The signal cable carries a voltage signal of only a few millivolts and must, therefore, be
routed over the shortest possible distance. The max. allowable signal cable length is 50 m
(164 ft) without pre-amplifier and 200 m (656 ft) with pre-amplifier.
• Avoid routing the cable in the vicinity of electrical equipment or switching elements that can
create stray fields, switching pulses, and induction. If this is not possible, run the signal /
magnet coil cable through a metal pipe and connect this to the station ground.
• All leads must be shielded and connected to the station ground potential.
• To shield against magnetic interspersion, the cable contains outer shielding. This is attached
to the SE clamp.
• The supplied stranded steel wire is also connected to the SE clamp
• Do not damage the sheathing of the cable during installation.
• Make sure during installation that the cable
is provided with a water trap (1). For vertical
installation, align the cable glands pointing
downward.
Fig. 33

5.2 Preparing the signal and magnet coil cable in the case of transmitters with dual-compartment
housing
5.2.1 Cable with part number D173D027U01

Prepare both cable ends as shown.
IMPORTANT (NOTE)
Use wire end sleeves.
• Wire end sleeves 0.75 mm2 (AWG 19), for shielding (1S, 2S)
• Wire end sleeves 0.5 mm2 (AWG 20), for all other wires
The shields may not touch (signal short circuit).
Fig. 34: Flowmeter sensor side, dimensions in mm (inch)
Fig. 35: Transmitter side, dimensions in mm (inch)

L1 maximum stripped length = 105 (4.10)
1 Measurement potential 3, green L2 = 70 (2.76) 7 Data line, D1, orange L2 = 70 (2.76)
2 Signal line E1, violet L2 = 60 (2.36) 8 Magnet coil, M2, red L2 = 90 (3.54)
3 Shield 1S L2 = 60 (2.36) 9 Magnet coil, M1, brown L2 = 90 (3.54)
4 Shield 2S L2 = 60 (2.36) 10Ground wire, steel
5 Signal line, E2, blue L2 = 60 (2.36) 11SE clamp
6 Data line, D2, yellow L2 = 70 (2.76)

Prepare both cable ends as shown.
IMPORTANT (NOTE)
• Wire end sleeves 0.75 mm2 (AWG 19), for shielding (1S, 2S)
• Wire end sleeves 0.5 mm2 (AWG 20), for all other wires
The shields may not touch (signal short circuit).
Flowmeter sensor side

"X"
70 (2.76)
X
1
8 (0.31) 2
3
25 (0.98) 4
5
6
7
8
9
13 12 11 10
"X"
L2
1
2
3 8 (0.31)
4
5 25 (0.98)
6
7
8
9
X 10 11 12 13
G01030-01
Transmitter side
Fig. 36: Flowmeter sensor side, dimensions in mm (inch)
1 Measurement potential 3, green L2 = 70 (2.76) 8 Magnet coil, M2, red L2 = 90 (3.54)
2 Signal line E1, violet L2 = 60 (2.36) 9 Magnet coil, M1, brown L2 = 90 (3.54)
3 Shield 1S L2 = 60 (2.36) 10Foil shield (D1, D2)
4 Shield 2S L2 = 60 (2.36) 11Foil shield continuity wire (D1, D2)
5 Signal line, E2, blue L2 = 60 (2.36) 12Ground wire, steel
6 Data line, D2, yellow L2 = 70 (2.76) 13SE clamp
7 Data line, D1, orange L2 = 70 (2.76)

5.3 Preparing the signal and magnet coil cable in the case of transmitters with single-compartment
housing
M1 M2 D1 D2 SE 3 2S E2 E1 1S
D173D027U01
M1 M2 D1 D2 SE 3 2S E2 E1 1S
D173D031U01
G01323
Fig. 37: Transmitter side, dimensions in mm (inch)

1 Ground wire 5 Foil shield continuity wire D1, D2
2 Wire mesh shield (D173D027U01 only) (D173D031U01 only)
4 Twisted wire mesh shield (D173D027U01 only) 6 Foil shield D1, D2 (D173D031U01 only)
Terminal Description, wire color Length in mm (inch)

M1 Magnet coil, brown 70 (2.76)
M2 Magnet coil, red 70 (2.76)
D1 Data line, orange 70 (2.76)
D2 Data line, yellow 70 (2.76)
SE Shield -
3 Measurement potential, green 70 (2.76)
2S Shield for E2 60 (2.36)
E2 Signal line, blue 60 (2.36)
E1 Signal line, violet 60 (2.36)
1S Shield for E1 60 (2.36)
IMPORTANT (NOTE)
• Use wire end sleeves.
- Wire end sleeves 0.75 mm2 (AWG 19), for shielding (1S, 2S)
- Wire end sleeves 0.5 mm2 (AWG 20), for all other wires
• The shields may not touch (signal short circuit).
en

Prepare the cable end on the transmitter side as shown in Fig. 37.
• Twist the wire mesh shield of the cable and connect to the ground terminal.
• Connect the ground wire of the cable to the SE clamp of the terminal strip.
• Connect all other wires as shown in Fig. 37.
• Connect the cable ground wire together with the foil shield continuity wire from D1, D2 to the
SE clamp of the terminal strip.
• When using the flowmeter sensor in systems with cathodic corrosion protection (CCP),
connect the cable ground wire together with the foil shield continuity wire from D1, D2 to the
SE clamp of the terminal strip.
• Connect all other wires as shown in Fig. 37.

5.4 Connecting the flowmeter sensor
5.4.1 Metal terminal box for ProcessMaster and HygienicMaster
Connections can only be made with the power supply switched off.
The device must be earthed according to instructions. The sensor is connected to the
transmitter via the signal / magnetic coil cable (part no. D173D027U01 or D173D031U01).
1S E1 E2 2S 3 D2 D1 M2 M1 1S E1 E2 2S 3 D2 D1 M2 M1
1S E1 E2 2S 3 D2 D1 M2 M1
5
1 1
6
2 2
D173D027U01 D173D031U01
G00671-02
Fig. 38
1 Earth wire. 5 Foil shield D1, D2 (D173D031U01 only).
2 Earth clamp. 6 Continuity wire of the foil shield (D1, D2)
4 Braided shield (D173D027U01 only). (D173D031U01 only).
Terminal Description, wire color

M1 Magnetic coil, brown
M2 Magnetic coil, red
D1 Data line, orange
D2 Data line, yellow
PE Shielding
3 Measurement potential, green
2S Shield for E2
E2 Signal line, blue
E1 Signal line, violet
1S Shield for E1

IMPORTANT (NOTE)
The cable with the part number D173D027U01 can be used for all device designs.
The cable with the part number D173D031U01 can be used for all device designs.
• Sensor without explosion protection from nominal diameter DN 15 (models FEP321,
FEH321, FEP521, FEH521)
• Sensor for use in Zone 2, Div. 2 from nominal diameter DN 15 (models FEP325, FEH325,
FEP525, FEH525)
IMPORTANT (NOTE)
• Wire end ferrules 0.75 mm2 (19 AWG), for shielding (1S, 2S)
• Wire end ferrules 0.5 mm2 (20 AWG), for all other wires
The shielding may not touch (signal short circuit).
Cable with part number D173D027U01

• Uncover the braided shield of the cable and connect to the earth clamp together with the
earth wire
• Connect all other wires as shown in Fig. 38
Cable with part number D173D031U01

• Connect the earth wire of the cable together with the continuity wire of the foil shield from
D1, D2 to the earth clamp
• Connect all other wires as shown in Fig. 38
5.4.2 Connection via cable conduit
NOTICE - Condensate formation in terminal box

If the flowmeter sensor is permanently connected to cable conduits, there is a possibility that
moisture may get into the terminal box as a result of condensate formation in the cable
conduit.
Ensure that the cable entry points on the terminal box are sealed.
G01312
Fig. 39: Installation set for cable conduit
An installation set for sealing the cable conduit is available via order number
3KXF081300L0001.

5.4.3 IP rating IP 68
For sensors with IP rating IP 68, the maximum flooding height is 5 m (16.4 ft). The supplied
cable (part no. D173D027U01 or D173D031U01) fulfills all submersion requirements.
G00171
Fig. 40
1 Max. flooding height 5 m (16.4 ft)
The sensor is type-tested in accordance with EN 60529. Test conditions: 14 days at a flooding
height of 5 m (16.4 ft).
5.4.3.1 Connection
1. Use the supplied cable to connect the sensor and the transmitter.
2. Connect the cable in the terminal box of the sensor.
3. Route the cable from the terminal box to above the maximum flooding height of 5 m (16.4 ft).
4. Tighten the cable gland.
5. Carefully seal the terminal box. Make sure the gasket for the cover is seated properly.
NOTICE – potential adverse effect on IP rating IP 68!

The IP rating IP 68 of the sensor may be adversely affected as a result of damage to the
signal cable.
The sheathing of the signal cable must not be damaged. Otherwise, the IP rating IP 68 for the
sensor cannot be ensured.
IMPORTANT (NOTE)
As an option, the sensor can be ordered with the signal cable already connected to the sensor
and the terminal box already potted.

5.4.3.2 Potting the terminal box
On sensors without explosion protection or explosion protection Zone 2, Div. 2, the terminal box
can be subsequently potted.
If the terminal box is to be potted subsequently on-site, a special two-component potting
compound can be ordered separately (order no. D141B038U01). Potting is only possible if the
sensor is installed horizontally. Observe the following instructions during work activity:
WARNING - General dangers!

The two-component potting compound is toxic – observe all relevant safety measures!
Hazard warnings: R20, R36 / 37 / 38, R42 / 43
Harmful by inhalation. Avoid direct skin contact. Irritating to eyes.
Safety advice: P4, S23-A, S24 / 25, S26, S37, S38
Wear suitable protective gloves and ensure sufficient ventilation.
Follow the instructions that are provided by the manufacturer prior to starting any
preparations.
Preparation
• Complete the installation before potting in order to avoid moisture penetration. Before
starting, check all the connections for correct fitting and stability
• Do not overfill the terminal box. Keep the potting compound away from the O-ring and the
gasket / groove (see fig. Fig. 41)
• Prevent the two-component potting compound from penetrating the cable conduit if an NPT
1/2" installation is used
Procedure
1. Cut open the protective enclosure of the two-component potting compound (see packing).
2. Remove the connection clamp of the potting compound.
3. Knead both components thoroughly until a good mix is reached.
4. Cut open the bag at a corner. Perform work activity within 30 minutes.
5. Carefully fill the terminal box with the two-component potting compound until the connection
cable is covered.
6. Wait a few hours before closing the cover in order to allow the compound to dry, and to
release any possible gas.
7. Ensure that the packaging material and the drying bag are disposed of in an environmentally
sound manner.
1 2 3
5
G00676
Fig. 41
1 Packing bag 4 Max. filling level
2 Connection clamp 5 Drying bag
3 Two-component potting compound

5.5 Connecting the transmitter
IMPORTANT (NOTE)
5.5.1 Connecting the power supply
The line voltage and power consumption are indicated on the name plate for the transmitter.
A circuit breaker with a maximum rated current of 16 A must be installed in the power supply
line of the transmitter.
The wire cross-sectional area of the power supply cable and the circuit breaker used must
comply with VDE 0100 and must be dimensioned in accordance with the current consumption of
the flowmeter measuring system. The cables must comply with IEC 227 and/or IEC 245.
The circuit breaker should be located near the transmitter and marked as being associated with
the device.
The power supply is connected to terminal L (phase), N (neutral), or 1+, 2-, and PE, as stated
on the name plate.
Connect the transmitter and sensor to functional earth.
IMPORTANT (NOTE)
• Observe the power supply limit values in accordance with the information on the name
plate and from chapter „Power supply“ on page 163
• Observe the voltage drop for large cable lengths and small conductor cross-sections. The
voltage at the terminals of the device may not fall below the minimum value required in
accordance with the information on the name plate and from chapter „Power supply“ on
page 163,
• Complete the electrical connection in accordance with the connection diagram

5.5.2 Transmitter with dual-compartment housing
The terminals for the power supply can be found under the terminal cover (1).
G00678
Fig. 42
1Terminal cover
5.5.3 Transmitter with single-compartment housing
G01320
Fig. 43
1 Terminals (power supply)

5.5.4 Connecting the signal and magnet coil cables
The outer shielding of the signal and magnet coil cable is attached to the busbar via the clip (4)
(from the accessory bag in the connection area) (dual-compartment transmitter housing only).
In the case of the single-compartment transmitter housing, the outer shielding of the signal and
magnet coil cable is connected to the corresponding terminal for the signal and magnet coil
cable.
The shielding for the signal wires functions as a driven shield to transmit the measurement
signal.
The cable is attached to the flowmeter sensor and transmitter according to the connection
diagram.
1 2
6 2
5 4 3 7 3 G00677-01
Dual-compartment transmitter housing Single-compartment transmitter housing

Fig. 44
1 Terminal cover 6 SE terminal for signal and magnet coil cable shield
2 Terminals for signal and magnet coil cable 7 Terminals for cable shields
3 Signal and magnet coil cable
4 Clip
5 Busbar (SE)
IMPORTANT (NOTE)
The power supply for the optional pre-amplifier is provided via terminals 1S and 2S.
The transmitter automatically detects the sensor and switches to the required supply voltage
on terminals 1S and 2S.

5.6 Terminal connection diagrams
5.6.1 HART, PROFIBUS PA and FOUNDATION fieldbus protocol
IMPORTANT (NOTE)
Important (Note)
For detailed information about earthing the transmitter and the sensor, please refer to chapter
4.6 "Ground" on page 35!
A HART
24 V
+ - + - + - + -
31 32 51 52 81 82 41 42 M1 M2 D1 D2 3 2S E2 E1 1S
PROFIBUS PA, FOUNDATION fieldbus

FF+ FF-
1+ 2-
PA+ PA- + -
L N
97 98 41 42
< 50 m (200 m)
< 164 ft (656 ft)
PE
B M1 M2 D1 D2 3 2S E2 E1 1S
G01350
A = transmitter, B = sensor
Fig. 45
Power supply connections Output connections
AC power supply Terminal Function / Notes

Terminal Function / Notes 31 / 32 Current / HART output
L Live / Phase The current output is available in "active" or "passive"
N Neutral mode.
PE / Protective earth (PE) 97 / 98 Digital communication
PROFIBUS PA (PA+ / PA-) or FOUNDATION
DC power supply fieldbus (FF+ / FF-) in acc. with IEC 61158-2.
51 / 52 Digital output DO1 active / passive
Terminal Function / Notes
Function can be configured locally as „Pulse Output"
1+ +
or „Digital Output". Factory setting is „Pulse Output".
2- -
81 / 82 Digital input / contact input
PE / Protective earth (PE) Function can be configured locally as „External
output switch-off“, „external totalizer reset“, „external
Sensor cable terminal connections totalizer stop“ or „other“.
Only on remote mount design. 41 / 42 Digital output DO2 passive
Function can be configured locally as „Pulse Output"
Terminal Function / Notes Wire color or „Digital Output". Factory setting is „Digital Output",
M1 Magnet coil Brown flow direction signaling.
M2 Magnet coil Red Functional ground
D1 Data line Orange
D2 Data line Yellow
/ SE Shield -
E1 Signal line Violet
1S Schield for E1 -
E2 Signal line Blue
2S Schield for E2 -
3 Measurement potential Green

5.7 Electrical data
5.7.1 Current / HART output

700
A I E B I E
RB RB 650
+31 +31 V 600

U1 U2 550
-32 -32 500
RB[Ω]
G00475-01 450
400
The current / HART output can be operated in "active" or "passive" mode. 350
A Active: 4 ... 20 mA, HART protocol (standard), load: 250 Ω ≤ R ≤ 650 Ω 300
B Passive: 4 ... 20 mA, HART protocol (standard), load: 250 Ω ≤ R ≤ 650 Ω 250
Supply voltage for the current output: minimum 11 V, maximum 30 V. 200
17 18 19 20 21 22 23 24 25 26 27 28 29 30
U2 [V] G00592
For Ex zone 1 / Div. 1 the maximum load is 300 Ω. Max. permissible load (RB) as a function of the source
voltage (U2)
Fig. 46: (I = internal, E = external)
5.7.2 Digital output DO1

1550
A I E B I E 1450
1350
RB*
19 ... 21 V+ ≤ 30 V+ 1250
51 51 1150
1050
U2 950
- 52 52 - 850
RB [Ω]
Imax = 220 mA
* RB UCE
750
ICE 650
G00476-04 550
The output can be configured as an "active (A)" or "passive (B)" output (in the case 450
350
of the transmitter with the dual-compartment housing, the output is configured 250
using the software; in the case of the transmitter with the single-compartment 150
50
housing, it is configured by means of jumpers on the transmitter backplane). 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
Configuration as "active" output: U2 [V] G00593
- U = 19 ... 21 V, Imax = 220 mA , fmax ≤ 5250 Hz

Configuration as "passive" output Max. permissible load (RB) as a function of the source
- Umax = 30 V, Imax = 220 mA, fmax ≤ 5250 Hz voltage (U2).  = Permissible range
Configuration as pulse output:
- Max. pulse frequency: 5250 Hz.
- Pulse width: 0.1 … 2000 ms.
- The pulse factor and pulse width are interdependent and are calculated
dynamically.
Configuration as contact output:
- Function: System alarm, empty pipe alarm, max. / min. alarm, flow direction
signaling, other
I E The output is always a "passive" output (optocoupler).

R B* Data for the optocoupler:
+U Umax = 30 V, Imax = 220 mA, fmax ≤ 5250 Hz
41
For maximum load see diagram Fig. 47.
42
Imax = 220 mA
* RB UCE
ICE G00792-01
5.7.4 Digital input DI

I E Data for the optocoupler:
16 V ≤ U ≤ 30 V, Ri = 2 kΩ
Ri = 2 k
81 24V+
82 0V
G00477-01

5.7.5 Digital communication
I E I E
PA- FF-
98 98
R R
PA+ FF+
C C
97 97
G00248-01
PROFIBUS PA (PA+ / PA-) FOUNDATION fieldbus (FF+ / FF-)
U = 9 ... 32 v, I = 10 mA (normal operation), I = 13 mA (in the event of U = 9 ... 32 v, I = 10 mA (normal operation), I = 13 mA (in the event of
an error / FDE) an error / FDE)
Bus connection with integrated protection against polarity reversal. Bus connection with integrated protection against polarity reversal
The bus address can be set via the DIP switches in the device (with
dual-compartment transmitter housing only), the transmitter display or
the fieldbus.
The resistance R and condenser C form the bus termination. They must be installed when the device is connected to the end of the entire bus
cable. R = 100 Ω; C = 1 µF
5.8 Connection examples

E.g., for system monitoring, max. / min. alarm, empty meter tube or forward / reverse signal, or counting pulses
(function can be configured using software)
I E
R B*
+U
41
42
Imax = 220 mA
* RB UCE
ICE G00792-01
5.8.2 Digital outputs DO1 and DO2
Separate forward and reverse pulses Separate forward and reverse pulses (alternative connection)
I E I E
51 51
52 52
-
V +
24V+
24V
42 42
41 41
G00791
5.8.3 PROFIBUS PA - Connection via M12 plug
Only in non-hazardous areas
Pin assignment
(Front view showing pin insert and pins)
PIN 1 = PA+
PIN 2 = nc
PIN 3 = PA-
PIN 4 = shield
4 3
1 2
G01003-01
Fig. 53
IMPORTANT (NOTE)
For additional information on configuring the current output, see chapter 7.2 „Configuring the
current output“

Digital communication
6 Digital communication 6.2 PROFIBUS PA

The interface conforms to profile 3.01 (PROFIBUS standard, EN
50170, DIN 19245 [PRO91]).
6.1 HART protocol
The unit is registered with the HART Communication Foundation. PROFIBUS DP PROFIBUS PA
100
H2-Bus A 1 F
PA+ PA- PA+ PA- PA+ PA-
G00111
A = Segment coupler (incl. bus supply and termination)

Fig. 55: Example for PROFIBUS PA interface connection
PROFIBUS PA ID no 0x3430
Fig. 54
Alternative 0x9700 or 0x9740
standard ID no
Configuration Directly on the device
Configuration Directly on the device
Software DAT200 Asset Vision Basic
Software DAT200 Asset Vision Basic (+
(+ HART-DTM)
PROFIBUS PA-DTM)
Transmission FSK modulation on current output
Transmission signal Acc. to IEC 61158-2
4 ... 20 mA acc. to Bell 202 standard
Cable Shielded, twisted cable (acc. to IEC
Max. signal amplitude 1.2 mAss
61158-2, types A or B are preferred)
Current output load Min. 250 Ω, max. = 560 Ω
Cable AWG 24 twisted
Max. cable length 1500 m 6.2.1 Bus topology
Baud rate 1,200 baud
• Tree and/or line structure
Display Log. 1: 1,200 Hz
• Bus termination: passive at both ends of the main bus line (RC
Log. 0: 2,200 Hz element R = 100 Ω, C = 1 µF)
For additional information, see separate interface documentation.

6.2.2 Voltage / current consumption
6.1.1 System integration • Average current consumption: 10 mA
• In the event of an error, the integrated FDE function (=Fault
In conjunction with the DTM (Device Type Manager) available for the Disconnection Electronic) integrated in the device is ensures that
device, communication (configuration, parameterization) can occur the current consumption can rise to a maximum of 13 mA.
with the corresponding framework applications according to FDT 1.21 • The upper current limit is restricted electronically.
(DAT200 Asset Vision Basic). • The voltage on the bus line must lie in the range of 9 ... 32 V DC.
Other tool/system integrations (e.g., Emerson AMS/Siemens PCS7)
are available upon request. For additional information, see separate interface documentation.
A free of charge version of the DAT200 Asset Vision Basic framework
application for HART® or PROFIBUS is available upon request.
The required DTMs are contained on the DAT200 Asset Vision Basic 6.2.3 System integration
DVD or in the DTM Library.
They can also be downloaded from www.abb.com/flow. ABB provides three different GSD files (equipment master data) which
can be integrated in the system.
Users decide at system integration whether to install the full range of
functions or only part.
The change-over is done using the “ID-number selector” parameter.
ID number 0x9700, GSD file name: PA139700.gsd
ID number 0x9740, GSD file name: PA139740.gsd
ID number 0x3430, GSD file name: ABB_3430.gsd
The GSD files can be downloaded from www.abb.com/flow.

The files required for operation can be downloaded from
www.profibus.com.

Digital communication
6.3 FOUNDATION fieldbus (FF) 6.3.3 Bus address
The bus address is automatically assigned or can be set in the system
Ethernet FOUNDATION fieldbus H1
manually.
The identifier (ID) is formed using a unique combination of
manufacturer ID, device ID, and device serial number.
100
HSE-Bus B 1 F
6.3.4 System integration
FF+ FF- FF+ FF- FF+ FF- The following are required:
G00112 • DD (Device Description) file, which includes the device
description.
B = Linking device (incl. bus supply and termination)
• The CFF (Common File Format) file is required for engineering
Fig. 56: Example for FOUNDATION fieldbus interface connection the segment. Engineering can be performed online or offline.
Interoperability test ITK 5.20 The files can be downloaded from www.abb.com/flow.
campaign no. The files required for operation can also be downloaded from
Manufacturer ID 0x000320 http://www.fieldbus.org.
Device ID 0x0124
Configuration • Directly on the device
• Via services integrated in the
system
• National configurator
Transmission signal Acc. to IEC 61158-2
6.3.1 Bus topology

• Tree and/or line structure
• Bus termination: passive at both ends of the main bus line (RC
element R = 100 Ω, C = 1 µF)

• Average current consumption: 10 mA
• In the event of an error, the integrated FDE function (=Fault
Disconnection Electronic) integrated in the device is ensures that
the current consumption can rise to a maximum of 13 mA.
• Upper current limit: electronically restricted.
• The voltage on the bus line must lie in the range of 9 ... 32 V DC.

Commissioning
7 Commissioning
IMPORTANT (NOTE)
7.1 Preliminary checks prior to start-up
The following points must be checked before commissioning:

• The supply power must be switched off.
• The supply power must match information on the name plate.
• The pin assignment must correspond to the connection diagram.
• Sensor and transmitter must be grounded properly.
• The temperature limits must be observed.
• The sensor must be installed at a largely vibration-free location.
• The housing cover and its safety locking device must be sealed before switching on the
supply power.
• For devices with remote mount design and an accuracy of 0.2 % of rate make sure that the
flowmeter sensor and the transmitter match correctly.
For this purpose, the final characters X1, X2, etc. are printed on the name plates of the
flowmeter sensors, whereas the transmitters are identified by the final characters Y1, Y2,
etc.
Devices with the end characters X1 / Y1 or X2 / Y2, etc. fit with each other.
7.2 Configuring the current output
The factory setting for the current output is 4 ... 20 mA.
For devices without explosion protection or for operation in Zone 2 / Div. 2 the following
is valid:
The signal can be configured in "active" or "passive" mode. The current setting is contained in
the order confirmation.
For devices for operation in Zone 1 / Div. 1 the following is valid:

For devices designed for use in Ex Zone 1 / Div.1, the current output cannot be reconfigured
subsequently. The configuration required for the current output (active / passive) must be
specified when the order is placed.
For the correct current output design (active / passive), see the marking contained in the
device's terminal box.
If the signal is configured in "active" mode, no external power may be supplied to the current
output.
If the signal is configured in "passive" mode, external power must be supplied to the current
output (similar to pressure and temperature transmitters).

Commissioning
7.2.1 Transmitter with dual-compartment housing
„A“ 1 „B“
2 3
3
G00679-02
Fig. 57
A Integral mount design 4 Backplane (in the transmitter housing)
B Remote mount design 5 Jumper (BR901) for active / passive current output
1 Housing cover 6 Jumper (BR903) for integral / remote mount design
2 Transmitter plug-in module 7 Jumper (BR902) for hardware write protection
3 Fixing screws
IMPORTANT (NOTE)
The backplane is mounted in the transmitter housing (not the transmitter plug-in module).
Configure the outputs as follows:

1. Switch off power supply.
2. Open the housing cover.
3. Remove the mounting screws for the transmitter electronics unit
4. Pull out the transmitter electronics unit
5. Set jumpers on backplane in accordance with the following table.
Jumper Number Function

BR901 active Current output 31 / 32 active
passive Current output 31 / 32 passive
BR902 Read only Hardware write protection active
BR903 integral Transmitter with integral mount design
remote Transmitter with remote mount design
6. Reinstall the transmitter electronic unit in reverse order

Commissioning
7.2.2 Transmitter with single-compartment housing
7 8
„A“ 1 „B“
5
2 3
4
3
G01321
Fig. 58: Jumpers in the single-compartment housing

A Integral mount design 5 Jumpers (BR905, BR906) for communication
1 Housing cover 7 Jumper (BR904) for active / passive pulse output
2 Transmitter plug-in module 8 Jumper (BR903) for integral / remote mount design
3 Fixing screws 9 Jumper (BR902) for hardware write protection
4 Backplane (in the transmitter housing)
IMPORTANT (NOTE)
The backplane is mounted in the transmitter housing (not the transmitter plug-in module).
Configure the outputs as follows:
BR901 active Current output 31 / 32 active
passive Current output 31 / 32 passive
BR904 active Pulse output 51 / 52 active
passive Pulse output 51 / 52 passive
BR905, BR906 HART Digital communication via HART protocol
PA/FF Digital communication via PROFIBUS PA or
FOUNDATION Fieldbus
6. Install the transmitter in reverse order.

Commissioning
7.3 Start-up of PROFIBUS PA units
For units with PROFIBUS PA, the bus address must be checked or configured prior to start-up.
If no bus address information was supplied by the customer, the unit was shipped with its BUS
address set to “126”.
The address must be set during start-up to a number within the valid range (0 … 125).
IMPORTANT (NOTE)
The address selected may only appear once in the segment.
The PROFIBUS PA interface of the device conforms with Profile 3.01 (fieldbus standard
PROFIBUS, EN 50170, alias DIN 19245 [PRO91]).
The transmitter transmission signal is designed according to IEC 61158-2.
IMPORTANT (NOTE)
The manufacturer-specific PROFIBUS PA ID no. is: 0x3430.
The unit can also be operated with the PROFIBUS standard ID nos. 0x9700 or 0x9740.
Address setting in the case of transmitters with dual-compartment housing

The address can be set either locally on the device (via the DIP switches on the backplane),
using system tools, or via a PROFIBUS DP master class 2 such as Asset Vision Basic
(DAT200).
The factory setting for DIP switch 8 is OFF, i.e., the address is set using the fieldbus.
The front cover must be unscrewed to change the settings. It is also possible to set the address
via menu by using the keys on the display board.
Address setting in the case of transmitters with single-compartment housing

The address can be set using system tools or via a PROFIBUS DP master class 2 such as
Asset Vision Basic (DAT200).
It is also possible to set the address via a menu by using the transmitter LCD display (refer to
the the "Parameterization" section).
It is not possible to set the address locally via DIP switch because there are no DIP switches
present in the case of transmitters with single-compartment housing.

Commissioning
7.3.1 Local address setting in the case of transmitters with dual-compartment housing
Integral mount design Remote mount design
1 1
On
1 2 3 4 5 6 7 8
G01033
Fig. 59: Position of DIP switches

1 Transmitter plug-in module 2 DIP switch
Switch assignments
Switch Assignment
1…7 PROFIBUS address
8 Defines the addressing mode:
Off = Set address via bus (factory setting)
On = Set address via DIP switches 1 ... 7 (local)
Device behavior with power supply switched on

After the power supply has been switched on, DIP switch 8 is polled:
Status
ON The address defined by DIP switches 1 ... 7 applies.
The address can no longer be changed via the bus once the device is in operation,
since DIP switch 8 is polled only once when the power supply is turned on.
OFF The transmitter uses the address stored in the FRAM of the gateway. At shipment
(Default) the address is set to “126” or to the address specified by the customer.
Once the unit is in operation, the address can be changed via the bus or directly on
the unit using the keys on the display board. The unit must be connected to the bus.
Address setting
Switches 1, 5, 7 = ON means: 1+16+64 = 81  Bus address 81
Switch 1 2 3 4 5 6 7 8
Status Device address Address mode
Off 0 0 0 0 0 0 0 Bus
On 1 2 4 8 16 32 64 Local

Commissioning
7.3.2 Configuration in the case of transmitters with single-compartment housing
7 8
„A“ 1 „B“
5
2 3
4
3
G01321
Fig. 60:
Set jumpers on backplane in accordance with the following table.

BR901 passive For PROFIBUS PA, set position to "passive"
BR904 active For PROFIBUS PA without function
passive
BR905, BR906 PA/FF Digital communication via PROFIBUS PA

Commissioning
• Average current consumption: 10 mA.

• In the event of an error, the integrated FDE (= Fault Disconnection Electronic) function
integrated in the device ensures that the current consumption can rise to a maximum of 13
mA.
• The upper current limit is restricted electronically.
• The voltage on the bus line must lie in the range of 9 ... 32 V DC.
7.3.4 System integration
Use of PROFIBUS PA profile B, B3.01 ensures interoperability and interchangeability of

devices. Interoperability means that devices from different manufacturers can be physically
connected to a bus and are communication-ready. In addition, third-party devices can be
interchanged without having to reconfigure the process control system.
To support interchangeability, ABB provides three different GSD files (equipment master data)
that can be integrated in the system.
Users decide at system integration whether to install the full range of functions or only part.
IMPORTANT (NOTE)
Devices are interchanged using the parameter "ID number selector", which can only be
modified on an acyclical basis.
The following table describes the available GSD files:
Number and type of

ID number GSD file name
function blocks
1 x AI 0x9700 PA139700.gsd
1 x AI; 1 x TOT 0x9740 PA139740.gsd
4 x AI, 2 x TOT,
1 x AO, 1 x DI, 1 x DO
0x3430 ABB_3430.gsd
and all manufacturer-specific
parameters
The manufacturer-specific GSD file "ABB_3430.gsd" is available to download from the ABB
homepage http://www.abb.com/flow.
The standard "PA1397xx.gsd" GSD files are available for download from the Profibus
International homepage: http://www.profibus.com

Commissioning
7.4 Start-up of FOUNDATION FIELDBUS devices
For devices with a FOUNDATION Fieldbus, the settings of the DIP switch must be checked
prior to start-up.
The DIP switches on the unit must be set correctly as follows:
• DIP switch 1 must be OFF.
• DIP switch 2 must be OFF.
Otherwise, the hardware write protection and the process control system prevent the unit from
recording information.
When integrating the unit in a process control system, a DD file (device description) and a CFF
file (common file format) are required. The DD file contains the device description. The CFF file
is required for segment engineering. Engineering can be performed online or offline.
The DD and CFF files are available to download from the ABB homepage
http://www.abb.com/flow.
The FOUNDATION Fieldbus interface for the device is compliant with the standards FF-890/891
and FF-902/90. The transmission signal of the transmitter is designed in accordance with IEC
61158-2.
The device is registered with the FOUNDATION fieldbus.
Registration for the FOUNDATION fieldbus is recorded under Manufacturer ID 0x000320 and
Device ID 0x0124.

Commissioning
7.4.1 Configuration of transmitters with dual-compartment housing
1 1
On
1 2 3 4 5 6 7 8
G01033
Fig. 61: Position of DIP switches

1 Transmitter plug-in module 2 DIP switch
Assigning of DIP switches

DIP switch 1:
Enables the simulation of the AI function blocks.
DIP switch 2:
Hardware write protection for write access via bus (locks all blocks).
DIP switch 1 2
Status Simulation Mode Write Protect
Off Disabled Disabled
On Enabled Enabled

Commissioning
7.4.2 Configuration of transmitters with single-compartment housing
7 8
„A“ 1 „B“
5
2 3
4
3
G01321
Fig. 62:
Set jumpers on backplane in accordance with the following table.

BR901 passive For FOUNDATION Fieldbus, set position to
"passive"
BR904 active For FOUNDATION Fieldbus without function
passive
BR905, BR906 PA/FF Digital communication via
FOUNDATION Fieldbus

Commissioning
7.4.3 Bus address settings
The bus address is automatically allocated at the FF via LAS (link active scheduler). For
address detection, a unique number is used (DEVICE_ID). This number is a combination of
manufacturer ID, device ID and device serial number.
The behavior when switching on the unit corresponds to Draft DIN IEC/65C/155/CDV of June
1996.
The mean current consumption of the device is 10 mA.
The voltage on the bus line must lie in the range of 9 … 32 V DC.
IMPORTANT (NOTE)
The upper limit of the current is electronically limited. In the event of an error, the FDE (= Fault
Disconnection Electronic) function integrated in the device ensures that the current
consumption cannot exceed a maximum of 13 mA.

Commissioning
7.5 Commissioning the unit
7.5.1 Downloading the system data
1. Switch on the power supply. After switching on the power supply, the following messages
appear in succession on the LCD display:
System Startup System Startup System Startup

LOADING SYSTEM DATA VERIFYING SYSTEM DATA INSTALLATION CHANGED
Identify Changed Item
Transmitter Sensor
2. Download the system data as follows:
For a completely new system or initial start-up

• The calibration data of the flowmeter sensor and the transmitter settings are loaded from the
SensorMemory1) into the transmitter.
After replacing the complete transmitter or transmitter electronic unit

• Select "Transmitter" with . The calibration data of the flowmeter sensor and the
transmitter settings are loaded from the SensorMemory1) into the transmitter.
After replacing the sensor

• Select "Sensor" with . The calibration data of the flowmeter sensor are loaded from the
SensorMemory1) into the transmitter. The transmitter settings are stored in the
SensorMemory1). If the new sensor is a different size, check the currently configured flow
range.
3. The flowmeter is ready for operation and will operate with factory settings or settings
requested by the customer. To change the factory settings, refer to chapter 8
"Parameterization".
1) The SensorMemory is a data memory integrated in the flowmeter sensor.
IMPORTANT (NOTE)
System data must only be loaded during initial start-up. If the power supply is later switched
off, the transmitter automatically loads all data the next time the power supply is switched on
again.
A selection as described below (1-3) is not required.

Commissioning
7.5.1.1 Error message "Incompatible sensor"
IMPORTANT (NOTE)
When commissioning the device, make sure that the transmitter is assigned to the sensor
correctly. It is not possible to operate a flowmeter sensor of the 300 series with a transmitter of
the 500 series.
If the transmitter is operated with a flowmeter sensor of another series, the following message
appears on the transmitter display:
Boiler 9 In the process display, a flow of zero flow is indicated, no

Q 0.00 l/min flow measurement is performed.
Σ+ 1403.09 m3
Σ- 591.74 m3 1. Use to switch to the information level.
Sensor
-Operator Menu- 2. Use or , select the "Diagnostics" submenu.

Diagnostics
3. Use to confirm your selection.
Operator Page 1
Operator Page 2
Back Select
Sensor When attempting to commission a mixed installation, the

-- F248.036-- shown error message appears.
Incompatible sns
The device cannot measure.
Tx+snr are not
the same series The indicated value for the current flowrate is zero flow.
Back Exit The current output assumes its pre-configured state (Iout
for alarm).
Make sure that the flowmeter sensor and the transmitter
are from the same series.
(e.g., flowmeter sensor ProcessMaster 300, transmitter
ProcessMaster 300)

Commissioning
7.5.2 Parameterization via the "Commissioning" menu function
The device can be factory parameterized to customer specifications upon request.

If no customer information is available, the device is delivered with factory settings.
The setting of the most current parameters is summarized in the "Commissioning" menu. This
menu provides the quickest way to configure the device.
The "Commissioning" menu allows you to select the language, the physical unit for flow rate, the
measuring range, the totalizer unit, the pulse / frequency mode, the pulse per unit, the pulse
width, damping, and the status of the current output during an alarm (Iout for alarm, Iout: Low
Alarm, Iout: High Alarm).
For detailed descriptions of these menus and parameters, see the chapter on the "Parameter
overview".
The following section describes parameterization via the "Easy Setup" menu function.
Boiler 9
Q 0.00 l/s 4. Use to switch to the configuration level.
Σ+ 0000.00 m³
Σ- 0000.00 m³
Access levels 5. Use or to select "Standard".

Read only
Standard 6. Confirm the selection with .
Advanced mode
Back Select
Enter password
********** 7. Use to confirm the password. A password is not
RSTUVWXYZ012345 available as factory default; you can continue without
entering a password.
Next OK
Menu 8. Use or to select "Commissioning".

Easy Setup
9. Confirm the selection with .
Exit Select

Commissioning
Easy Setup
Language 10.Use to call up the edit mode.
German 11. Use or to select the desired language.
Next Edit
Easy Setup
Q (Flowrate) Unit 13.Use to call up the edit mode.
l/s 14.Use or to select the desired unit.
Next Edit
Easy Setup
Qmax 16.Use to call up the edit mode.
25.000 l/s 17. Use or to set the desired upper range value.
Next Edit
18.Use to confirm your setting.
Easy Setup
Totalizer/Pulse Unit 19.Use to call up the edit mode.
m³ 20.Use or to select the desired unit.
Next Edit
Easy Setup
Operation 22.Use to call up the edit mode.
Pulse Mode 23. Use or to select the required operating mode.
• "Pulse Mode": In pulse mode, pulses per unit are
Next Edit output. The relevant settings are provided in the next
menu
• "Fullscale Frequency": In frequency mode, a frequency
proportional to the flow rate is output. The maximum
frequency can be configured according to the flow
measuring range
The factory default for the operating mode is "Pulse Mode".

Commissioning
Easy Setup
Pulses per Unit 25.Use to call up the edit mode.
10.000 / m³ 26.Use or to set the desired value.
Next Edit
Easy Setup
Pulse Width 28.Use to call up the edit mode.
30.00 ms 29. Use or to set the required pulse width.
Next Edit
Easy Setup
Damping 31.Use to call up the edit mode.
30.00 ms 32.Use or to set the desired damping.
Next Edit
Easy Setup
Iout at Alarm 34.Use to call up the edit mode.
High Alarm 35.Use or to select the alarm mode.
Next Edit
Easy Setup
Low Alarm Value 37.Use to call up the edit mode.
3.5000 mA 38. Use or to set the required current for Low
Alarm.
Next Edit
Easy Setup
High Alarm Value 40.Use to call up the edit mode.
21.800 mA 41. Use or to set the required current for High
Alarm.
Next Edit

Commissioning
Easy Setup
System Zero 43.Use to start automatic balancing of the zero point
for the system.
███████
Next OK
IMPORTANT (NOTE)
Prior to starting the zero point balancing, make sure
that:
• There is no flow through the sensor (close all
valves, shut-off devices etc.)
• The sensor is completely filled with the medium to
be measured
Easy Setup Enter the signal cable length between the transmitter and
Cable length the sensor. For devices with an integral mount design
5.0000 m 0.01 m must be entered.
Next Edit 44.Use to call up the edit mode.

45.Use or to set the signal cable length.
Menu Once all parameter have been set, the main menu appears
Easy Setup again. The most important parameters are now set.
47. Use to switch to the process display.
Exit Select
IMPORTANT (NOTE)
• For additional information regarding operation of the LCD display, refer to chapter "8.1
„Operation".
• For detailed descriptions of all menus and parameters, see chapter 8.4 „Description of
parameters“.
The LCD display is provided with capacitive control buttons. These enable you to control the
device through the glass of the closed cover.
IMPORTANT (NOTE)
The transmitter automatically calibrates the capacitive control buttons on a regular basis. If the
cover should be opened during operation, the buttons' sensitivity is at first increased. As a
result, operating errors may occur. The button sensitivity will return to normal during the next
automatic calibration.

Commissioning
Instructions on using the Qmax menu (flow range end value)
The device is factory calibrated to the flow range end value QmaxDN, unless other customer
information is available. The ideal flow range end values are approximately 2-3 m/s (0.2 ... 0.3 x
QmaxDN).
The smallest and largest possible flow range end values are shown in the table in chapter 7.6
"Flowmeter sizes, flow range".
Information regarding factory settings for further parameters (unless customer has
requested a specific parameterization)
Possible parameter settings Factory setting
Qmax Depending on the size (see QmaxDN (see table)
table)
Sensor TAG Alphanumeric, max. None
20 characters
Sensor Location TAG Alphanumeric, max. None
20 characters
Q (Flowrate) Unit l/s; l/min; l/h; ml/s; ml/min; l/min
m3/s; m3/min; m3/h; m3/d;
hl/h; g/s; g/min; g/h; kg/s;
kg/min; kg/h; kg/d; t/min; t/h;
t/d
Totalizer/Pulse Unit m3; l; ml; hl; g; kg; t l
Pulses per Unit 1
Pulse Width 0,1 ... 2,000 ms 100 ms
Damping ( 1 Tau) 0,02 ... 60 sec. 1
DO1 Alarm Config Pulse F/Pulse R, Pulse F, Pulse F/Pulse R
General Alarm, Min. Flowrate
Alarm, Max. Flowrate Alarm,
Empty Pipe, TFE
Only available for
FEP500 / FEH500 are:
Gas Bubble, Conductivity,
Coating, Sensor Temp
DO1 Action Active, Passive Passive
DO2 Alarm Config F/R Signal, Pulse R, General F/R Signal
Alarm, Min. Flowrate Alarm,
Max. Flowrate Alarm, Empty
Pipe, TFE
Only available for
Gas Bubble, Conductivity,
Coating, Sensor Temp

Commissioning

Digital Input Setup No Function, Totalizer Flowrate to Zero
Reset(All), Flowrate to Zero,
System Zero Adjust, Totalizer
Stop(All), Only available for
Dual Range, Start/Stop
Batching
Current Output 4 … 20 mA, 4 … 12 … 20 mA 4 - 20 mA
Iout at Alarm High Alarm, can be set to High Alarm, 21.8 mA
21 … 23 mA or
Low Alarm, can be set to For details refer to Section
3.5 … 3.6 mA 9.2.
Iout at Flow >103% Off (no signaling, current Off
output holds 20.5 mA), High
Alarm, Low Alarm
Low Flow Cut Off 0 … 10 % 1%
Empty Pipe Detector On / Off Off
TFE Detector On / Off Off
For PROFIBUS PA version

PA Addr. (BUS) 0 … 126 126
ID Nr Selector 0x9700, 0x9740, 0x3430 0x3430

Commissioning
7.6 Flowmeter sizes, flow range
The flow range end value can be set between 0.02 x QmaxDN and 2 x QmaxDN.
Nominal diameter Min. flow range end value QmaxDN Max. flow range end value
DN " 0.02 x QmaxDN (≈ 0.2 m/s) 0 … ≈ 10 m/s 2 x QmaxDN (≈ 20 m/s)
1 1/25 0,012 l/min (0,0032 US gal/min) 0,6 l/min (0,16 US gal/min) 1,2 l/min (0,32 US gal/min)
1,5 1/16 0,024 l/min (0,0063 US gal/min) 1,2 l/min (0,32 US gal/min) 2,4 l/min (0,63 US gal/min)
2 1/12 0,04 l/min (0,0106 US gal/min) 2 l/min (0,53 US gal/min) 4 l/min (1,06 US gal/min)
3 1/10 0.08 l/min (0.02 US gal/min) 4 l/min (1.06 US gal/min) 8 l/min (2.11 US gal/min)
15 1/2 2 l/min (0.53 US gal/min) 100 l/min (26.4 US gal/min) 200 l/min (52.8 US gal/min)
20 3/4 3 l/min (0.79 US gal/min) 150 l/min (39.6 US gal/min) 300 l/min (79.3 US gal/min)
25 1 4 l/min (1.06 US gal/min) 200 l/min (52.8 US gal/min) 400 l/min (106 US gal/min)
32 1 1/4 8 l/min (2.11 US gal/min) 400 l/min (106 US gal/min) 800 l/min (211 US gal/min)
40 1 1/2 12 l/min (3.17 US gal/min) 600 l/min (159 US gal/min) 1200 l/min (317 US gal/min)
50 2 1.2 m3/h (5.28 US gal/min) 60 m3/h (264 US gal/min) 120 m3/h (528 US gal/min)
65 2 1/2 2.4 m3/h (10.57 US gal/min) 120 m3/h (528 US gal/min) 240 m3/h (1057 US gal/min)
125 5 8.4 m3/h (37 US gal/min) 420 m3/h (1849 US gal/min) 840 m3/h (3698 US gal/min)
150 6 12 m3/h (52.8 US gal/min) 600 m3/h (2642 US gal/min) 1200 m3/h (5283 US gal/min)
250 10 36 m3/h (159 US gal/min) 1800 m3/h (7925 US gal/min) 3600 m3/h (15850 US gal/min)

Parameterization
8 Parameterization
8.1 Operation
The LCD display is provided with capacitive control buttons. These enable you to control the
device through the glass of the closed cover.
IMPORTANT (NOTE)
The transmitter automatically calibrates the capacitive control buttons on a regular basis. If the
cover should be opened during operation, the buttons' sensitivity is at first increased. As a
result, operating errors may occur. The button sensitivity will return to normal during the next
automatic calibration.
8.1.1 Menu navigation
2 -----------------Menu---------------- 3
4
1
5 Exit Select 5
G00822-01
Fig. 63: LCD-indicator

1 Control buttons for menu navigation 4 Marker for indicating relative position
2 Menu name within the menu
3 Menu number 5 Function currently assigned to the
and control buttons
You can use the or control buttons to browse through the menu or select a number or
character within a parameter value.
Different functions can be assigned to the and control buttons. The function that is
currently assigned to them (5) is shown on the display.
8.1.1.1 Control button functions
Meaning
Exit Exit menu

Back Go back one submenu
Cancel Cancel a parameter entry
Next Select the next position for entering numerical and alphanumeric values
Meaning
Select Select submenu / parameter

Edit Edit parameter
OK Save parameter entered

Parameterization
8.2 Menu levels
Two levels exist under the process display.
Process display
Information level Configuration level
Diagnostics Easy Setup

Operator Page 1 ... 3 Device Info
Autoscroll Device Setup
Signals View Display
Input/Output
Process Alarm
Communication
Diagnostics
Totalizer
Fig. 64: Menu levels

Process display
The process display shows the current process values.
Information level
The information level contains the parameters and information that are relevant for the user.
The device configuration cannot be changed on this level.
Configuration level
The configuration level contains all the parameters required for device commissioning and
configuration. The device configuration can be changed on this level.
Note
For a detailed description of the individual parameters and menus on the configuration level
refer to the sections 8.3 "Overview of parameters on the configuration level" and 8.4
"Description of parameters".

Parameterization
8.2.1 Process display
3 4 3 G00756
Fig. 65: Process display (example)

1 Measuring point identifier 3 Symbol indicating button function
2 Current process values 4 Symbol indicating "Parameterization
protected"
The process display appears on the LC display when the device is switched on. It shows
information about the device and current process values.
The way in which the current process values (2) are shown can be adjusted on the configuration
level.
8.2.1.1 Description of symbols
Symbol Description
Call up information level.
When Autoscroll mode is enabled, a  symbol appears here and the operator
pages are automatically displayed one after the other.
Call up configuration level.
The device is protected against changes to the parameter settings.
Q Display of the current flowrate

Σ+ Totalizer status in forward direction
Σ- Totalizer status in reverse direction

Parameterization
8.2.2 Switching to the information level (operator menu)
On the information level, the operator menu can be used to display diagnostic information and
choose which operator pages to display.
Process display
1. Use to switch to the information level.
Operator Menu 2. Use or to select a submenu.

Diagnostics
Operator Page 1 3. Use to confirm your selection.
Operator Page 2
Back Select
Menu Description
... / Operator Menu

Diagnostics Selects the "Diagnostics" submenu, see also Chapter
8.2.2.1 "Error messages on the LCD display".
Operator Page 1 Selects the operator page to be displayed
Operator Page 2
Operator Page 3
Operator Page 4
Autoscroll When "Multiplex Mode" is enabled, this initiates automatic
switching of the operator pages on the process display.
Signals View Selects the "Signals View" submenu (for service, only).

Parameterization
8.2.2.1 Error messages on the LCD display
In case of an error, a message consisting of an icon and text appears at the bottom of the
process display. The text displayed provides information about the area in which the error has
occurred.
Process display
Electronics
The error messages are divided into four groups in accordance with the NAMUR classification
scheme:
Symbol Description
Error / Failure
Functional check
Out of specification
Maintenance required
Additionally, the error messages are divided into the following areas:
Area Description
Electronics Error / alarm of the electronics.
Sensor Error / alarm of the flowmeter sensor.
Status Alarm due to the current device status.
Operation Error / alarm due to the current operating conditions.

Parameterization
8.2.2.2 Invoking the error description
Additional details about the occurred error can be called up on the information level.
Process display
Electronics
Operator Menu 2. Use or , select the "Diagnostics" submenu.

Diagnostics
Operator Page 1 3. Use to confirm your selection.
Operator Page 2
Back Select
Electronics The first line shows the area in which the error has
F123,321 occurred.
Brief description
The second line shows the unique error number.
Information
Back Exit The next lines show a brief description of the error and
information on how to remedy it.
Note
For a detailed description of the errors and information on their remedy refer to Chapter 10
"Error messages".

Parameterization
g
8.2.3 Switching to the configuration level (parameterization)
The device parameters can be displayed and changed on the configuration level.
Process display
Access Level 2. Use or to select the access level.

Read Only
Standard 3. Use to confirm your selection.
Advanced
Next OK
IMPORTANT (NOTE)
There are four access levels: For the "Standard" and "Advanced" levels you can define
passwords. There are no factory default passwords.
• On the „Read Only“ level all entries are disabled. Parameters are read only and cannot be
modified.
• On the "Standard" level you can edit all parameters described in Chapter 8.4 "Description
of parameters" except for those written in italics.
• On the "Advanced" level all parameters can be modified.
• The Service menu is reserved to the customer service.
Once you have logged on to the corresponding access level, you can edit or reset the
password. Resetting to the "No password defined" state is done by selecting "" as the
password.
Enter Password 4. Enter the corresponding password (see Chapter

******** "Selecting and changing parameters").
There is no factory default for the password. You can
QRSTUVWXYZ0123456 switch to the configuration level without entering a
Next OK
password.
The selected access level remains active for 3 minutes.
Within this time period you can toggle between the
process display and the configuration level without re-
entering the password.
5. Use to confirm your password.
The LCD display now indicates the first menu item on the
configuration level.
6. Use or to select a menu.
7. Use to confirm your selection.

Parameterization
8.2.4 Hardware write protection
In addition to password protection, it is possible to activate hardware write protection.
„A“ 1 „B“
„A“ 1 „B“
G01322

Fig. 66: Jumper for hardware write protection
A Integral mount design 1 Housing cover
B Remote mount design 2 Jumper (BR902) for hardware write protection


6. Reinstall the transmitter electronic unit in reverse order

Parameterization
8.2.5 Selecting and changing parameters
8.2.5.1 Entry from table

When an entry is made from a table, a value is selected from a list of parameter values.
Menu name 1. Select the parameters you want to set in the menu.
Parameter name
Value currently set 2. Use to call up the list of available parameter
values. The parameter value that is currently set is
Next Edit highlighted.
Parameter name 3. Use or to select the required value.

Parameter 1
Parameter 2 4. Use to confirm your selection.
Parameter 3 This concludes the procedure for selecting a parameter
Cancel OK value.
8.2.5.2 Numerical entry

When a numerical entry is made, a value is set by entering the individual decimal positions.
----Menu name---- 1. Select the parameters you want to set in the menu.
Parameter name
1 2 .34 56 [unit] 2. Use to call up the parameter for editing. The
position that is currently selected is highlighted.
Next Edit
-----Parameter name----
1 2 .34 56 [unit] 3. Use to select the decimal position to be changed.
4. Use or to set the required value.
Next OK 5. Use to select the next decimal position.

6. If necessary, select and set other decimal positions
using the same procedure as described in steps 3 and
4.
7. Use to confirm your setting.
This concludes the procedure for changing a parameter
value.

Parameterization
8.2.5.3 Alphanumeric entry
When an alphanumeric entry is made, a value is set by entering the individual decimal
positions.
-----Menu name---- 1. Select the parameters you want to set in the menu.
Parameter name
Value currently set 2. Use to call up the parameter value for editing. The
position that is currently selected is highlighted.
Next Edit
-----Parameter name----
ABC.......................... 3. Use to select the position to be changed.
4. Use or to select the required character.
ABCDEFGHIJKLMNOPQ
Next OK 5. Use to select the next position.
6. If necessary, select and set other decimal positions
using the same procedure as described in steps 3 and 4.
7. Use to confirm your setting.
This concludes the procedure for changing a parameter
value.
8.2.5.4 Exiting the setup

For some menu items, values must be entered. If you don't want to change the parameter, you
can exit the menu as described below.
1 By pressing (Next) repeatedly you can move the cursor to the right. Once the cursor
reaches the end position, "Cancel" is displayed in the lower right.
2 With you can terminate editing and exit the menu item. With you can return to the
start.
IMPORTANT (NOTE)
The LCD display automatically returns to the process display three minutes after the last
button has been actuated.

Parameterization
8.3 Overview of parameters on the configuration level
IMPORTANT (NOTE)
This overview of parameters shows all the menus and parameters available on the device. Depending on the version
and configuration of the device, not all of the menus and parameters may be visible on it.
Easy Setup 1 Language

Q (Flowrate) Unit
Qmax
Totalizer/Pulse Unit
Pulse Mode
Pulses per Unit
Pulse Width
Damping
Iout at Alarm
Low Alarm Value
High Alarm Value
System Zero Manual

Automatic
Cable length
Device Info 2 Sensor Sensor Type

Sensor Model
Acquisition Sensor Size
QmaxDN
Qmax
Qmax2
Span Ss
Zero Sz
User Span
Mains Frequency
Excitation Freq.
Coil Current
Pre-Amp
Sensor ID
SAP / ERP No.
Term Board S/W
Sensor Run Hours
Calibration First Cal. Date
Last Cal. Date
Cal. Cert. No.
First Cal. Location
Last Cal. Location
Cal. Mode
Cal. Status
Properties Electrode Material

Lining Material
Rate ADC
Analog Reset Noise Reset Max
Noise-Reset ON
Driver Driver DAC

Loop Control Mode
Diff Current Control
Control Timer
italics = Parameter can only be changed at the "advanced" password level.

Parameterization
Analog Range Amplifier

Adjust CMReject CMR Value
Adjust Gain 1...64 Adjust Gain 1

Adjust Gain 8
Adjust Gain 32
Adjust Gain 64
Transmitter Device Version
ScanMaster Option
Tx Typ
Tx Spanne
Tx Nullpunkt
Offset Iout
Gain Iout
Simulator
Transmitter ID
SAP / ERP Nr.
Tx Version TX Firmware Ver
TX Hardware Ver
TX Run Hours Com Controller Ver
Bootloader Ver
Calibration First Cal. Date

Last Cal. Date
Manufacturer Cal. Cert. No.
Street First Cal. Location
City Last Cal. Location
Phone
Device Setup 3 Access Control Standard Password

Advanced Password
Read Only Switch
Custody Switch
Sensor QmaxDN
Qmax
Qmax2
Range Mode
Sensor Location TAG
Sensor TAG
Transmitter Units Totalizer/Pulse Unit

Q (Flowrate) Unit
Damping Velocity Unit
Density Custom Vol. Type
Custom Vol. Factor
Custom Vol. String
Custom Tot. Type
Custom Tot. Factor
Custom Tot. String
Low Flow Cut Off

Flow Cut Off Level
TX Location TAG Hysteresis
TX TAG

Parameterization
Operating Mode Meter Mode

Flow Indication
System Zero Manual Adjust

Auto Adjust
Noise Reduction Off

Mean Filter
Notch Filter
Lowpass V=Auto
Lowpass V=1
Display 4 Language
Contrast
Operator Pages Operator Page 1 Display Mode
1st Line
Autoscroll Operator Page 2 2nd Line
Flowrate Format 3st Line
Volume Format Operator Page 3 Bargraph
Date/Time Format
Display Test
Operator Page 4
Input / Output 5 Digital Out Mode DO1 / DO2 Function Pulse F/Pulse R,
Pulse F/Logic,
Pulse VR/Logic,
Logic/Logic
DO1 Drive Passive,

Active
Logic Setup DO1 Signal No Function,

F/R Signal,
Alarm Signal
Dual Range
Batch end contact
DO1 Alarm Config General Alarm,

Min. Flowrate Alarm,
Max. Flowrate Alarm,
Empty Pipe
TFE
Gas Bubble
Conductivity
Coating
Sensor Temp
DO1 Action Normally Open,

Normally Closed
DO2 Signal No Function,

F/R Signal,
Alarm Signal
Dual Range
Batch end contact

Parameterization
DO2 Alarm Config General Alarm,

Min. Flowrate Alarm,
Max. Flowrate Alarm,
Empty Pipe
TFE
Gas Bubble
Conductivity
Coating
Sensor Temp
DO2 Action Normally Open,

Normally Closed
Pulse Setup Pulse Mode

Pulses per Unit
Pulse Width
Limit Frequency
Fullscale Frequency
Digital Input Setup No Function,

Totalizer Reset(All),
Flowrate to Zero,
System Zero Adjust,
Totalizer Stop(All)
Dual Range
Start/Stop Batching
Current Output Iout at Alarm High Alarm,

Low Alarm
Low Alarm Value

High Alarm Value
Iout at EP Alarm
Iout at Flow >103%
Iout at TFE Alarm
Iout Mode

Parameterization
Process Alarm 6 Clear Alarm History
Group Masking Maintenance Required

Function Check
Out of Specification
Individual Masking Min Flowrate Alarm

Max Flowrate Alarm
Flow >103%
Com Controller Alarm
TFE Alarm
Empty Pipe Alarm
Alarm Simulation Off

On
Communication 7 HART Device Address

HART Tag
HART Descriptor
HART Message
HART Manf. ID
HART Device ID
Last HART Command
Cyclic Data Out Cyclic Upd. Rate
Cyclic Upd. Select Flow Group

Outputs Group
Status Group
Coil Group
TX Group
Vol. Totals Group
Electrodes Group
Service Port Max Baud Rate

HART Access
PROFIBUS PA PA Addr. (BUS)

Ident Nr. Selector
Comm State
AI1-Q Durchfluss
TOT1-Q Durchfluss
TOT2-Q Durchfluss
AI2-Interner Tot Vor
AI3-Interner Tot Rev
AI4-Diagnose
AI4-Channel
AO-Dichte
DI-Alarm Info
DI-Channel
DO-Cyclic Control
DO-Channel

Parameterization
FF
Show FF Address
AI1-Q Flowrate
INT1-Q Flowrate
AI2-Internal Tot Fwd
AI3-Internal Tot Rev
AI4-Diagnostics
AO-Density Adjust
DI-Alarm Info
DO-Cyclic Control
Diagnostics 8 Diagnosis Control Empty Pipe Detector Empty Pipe Detector

Adjust EP
Manual Adjust EP F.
Threshold
Detector EP Value
Sensor Measurements
Sensor Measurements
One shot Sensor Mea
Coil Current
Coil Resistor
Coil Voltage
Coil R. Max Alarm
Coil R. Min Alarm
Signal-Cable length
Sensor Temp Value
Adj. Sensor T. Value
Sensor T. Min Alarm
Sensor T. Max Alarm
Gas Bubble Detector Gas Bubble Detector

Adjust Gas Bubble
Threshold Gas Bubble
Gas Bubble Value
Coating Detector Coating Detector

One shot Coating
Coating Value QE1
Coating Value QE2
Coating QE Min Alarm
Coating QE Max Alarm
Cond. Detection
Cond. Detection
One shot Cond.
Cond. Value
Adj. Cond. Value
Cond. Min Alarm
Cond. Max Alarm
Elec. Imp. E1-GND
Elec. Imp. E2-GND
Elec. Imp Min Alarm
Elec. Imp Max Alarm

Parameterization
Grounding Check Grounding Check

Power Spectrum
Amplitude 1 Value
Amplitude 2 Value
Amplitude 3 Value
Amplitude 4 Value
TFE Detector TFE Detector

Adjust TFE Full
SIL detector TFE Threshold
TFE Value
Diagnosis Values
SNR Value
Slope Value
Slope Variation
Reference
Signal Ratio
Signal max
Signal min
NV Resets/sec
Amplification Int.
Fingerprints Factory F.P.

Sensor Coil R.
Elec. Coat. QE1
Elec. Coat, QE2
Elec. Imp. E1-GND
Elec. Imp. E2-GND
Tx check CMR
Tx check 5 m/s
Tx check 10 m/s
Startup F.P.
Startup F.P.
Sensor Coil R
Elec. Coat. QE1
Elec. Coat. QE2
Elec. Imp. E1-GND
Elec. Imp. E2-GND
Start Tx Startup F.P
Tx check CMR
Tx check 5 m/s
Tx check 10 m/s
On demand F.P.
Start On demand F.P.
Sensor Coil R
Elec. Coat. QE1
Elec. Coat. QE2
Elec. Imp. E1-GND
Elec. Imp. E2-GND
Start Tx Startup F.P
Tx check CMR
Tx check 5 m/s
Tx check 10 m/s

Parameterization
Trend Conductivity
Electrode Coat. QE1
Electrode Coat. QE2
Logtime Interval
Trend-Logging
Flowrate Alarm Max. Flowrate Alarm

Min. Flowrate Alarm
Simulation Mode Off, Flow Simulation,

Q [Unit],
Q [%],
CurrentOut,
Pulse on DO1,
Pulse on DO2,
Logic on DO1,
Logic on DO2,
HART Freq,
Digital input
Output Readings Current

DO1 Frequency
DO1 State
Digital In State
Totalizer 9 Reset Vol. Totals Totalizer Fwd

Totalizer Rev
Totalizer Net
All Vol. Totalizer
Batching Damping
Preset Batch Tot.
Lag Corr. Mode
Lag Corr. Quantity
Batch Tot.
Total Batch Counter
Reset Batch Counter
Start/Stop Batching
Edit Vol. Totals Edit Totalizer Fwd

Edit Totalizer Rev
Edit Totalizer Net

Parameterization
8.4 Description of parameters
8.4.1 Menu: Easy Setup
Menu / Parameter Value range Description
Easy Setup "Easy Setup" Menu

Language Deutsch, English, Français, Select the menu language.
Español, Italiano, Dansk,
Svenska, Polski, Russki,
Zhongweng, Turkce
Q (Flowrate) Unit l/s; l/min; l/h; ml/s; ml/min; Select the unit for the flow indicator.
m3/s; m3/min; m3/h; m3/d; Default setting: l/min
Ml/d; ft3/s; ft3/min; ft3/h; ft3/d;
ugal/s; ugal/min; ugal/h;
ugal/d; Mugal/d; igal/s;
igal/min; igal/h; igal/d; bls/s;
bls/min; bls/h; bls/d; hl/h; g/s;
g/min; g/h; kg/s; kg/min; kg/h;
kg/d; t/min; t/h; t/d; lb/s;
lb/min; lb/h; lb/d; custom/s
Qmax Min. flow range: 0 ... 0.2 m/s Select the flow range for forward and reverse flow.
(0 ... 0.02 x QmaxDN) Default setting: 1 x QmaxDN.
Max. flow range: 0 ... 20 m/s
(0 ...2 x Qmax DN)
Totalizer/Pulse Unit m3; l; ml; ft3; hl; g; kg; t; lb; Select the unit for the flowmeters.
igal; ugal; bls; Ml; Mugal; Default setting: l
custom
Operation Pulse Mode, Fullscale Select the operating mode for the digital output.
Frequency There are two operating modes available:
• „Pulse Mode“: In pulse mode, pulses per unit are
output (e.g., 1 pulse per m3).
• „Fullscale Frequency“: In frequency mode, a
frequency proportional to the flowrate is output.
The maximum frequency corresponding to the flow
range end value is configurable (max. 5.25 kHz).
Default setting: „Pulse Mode“
Pulses per Unit - Display of the pulses per unit output by the digital
output. The max. possible number of pulses is 5250
per second.
Fullscale Frequency 0 ... 5250 Hz Set the frequency for the flow range end value in
Fullscale Frequency operating mode.
italics = Parameter can only be viewed at the "Advanced" password level.
1) Parameter / menu only available for FEP500 / FEH500.

Parameterization
Easy Setup (continued) "Easy Setup" Menu

Pulse Width 0.1 ... 2000 ms Select the pulse width for the digital output. The pulse
factor and pulse width are interdependent and are
calculated dynamically.
Damping 0.02 ... 60 s Select the damping.
The value set here relates to 1 Τ (Tau).
The value refers to the response time for a step
flowrate change. It affects the instantaneous value in
the display and at the current output.
Default setting: 1 second
Iout at Alarm Low, High Status of the current output during an error.
The “low” or “high” status is set in the subsequent
menu.
Default setting: "High".
Low Alarm Value 3.5 ... 3.6 mA Current for Low Alarm.
Default setting: 3.5 mA
High Alarm Value 21 ... 23 mA Current for High Alarm.
Default setting: 21.8 mA
System Zero Select the "System Zero" submenu.

Parameterization
Easy Setup (continued) "Easy Setup" Menu

Cable length 0.01 ... 200 m Enter the signal cable length between the transmitter
and the flowmeter sensor.
For devices with a compact design
(FEP311, FEH311, FEP315, FEH315) 0.01 m must be
entered.
IMPORTANT (NOTE)
The entry is required for FEP500, FEH500 if the
diagnostic functions are to be used.
When using the ScanMaster verification software
you also have to enter the signal cable length.
Easy Setup / System Zero Submenu "System Zero"

Manual Starts the manual zero adjustment.
Automatic Starts the automatic zero adjustment.
IMPORTANT (NOTE)
Prior to starting the zero adjustment, make sure
that:
• There is no flow through the flowmeter sensor
(close all valves, shut-off devices, etc.)
• The flowmeter sensor is completely filled with
the fluid to be measured.

Parameterization
8.4.2 Menu: Device Info
IMPORTANT (NOTE)
This menu is used only to display the device parameters. The parameters are displayed
independently of the configured access level, but cannot be changed.
Device Info
Sensor Select the "Sensor" submenu.
Acquisition Select the "Acquisition" submenu.
Analog Range Select the "Analog Range" submenu.
Transmitter Select the "Transmitter" submenu.
Device Info / Sensor

Sensor Type - Type of flowmeter sensor (ProcessMaster 300 / 500,
HygienicMaster 300 / 500).
IMPORTANT (NOTE)
When commissioning the device, make sure that
the transmitter is assigned to the sensor
correctly. It is not possible to operate a flowmeter
sensor of the 300 series with a transmitter of the
500 series.
Sensor Model - Indication of model number (e.g., FEP315)
Sensor Size - Size of sensor.
QmaxDN - This value is the maximum flow at a velocity of 10
m/s.
The value is set automatically via the selected
flowmeter size.
Qmax - Set flow range end value for flow range 1.
Factory setting: Flow range 1 activated.
Qmax2 - Set flow range end value for flow range 2.
Factory setting: Flow range 2 deactivated.
IMPORTANT (NOTE)
The switchover between the two measuring
ranges is done via the digital input or via the
menu "Config. Device / Sensor / 2 flow ranges“
Span Ss - Calibration value for the sensor (span)
Zero Sz - Calibration value for the sensor (zero)

Parameterization
Device Info / Sensor

User Span Indication of the correction value for the sensor span
Mains Frequency - Mains frequency for the supply power.
Excitation Freq. - Frequency used to operate the magnet coils of the
flowmeter sensor.
Coil Current - Current used to operate the magnet coils of the
flowmeter sensor.
Pre-Amp - Indication whether a preamplifier exists in the
flowmeter sensor or not (Yes / No).
Sensor ID - ID number of the sensor.
SAP / ERP No. - Order number of the sensor.
Term Board S/W - Software version of the sensor memory integrated in
the sensor.
Sensor Run Hours - Run hours of the flowmeter sensor.
Calibration Select the "Calibration" submenu.
Properties Select the "Properties" submenu.
Device Information / Sensor / Calibration

First Cal. Date - Date of first calibration of sensor (calibration of new
device).
Last Cal. Date - Date of last calibration of sensor.
Cal. Cert. No. - Identification (no.) of the relevant calibration
certificate.
First Cal. Location - Place of first calibration of the sensor.
Last Cal. Location - Place of last calibration of sensor.
Cal. Mode - Calibration mode of the sensor.
Cal. Status - Calibration status of the sensor.
Device Info / Sensor / Properties

Electrode Material - Electrode material of the sensor.
Lining Material - Liner material of the sensor.

Parameterization
Device Info / Acquisition

Rate ADC - Display for service purposes, only.
Analog Reset Select the "Analog Reset" submenu.
Driver Select the "Driver" submenu.
Device Info / Acquisition / Analog Reset

Noise Reset Max - Display for service purposes, only.
Noise Reset On -
Device Info / Acquisition / Driver

Driver DAC - Display for service purposes, only.
Loop Control Mode -
Diff Current Control -
Control Timer -
Device Info / Analog Range

Amplifier - Display for service purposes, only.
Adjust CMReject Select the "Adjust CMReject" submenu.
Adjust Gain 1 ... 64 Select the "Adjust Gain" submenu.
Device Info / Analog Range / Adjust CMReject

CMR Value - Display for service purposes, only.
Device Info / Analog Range / Adjust Gain 1 ... 64

Adjust Gain 1 - Display for service purposes, only.
Adjust Gain 8
Adjust Gain 16
Adjust Gain 64

Parameterization
Device Info / Transmitter

Device Version Indication of the transmitter series (300 HART series,
300 PA series, 300 FF series, 500 HART series, 500
PA series, 500 FF series)
Scanmaster option Indication whether the ScanMaster option is activated
or not.
For diagnostics or verification, the device can be
checked with a separate tool (ScanMaster). This
option is available for an extra charge and must be
activated in the transmitter.
TX Type - Display the transmitter type.
TX Span - Calibration value for the transmitter (span)
TX Zero - Calibration value for the transmitter (zero)
Offset Iout Indication of the adjustment value for the current
output (zero).
Gain Iout Indication of the adjustment value for the current
output (span).
Simulator Display for service purposes, only.
Transmitter ID - ID number of the transmitter.
SAP / ERP No. - Order number of the transmitter.
TX Version Select the "TX Version" submenu.
TX Run Hours - Run hours of the transmitter.
Calibration Select the "Calibration" submenu.
Manufacturer - Name of manufacturer
Street - Address of manufacturer (street).
City - Address (town) of manufacturer.
Phone - Phone number of manufacturer
Device Info / Transmitter / TX Version

TX Firmware Ver. - Software version of the transmitter.
TX Hardware Ver. - Hardware version of the transmitter.
Com-Controller Ver. - Software version of the COM controller.
Bootloader Ver. - Software version of the bootloader.
Device Info / Transmitter / Calibration

First Cal. Date - Date of first calibration for transmitter (calibration of
new device).
Last Cal. Date - Date of last calibration of transmitter.
Cal. Cert. No. - Identification (no.) of the relevant calibration
certificate.
First Cal. Location - Place of first calibration for the transmitter.
Last Cal. Location - Place of last calibration of transmitter.

Parameterization
8.4.3 Menu: Device Setup
Menu / parameter Value range Description
Device Setup
....Access Control Select the "....Access Control" submenu.
....Sensor Select the "....Sensor" submenu.
....Transmitter Select the "....Transmitter" submenu.
Device Setup / ....Access Control

Standard Password Alphanumeric Enter / change the password for the "Standard"
access level.
Advanced Password Alphanumeric Enter / change the password for the "Advanced"
access level.
Read Only Switch Display only (ON / OFF) Display of switch position of BR902 (hardware write
protection).
See Chapter 8.2.4 "Hardware write protection" on
page 86.
Custody Switch Display only (ON / OFF) Display of the switch position of the calibration circuit
breaker
(must be activated for calibrated devices).
Device Setup / ....Sensor

QmaxDN Read only The displayed value is the flow rate at a flow velocity
of 10 m/s. The value is determined automatically via
the selected nominal diameter.
Qmax Min. measuring range: Select the upper range value measuring range 1) for
0 ... 0.2 m/s forward and reverse flow.
(0 ... 0.2 x QmaxDN) Default setting: 1 x QmaxDN.
Max. measuring range:
0 ... 20 m/s (0 ...2 x QmaxDN)
Qmax2 See Qmax Select the upper range value measuring range 2) for
forward and reverse flow.
Default setting: 1 x QmaxDN, measuring range 2 is
deactivated.
IMPORTANT (NOTE)
The switchover between the two measuring
ranges is performed via the digital input or via the
menu "Device Setup / ....Sensor / Range Mode".

Parameterization
Device Setup / ....Sensor (continued)

Range Mode Qmax enabled Manual switchover between flow ranges Qmax and
Qmax2.
Qmax2 enabled
Sensor Location TAG Alphanumeric, max. Enter the measuring point tag of the sensor (the
20 characters measuring point tag is shown in the upper left-hand
corner of the process display).
Sensor TAG Alphanumeric, max. Enter the TAG number of the sensor.
20 characters
Device Setup / ....Transmitter

....Units Select the "....Units" submenu.
Damping 0,02 ... 60 s Set the damping (the value relates to 1 T (Tau).
The value relates to a step flow rate change.
It affects the instantaneous value in the display and at
the current output.
Default setting: 1 second
Density 0,01 ... 5,0 g/cm³ If the flow is measured and indicated in the units g/s,
g/min, g/h, kg/s, kg/min, kg/h, kg/d, t/min, t/h, t/d, lb/s,
lb/min, lb/h and lb/d, a fixed density must be taken into
account for the calculations.
To convert the flow rate to mass flow units, a density
value from 0.01 to 5.0 g/cm³ can be entered.
....Low Flow Cut Off Select the "....Low Flow Cut Off" submenu.
TX Location TAG Alphanumeric, max. Enter the measuring point tag for the transmitter.
20 characters
TX TAG Alphanumeric, max. Enter the TAG number for the transmitter.
20 characters
....Operating Mode Select the "....Operating Mode" submenu.
....System Zero Select the "....System Zero" submenu.
Noise Reduction Off Activates noise reduction in case of unstable flow

Mean Filter signal. Activating noise reduction increases the
response time.
Notch Filter Factory setting: Off
Lowpass V=Auto
Lowpass V=1

Parameterization
Device Setup / ....Transmitter / ....Units

Totalizer/Pulse Unit m3, l, ml, ft3, hl, g, kg, t, lb, Select the unit for the flowmeters.
igal, ugal, bls, Ml, Mugal, IMPORTANT (NOTE)
customer-specific unit
If a mass flow unit is selected, the corresponding
density must be set in the "Device Setup /
....Transmitter / Density" menu.
Q (Flowrate) Unit l/s, l/min, l/h, ml/s, ml/min, Select the unit for the flow indicator.
m3/s, m3/min, m3/h, m3/d, IMPORTANT (NOTE)
Ml/d, ft3/s, ft3/min, ft3/h, ft3/d,
ugal/s, ugal/min, ugal/h,
ugal/d, Mugal/d, igal/s,
igal/min, igal/h, igal/d, bls/s,
bls/min, bls/h, bls/d, hl/h, g/s,
g/min, g/h, kg/s, kg/min, kg/h,
kg/d, t/min, t/h, t/d, lb/s,
lb/min, lb/h, lb/d, customer-
specific unit
Velocity Unit m/s, m/min, cm/s, cm/min, Select the unit for the display of the flow velocity.
feet/s, feet/min, inch/s,
inch/min
Custom Vol. Type Volume flow Select whether the user-defined flow unit is displayed
Mass flow as a mass flow rate (with density) or volume flow rate
(without density).
IMPORTANT (NOTE)
Custom Vol. Factor 0,0001 ... 100000 l/s Enter the factor for a user-defined flow unit. The factor
relates to the flow per liter.
Custom Vol. String Alphanumeric, max. Enter the name for the user-defined flow unit.
20 characters
Custom Tot. Type Volume flow Select whether the user-defined totalizer unit is
Mass flow displayed as a mass flow rate (with density) or volume
flow rate (without density).
IMPORTANT (NOTE)
Custom Tot. Factor 0,0001 ... 100000 l Enter the factor for a user-defined totalizer unit. The
factor relates to the flow per liter.
Custom Tot. String Alphanumeric, max. Enter the name for the user-defined totalizer unit.
20 characters

Parameterization
Device Setup / ....Transmitter / ....Low Flow Cut Off

Threshold 0 ... 10 % Select the switching threshold for leak flow volume
monitoring.
If the flow rate is below the switching threshold, there
is no flow measurement. The current output is set to
zero.
The switching threshold for low flow monitoring is
dependent on the currently set measuring range.
Default setting: 1 %
Hysteresis 0 ... 50 % Set the hysteresis for the leak flow volume.
Device Setup / ....Transmitter / ....Operating Mode

Meter Mode Forward only, Forward and Setting of the measuring direction for the sensor.
Reverse • "Forward only": The device measures and counts
in the forward direction only
• "Forward and Reverse": The device measures and
counts in both directions
Default setting: "Forward and Reverse"
Flow Indication Normal, Reverse Inverts the flow direction displayed.
Default setting: "Normal"
Device Setup / ....Transmitter / ....System Zero

Manual Adjust -50 ... +50 mm/s Enter the flow velocity for system zero.
Auto Adjust Starts the automatic zero point balancing.

IMPORTANT (NOTE)
Prior to starting the zero point balancing, make
sure that:
• There is no flow through the sensor (close all
valves, shut-off devices etc.)
• The sensor is completely filled with the
medium to be measured

Parameterization
8.4.4 Menu: Display
Display
Language Deutsch, English, Français, Select the menu language.
Español, Italiano, Dansk,
Svenska, Polski, Russki,
Zhongweng, Turkce
Contrast 0 ... 100 % Contrast setting for the LCD display
Operator Pages Select the "Operator Pages" submenu.
IMPORTANT (NOTE)
Up to four user-specific operator pages (layouts)
can be configured for the process display. If
several operator pages have been configured,
these can be scrolled manually. In the factory
setting only Operator Page 1 is enabled.
Autoscroll On / Off If Multiplex mode is enabled, you can also activate the
"Autoscroll" function on the information level.
In this function, operator pages appear on the LCD
window in ten-second intervals. Manual scrolling
through pre-configured operator pages as described
above is no longer necessary.
When Autoscroll mode is enabled, the  icon is
displayed on the lower left.
Default setting: Off
Flowrate Format x, x.x, x.xx, x.xxx, x.xxxx Select the decimal places for the flow indicator.
Default setting: x.xx
Volume Format x, x.x, x.xx, x.xxx, x.xxxx Select the decimal places for the flow totalizer.
Factory setting: x.xx
Date/Time Format DD-MM-YYYY, MM-DD- Set the display format for the date and time. Factory
YYYY, YYYY-MM-DD setting: YYYY-MM-DD
Display Test Start the test of the LCD display with "OK".
Display / Operator Pages

Operator Page 1 Select the "Operator Page 1" submenu.

Parameterization
Display / Operator Pages / Operator Page 1 (n)

Display Mode • 1 line with 6 characters. Configure each operator page. The following variants
• 1 line with 6 characters + in the value range can be selected:
bar graph.
• 1 line with 9 characters.
• 1 line with 9 characters +
bar graph.
• 2 lines with 9 characters.
• 2 lines with 9 characters +
bar graph.
• 3 lines with 9 characters
(factory default).
• Graphic (line recorder)
• Off (the option disables the
respective operator page)
1st Line • Flowrate [%] Select the value displayed in each line. The following
• Flowrate [Unit] variants in the value range can be selected:
• Totalizer Fwd
• Totalizer Rev
• Totalizer Net
2nd Line • Flow Velocity [Unit]
• Current Output [mA]
• SignalProportion
• Reference
• Signal Max
• Signal Min
3st Line • Amplification
• Noise Reset Counter
• Total Batch Counter 1
• Batch Totalizer 1
• Conductivity 1
• Sensor Temp 1
Bargraph • Flowrate [%] Select the value displayed in the bar graph. The
• Current Output [mA] measuring values in the value range can be selected.

Parameterization
8.4.5 Menu: Input/Output
Input/Output
....Digital Out Mode Select the "....Digital Out Mode" submenu.
....Logic Setup Select the "....Logic Setup" submenu.
....Pulse Setup Select the "....Pulse Setup" submenu.
Digital Input Setup No Function, Totalizer Select the operating mode for the digital output. There
Reset(All), Flowrate to Zero, are four operating modes available:
System Zero Adjust, Totalizer • Totalizer reset for all totalizers (forward, reverse
Stop(All), Dual Range, and difference totalizer)
Start/Stop Batching 1) • External switch-off
• External zero point balancing
• External totalizer stop for all totalizers (forward,
reverse and difference totalizer)
• Switchover between measuring ranges 1 and 2
(Qmax and Qmax2)
• Start / stop of the fill function (batch) 1).
Default setting: external switch-off
IMPORTANT (NOTE)
If the fill operation is stopped before the set fill
quantity is reached, the fill totalizer is set to zero.
When the fill function is restarted, the interrupted
fill operation is not continued.
Current Select the "Current" submenu.

Parameterization
Input/Output / ....Digital Out Mode

DO1/DO2 Function Pulse F/Pulse R, Pulse Select the functions for the digital outputs DO1 and
F/Logic, Pulse FR/Logic, DO2.
Logic/Logic • Pulse F/Pulse R:
- DO1 = Pulse output for the forward direction.
- DO2 = Pulse output for the reverse direction.
• Pulse F/Logic:
- DO1 = Pulse output for the forward direction.
- DO2 = Binary output.
• Pulse FR/Logic:
- DO1 = Pulse output for the forward and reverse
direction.
• Logic/Logic:
Default setting: pulse VR / binary.
IMPORTANT (NOTE)
The function for the binary outputs is defined in
the "....Logic Setup" menu.
DO1 Drive Passive, Active The digital output DO1 can be configured as an
"active" or "passive" output. For information on the
current configuration, refer to the order confirmation.
Default setting: passive
IMPORTANT (NOTE)
In the case of devices with a transmitter with
single-compartment housing and devices for use
in Zone 1, Div. 1, this parameter is disabled.
In the case of devices with a transmitter with
single-compartment housing, configuration is
performed via jumpers on the transmitter
backplane (refer to the "Commissioning"
chapter).

Parameterization
Input/Output / ....Logic Setup

DO1 Signal No Function, F/R Signal, The menu is displayed only if the binary / binary
Alarm Signal, Dual Range 1, function is set in the "Function DO1 / DO2" menu.
Batch end contact 1 This menu is not displayed in the factory setting.
• F/R Signal:
The digital output signals the flow direction.
• Alarm Signal:
The digital output functions as an alarm output.
The alarm type is set in the "DO1 Alarm Config"
menu.
• Range Mode:
The digital output is activated when measuring
range 2 (Qmax2) is selected
• Batch end contact:
The digital output is activated when the set fill
quantity is reached
Default setting: forward / reverse signal.
.... DO1 Alarm Config Select the ".... DO1 Alarm Config" submenu.
The menu is displayed only if the "Alarm Signal"
function is set in the "DO1 Signal" parameter.
DO1 Action Normally Open, Normally Select the switching behavior for the digital output.
Closed Default setting: Normally Open.
DO2 Signal No Function, F/R Signal, Refer to the description "DO1 Signal".
Alarm Signal, Dual Range 1,
Batch end contact 1
.... DO2 Alarm Config Select the ".... DO2 Alarm Config" submenu.
The menu is displayed only if the "Alarm Signal"
function is set in the "DO2 Signal" parameter.
DO2 Action Normally Open, Normally Refer to the description "DO1 Action".
Closed

Parameterization
Input/Output / ....Logic Setup / .... DO1 Alarm Config

General Alarm ON / OFF Each alarm can be activated separately. This allows
Min Flowrate Alarm ON / OFF for individual configuration when the digital output
Max Flowrate Alarm ON / OFF DO1 signals an alarm.
Empty Pipe Alarm ON / OFF
TFE ON / OFF
Gas Bubble 1) ON / OFF
Conductivity 1) ON / OFF
Coating 1) ON / OFF
Sensor Temp 1) ON / OFF
Input/Output / ....Logic Setup / .... DO2 Alarm Config

- - Refer to the description ".... DO1 Alarm Config".
Input/Output / ....Pulse Setup

Operating mode Pulse Mode, Fullscale The menu is displayed only if a pulse ... function has
Frequency been selected under "Input/Output / ....Digital Out
Mode / DO1/DO2 Function".
Select the operating mode for the digital output.
There are two operating modes available:
• In pulse mode, pulses per unit are output
(e.g. 1 pulse per mPulse Mode3)
• "Fullscale Frequency": In frequency mode, a
frequency proportional to the flow rate is output.
The maximum frequency corresponding to the
upper range value is configurable (max. 5 kHz).
Default setting: "Pulse Mode"
Pulses per Unit 1 ... 5250/s Set the pulses per unit in the "Pulse Mode" operating
mode.
Pulse Width 0.1 ... 2000 ms Set the pulse width in the "Pulse Mode" operating
mode. The pulse factor and pulse width are
interdependent and are calculated dynamically.
Limit Frequency Read only Display of the limiting frequency for the pulse output.
Fullscale Frequency 0 ... 5000 Hz Set the frequency for the upper range value in
"Fullscale Frequency" operating mode.

Parameterization
Input/Output / Current
Iout at Alarm High Alarm, Select the status of the current output in error
condition.
Low Alarm
The output "low" or "high" current is set in the
subsequent menu.
Default setting: "High".
Low Alarm Value 3,5 ... 3,6 mA Select the current for Low Alarm.
Default setting: 3.5 mA.
High Alarm Value 21 ... 23 mA Select the current for High Alarm.
Factory setting: 21.8 mA.
Iout at EP Alarm Off, Q=0%, Select the status of the current output for an empty
meter tube.
High Alarm,
• Off:
Low Alarm
Error is not output at the current output.
• Q = 0 %:
The current output assumes the value for "No
flow".
• High Alarm:
The current output assumes the value for "High
Alarm".
• Low Alarm:
The current output assumes the value for "Low
Alarm".
Default setting: Off.
Iout at Flow >103% Off, High Alarm, Low Alarm Select the status of the current output for overshoot of
the upper range value.
• Off:
• High Alarm:
Alarm".
• Low AlarmThe current output assumes the value
for "Low Alarm".

Parameterization
Input/Output / Current (continued)

Iout at TFE Alarm Off, Q=0%, Select the status that the current output shall assume
in the case of a partial filling alarm.
High Alarm,
• Off:
Low Alarm
• Q = 0 %:
The current output assumes the value for "No
flow".
• High Alarm:
Alarm".
• Low Alarm:
The current output assumes the value for "Low
Alarm".
Iout Mode 4 ... 20 mA, 4 - 12 - 20 mA Select the operating mode for the current output.
• 4 ... 20 mA
- 4 mA = No flow
- 20 mA = Maximum flow
• 4 - 12 - 20 mA
- 4 mA = Maximum reverse flow
- 12 mA = No flow
- 20 mA = Maximum forward flow

Parameterization
8.4.6 Menu: Process Alarm
Process Alarm
Clear Alarm History - Allows you to clear the alarm list.
Group Masking Select the "Group Masking" submenu.
Individual Masking Select the "Individual Masking" submenu.
Alarm Simulation Off, ... A variety of alarm messages and output conditions
can be simulated.
For further information read and observe chapter
“Alarm simulation”.
Process Alarm / Group Masking

Maintenance Required On / Off Alarm messages are divided into groups. If masking is
Function Check On / Off activated for a group (On), no alarm occurs.
Out of Specification On / Off For further information read and observe Chapter
"Error conditions and alarms".
Process Alarm / Individual Masking

Min Flowrate Alarm On / Off Individual alarm messages can also be masked.
Max Flowrate Alarm On / Off These are not included in the masking for the group. If
Flow >103% On / Off masking is activated for an alarm (On), no alarm
occurs.
Com Controller Alarm On / Off
TFE Alarm On / Off For further information read and observe chapter
"Error conditions and alarms".
Empty Pipe Alarm On / Off

Parameterization
8.4.7 Menu: Communication
Communication
HART Select the "HART" submenu.
Cyclic Data Out Select the "Cyclic Data Out" submenu.
Service Port Select the "Service Port" submenu.
PROFIBUS Select the "PROFIBUS" submenu.
The menu is displayed only for devices with
PROFIBUS PA.
FIELDBUS Foundation Select the "FF" submenu.
The menu is displayed only for devices with
FOUNDATION Fieldbus.
Communication / HART
Device Address 0 ... 15 Select the HART device address.
The HART protocol has provisions for creating a bus
with up to 15 devices (1 ... 15).
IMPORTANT (NOTE)
If an address greater than 0 is set, the device
operates in multidrop mode. The current output is
fixed at 4 mA. Apart from that, the current output
is only used for HART communication.
Default setting: 0
HART TAG 8 characters, uppercase only, Enter a HART TAG number as unique identifier for the
no special characters. device.
HART Descriptor 16 characters, uppercase Enter a HART descriptor.
only, no special characters.
HART Message Display only. Display of the alphanumeric TAG number.
HART Manf. ID Display only. Display of the HART manufacturer ID.
ABB = 26
HART Device ID Display only. Display of the HART device ID.
FEX300 / FEX500 = 30
Last HART Command Display only. Display of the most recently sent HART command.
Communication / Cyclic Data Out

Cyclic Upd. Rate 0,2 ... 3600 sec Set the interval for data output via the infrared service
port
Default setting: 1 sec
IMPORTANT (NOTE)
For detailed information about how to use the
infrared service port refer to the separate
operating instructions OI/FZA100.
Cyclic Upd. Select Select the "Cyclic Upd. Select" submenu.

Parameterization
Communication / Cyclic Data Out / Cyclic Upd. Select

Flow Group ON / OFF Select the data to be output via the infrared service
Contents: Q(%), Q(l/s), v(m/s) port. Diagnostic data is compiled in groups. Each
Outputs Group ON / OFF group can be separately switched on or off, and
Contents: 20mA output thereby added to the diagnostic data set.
[Io(mA)], frequency at digital
output DO1 [f1(Hz)],
frequency at digital output
DO2 [f2(Hz)]
Status Group ON / OFF
Contents: Alarm, Empty Pipe
Frequency [EPD (Hz)], TFE
Frequency [TFE (Hz)]
Coil Group ON / OFF
Contents: Coil current
[Ic(mA)], Coil voltage [CV(V)],
Total coil resistance
[CR(Ohm)]
TX Group Contents:
Reference voltage digits [Ref],
Differential signal at ADC
[SP], SignalMax [SM],
SignalMin [Sm], SignalError
from NR filter [SE], Signal DC
errors [SDE], Internal
amplification [Api], Signal to
noise ratio SNR
Vol. Totals Group ON / OFF
Contents:
Forward totalizer [Fwd (m3)],
Reverse totalizer [Rev (m3)],
Differential totalizer [Net (m3)]
Electrodes Group ON / OFF
Contents: Electrode
impedance E1 to ground [IE1
(kOhm)], Electrode
impedance E2 to ground [IE2
(kOhm)], Deposit values of
electrode 1 [QE1] and aE1,
Electrode values of electrode
2
[QE2] and aE2, Gas bubble
value [Gasb], Conductivity
[conduS], Sensor temperature
[sensorT°C]

Parameterization
Communication / Service Port

Max Baud Rate 2400, 4800, 9600, 19200, Set the transmission rate (baud rate) for the infrared
38400 service port.
HART Access On / Off Activate / deactivate the infrared service port
Communication / PROFIBUS The menu is displayed only for devices with

PROFIBUS PA.
PA Addr. (-BUS-) 0 ... 126 The "PROFIBUS" is displayed only if this option has
been ordered for the device. Displays the slave
address.
Factory setting: 126
Information about the DIP switches (transmitters with
dual-compartment housing only):
• DIP switches 1 to 7 define the PROFIBUS
address,
• DIP switch 8 defines the address mode:
• DIP switch 8 = Off = Addressing via bus or keypad
using the menus for the device. The message "-
BUS-" is displayed.
• DIP switch 8 = On = Addressing via DIP switches
1-7; the message "(HW Switch)" is displayed.
The address switch setting is only adopted when
the device is restarted, not during running
operation.
Factory setting for DIP switch 8: Off
For further information read and observe chapter 7.3
“Start-up of PROFIBUS PA units”.
Ident Nr. Selector 0x9700, 0x9740, 0x3430 Selection of the ID No. Selector. The parameter can
be changed only when cyclic communication is
stopped (Com State = OFF).
Default setting: 0x3430
Comm State Offline, Operate, Clear, Stop Display of the communication status.
• Offline:
BUS communication is deactivated.
• Operate:
Cyclic communication is running.
• Clear:
Device is being initialized.
• Stop:
Cyclic communication is stopped, BUS
communication remains active.

Parameterization
Communication / PROFIBUS (continued) The menu is displayed only for devices with
PROFIBUS PA.
AI1-Q Flowrate Display only Current flow in the selected unit from the Transducer
Block Flow, including status.
TOT1-Q Flowrate Display only Current totalizer status in the selected unit from the
Transducer Block Flow, including status.
TOT2-Q Flowrate Display only Current totalizer status in the selected unit from the
Transducer Block Flow, including status.
AI2-Internal Tot Fwd Display only Current totalizer status of the forward totalizer in the
selected unit from the Transducer Block Flow,
including status.
AI3-Internal Tot Rev Display only Current totalizer status of the reverse totalizer in the
including status.
AI4-Diagnostics Display only Current output value, including status. The channel
can be selected using the "AI4 Channel" parameter.
This function block delivers active values for FEX500
only. For this purpose, the sensor measurement or the
conductivity measurement must be switched on. For
FEX300 this function block delivers "0".
AI4-Channel Sensor Temp, Selection of the channel output by AI4. The
Conductivity PV_SCALE and OUT_SCALE structure is not
adapted. This channel is active for FEX500 only.
AO-Density Adjust Display only Current density output value from the Transducer
DI-Alarm Info Display only Current output value, including status. The channel
can be selected using the "DI Channel" parameter.
DI-Channel Maintenance, Out of Spec, Select the channel output by "DI Alarm Info".
Function Check, Failure
DO-Cyclic Control Display only Current function, including status. The function can be
selected using the "DO Channel" parameter.
DO-Channel Off, Totalizer Reset(All), Select the function for "DO Cyclic Control".
Flowrate to Zero, System
Zero Adjust, Totalizer
Stop(All), Dual Range,
Start/Stop Batching

Parameterization
Communication / FF The menu is displayed only for devices with

FOUNDATION Fieldbus.
Show FF Address Display only Display of the FOUNDATION Fieldbus address. The
address is set via the FOUNDATION Fieldbus Master.
AI1-Q Flowrate Display only Current flow in the selected unit from the Transducer
INT1-Q Flowrate Display only Current output value, with status.
AI2-Internal Tot Fwd Display only Current totalizer status of the forward totalizer in the
including status.
AI3-Internal Tot Rev Display only Current totalizer status of the reverse totalizer in the
including status.
AI4-Diagnostics Display only Current output value, including status. The channel
can be selected via the bus, only.
AO-Density Adjust Display only Current density output value from the Transducer
DI-Alarm Info Display only Current output value, including status. The channel
can be selected via the bus, only.
DO-Cyclic Control Display only Current function, including status. The channel can be
selected via the bus, only.

Parameterization
8.4.8 Menu: Diagnostics
Diagnostics
Diagnosis Control Select the "Diagnosis Control" submenu.
Diagnosis Values Select the "Diagnosis Values" submenu.
Fingerprints Select the "Fingerprints" submenu.
Trend Select the "Trend" submenu.
Flowrate Alarm Select the "Flowrate Alarm" submenu.
Simulation Mode Off, Flow Velocity, Q [units], Q Manual simulation of measured values.
[%],Iout, Freq on DO1, Freq The output values correspond to the simulated
on DO2, Logic DO1, Logic flowrate entered.
DO2, HART Freq, Digital in The "Configuration" information is displayed in the
lower line of the display.
Restore the Simulation mode to "Off" once completed.
The values in the "Value range" column can be
simulated.
Output Readings Select the "Output Readings" submenu.
Diagnostics / Diagnosis Control

Empty Pipe Detector Select the "Empty Pipe Detector" submenu.
Sensor Measurements Select the "Sensor Measurements" submenu.
Gas Bubble Detector 1) Select the "Gas Bubble Detector" submenu.
Coating Detector 1) Select the "Coating Detector" submenu.
Cond. Detection 1) Select the "Cond. Detection" submenu.
Grounding Check 1) Select the "Grounding Check" submenu.
TFE Detector Select the "TFE Detector" submenu.
Sil Detection Select the "Sil Detection" submenu.

Parameterization
Diagnostics / Diagnosis Control / Empty Pipe Detector

Empty Pipe Detector On / Off Activate the "Empty Pipe Detector" function (only for
sizes ≥ DN 10 and without preamplifier).
An entirely full measuring tube is essential for an
accurate measurement. The "Empty Pipe Detector"
function detects an empty measuring pipe.
In the case of an alarm, the current output assumes
the status that was defined in the "Input / Output /
Current Output / Iout at EP Alarm" menu, and the
pulse output is stopped.
Adjust EP The Empty Pipe Detector function must be adjusted
according to the conditions on site. The switching
threshold is set during the automatic adjustment.
Start automatic adjustment of the Empty Pipe
Detector function.
Manual Adjust EP F. 0 ... 255 Manually adjust the Empty Pipe Detector function.
The value must be modified in such a way that the
frequency for empty pipe detection (Detector EP
Value) is close to 2000 Hz.
IMPORTANT (NOTE)
Prior to starting the (manual / automatic)
adjustment, make sure that:
Threshold 100 ... 60000 Hz Set the switching threshold for empty pipe detection.
The switching threshold is set automatically during
automatic adjustment. The switching threshold can be
changed in order to obtain manual fine adjustment.
Detector EP Value Display only Display of the frequency for empty pipe detection. If
the current value exceeds the defined switching
threshold, a message appears on the display and an
alarm is output via the digital output, if configured
accordingly.

Parameterization
Diagnostics / Diagnosis Control / Sensor Measurements

One shot Sensor Mea Start the measurement. The measured values for the
start moment are acquired.
Coil Current Display only Display the coil current.
Coil Resistor Display only Display the coil resistance.
Coil Voltage Display only Display the coil voltage.
Coil R. Max Alarm 0 ... 1000 Ω Set the maximum limit value for the coil resistance. In
the case of overshoot an alarm is tripped.
Default setting: 1000 Ω
Coil R. Min Alarm 0 ... 1000 Ω Set the minimum limit value for the coil resistance. In
the case of undershoot an alarm is tripped.
Signal-Cable length 0.01 ... 200 m Enter the signal cable length between the transmitter
and the flowmeter sensor. For devices with a compact
design 0.01 m must be entered.
Default setting: 0 m
Sensor Temp Value 1) Display only Display the sensor temperature.
Adj. Sensor T. Value 1) -50 ... +200 °C The sensor temperature must be adjusted according
to the conditions on site. The temperature measured
with a separate thermometer can be entered here.
Sensor T. Max Alarm 1) -50 ... +200 °C Set the maximum limit value for the sensor
temperature. In the case of overshoot an alarm is
tripped.
Default setting: +200 °C
Sensor T. Min Alarm 1) -50 ... +200 °C Set the minimum limit value for the sensor
temperature. In the case of undershoot an alarm is
tripped.
Default setting: -50 °C

Parameterization
Diagnostics / Diagnosis Control / Gas Bubble Detector 1)

Gas Bubble Detector On / Off Activate the "Gas Bubble Detector" function.
IMPORTANT (NOTE)
The gas bubble detector can be used in the
nominal diameter range DN 10 ... 300.
“Extended diagnostic functions”.
Adjust Gas Bubble The Gas Bubble Detector must be adjusted according
to the conditions on site. Start automatic adjustment of
the Gas Bubble Detector function.
IMPORTANT (NOTE)
Prior to starting the adjustment, make sure that:
the fluid to be measured and free from gas
bubbles.
Threshold Gas Bubble Set the switching threshold. If the current value
exceeds the defined switching threshold, a message
appears on the display and an alarm is output via the
digital output, if configured accordingly.
Gas Bubble Value Display only Display the current gas bubble value.
Diagnostics / Diagnosis Control / Coating Detector 1)

Coating Detector On / Off Activate the "Electrode Deposit Detector" function.
IMPORTANT (NOTE)
The electrode deposit detector can be used in the
nominal diameter range DN 10 ... 300.
One shot Coating The electrode deposits are measured cyclically at
defined intervals. Here, a current measurement can
be started.
Coating Value QE1 Display only Current deposit value for electrode 1
Coating Value QE2 Display only Current deposit value for electrode 1

Parameterization
Diagnostics / Diagnosis Control / Coating Detector (continued) 1)

Coating QE Min Alarm 0 ... 100.000 Set the minimum limit value for the electrode deposit
detection. When the smaller value, QE1 or QE2, is
undershot, an alarm is tripped.
Default setting: 0
Coating QE Max Alarm 0 ... 100.000 Set the maximum limit value for the electrode deposit
detection. When the greater value, QE1 or QE2, is
overshot, an alarm is tripped.
Default setting: 100.000
Diagnostics / Diagnosis Control / Cond. Detection 1)
Cond. Detection On / Off Activate the "Cond. Detection" function.

IMPORTANT (NOTE)
The conductivity measurement function can be
used in the nominal diameter range DN 10 ...
300.
One shot Cond. The conductivity is measured cyclically at defined
intervals. Here, a current measurement can be
started.
Cond. Value Display the conductivity.
Adj. Cond. Value 5 ... 20,000 µS/cm The conductivity must be adjusted according to the
fluid on site. The conductivity measured with a
separate meter can be entered here.
Cond. Min Alarm 5 ... 20,000 µS/cm Set the minimum limit value for the conductivity. In the
case of undershoot an alarm is tripped.
Default setting: 5 µS/cm
Cond. Max Alarm 5 ... 20,000 µS/cm Set the maximum limit value for the conductivity. In
the case of overshoot an alarm is tripped.
Default setting: 20,000 µS/cm
Elec. Imp. E1-GND Display only Current impedance between electrode E1 and GND
(ground potential).
Elec. Imp. E2-GND Display only Current impedance between electrode E2 and GND
(ground potential).
Elec. Imp Min Alarm 0 ... 20,000 Ω Set the minimum limit value for the impedance. In the
case of undershoot an alarm is tripped.
Elec. Imp Max Alarm 0 ... 20,000 Ω Set the maximum limit value for the impedance. In the
case of overshoot an alarm is tripped.
Default setting: 20,000 Ω

Parameterization
Diagnostics / Diagnosis Control / Grounding Check 1)

Grounding Check Start the "Grounding Check" function.
Power Spectrum Display only Current power spectrum.
Amplitude 1 Value Display only Display the four highest amplitudes in the power
Amplitude 2 Value Display only spectrum.
Amplitude 3 Value Display only
Amplitude 4 Value Display only
Diagnostics / Diagnosis Control / TFE Detector

TFE detector Activate the "Partial Filling Detector" (TFE) function.
IMPORTANT (NOTE)
This function can be used only if the flowmeter
sensor is provided with a measuring electrode for
the detection of partially filled tubes (option). The
flowmeter sensor must be installed horizontally,
with the terminal box pointing upward. This
function can be used for flowmeter sensors from
size DN 50 without explosion protection or with
explosion protection for Zone 2 / Div.2.
9 “Extended diagnostic functions”.
Adjust TFE Full The partial filling detector must be adjusted according
to the conditions on site.
Start automatic adjustment of the Partial Filling
Detector function.
IMPORTANT (NOTE)
Prior to starting the adjustment, make sure that:
TFE Threshold Manual fine adjustment of the switching
threshold.
The switching threshold is automatically set
during the automatic adjustment.
If the current value exceeds the defined switching
threshold, a message appears on the display and
an alarm is output via the digital output, if
configured accordingly.
TFE Value Display the current measuring value.

Parameterization
Diagnostics / Diagnosis Control / Sil Detection

SIL Detection On / Off By switching on the detector the monitoring of safety-
relevant components is increased.
With the detector switched on an SFF value of 91.6 is
achieved for the FMEDA analysis (SIL2).
With the detector switched off an SFF value of 85.5 is
achieved for the FMEDA analysis (SIL1).
This is valid for all devices with HART protocol.
Diagnostics / Diagnosis Values

SNR Value Display only Display the current diagnostic values for service
Slope Value purposes.
Slope Variation
Reference
Signal Ratio (signal
difference)
Signal Max (Max.value of
pos. signal)
Signal Min (Max.value of
neg. signal)
Signal Error (signal error
portion)
NV Resets/sec
Amplification Int.
Diagnostics / Fingerprints 1)
Factory F.P. Select the "Factory F.P." submenu.
Startup F.P. Select the "Startup F.P." submenu.
On demand F.P. Select the "On demand F.P." submenu.
The “fingerprint” database integrated in the transmitter allows you to compare the values at the
time of factory calibration or commissioning with the currently recorded values.
As a result, changes of the measuring system can be detected early, and the appropriate
measures can be taken.

Parameterization
Diagnostics / Fingerprints / Factory F.P. 1)

Sensor Coil R. Display only The factory fingerprint is created when the device are
Elec. Coat. QE1 calibrated in the factory.
Elec. Coat, QE2
Elec. Imp. E1-GND
Elec. Imp. E2-GND
Tx check CMR
Tx check 5 m/s
Tx check 10 m/s
Diagnostics / Fingerprints / Startup F.P. 1)

Startup F.P. Create the commissioning fingerprint for the flowmeter
sensor.
Sensor Coil R Display only The commissioning fingerprint is created on site
Elec. Coat. QE1 during commissioning. The values measured for this
Elec. Coat, QE2 fingerprint are indicated here.
Elec. Imp. E1-GND
Elec. Imp. E2-GND
Start Tx Startup F.P. Create the commissioning fingerprint for the
transmitter.
Tx check CMR Display only
Tx check 5 m/s
Tx check 10 m/s
Diagnostics / Fingerprints / On demand F.P. 1)

Start On demand F.P. Creating the manual fingerprint.
Sensor Coil R Display only The manual fingerprint can be created at any time.
Elec. Coat. QE1 The values measured for this fingerprint are indicated
here.
Elec. Coat, QE2
Elec. Imp. E1-GND
Elec. Imp. E2-GND
Start Tx Startup F.P. Create the manual fingerprint for the transmitter.
Tx check CMR
Tx check 5 m/s
Tx check 10 m/s

Parameterization
Diagnostics / Trend 1)
Conductivity The measured values are shown as a line diagram.
Electrode Coat. QE1 When the "Trend-Logging" function is enabled, the
Electrode Coat. QE2 measured values are stored at the defined interval
(cycle time). The last 12 measured values are stored
and indicated as a line diagram. The oldest data
record is overwritten.
Logtime Interval 1 ... 45,000 min. Interval for measured value logging.
Trend-Logging ON / OFF Activate the "Trend-Logging" function.
When the "Trend-Logging" function is enabled, the
measured values are stored at the defined interval
(cycle time).
The data records can be read out by the
"ScanMaster" verification software and analyzed as
trends.
Diagnostics / Flowrate Alarm

Max. Flowrate Alarm 0 ... 130 % Set the maximum limit value for the flow.
Min. Flowrate Alarm 0 ... 130 % Set the minimum limit value for the flow.
Diagnostics / Output Readings

Current mA Display the current values and statuses of the listed
DO1 Frequency Hz inputs and outputs.
DO2 State open / closed
Digital In State open / closed

Parameterization
8.4.9 Menu: Totalizer
Totalizer
....Reset Vol. Totals Select the "....Reset Vol. Totals" submenu.
....Batching 1) Select the "....Batching" submenu.
....Edit Vol. Totals Select the "....Edit Vol. Totals" submenu.
Totalizer / ....Reset Vol. Totals

Edit Totalizer Fwd Resets forward totalizer to zero.
Edit Totalizer Rev Resets reverse totalizer to zero.
Edit Totalizer Net Resets the difference totalizer to zero.
All Vol. Totalizer Resets all totalizers to zero.
Totalizer / ....Batching 1)
Damping ON / OFF Switches the damping on / off.
Default setting: ON
IMPORTANT (NOTE)
In order to achieve a shorter response time for
the fill function, the damping must be switched
off.
The fill time should be > 3 seconds.
Preset Batch Tot. - Setting of the fill quantity. When the defined fill
quantity is reached, the configured digital output is
activated.
Lag Corr. Mode Automatic / Manual Select the overrun correction.
Closing the fill valve takes some time and as a
consequence more liquid is added, even though the
fill quantity is reached and the contact for closing the
valve is actuated.
With "Automatic overrun correction" the set fill quantity
is corrected with the overrun quantity.
Lag Corr. Quantity -100.000 ... 100.000 Manual entry of the overrun quantity.

Parameterization
Totalizer / ....Batching (continued) 1)

Batch Tot. Read only Once a fill operation has been started, the quantity
already filled is shown here.
The totalizer restarts at zero for each fill operation
initiated and then counts up to the set fill quantity.
Total Batch Counter Read only Total number of fill operations.
Reset Batch Counter Resets fill operation totalizer to zero.
Start/Stop Batching Manual start / stop of the fill operation.

Alternatively, the digital input can be configured for
starting / stopping the fill operation.
Totalizer / totalizer default setting.

Edit Totalizer Fwd - Enter totalizer statuses (e.g. when replacing the
transmitter).
Edit Totalizer Rev -
Edit Totalizer Net -


Parameterization
8.5 Alarm Simulation
In the "Process Alarm / Alarm Simulation" menu a variety of alarms can be simulated.
Parameter Description
Process Alarm
... / Alarm Simulation
Off Alarm Simulation switched off.
0-Sim.CurrentOut Simulate current output
1-Sim.Logic on DO1 Switch on/off contact output (terminals 51, 52)
2-Sim.Pulse on DO1 Simulate pulse output (terminal 51/52)
3-Sim.Logic on DO2 Switch on/off contact output (terminals 41, 42)
4-Sim.Pulse on DO2 Simulate pulse output (terminal 51/52)
5-Min Alarm Flowrate Simulate flowrate min. alarm
6-Max Alarm Flowrate Simulate flowrate max. alarm
7-Flowrate >103% Simulate flowrate > 103 % as alarm
8-Flow Simulation Run flowrate simulation
9-Calbration Mode Run transmitter alarm on simulator
10-Flowrate to Zero Simulate external output switch-off
11-Totalizer Stop Simulate external totalizer stop
12-Tot.Display<1600h Simulate display value <1600 h for Qmax.
13-Totalizer Reset Simulate external totalizer reset
14-Err.Sensor-Comms Simulate distorted communication to SensorMemory.
15-HART Address <> 0 Simulate HART Multiplex mode
16-FRAM-Com Fail Simulate FRAM error in the transmitter
17-No Sensor Simulate error "No communication to SensorMemory"
18-Sim.Digital Input Simulate digital input "ON/OFF"
19-ADC saturated Simulate "AD converter override" error
20-Error Coil circ Simulate error in coil loop
21-Coil Resistor Simulate "Coil resistance out of limits" error
22-Driver Err Uref=0 Simulate "Reference voltage = 0" error
23-El.Noise too High Simulate "Noise signal too high" error
24-DC to High Simulate "DC too high, several NV resets" error
25-Empty Pipe Simulate "Empty pipe" error
27-NV Corrupt Simulate "NV Corrupt" error
29-Electrode Imp. Simulate "Electrode impedance out of limits" error
30-Hold Last Value Simulate "Hold last good value" error
32-Digi-Pot Error Simulate "Digital potentiometer" error
33-TFE Simulate "Partial filling alarm" error
34-CurrentOut Error Simulate "Loop current output interrupted" error
35-Not Calibrated Simulate "Not calibrated" error
36-SensorIncompatib. Simulate "Calibration mode incompatible" error
37-ROM Error Simulate ROM error in the transmitter
38-RAM Error Simulate RAM error in the transmitter
39-Sim. HART Freq. Simulate a HART frequency
40-SIL Simulate "Self check alarm" error
41-Conductivity Simulate "Conductivity alarm" error
42-Elec.Coated Simulate "Electrode deposits" error
43-Gas bubble Simulate "Gas bubbles" error
44-Pulse Cut Off Simulate "Pulse output" error
46-Sensor Temp Simulate "Sensor temperature alarm" error

Parameterization
8.6 FEP500 and FEH500 during fill operation
2
1
Q
DI O C
DO
4
M 0 t
tv
tn
5
G01046
Fig. 67: Fill function (batch)

1 Supply tank O Valve open (filling started)
2 Start / stop contact (digital input) C Valve closed (fill quantity reached)
3 Sensor tv Valve closing time
4 Motor valve tn Overrun time
5 Tank to be filled
DI Digital input
DO Digital output
The integrated fill function (batch) of the ProcessMaster FEP500 and HygienicMaster FEH500
models allows you to control filling processes with a filling time >3 seconds.
During this process, the fill quantity is given via an adjustable totalizer.
The fill operation is started via the digital input (DI) or via the fieldbus.
The valve is triggered via one of the digital outputs (DO) and closed again once the preset fill
quantity is reached.
The transmitter measures the overrun quantity (tn) and uses this value to calculate the overrun
quantity correction value.
Additionally, the low flow cut-off can be activated if required.
8.6.1 Configuration
The fill function is configured via menus using the LCD indicator.
1. If the fill operation is to be controlled via the digital input (DI), the following settings must be
applied in the "Input/Output" menu.
Menu / parameter Selection Description
Input/Output
Digital Input Setup Start/Stop Batching Select the operating mode for the digital
1) output.
• Start / stop of the fill function (batch)
1).

Parameterization
2. To control the fill valve, the following settings must be applied:
Input/Output / ....Digital Out Mode

DO1/DO2 Function Logic/Logic Select the functions for the digital
outputs DO1 and DO2.
• Logic/Logic:
Input/Output / ....Logic Setup

DO1 Signal Batch end contact 1 The menu is displayed only if the
"Logic/Logic" function is set in the
DO2 Signal "DO1/DO2 Function" menu. This menu
is not displayed in the factory setting.
• Batch end contact:
The digital output is activated when
the set fill quantity is reached
3. The parameters for the fill function must be configured.
Damping Off Switches the damping on / off.
Default setting: ON
IMPORTANT (NOTE)
In order to achieve a shorter response time for the fill function,
the damping must be switched off.
The fill time should be > 3 seconds.
Preset Batch Tot. - Setting of the fill quantity. When the
defined fill quantity is reached, the
configured digital output is activated.
Lag Corr. Mode Automatic / Manual Select the overrun correction.
Closing the fill valve takes some time and
as a consequence more liquid is added,
even though the fill quantity is reached
and the contact for closing the valve is
actuated.
With "Automatic overrun correction" the
set fill quantity is corrected with the
overrun quantity.

Parameterization
Lag Corr. Quantity -100.000 ... 100.000 Manual entry of the overrun quantity.
Batch Tot. Read only Once a fill operation has been started,
the quantity already filled is shown here.
The totalizer restarts at zero for each fill
operation initiated and then counts up to
the set fill quantity.
Total Batch Counter Read only Total number of fill operations.
Reset Batch Counter Resets fill operation totalizer to zero.
Start/Stop Batching Manual start / stop of the fill operation.

Alternatively, the digital input can be
configured for starting / stopping the fill
operation.
4. To display all the data relevant to the fill operation in the process display, one of the operator
pages in the "Display" menu must be configured accordingly.
Display / ....Operator Pages / ....Operator Page 1 (n)

Display Mode 3 lines with 9 Configure each operator page.
characters
1st Line Flow rate [unit] Select the measured value displayed in
each line. The following variants in the
2st Line Number of fill
value range can be selected:
operations
3st Line Batch totalizer

Parameterization
8.7 Software – history
8.7.1 Devices with HART protocol
Software D200S062U01
Software Version Type of changes Operating instruction
00.01.01 Original software OI / FEP300 / FEH300, rev. A
00.01.02 Function extension, incorporated OI / FEP300 / FEH300, rev. A
new HART commands
00.02.00 Optimized measured value OI / FEP300 / FEH300, rev. B
processing
00.02.01 Optimized measured value OI / FEP300 / FEH300, rev. B
processing
00.02.04 Optimized boot sequence OI / FEP300 / FEH300, rev. B
Software D200S069U01
01.01.02 Optimized access to the service OI / FEX300 / FEX500, rev. C
menu. Implemented TFE
functionality. Added diagnostic
functions and batch mode
(for 500 series, only)
01.01.04 Optimized sensitivity of the keys OI / FEX300 / FEX500, rev. D
on the display
01.01.06 Optimized view on the display OI / FEX300 / FEX500, rev. D
01.02.00 Totalizer preset for ProcessMaster OI / FEX300 / FEX500, rev. E
300 implemented.Error with
Swedish menu navigation
corrected.
01.02.01 TFE functionality optimized for OI / FEX300 / FEX500, rev. F
integral mount design.
01.03.01 Software optimized for ScanMaster OI / FEX300 / FEX500, rev. F
verification tool.
8.7.2 Devices with PROFIBUS PA or FOUNDATION fieldbus
Software D200S069U02 (PA) Software D200S069U03 (FF)

Software Version Type of changes Operating instruction
00.01.02 Original software for OI / FEX300 / FEX500, rev. C
PROFIBUS PA,
FOUNDATION Fieldbus
00.01.04 Optimized sensitivity of the keys OI / FEX300 / FEX500, rev. D
on the display
00.01.05 Optimized view on the display OI / FEX300 / FEX500, rev. E
00.02.00 Totalizer preset for ProcessMaster OI / FEX300 / FEX500, rev. F
300 implemented.

Extended diagnostic functions
9 Extended diagnostic functions
9.1 General remarks
IMPORTANT (NOTE)
• The extended diagnostic functions are available for ProcessMaster 500 and
HygienicMaster 500 only.
• The "Partial Filling Detector" function is not available for HygienicMaster 500.
• When using the extended diagnostic functions the external flowmeter sensor must not be
provided with a preamplifier.
• To facilitate initial start-up, the extended diagnostic functions are deactivated (factory
default).
• To use the extended diagnostic functions, a "start-up fingerprint" must be created during
start-up of the flowmeter.
• Each diagnostic function (e.g. Gas Bubble Detector or Electrode Deposit Detector) can be
individually activated. Once activated, the diagnostic function must be calibrated according
to the conditions on site and the limit values must be set.
9.1.1 Detection of partial filling
Optionally, a measuring electrode (TFE electrode) is available for detecting a partially filled
flowmeter sensor. The alarm for partial filling is output via the programmable digital output.
Conditions for using the function:
• Nominal diameter from DN 50 (2“) with sensor design level B
• Max. signal cable length for version with external transmitter 200 m (656 ft).
• Conductivity of the measuring medium: 20 μS/cm ... 20,000 μS/cm
• The function is only available for ProcessMaster 300 / 500 without explosion protection or
with explosion protection for Zone 2 / Div. 2.
Additional installation conditions:
• The flowmeter sensor must be installed horizontally with the terminal box pointing upward.
9.1.2 Detection of gas bubbles
Gas bubbles in the fluid are detected by using an adjustable maximum limit value. When this
limit value is exceeded, an alarm is tripped via the programmable digital output, depending on
the configuration.
• This function is available in the nominal diameter range 1) of DN 10 … 300 (3/8 “ ... 12 “).
• The signal cable length of the remote transmitter must not exceed a maximum value of 50 m
(164 ft) .
• For this function, the conductivity of the measuring medium must be in the range
20 μS/cm ... 20,000 μS/cm.
• The flowmeter sensor can be installed either horizontally or vertically. Vertical installation is
preferred.
1) The specified nominal diameter range is valid for ProcessMaster, only. The nominal diameter range valid for
HygienicMaster is DN 10 … 100 (3/8 “ ... 4 “).

9.1.3 Electrode coating detection
This function provides the opportunity to detect coatings on the measuring electrodes by using
an adjustable maximum limit value.
When the set limit value is exceeded, an alarm is tripped via the programmable digital output,
depending on the configuration.
(164 ft) .
20 μS/cm ... 20,000 μS/cm.
• When using plastic tubes, install a grounding plate at the front and back of the device.
9.1.4 Conductivity monitoring
The conductivity of the fluid is monitored by using an adjustable minimum / maximum limit
value.
When the value falls below or exceeds the set limit value, an alarm is tripped via the
programmable digital output, depending on the configuration.
(164 ft) .
20 μS/cm ... 20,000 μS/cm.
• There must not be any deposits on the measuring electrodes.
9.1.5 Electrode impedance monitoring
The impedance between the electrode and ground is monitored by using a minimum / maximum
limit value. This enables the transmitter to detect an electrode fine short or leakage.
When the value falls below or exceeds the set limit value, an alarm is tripped via the
(164 ft) .
20 μS/cm ... 20,000 μS/cm.
• There must not be any deposits on the measuring electrodes.
• The measuring tube must always be completely full, and the fluid must feature only minor
conductivity variations.

9.1.6 Sensor measurements
This function includes the monitoring of the sensor temperature and the monitoring of the
resistance of the flowmeter sensor's coils.
9.1.6.1 Sensor temperature monitoring

The temperature of the coils in the flowmeter sensor can be monitored by using adjustable
minimum / maximum limit values. When a set limit value is exceeded, an alarm is tripped via the
The coil temperature is a factor of the ambient and fluid temperatures. The measurement can,
e.g., be used to monitor overtemperature due to the fluid. The coil temperature is measured
indirectly via the coil DC resistance.
9.1.6.2 Monitoring of the sensor coil resistance

The coils in the flowmeter sensor can be monitored by using adjustable minimum / maximum
limit values for the coil resistance. When a set limit value is exceeded, an alarm is tripped via
the programmable digital output, depending on the configuration.
9.1.7 Trend
The device has an internal memory where the measured value for the electrode deposits and
the conductivity are cyclically stored as a data set with an adjustable time (1 min ... 45000 min).
A maximum of 12 data sets is stored. When the thirteenth record is stored, the oldest data set is
overwritten automatically.
The data sets can be read out or analyzed as a trend using the external diagnostic tool
(ScanMaster).
9.1.8 Fingerprint
The “fingerprint” database integrated in the transmitter allows you to compare the values at the
time of factory calibration or commissioning with the currently recorded values.
9.1.9 Checking the grounding
This function allows you to check the electrical grounding of the device.
While the check is in progress, no flow measurement can take place.
• The measuring tube must be completely full.
• No flow must occur in the flowmeter sensor.
• The flowmeter sensor must not be provided with a preamplifier.

9.2 Performing the earthing check
... / Diagnostics / ....Diagnosis Control / ....Grounding Check1)

Grounding Check Start the "Grounding Check" function.
Power Spectrum Read only Current power spectrum.
Amplitude 1 Value Read only Display the four highest amplitudes in the power
spectrum.
Amplitude 2 Value Read only

....Grounding Check 5. Use or to select the "Grounding Check" entry.

Grounding Check
Power Spectrum 6. Use to start the "Grounding Check" function.
Amplitude 1 Value
Back OK
....Grounding Check Once the earthing check has been started, the frequency
Grounding Check 46,75 range up to 250 Hz is measured. The four most intensive
48,65 frequencies of the spectrum are shown at the right of the
50,08 display.
52,00 The corresponding amplitudes and the power spectrum
Back OK over the frequency range can be called up for display using
the following parameters.
....Grounding Check 7. Use or to select the "Power Spectrum" entry.
Power Spectrum 8. Use to display the parameter.
335
Back OK
....Grounding Check 9. Use or to select the "Amplitude 1 Value (n)"

entry.
Amplitude 1 Value (n)
2,7 10. Use to display the parameter.
Back OK
The measured values indicate possible disturbances to the earthing line of the device at the
time of the test.
No or minor disturbance:
• When the power spectrum is below 1000
• When the four measured amplitude values are above 10
Check the device earthing (!):

• When the power spectrum is above 1000
• When the four measured amplitude values are above 10

9.3 Recommended settings for diagnostic limit values
In the "Diagnostics / Diagnosis Control / ..." menu, limit values for the diagnostic values can be
specified.
In order to simplify their setting, recommendations for the individual limit values are shown here.
The values indicated are only intended as a rough guide and may need to be adapted in line
with on-site conditions.
9.3.1 Limit values for the coil resistance
Coil resistance monitoring is switched off (factory default).

Monitoring can be switched on in the "Diagnostics / Diagnosis Control / Sensor
Measurements" menu.
Parameter Factory setting

Coil R. Min Alarm 0 ohms
Coil R. Max Alarm 1000 ohms
The coil resistance depends on the measuring medium temperature Tmedium and the ambient
temperature.
Parameter
Tmedium R coil min alarm R coil max alarm
-40 °C Factory for Fingerprint Factory for Fingerprint
(-40 °F) (coil resistance) x 0.71 (coil resistance) x 0.79
-20 °C Factory for Fingerprint Factory for Fingerprint
(-4 °F) (coil resistance) x 0.81 (coil resistance) x 0.89
0 °C Factory for Fingerprint Factory for Fingerprint
(32 °F) (coil resistance) x 0.9 (coil resistance) x 1.0

9.3.2 Limit values for the electrode deposits
Electrode deposit monitoring is switched off (factory default). Monitoring can be switched on in
the "Diagnostics / Diagnosis Control / Coating Detector" menu.

Coating QE Min Alarm 0 ohms
Coating QE Max Alarm 100.000 ohms
Recommended settings in the "Diagnostics / Diagnosis Control / Coating Detector" menu

• Coating QE Min Alarm = 0.5 x coating value QE
• Coating QE Max Alarm = 2.0 x coating value QE
IMPORTANT (NOTE)
The deposit value QE is the mean value of Startup Fingerprint QE1 and QE2. The value is
determined using the following formula:
QE = (Startup Fingerprint QE1 + Startup Fingerprint QE2) / 2
9.3.3 Limit values for the electrode impedance
Electrode impedance monitoring is switched off (factory default). Monitoring can be switched on
in the "Diagnostics / Diagnosis Control / Cond. Detection" menu.

Elec.Imp.Min Alarm 0 ohms
Elec.Imp.Max Alarm 20.000 ohms
The limit values for parameters "Elec.Imp.Min Alarm" and "Elec.Imp.Max Alarm" depend on
the measuring media conductivity and must be determined on site.
Recommended settings
• Elec.Imp.Min Alarm = 0.2 x average impedance value
• Elec.Imp.Max Alarm = 3.0 x average impedance value
IMPORTANT (NOTE)
The average impedance value is the value of Startup Fingerprint "Elec. Imp. E1-GND" and
"Elec. Imp. E2-GND". The value is determined using the following formula:
Average impedance value = (Startup Fingerprint "Elec. Imp. E1-GND" + Startup Fingerprint
"Elec. Imp. E2-GND") / 2
9.3.4 Recommended settings for the Trend Logger
"Diagnostics / Trend" menu

• Logtime Interval = 43,200 minutes

Error messages
10 Error messages
10.1 Invoking the error description

Additional details about the error that has occurred can be called up on the information level.
Process display
1. Use to go to the information level.
Electronic
unit
Operator menu 2. Use or select the submenu "Diagnostics".

Diagnostics
....Operator Page 1 3. Confirm the selection with .
....Operator Page 2
Back Select
Electronic unit The first line shows the area in which the error has
F123.321 occurred.
Brief description
The second line shows the unique error number.
Information
Back Exit The next lines show a brief description of the error and
information on how to remedy it.

Error messages
10.2 Error states and alarms
10.2.1 Errors
Error no. / Text on the LCD display Cause Remedy

Range
F254.038 RAM Error in Transmitter Error in the transmitter electronics unit. Replace the electronics unit or contact
Contact ABB Service.
Electronics ABB Service
unit
F253.037 ROM Error in Transmitter Error in the transmitter electronics unit. Replace the electronics unit or contact
unit
F252.017 No Sensor Memory Incorrectly wired terminals D1 and D2. Check the wiring for terminals D1, D2.
Check wiring Short circuit or break in wires for D1, If an old flowmeter sensor (e.g., model
Sensor Check switch SW3 D2. DE41F) is connected without
Jumper SW3 is not correctly plugged SensorMemory, plug the jumper on the
into the backplane. backplane in the "ON" position.
Old flowmeter sensor connected
without SensorMemory.
F251.040 Self Check Alarm The SIL monitoring function has Replace the transmitter or contact ABB
detected a transmitter error. Service.
Electronics
unit
F250.016 Tx. memory fault detected Error in the transmitter electronics unit. Replace the electronics unit or contact
unit
F248.036 Incompatible snsTx+ Calibration mode is not compatible. Contact ABB Service.
snr are not the same series
Sensor
F246.032 Defect digital potentiometer Internal digital potentiometer for Replace the electronics unit or contact
Transmitter Hardware fault common mode rejection is defective. ABB Service.
unit
F245.047 Stack NV Corrupt The internal stack memory for Replace the electronics unit or contact
Contact PROFIBUS PA / ABB Service.
Electronics ABB Service FOUNDATION Fieldbus is defective.
unit
F244.031 Internal supply voltage error Failure of transmitter internal power Replace the electronics unit or contact
Contact supply. ABB Service.
unit
F236.024 DC to High Multi-phase measuring media that Check electrical connections and
Lot of NV-Resets produce a very high level of noise. grounding of device.
Operation Refer to instr. Manual Stones or solids that produce a very Activate empty pipe detector and
high level of noise. calibrate if the meter tube is empty.
Galvanic voltages at the measuring Contact ABB Service.
electrodes.
Conductivity of measuring medium is
not evenly distributed (e.g., directly
after injection points).
F232.022 Driver Error Incorrect wiring (terminals M1, M2) or Check that the wiring (terminals M1,
Uref = 0 wire break / short circuit. M2) is connected properly, check for
Electronics Check wiring for Defective fuse in the coil circuit or wire breaks and short circuits.
unit open circuit moisture in the terminal box. Check the coil circuit fuse.
Check fuse Check the connection box for moisture.
F228.020 Error in Incorrect wiring (terminals M1, M2) or Check that the wiring (terminals M1,
Coil circuit wire break / short circuit. M2) is connected properly, check for
Electronics Check wiring for wire breaks and short circuits.
Fuse in the coil circuit is defective.
unit short circuit Check the coil circuit fuse.
Continued on next page.

Error messages

Range
F226.019 AD Converter Signal at the input of the AD converter If the pipeline is empty, check whether
saturated exceeds the maximum value of 2.5 V. the empty pipe detection function is
Electronics Check empty pipe No further measurement is possible. activated.
unit or Galv. Voltage In the "Diagnostics" menu, activate the
empty pipe detection function.
Check whether the current flowrate
exceeds the configured flow range end
value. If yes, increase Qmax (= flow
range end value).
10.2.2 Function check

Range
C190.045 An alarm is Simulation mode is activated. In the "Diagnostics" menu, deactivate
simulated simulation mode.
Config. Switch off
alarm simulation
C186.009 Tx Simulator/ The transmitter is operated on In the "Diagnostics" menu, deactivate
Calibrator mode simulator 55XC4000. simulation mode.
Config. Switch off
Calibrator Mode
C185.030 Hold last good The noise exceeds the bandwidth set Switch off noise reduction in the
known value for noise reduction for a longer period "Device Setup" menu or contact ABB
Operation Switch OFF of time. Service.
Noise Reduction
ABB Service
C184.010 The Flowrate The function of the digital input (DI) is Set the digital input (DI) to low signal (0
is set to zero set to "External output switch-off" and VDC).
Config. Check digital in the digital input (DI) is set to high
terminals 81,82 signal (+24 V DC).
C182.008 Flowrate Simulation mode is activated. One of In the "Diagnostics" menu, deactivate
Simulation the following functions is simulated: simulation mode.
Config. Switch off Flowrate [%] or flowrate [unit] or flow
Simulation Mode velocity.
These readings in simulation mode do
not represent the system conditions.
C178.000 Simulated/ The current output is simulated and is Deactivate simulation mode in the
Fixed Current Output currently set to a specific value. "Process Alarm" menu or set the HART
Config. Simulation Mode? address to 0 in the "Communication"
The error message is displayed if the
HART address>0? HART address is not 0 (HART menu.
multidrop mode, current output is set
permanently to 4 mA).
C177.015 HART Address <>0 HART address not 0 Set the HART address to 0 in the
Multidrop Mode (HART multidrop mode, current output "Communication" menu.
Config. Set HART is set permanently to 4 mA).
Addr. = 0
C176.011 Totalizer Stop The function of the digital input (DI) is Set the digital input (DI) to low signal
Check digital in set to "external totalizer stop" and the (0 V DC).
Config. terminals 81,82 digital input (DI) is set to high signal
(+24 V DC).

Error messages

Range
C175.013 Totalizer Reset The function of the digital input (DI) is Set the digital input (DI) to low signal
Check digital in set to "External totalizer reset" and the (0 V DC).
Config. terminals 81,82 digital input (DI) is set to high signal
(+24 V DC).
C174.002 Pulse Simulation Simulation mode is activated. In the "Process Alarm" menu,
selected on DO1 deactivate simulation mode.
Config. Switch off
Simulation Mode
C172.004 Pulse Simulation Simulation mode is activated. In the "Process Alarm" menu,
Config. Switch off
Simulation Mode
C168.001 Logic Simulation Simulation mode is activated. In the "Process Alarm" menu,
Config. Switch off
Simulation Mode
C164.003 Logic Simulation Simulation mode is activated. In the "Process Alarm" menu,
Config. Switch off
Simulation Mode
C158.039 Simulation of Simulation mode is activated. In the "Process Alarm" menu,
HART frequency deactivate simulation mode.
Config. Switch off
Simulation Mode
C154.018 Simulation Simulation mode is activated. In the "Process Alarm" menu,
Digital In deactivate simulation mode.
Config. Switch off
Simulation Mode

Error messages
10.2.3 Operation outside of specifications (Off Spec)

Range
S149.021 Coil resistor Coil resistance too high: Coil or fuse Check wiring, check fuse for coil
out of limits for coil circuit is defective, or M1/M2 circuit, contact ABB Service.
Operation Check wiring wired incorrectly, or wire break, or fluid
Contact is too hot.
ABB Service Coil resistance too low: Coil is
defective or short circuit in M1 / M2
wiring.
S148.025 Empty Pipe The pipeline in the system is empty. Fill pipeline.
Check Pipe
Operation
S146.043 Gas Bubble Alarm Gas bubbles were detected in the fluid. Check the process.
The measured value is above the set
Operation
switching threshold.
S144.033 Partially Alarm tripped by Partial Filling Check process, fill pipeline.
filled pipe(TFE) Detector.
Operation Check Pipe
Or adjust
Detector
S143.042 Electrode Insulating or conductive deposits Check process, flush pipeline, clean
Coating Alarm detected on measuring electrodes. The measuring electrodes.
Operation
deposit value is above the set
switching threshold.
S142.041 Conductivity Alarm The fluid conductivity is outside the Check process, adjust alarm limits if
configured limit values. required.
Operation
S141.046 Sensor and or Housing The flowmeter sensor temperature is Check process, adjust alarm limits if
Temperature to high outside the configured limit values. required.
Operation
S140.007 Flowrate >103% The flowrate in the system exceeds the Increase the flow range end value in
Check Flowrate configured flow range end value by the "Easy Set-up - Qmax" menu.
Operation Check Range more than 3 %.
Setting
S136.006 Max Alarm The current flowrate in the pipeline is Reduce the flowrate or increase the
Flowrate greater than the max. alarm value for the max. alarm.
Operation
configured.
S132.005 Min Alarm The current flowrate in the pipeline is Increase the flowrate or increase the
Flowrate lower than the min. alarm configured. value for the min. alarm.
Operation

Error messages

Range
S124.029 Electr.Impedance This could be caused by insulating If the pipeline is empty, check whether
too high deposits on the electrodes, the empty pipe detection function is
Operation Coating? conductivity that is too low, or an activated.
Conductivity? empty meter tube. In the "Diagnostics" menu, activate the
Empty Pipe? empty pipe detection function.
Check conductivity, check deposits on
the electrodes.
Increase the value for "Elec. Imp. Max.
Alarm" in the "Diagnostics - Alarm
Limits" menu.
S122.026 Short-ciruit E1 Galvanic voltages. Increase the value in the "Diagnostics -
E2 with shield. Alarm Limits - Electr. V Max Alarm"
Operation
menu and decrease the value for
"Electr. V Min Alarm".
S120.023 Electrode Noise too high The noise at the measuring electrodes Check process.
Switch on is above the limit value.
Operation Noise Reduction
S110.035 Sensor setup Sensor is uncalibrated or Cal status is Contact ABB Service.
Cal-Status not set to "calibrated".
Operation Set Cal-Status
to calibrated
S108.044 Pulse output is Incorrect configuration. In the "Easy Set-up" menu, reduce the
cutted off "Pulses per unit" value.
Operation Check pulse out
configuration
10.2.4 Maintenance

Range
M099.027 NV Corrupt NV Memory, SensorMemory, FRAM Contact ABB Service.
defective.
Electronics
unit
M094.034 Current 20 mA loop open, wire break or no Check for incorrect wiring, wire break.
out fault power connected during operation as Check that the jumper to the 20 mA
Electronics Comms. to MSP passive 20 mA output, max. active / passive switchover is
unit Check wiring! permissible load exceeded or connected correctly to the backplane in
20mA passive? hardware defective. the transmitter housing.
Check BR901! Check whether the external power is
connected during operation as 20 mA
passive.
M090.014 Errors EMC environment or loose contact on Check for incorrect wiring (terminals
Sensor Comms the D1 or D2 terminals, or incorrect D1, D2), check terminal box.
Sensor Bad EMC wiring, or short circuit, or moisture in
environment the terminal box.
Check wiring
M080.012 Display value is Display value <1,600 h for Qmax. Change the totalizer unit.
<1600h at Qmax
Operation Change eng.
Unitfor Totalizer

Error messages
10.3 Overview of error states and alarms
Error no. / Text on the LCD Current Digital output Pulse Display Error
Range display output behavior output maskable?
behavior behavior
F254.038 RAM Error in Transmitter Iout at Alarm General Alarm 0 Hz 0% No
Contact
unit
F253.037 ROM Error in Transmitter Iout at Alarm General Alarm 0 Hz 0% No
Contact
unit
F252.017 No Sensor Memory Iout at Alarm General Alarm 0 Hz 0% No
Check wiring
Sensor Check switch SW3
F251.040 Self Check Alarm Iout at Alarm General Alarm 0 Hz 0% No
Electronics
unit
F250.016 Tx. memory fault Iout at Alarm General Alarm 0 Hz 0% No
detected
Electronics Contact
unit ABB Service
F248.036 Incompatible snsTx+ Iout at Alarm General Alarm 0 Hz 0% No
snr are not the same
Sensor series
F246.032 Defect digital Iout at Alarm General Alarm 0 Hz 0% No
potentiometer
Electronics Transmitter Hardware
unit fault
ABB Service
F245.047 Stack NV Corrupt Iout at Alarm General Alarm 0 Hz 0% No
Contact
unit
F244.031 Internal supply voltage Iout at Alarm General Alarm 0 Hz 0% No
error
Electronics Contact
unit ABB Service
F236.024 DC to High Iout at Alarm General Alarm 0 Hz 0% No
Lot of NV-Resets
Operation Refer to instr. Manual
F232.022 Driver Error Iout at Alarm General Alarm 0 Hz 0% No
Uref = 0
Electronics Check wiring for
unit open circuit
Check fuse
F228.020 Error in Iout at Alarm General Alarm 0 Hz 0% No
Coil circuit
Electronics Check wiring for
unit short circuit
F226.019 AD Converter Iout at Alarm General Alarm 0 Hz 0% No
saturated
Electronics Check empty pipe
unit or Galv. Voltage

Error messages
Error no. / Text on the LCD Current Digital output Pulse Display Error
Range display output behavior output maskable?
behavior behavior
An alarm is Current value No response Current value Current No
C190.045 simulated value
Configuration Switch off
alarm simulation
Tx Simulator/ Current value Current value Current value Current Mask group
C186.009 Calibrator mode value
Calibrator Mode
Hold last good Current value No response Current value Current Mask group
C185.030 known value value
Operation Switch OFF
Noise Reduction
ABB Service
The Flowrate 4 mA (0 % flow) No response 0 Hz 0% Mask group
C184.010 is set to zero
Configuration Check digital in
terminals 81,82
Flowrate Current Value No response, Current value Current Mask group
C182.008 Simulation or High Alarm Min/Max or General value
Configuration Switch off (flow > 105 %) Alarm
Simulation Mode
Simulated/ Simulated No response Current value Current Mask group

C178.000 Fixed Current Output value value
Configuration Simulation Mode?
HART address>0?
HART Address <>0 4 mA Current value Current value Current Mask group
C177.015 Multidrop Mode value
Configuration Set HART
Addr. = 0
Totalizer Stop Current value No response 0 Hz Current Mask group
C176.011 Check digital in value
Configuration terminals 81,82
Totalizer Reset Current value No response Current value Current Mask group
C175.013 Check digital in value
Configuration terminals 81,82
Pulse Simulation Current value No response Simulated value Current Mask group
C174.02 selected on DO1 value
Simulation Mode
Pulse Simulation Current value No response Simulated value Current Mask group
Simulation Mode
Logic Simulation Current value Simulated value No response Current Mask group
Simulation Mode
Logic Simulation Current value Simulated value No response Current Mask group
Simulation Mode
Simulation of Current value No response Current value Current Mask group
C158.039 HART frequency value
Simulation Mode

Error messages
Error no. Text on the LCD Current Digital output Pulse Display Error
range display output behavior output maskable?
behavior behavior
Simulation Current value No response Current value Current Mask group
C154.018 Digital In value
Simulation Mode
Coil resistor Current value No response Current value Current Mask group
C149.021 out of limits value
Sensor Check wiring
Contact
ABB Service
Empty Pipe Programmed Programmed alarm 0 Hz 0% Mask single
S148.025 Check Pipe alarm alarm
Operation
Gas Bubble Alarm No response No response No response No Mask group
S149.021
response
Operation
S146.043 Partially Current value Programmed alarm Current value Current Mask group
filled pipe(TFE) value
Operation Check Pipe
Or adjust
Detector
S144.033 Electrode Programmed Programmed alarm Current value Current Mask group
Coating Alarm alarm value
Operation
S143.042 Conductivity Alarm Current value Programmed alarm Current value Current Mask group
value
Operation
S142.041 Sensor and or Housing Current value Programmed alarm Current value Current Mask group
Temperature to high value
Operation
S141.046 Flowrate >103% Current value Programmed alarm Current value Current Mask group
Check Flowrate value
Operation Check Range
Setting
Max Alarm Programmed Collective Alarm Current value Current Mask single
S140.007 Flowrate alarm value alarm
Operation
Min Alarm Current value Programmed alarm Current value Current Mask single
S136.006 Flowrate value alarm
Operation
Coil resistor Current value Programmed alarm Current value Current Mask single
S132.05 out of limits value alarm
Operation Check wiring
Contact
ABB Service
Electr.Impedance Current value No response Current value Current Mask group
S124.029 too high value
Operation Coating?
Conductivity?
Empty Pipe?
Short-ciruit E1 Current value No response Current value Current Mask group
S122.026 E2 with shield. value
Operation

Error messages
Error no. Text on the LCD Current Digital output Pulse Display Error
range display output behavior output maskable?
behavior behavior
S120.023 Electrode Noise too high Current value No response Current value Current Mask group
Switch on value
Operation Noise Reduction
Sensor setup Current value Current value Current value Current Group
S110.035 Cal-Status value mask
Sensor Set Cal-Status
to calibrated
Pulse output is Current value No response Maximum Current Group
S108.044 cutted off possible value value mask
Operation Check pulse out
configuration
M099.027 NV Corrupt Current value No response Current value Current Group
value mask
Elektronics
unit
Current Low Alarm No response Current value Current Single Alarm
M94.034 out fault value mask
Electronics Comms. to MSP
unit Check wiring!
20mA passive?
Check BR901!
Errors Current value No response Current value Current Group
M90.014 Sensor Comms value mask
Sensor Bad EMC
environment
Check wiring
Display value is Current value No response Current value Current Group
M80.012 <1600h at Qmax value mask
Operation Change eng.
Unitfor Totalizer

Error messages
10.3.1 Error messages during commissioning
10.3.1.1 No sensor detected
-System Startup- Once the device has been switched on, the sensor
NO SENSOR DETECTED calibration data and the transmitter settings are loaded
Device Resetting from the SensorMemory into the transmitter.
If it is not possible to establish a communication with the
Offline SensorMemory1), the shown message appears on the LCD
display.
Possible cause Remedy

Terminals D1 / D2 wired incorrectly. Check wiring.
Short-circuit or wire-break of wires D1 / D2. Check signal cable.
Jumper SW3 not correctly connected to the Check jumper SW3. Refer to Chapter 7.2
backplane. "Configuring the current output".
• off: SensorMemory provided in the
flowmeter sensor (standard)
• on: No SensorMemory in flowmeter
sensor
SensorMemory1) defective. Contact ABB Service
The device will restart after the progress bar is complete until either the communication with the
SensorMemory1) is re-established successfully or the process is canceled by selecting "Offline".
In Offline mode the device can be operated or parameterized, but no measurement is
performed.
In Offline mode the error message "F252.017" is set.

Error messages
10.3.1.2 Error message "Incompatible sensor"
IMPORTANT (NOTE)
When commissioning the device, make sure that the transmitter is assigned to the sensor
correctly. It is not possible to operate a flowmeter sensor of the 300 series with a transmitter of
the 500 series.
If the transmitter is operated with a flowmeter sensor of another series, the following message
appears on the transmitter display:
Boiler 9 In the process display, a flow of zero flow is indicated, no

Q 0.00 l/min flow measurement is performed.
Σ+ 1403.09 m3
Σ- 591.74 m3 1. Use to switch to the information level.
Sensor
-Operator Menu- 2. Use or , select the "Diagnostics" submenu.

Diagnostics
3. Use to confirm your selection.
Operator Page 1
Operator Page 2
Back Select
Sensor When attempting to commission a mixed installation, the

-- F248.036-- shown error message appears.
Incompatible sns
The device cannot measure.
Tx+snr are not
the same series The indicated value for the current flowrate is zero flow.
Back Exit The current output assumes its pre-configured state (Iout
for alarm).
Make sure that the flowmeter sensor and the transmitter
are from the same series.
(e.g., flowmeter sensor ProcessMaster 300, transmitter
ProcessMaster 300)

Maintenance
11 Maintenance
Repair and maintenance activities may only be performed by authorized customer service
personnel.
When replacing or repairing individual components, original spare parts must be used.
NOTICE - Potential damage to parts!
The electronic components of the printed circuit board can be damaged by static electricity
(observe ESD guidelines).
Make sure that the static electricity in your body is discharged before touching electronic
components.
11.1 Flowmeter sensor
The flowmeter sensor is largely maintenance-free. The following items should be checked
annually:
• Ambient conditions (air circulation, humidity),
• Seal integrity of the process connections,
• Cable entry points and cover screws,
• Operational reliability of the power supply feed, the lightning protection, and the station
ground.
The flowmeter sensor electrodes must be cleaned when the flowrate information on the
transmitter changes when recording the identical flowrate volume. If the display shows a higher
flowrate, the contamination is insulating. If a lower flowrate is displayed, the contamination
results in a short-circuit.
For repairs to the lining, electrodes or magnet coil, the flowmeter must be returned to the head
office in Göttingen.
IMPORTANT (NOTE)
When sending the flowmeter sensor for repair to the head office of ABB Automation Products
GmbH, complete the return form in the appendix and include with device.
When cleaning the exterior of meters, make sure that the cleaning agent used does not corrode
the housing surface and the gaskets.
11.2 Gaskets
Some device designs are shipped with special gaskets. These gaskets must be used and
installed properly to prevent leakage and ensure 3A conformity.
For all other device designs, use commercially available gaskets made from a compatible
material for the measuring medium and prevailing temperature (rubber, PDFE, lt, EPDM, silicon,
Viton, etc.) or use 3A-compliant gasket material for HygienicMaster devices.
IMPORTANT (NOTE)
A wafer type sensor is installed without gaskets directly in the pipeline.

Maintenance
11.3 Replacing the transmitter or the sensor
IMPORTANT (NOTE)
When replacing the transmitter or sensor, ensure that they are assigned correctly. It is not
possible to operate a sensor from the 300 series with a transmitter from the 500 series.
The series (e.g. ProcessMaster 300 or ProcessMaster 500) is shown on the name plate of the
transmitter or sensor.
11.3.1 Transmitter
WARNING – danger due to electric current!

Before opening the housing, switch off the power supply.

1 2 3
4 3
1 2 3
3 G00689
G00689-02

Fig. 68
Replace the transmitter plug-in as follows:

1. Switch off the power supply.
2. Unscrew the housing cover (1).
3. Loosen the screws (3) and pull out the transmitter plug-in unit (2).
4. Insert the new transmitter plug-in unit and retighten the screws (3).
5. Close the housing cover (1).
6. Download the system data (see chapter 7.5.1 "Downloading the system data" on page 70).

Maintenance
11.3.2 Sensor
WARNING – danger due to electric current!

Before opening the housing, switch off the power supply.
1 2
G00698-03
Fig. 69
Replace the sensor as follows:

1. Switch off the power supply.
2. Open the cover safety device (3) if necessary.
3. Unscrew the housing cover (1).
4. Disconnect the signal cable (2) (if necessary, remove the potting compound).
5. Install the new sensor in accordance with the installation instructions.
6. Complete the electrical connection in accordance with the connection diagram.
7. Close the housing cover (1).
8. Download the system data (see chapter 7.5.1 "Downloading the system data" on page 70).

Maintenance
11.3.3 Downloading the system data
1. Switch on the power supply. After switching on the power supply, the following messages
appear in succession on the LCD display:
System Startup System Startup System Startup

LOADING SYSTEM DATA VERIFYING SYSTEM DATA INSTALLATION CHANGED
Identify Changed Item
Transmitter Sensor
2. Download the system data as follows:
For a completely new system or initial start-up

• The calibration data of the flowmeter sensor and the transmitter settings are loaded from the
SensorMemory1) into the transmitter.
After replacing the complete transmitter or transmitter electronic unit

• Select "Transmitter" with . The calibration data of the flowmeter sensor and the
transmitter settings are loaded from the SensorMemory1) into the transmitter.
After replacing the sensor

• Select "Sensor" with . The calibration data of the flowmeter sensor are loaded from the
SensorMemory1) into the transmitter. The transmitter settings are stored in the
SensorMemory1). If the new sensor is a different size, check the currently configured flow
range.
3. The flowmeter is ready for operation and will operate with factory settings or settings
requested by the customer. To change the factory settings, refer to chapter 8
"Parameterization".
IMPORTANT (NOTE)
System data must only be loaded during initial start-up. If the power supply is later switched
off, the transmitter automatically loads all data the next time the power supply is switched on
again.
A selection as described below (1-3) is not required.

Spare parts list
12 Spare parts list
12.1 Fuses for transmitter electronics
1 2
1
G00690-02
Fig. 70
No. Name of part Order number
1 Fuse (1.0 A) for power supply, suitable for all devices D151B003U05
2 Fuse (0.25 A) for the coil circuit in the field housing, suitable for D151B003U02
all devices
12.2 Spare parts for devices with integral mount design
1 2 3
G00878-01
Fig. 71
1 Housing cover for transmitter with single-compartment housing MJFA9915
with integral mount design
2 Universal backplane for transmitter with dual-compartment D685A1156U01
housing
3 Front housing cover for transmitter with dual-compartment D612A197U01
housing with integral mount design (standard, Ex Zone 2 / Div. 2)
Front housing cover for transmitter with dual-compartment D612A197U02
housing with integral mount design (Ex Zone 1 / Div. 1)

Spare parts list
12.3 Spare parts for devices with remote mount design
12.3.1 field-mount housing
1 2
4
3
G00879-01
Fig. 72
1 Contact board assy for dual-compartment transmitter housing D682A016U01
2 Universal backplane for dual-compartment transmitter housing D685A1156U01
3 Housing cover for transmitter with single-compartment housing MJBX9905
with remote mount design
4 Backplane for transmitter with single-compartment housing with 3KXF002058U0100
remote mount design
12.3.2 Round field-mount housing
1 2
G00876-01
Fig. 73
1 Front housing cover for transmitter with dual-compartment D612A197U01
housing with remote mount design (standard, Ex Zone 2 / Div. 2)
Front housing cover for transmitter with dual-compartment D612A197U02
housing with remote mount design (Ex Zone 1 / Div. 1)
2 Universal backplane for dual-compartment transmitter housing D685A1156U01

Spare parts list
12.3.3 Flowmeter sensor (Zone 2 / Div. 2)
G00880
Fig. 74
for FEH model for FEP model
1 Connection board (without preamplifier) D685A1090U01 D685A1090U01
Connection board (with preamplifier) D685A1089U01 D685A1089U01
12.3.4 Flowmeter sensor (Zone 1 / Div. 1)
G00877
Fig. 75
1 O-ring D101A034U06
2 Cable gland for Zone 1 / Div. 1, plastic, black, M20 x 1.5 D150A004U15

Performance specifications
13 Performance specifications
A
13.1 General 13.1.3 Reproducibility, response time

Reproducibility ≤ 0.11 % of measured value,
13.1.1 Reference conditions tmeas = 100 s, v = 0.5 ... 10 m/s
Response time of As step function 0 ... 99 %
In accordance with EN 29104
current output with 5   200 ms at 25 Hz excitation
Measuring medium 20 °C (68 °F) ± 2 K damping of frequency
temperature 0.02 seconds 5   400 ms at 12.5 Hz excitation
Ambient temperature 20 °C (68 °F) ± 2 K
frequency
Power supply Nominal voltage acc. to name plate 5   500 ms at 6.25 Hz excitation
Un ± 1 %, frequency f ± 1 %
frequency
Installation - Upstream > 10 x DN straight pipe
conditions section
- Downstream > 5 x DN straight pipe 13.1.4 Power supply
section
Warm-up phase 30 min Supply voltage 100 ... 230 V AC (-15 % / +10 %),
47 ... 64 Hz
24 V AC (-30 % / +10 %),
13.1.2 Maximum measuring error 47 ... 64 Hz
24 V DC (-30 % / +30 %),
Pulse output
ripple: < 5 %
- Standard calibration FEP300 / FEH300:
Power consumption
± 0.4 % of measured value, ± 0.02 % QmaxDN
AC ≤ 20 VA
(DN 3 ... 2000)
DC 12 W (switch-on current 5.6 A)
- Standard calibration FEP500 / FEH500:
Screw terminals Max. 2,5 mm2 (AWG 14)
(DN 1 … 600, 800)
Isolation of input / outputs
The current output, digital outputs DO1 and DO2, and digital
(DN 700 … 900, 2000) input are electrically isolated from the flowmeter sensor input
- Optional calibration: (DN 10 … 600, 800) circuit and from each other. The same is valid for the signal
± 0.2 % of measured value, ± 0.02 % QmaxDN outputs of the versions with PROFIBUS PA and
- Only for FEH500: (DN 1 … 2) FOUNDATION fieldbus.
Empty pipe detection
The function requires:
QmaxDN: See table in chapter 7.6 "Flowmeter sizes, flow range" on
A conductivity of the measured fluid ≥ 20 μS/cm, a signal
page 78. cable length ≤ 50 m (164 ft), a nominal diameter DN ≥ DN 10,
and the flowmeter sensor must not be provided with a
preamplifier.
Fig. 76
Y Accuracy ± of measured value in [%]

X Flow velocity v in [m/s], Q / QmaxDN [%]
Analog output effects

Same as pulse output plus ± 0.1 % of measured value ± 0.01 mA.

Performance specifications
13.2 Mechanical properties 13.3 IP rating
According to EN 60529
IP 65, IP 67, NEMA 4X
Integral mount Housing made of Housing made of
design Aluminium stainless steel
Housing Cast aluminum, Stainless steel CF3M 13.4 Vibration
painted
Paint Paint coat ≥ 80 µm According to EN 60068-2
-
thick, RAL 9002 - In the range 10 ... 58 Hz with max. 0.15 mm (0.006 inch)
(light gray) deflection 1)
Cable gland2) Polyamide Polyamide - In the range 58 ... 150 Hz max. 2 g acceleration 1)
Stainless steel1) Stainless steel1) 1) Peak load
Remote mount design 13.5 Temperature data

Housing Cast aluminum, painted
Paint Paint coat ≥ 80 µm thick, RAL 7012 (dark Ambient temperature
gray), front cover / rear cover RAL 9002 -20 ... 60 °C (-4 ... 140 °F) Standard range
(light gray) -40 ... 60 °C (-40 ... 140 °F) Extended range
Cable gland2) Polyamide
Stainless steel1) Storage temperature
Weight 4.5 kg (9.92 lb) -40 ... 70 °C (-40 ... 158 °F)
1) In the case of hazardous area design for ambient temperature of -40 °C (40 °F)
2) Cable Gland with M20x1,5 thread or NPT thread with plug to be specified through
modelcode

Functional and technical properties - ProcessMaster
14 Functional and technical properties - ProcessMaster

14.1 IP rating 14.5 Temperature data

According to EN 60529 The temperature range of the device is dependent upon a number of
IP 65, P 67, NEMA 4X factors which influence the specification. These factors include - fluid
IP 68 (for remote mount design only) temperature, ambient temperature, operating pressure, lining material
and hazardous area classifcation.
14.2 Pipeline vibration

14.5.1 Storage temperature
According to EN 60068-2-6, applies to aluminium transmitter
housing only -40 ... 70 °C (-40 ... 158 °F)
- In the 10 ... 58 Hz range with max. 0.15 mm (0.006 inch)
deflection
- In the 58 ... 150 Hz range with max. 2 g acceleration
14.5.2 Minimum permissible pressure as a function
of measuring medium temperature
14.3 Installation length Lining Nominal POperating at TOperating 1)
diameter mbar abs.
The flange devices comply with the installation lengths specified in Hard rubber 15 ... 2000 0 < 90 °C (194 °F)
VDI/VDE 2641, ISO 13359, or according to DVGW (process sheet (1/2 ... 80") < 80 °C (176 °F) 2)
W420, design WP, ISO 4064 short). Soft rubber 50 ... 2000 0 < 60 °C (140 °F)
(2 ... 80")
PTFE 10 ... 600 270 < 20 °C (68 °F)
14.4 Signal cable (3/8 ... 24") 400 < 100 °C (212 °F)
500 < 130 °C (266 °F)
For remote mount design only
Thick PTFE, 25 … 80 0 < 180 °C (356 °F)
A 5 m (16.4 ft) cable is supplied. high-temp. 100 … 250 67 < 180 °C (356 °F)
If you require more than 5 m (16.4 ft), a signal cable can be design 300 27 < 180 °C (356 °F)
separately purchased (for ordering informations see the following PFA 3 ... 200 0 < 180 °C (356 °F)
table or section "Accessory" in data sheet). (1/10 ... 8")
ETFE 25 ... 600 100 < 130 °C (266 °F)
Signal cable (1 ... 24")
Application D173D031U01 D173D027U01 Linatex 2) 50 .. 600 0 < 70 °C (158 °F)
Non-Ex. (< DN 15)   (2 … 24“)
Non-Ex. (≥ DN 15)   Ceramic 25 ... 1000 0 < 80 °C (176 °F)
Carbide (1 ... 40"
Zone 2 / Div. 2 (< DN 15)  
1) For CIP/SIP cleaning, higher temperatures are permitted for limited time periods; refer to
Zone 2 / Div. 2 (≥ DN 15)   the table titled "Maximum permissible cleaning temperature“.
2) Only China production site.
Zone 1 / Div. 1
(all nominal diameter)  
14.5.3 Maximum permissible cleaning temperature
 Application not permissible  Standard on delivery
 Application permissible CIP cleaning Sensor Tmax Tmax Tamb.
lining minutes
For the transmitter designed for use in zone 1, Div. 1 (model FET525), Steam cleaning PTFE, PFA 150 °C 60 25 °C
10 m (32.8 ft) of signal cable is permanently connected to the (302 °F) (77 °F)
transmitter. Fluids PTFE, PFA 140 °C 60 25 °C
(284 °F) (77 °F)
Signal cable length and preamplifier
A preamplifier is required for cables > 50 m (164 ft). If the ambient temperature is > 25 °C, the difference must be
Maximum signal cable length between flowmeter sensor and subtracted from the max. cleaning temperature. Tmax - ∆ °C.
transmitter: ( ∆ °C = Tamb - 25 °C)
Preamplifier Signal cable length

Without Max. 50 m (164 ft) for conductivity ≥ 5 µS/cm "Accessory" in data sheet
With Max. 200 m (656 ft) for conductivity ≥ 5 µS/cm

14.5.4 Maximum ambient temperature depending on measuring medium temperature
IMPORTANT (NOTE)
When using the device in potentially explosive areas, the additional temperature specifications in the section titled "Ex
relevant specifications" on the data sheet or in the separate Ex safety instructions (SM / FEX300 / FEX500 / ATEX /
IECEX) or (SM / FEX300 / FEX500 / FM / CSA) must be observed.
14.5.4.1 ProcessMaster with integral mount design (standard sensor design)

Ambient temperature Measuring medium temperature
Liner Flange material
Minimum temperature Max. temperature Minimum temperature Max. temperature
-10 °C (14°F) 90 °C (194 °F)
Hard rubber Steel -10 °C (14°F) 60 °C (140 °F)
-5 °C (23 °F) 1) 80 °C (176 °F) 1)
-15 °C (5 °F) 90 °C (194 °F)
Hard rubber Stainless steel -15 °C (5 °F) 60 °C (140 °F)
-5 °C (23 °F) 1) 80 °C (176 °F) 1)
Soft rubber Steel -10 °C (14°F) 60 °C (140 °F) -10 °C (14°F) 60 °C (140 °F)
Soft rubber Stainless steel -15 °C (5 °F) 60 °C (140 °F) -15 °C (5 °F) 60 °C (140 °F)
60 °C (140 °F) 90 °C (194 °F)
PTFE Steel -10 °C (14°F) -10 °C (14°F)
45 °C (113 °F) 130 °C (266 °F)
-20 °C (-4 °F) 60 °C (140 °F) 90 °C (194 °F)
PTFE Stainless steel -25 °C (-13 °F)
-40 °C (-40 °F) 2) 45 °C (113 °F) 130 °C (266 °F)
60 °C (140 °F) 90 °C (194 °F)
PFA 1) Steel -10 °C (14°F) -10 °C (14°F)
45 °C (113 °F) 130 °C (266 °F)
-20 °C (-4 °F) 60 °C (140 °F) 90 °C (194 °F)
PFA 1) Stainless steel -25 °C (-13 °F)
-40 °C (-40 °F) 2) 45 °C (113 °F) 130 °C (266 °F)
60 °C (140 °F) 90 °C (194 °F)
Thick PTFE 2) Steel -10 °C (14°F) -10 °C (14°F)
45 °C (113 °F) 130 °C (266 °F)
-20 °C (-4 °F) 60 °C (140 °F) 90 °C (194 °F)
Thick PTFE 2) Stainless steel -25 °C (-13 °F)
-40 °C (-40 °F) 2) 45 °C (113 °F) 130 °C (266 °F)
60 °C (140 °F) 90 °C (194 °F)
ETFE 3) Steel -10 °C (14°F) -10 °C (14°F)
45 °C (113 °F) 130 °C (266 °F)
-20 °C (-4 °F) 60 °C (140 °F) 90 °C (194 °F)
ETFE 3) Stainless steel -25 °C (-13 °F)
-40 °C (-40 °F) 2) 45 °C (113 °F) 130 °C (266 °F)
Linatex 1) Steel -10 °C (14 °F) 60 °C (140 °F) -10 °C (14 °F) 70 °C (158 °F)
Linatex 1) Stainless steel -20 °C (-4 °F) 60 °C (140 °F) -20 °C (-4 °F) 70 °C (158 °F)
60 °C (140 °F)
Ceramic carbide Steel -10 °C (14 °F) -10 °C (14°F) 80 °C (176 °F)
45 °C (113 °F)
60 °C (140 °F)
Ceramic carbide Stainless steel -20 °C (-4 °F) -20 °C (-4 °F) 80 °C (176 °F)
45 °C (113 °F)
14.5.4.2 ProcessMaster with integral mount design (high-temperature sensor design) 3)

PFA 1) Steel -10 °C (14°F) 60 °C (140 °F) -10 °C (14°F) 180 °C (356 °F)
1)
-20 °C (-4 °F)
PFA Stainless steel 60 °C (140 °F) -20 °C (-13 °F) 180 °C (356 °F)
-40 °C (-40 °F) 2)
Thick PTFE 2) Steel -10 °C (14°F) 60 °C (140 °F) -10 °C (14°F) 180 °C (356 °F)
-20 °C (-4 °F)
Thick PTFE 2) Stainless steel 60 °C (140 °F) -20 °C (-13 °F) 180 °C (356 °F)
-40 °C (-40 °F) 2)
ETFE 3) Steel -10 °C (14 °F) 60 °C (140 °F) -10 °C (14°F) 130 °C (266 °F)
3)
-20 °C (-4 °F)
ETFE Stainless steel 60 °C (140 °F) -20 °C (-13 °F) 130 °C (266 °F)
-40 °C (-40 °F) 2)
1) For China production site only.

2) For (optional) low-temperature version only.
3) With sensor design level "B" only.

IMPORTANT (NOTE)
When using the device in potentially explosive areas, the additional temperature specifications in the section titled "Ex
relevant specifications" on the data sheet or in the separate Ex safety instructions (SM / FEX300 / FEX500 / ATEX /
IECEX) or (SM / FEX300 / FEX500 / FM / CSA) must be observed.
14.5.5 ProcessMaster with remote mount design (standard sensor design)

-10 °C (14°F) 90 °C (194 °F)
Hard rubber Steel -10 °C (14°F) 60 °C (140 °F)
-5 °C (23 °F) 1) 80 °C (176 °F) 1)
-15 °C (5 °F) 90 °C (194 °F)
Hard rubber Stainless steel -15 °C (5 °F) 60 °C (140 °F)
-5 °C (23 °F) 1) 80 °C (176 °F) 1)
Soft rubber Steel -10 °C (14°F) 60 °C (140 °F) -10 °C (14°F) 60 °C (140 °F)
Soft rubber Stainless steel -15 °C (5 °F) 60 °C (140 °F) -15 °C (5 °F) 60 °C (140 °F)
PTFE Steel -10 °C (14°F) 60 °C (140 °F) -10 °C (14°F) 130 °C (266 °F)
-25 °C (-13 °F)
PTFE Stainless steel 60 °C (140 °F) -25 °C (-13 °F) 130 °C (266 °F)
-40 °C (-40 °F) 2)
-25 °C (-13 °F)
PFA 1) Stainless steel 60 °C (140 °F) -25 °C (-13 °F) 130 °C (266 °F)
-40 °C (-40 °F) 2)
-25 °C (-13 °F)
-40 °C (-40 °F) 2)
ETFE 3) Steel -10 °C (14°F) 60 °C (140 °F) -10 °C (14°F) 130 °C (266 °F)
ETFE 3) Stainless steel -25 °C (-13 °F) 60 °C (140 °F) -25 °C (-13 °F) 130 °C (266 °F)
Linatex 1) Steel -10 °C (14 °F) 60 °C (140 °F) -10 °C (14 °F) 70 °C (158 °F)
Linatex 1) Stainless steel -20 °C (-4 °F) 60 °C (140 °F) -20 °C (-4 °F) 70 °C (158 °F)
Ceramic carbide Steel -10 °C (14 °F) 60 °C (140 °F) -10 °C (14°F) 80 °C (176 °F)
Ceramic carbide Stainless steel -25 °C (-13 °F) 60 °C (140 °F) -20 °C (-4 °F) 80 °C (176 °F)
14.5.5.1 ProcessMaster with remote mount design (high-temperature sensor) 3)

-25 °C (-13 °F)
PFA 1) Stainless steel 60 °C (140 °F) -25 °C (-13 °F) 180 °C (356 °F)
-40 °C (-40 °F) 2)
-25 °C (-13 °F)
-40 °C (-40 °F) 2)
ETFE 3) Steel -10 °C (14°F) 60 °C (140 °F) -10 °C (14°F) 130 °C (266 °F)
-25 °C (-13 °F)
ETFE 3) Stainless steel 60 °C (140 °F) -25 °C (-13 °F) 130 °C (266 °F)
-40 °C (-40 °F) 2)
1) For China production site only.

2) For (optional) low-temperature version only.
3) With sensor design level "B" only.

14.5.6 Overview sensor design level "C" ASME flange, stainless steel, up to DN 400 (16") (CL150/300) up
to DN 1000 (40") (CL150)
Ambient temp. range: -20 ... 60 °C

PS PS
[bar] [PSI]
Sensor temp. Range: Standard

110 1595.4
100 1450.4
CL600
90 1305.3
80 1160.3
Carbon steel flange

70 1015.3
Electrode design:
60 870.2
Pressure rating
50 725.2
Hard rubber
CL300
Sensor Size
40 580.2
Standard
30 435.1
PTFE 20
CL150
290.1
10 145.0
0
DN 25 (1") X X — X X -30 -10 10 30 50 70 90 110 130 150 170 [°C]
-22 14 50 86 122 158 194 230 266 302 338 [°F]
DN 32 (1 1/4") X X — X X TS G00591
DN 40 (1 1/2") X X X X X Fig. 78
DN 50 (2") X X X X X
DIN flange, steel, up to DN 600 (24")
DN 65 (2 1/2") DIN PN 10, X X X X X
PS PS
DN 80 (3") DIN PN 16, X X X X X [bar] [PSI]
DN 100 (4") DIN PN 25, X X X X X

110 1595.4
DIN PN 40 100 1450.4

DN 125 (5") X X X X X PN 100
1305.3
DN 150 (6") X X X X X 90
ASME 80 1160.3
DN 200 (8") CL 150, X X X X X
70 1015.3
DN 250 (10") CL 300 X X X X X
DN 300 (12") X X X X X 60 PN 63 870.2
DN 350 (14") JIS 10 K X X X X X 50 725.2
DN 400 (16") X X X X X 40 PN 40
580.2
DN 450 (18") X X X X X 30 435.1
DN 500 (20") X X X X X 20
PN 25
290.1
PN 16
DN 600 (24") X X X X X 10 145.0
PN 10
0
-30 -10 10 30 50 70 90 110 130 150 170 [°C]
-22 14 50 122 122 158 194 230 266 302 338 [°F]
14.6 Material load TS G00588
Fig. 79
Limits for the permissible fluid temperature (TS) and permissible
pressure (PS) are calculated on the basis of the lining and flange
material used in the device (refer to the name plate on the device). ASME flange, steel, up to DN 400 (16") (CL150/300); up to
DN 1000 (40") (CL150)
PS
[bar]
14.6.1 Flowmeter sensor design level “B” 110
100
DIN flange stainless steel up to DN 600 (24") 90

PS PS
[bar] [PSI] 80
110 1595.4
70
100 1450.4
PN 100 60
90 1305.3 50
CL300
80 1160.3 40
70 1015.3 30
PN 63
60 870.2 20
CL150
10
50 725.2
0
40 580.2 -30 -10 10 30 50 70 90 110 130 150 170 [°C]
PN 40
-22 14 50 86 122 158 194 230 266 302 338 [°F]
30 435.1 TS G00590
20
PN 25
290.1
Fig. 80
PN 16
10
PN 10
145.0 JIS 10K-B2210 flange
0 Nominal Material PN TS PS
10 30 70 110 130 150 170 [°C]
-30
-22
-10
14 50 86
50
122 158
90
194 230 266 302 338 [°F] diameter
TS G00589
32 ... 400 Stainless steel 10 -25 ... 180 °C 10 bar
Fig. 77 (1 1/4 ... 16") (-13 ... 356 °F) (145 psi)
32 ... 400 Steel 10 -10 ... 180 °C 10 bar
(1 1/4 ... 16") (14 ... 356 °F) (145 psi)

DIN flange, stainless steel, DN 700 (28") up to DN 1000 (40") ASME flange, stainless steel, DN 25 ... 400 (1 ... 24“)
PS PS
[bar] [psi] PS PS
[bar] [psi]
17 246.5 CL2500
350 5076
16 DN 700 PN 16 232.0
15 217.5 300 4351

14 203.0
250 3625
13 188.5
DN 900 PN 16 CL1500
12 DN 800 PN 16 174.0 200 2900
11 DN 1000 PN 16 159.5
150 2175
10 145.0 CL900
9 DN 900 PN10 130.5 100 1450
DN 800 PN 10 CL600
8 DN 700 PN 10 116.0
50 725
7 DN 1000 PN 10 101.5
6 87.0 0 0
-30 -20 -10 0 10 20 30 40 50 60 70 80 90 [°C] -30 -10 0 10 30 50 70 90 110 130 150 180 °C
32 TS
-22 -4 14 50 68 86 104 122 140 158 176 194 [°F] -22 14 32 50 86 122 158 194 230 266 302 356 °F
G00219
Fig. 81 TS G01337
DIN flange, steel, DN 700 (28") up to DN 1000 (40") Fig. 84

PS PS
[bar] [psi]
17 246.5
14.6.2 Flowmeter sensor design level “C”
16 232.0
15 217.5 Steel casted housing, DN 25 ... 600 (1 ... 24“)

14 203.0
PS PS
13 DN 700 PN 16 188.5
[bar] [PSI]
12 174.0 40 PN40 580
11 DN 900 PN 16 159.5
35 508
DN 800 PN 16
10 145.0
DN 1000 PN 16 30 435
9 130.5
8 DN 900 PN 10 116.0 25 PN25 363

DN 800 PN 10
7 DN 700 PN 10 101.5 20 CL150 290
6 DN 1000 PN 10 87.0 PN16
80
15 218
-10 0 10 20 30 40 50 60 70 90 [°C]
TS
-14 32 50 68 86 104 122 140 158 176 194 [°F] G00220 10 PN10 145
Fig. 82
5 73
ASME flange, Steel, DN 25 ... 400 (1 ... 24“) 0 0

-10 0 10 20 30 40 50 60 70 80 90 100 110 120 130 °C
14 32 50 68 86 104 122 140 158 176 194 212 230 248 266 °F
PS PS TS
G01335
[bar] [psi]
450 CL2500 6527 Fig. 85
400 5801
350 5076 Welded steel housing, DN 25 ... 600 (1 ... 24“)

300 4351 PS PS
CL1500 [bar] [PSI]
250 3625
50 CL300 725
200 2900
CL900
150 2175 40 PN40 580
CL600
100 1450
30 435
50 725
PN25
0 0 20 CL150 290
-30 -10 0 10 30 50 70 90 110 130 150 180 °C
PN16
-22 14 32 50 86 122 158 194 230 266 302 356 °F
TS G01338 10 PN10 145
Fig. 83
0 0
-10 0 10 20 30 40 50 60 70 80 90 100 110 120 130 °C
14 32 50 68 86 104 122 140 158 176 194 212 230 248 266 °F
TS
G01336
Fig. 86

14.7 Materials for flowmeter sensors
14.7.3 Flowmeter sensor housing
14.7.1 Wetted parts Flowmeter sensor Design Level „B“
Part Standard Option
Lining PTFE, PFA, ETFE, Ceramic Carbide,
hard rubber, soft Linatex G01340
rubber
Housing
Measurement and Dual-shell casing, cast aluminum,
DN 3 ... 400
grounding painted, paint coat, ≥ 80 µm thick,
(1/10 ... 16")
electrode for: RAL 9002
- Hard rubber Stainless steel Hastelloy B-3 (2.4600), DN 450 ... 2000 Welded steel design, painted, paint coat,
1.4571 (AISI 316Ti) Hastelloy C-4 (18 ... 80") ≥ 80 µm thick, RAL 9002
- Soft rubber (2.4610), Titanium,
Terminal box Aluminum alloy, painted, ≥ 80 µm thick,
Tantalum,
light gray, RAL 9002
Platinum-iridium,
1.4539 (AISI 904L), Meter tube Stainless steel 3)
Tungsten carbide Cable gland 4) Polyamide
- PTFE, PFA, Stainless steel Stainless steel 1.4571 CrNi steel
ETFE 1.4539 (AISI 904L) (AISI 316Ti) (in the case of hazardous area design for
Hast. C-4 (2.4610) ambient temperature of -40 °C (40 °F))
Hast. B-3 (2.4600)
Titanium, Tantalum, Flowmeter sensor Design Level „B“
Platinum-iridium
Grounding plate Stainless steel On request
Protection plate Stainless steel On request
G01342
Housing + Meter tube

14.7.2 Non-wetted parts (process connection) DN 25 ...400 (1 ... 16") Stainless steel (AISI 316, 316L)
Flowmeter sensor Design Level „B“ Cable gland 4) Polyamide
Flowmeter sensor Design Level „C“
G01340
Nominal diameter Standard Option

G01341
DN 3 ... 15 Stainless steel 1) -
(1/10 ... 1/2") Housing + Meter tube
DN 20 ... 400 Steel (galvanized)2) Stainless steel 1) DN 25 ... 600 (1 ... 24") Steel, painted, paint coat, ≥ 80 µm thick,
(3/4 ... 16") RAL 9002
DN 450 ... 2000 Steel (painted) 2) - Terminal box Aluminum alloy, painted, ≥ 80 µm thick,
(18 ... 80") light gray, RAL 9002
Cable gland 4) Polyamide
Flowmeter sensor Design Level „B“
The meter tube is made of one of the materials listed below:
3) 1.4301, 1.4307, 1.4404, 1.4435, 1.4541, 1.4571

ASTM materials:
G01342 Grade TP304, TP304L, TP316L, TP321, TP316Ti, TP317L,0Cr18Ni9, 00Cr18Ni10,
0CR17Ni14Mo2, 0Cr27Ni12Mo3, 0Cr18Ni10Ti
Nominal diameter Standard Option 4) Cable Gland with M20x1,5 thread or NPT thread with plug to be specified through
DN 25 ... 400 Stainless steel - modelcode
(1 ... 16") (AISI 316, 316L)
Flowmeter sensor Design Level „C“
G01341
Nominal diameter Standard Option

DN 25 ... 600 Steel (painted) 2) -
(1 ... 24")
The process connections are made of one of the materials listed below:
1) 1.4301 (AISI 304), 1.4307, 1.4404 (AISI 316L) 1.4435 (AISI 316L), 1.4541 (AISI 321)
1.4571 (AISI 316Ti), ASTM A182 F304, ASTM A182 F304L, ASTM A182 F316L, ASTM
A182 F321, ASTM A182 F316TI, ASTM A182 F316, 0Cr18Ni9, 0Cr18Ni10,
0Cr17Ni13Mo2, 0Cr27Ni12Mo3, 1Cr18Ni9Ti, 0Cr18Ni12Mo2Ti
2) 1.0038, 1.0460, 1.0570, 1.0432, ASTM A105, Q255A, 20#, 16Mn

Functional and technical properties - HygienicMaster
15 Functional and technical properties - HygienicMaster

Min. permissible pressure as a function of measuring

15.1 Flowmeter sensor medium temperature
Lining Nominal POperating at TOperating1)
15.1.1 IP rating according to EN 60529 diameter mbar abs.
PFA DN 3 ... 100 0 < 180 °C (356 °F)
IP 65, IP 67, NEMA 4X
(1/10 ... 4")
IP 68 (for remote mount design only)
PEEK DN 1 ... 2 0 < 120 °C (248 °F)
(1/25 … 1/12")
15.1.2 Pipeline vibration according to EN 60068-2-6 1) For CIP/SIP cleaning, higher temperatures are permitted for limited time periods; refer to
the table titled "Maximum permissible cleaning temperature“.
For devices with integral mount design the following applies:
(transmitter mounted directly on the flowmeter sensor) Max. permissible cleaning temperature
• In the 10 ... 58 Hz range with max. 0.15 mm (0.006 inch)
deflection CIP cleaning Flowmeter Tmax Tmax Tamb.
sensor minutes
• In the 58 ... 150 Hz max. 2 g acceleration
lining
(does not apply to DN 1…2)
Steam cleaning PFA 150 °C 25 °C 60
For devices with remote mount design the following applies: (302 °F) (77 °F)
Transmitter Fluids PFA 140 °C 60 25 °C
• In the 10 ... 58 Hz range with max. 0.15 mm (0.006 inch) (284 °F) (77 °F)
deflection If the ambient temperature is > 25 °C, the difference must be
• In the 58 ... 150 Hz range with max. 2 g acceleration subtracted from the max. cleaning temperature. Tmax - ∆ °C.
( ∆ °C = Tamb - 25 °C)
Flowmeter sensor
• In the 10 ... 58 Hz range with max. 0.15 mm (0.006 inch)
Max. permissible temperature shock
deflection
• In the 58 ... 150 Hz max. 2 g acceleration Lining Max. temp. shock Temp. gradient
(does not apply to DN 1…2) Temp. diff. in °C °C / min
PFA Any Any
PEEK Any Any
15.1.3 Installation length
The flange devices comply with the installation lengths specified in
VDI/VDE 2641, ISO 13359, or according to DVGW (process sheet
W420, design WP, ISO 4064 short).
15.1.4 Signal cable (for external transmitters only)

A 5 m (16.4 ft) cable is supplied.
If you require more than 5 m (16.4 ft), a cable can be purchased using
order number D173D027U01.
Alternatively, the cable with order number AD173D031U01 can be
used for transmitters without explosion protection (model FEP321,
FEH321) from DN 15 and for transmitters for use in Zone 2 (model
FEP325, FEH325) from DN 15.
Preamplifier
Maximum signal cable length between flowmeter sensor and
transmitter:
a) Without preamplifier:
• Max. 50 m (164 ft) for conductivity ≥ 5 µS/cm
A preamplifier is required for cables > 50 m (164 ft).
b) With preamplifier
• Max. 200 m (656 ft) for conductivity ≥ 5 µS/cm
15.1.5 Temperature range

Storage temperature
- 40 ... 70 °C (-40 ... 158 °F)

Max. ambient temperature as a function of measuring medium temperature
IMPORTANT (NOTE)
When using the device in explosion hazardous areas, the additional temperature specifications in the section titled "Ex
relevant specifications" on the data sheet or in the the separate Ex safety instructions
(SM/FEX300/FEX500/ATEX/IECEX) or (SM/FEX300/FEX500/FM/CSA) must be observed.
Standard temperature design

Process Ambient temperature Measuring medium temperature
Model
connection Min. temp 1) Max. temp. Min. temp. Max. temp 2)
60 °C (140 °F) 100 °C (212 °F)
Flange -20 °C (-4 °F) -25 °C (-13 °F)
FEH311 40 °C (104 °F) 130 °C (266 °F)
FEH315 Variable process 60 °C (140 °F) 100 °C (212 °F)
-20 °C (-4 °F) -25 °C (-13 °F)
connections 40 °C (104 °F) 130 °C (266 °F)
60 °C (140 °F) 100 °C (212 °F)
Flange -20 °C (-4 °F) -25 °C (-13 °F)
FEH321 40 °C (104 °F) 130 °C (266 °F)
FEH325 Variable process 60 °C (140 °F) 100 °C (212 °F)
-20 °C (-4 °F) -25 °C (-13 °F)
connections 40 °C (104 °F) 130 °C (266 °F)
High temperature design (from size DN 10 (3/8“))

Process Ambient temperature Measuring medium temperature
Model
connection Min. temp 1) Max. temp. Min. temp. Max. temp.
FEH311
Flange -20 °C (-4 °F) 60 °C (140 °F) -25 °C (-13 °F) 180 °C (356 °F)
FEH315
FEH321
Flange -20 °C (-4 °F) 60 °C (140 °F) -25 °C (-13 °F) 180 °C (356 °F)
FEH325
1) The following is valid for the low temperature design (option): -40°C (-40°F).
2) For CIP/SIP cleaning, higher temperatures are permitted for limited time periods; refer to the table „Max. permissible cleaning temperature“ on page 171.

15.1.6 Material load

ASME flange, stainless steel, up to DN 100 (4") (CL150 / 300)
Limits for the permissible fluid temperature (TS) and permissible PS PS
pressure (PS) are calculated on the basis of the lining and flange [bar] [psi]
797.5
material used in the device (refer to the name plate on the device). 55
50 725.5
CL 300
45 652.5
Process Nominal PSmax TS 40 580.0
connection diameter bar 35 507.5
(PSI) 30 435.0
Wafer type DN 3 ... 50 40 -25 ... 130 °C 25 362.5
(1/10 ... 2“) (580) (-13 ... 266 °F) 20 290.0
CL 150
DN 65 ... 100 16 15 217.5
(2 1/2 ... 4“) (232) 10 145.0

5 72.5
Welded spuds DN 3 ... 40 40 -25 ... 130 °C 0
0
(1/10 ... 1 1/2“) (580) (-13 ... 266 °F) -30 -10 10 30 50 70 90 110 130 150 170 190 [°C]
-22 14 50 86 122 158 194 230 266 302 338 374 [°F] TS
DN 50, DN 80 16
(2“, 3“) (232) G00216
DN 65, DN 100 10 Fig. 88

(2 1/2“, 4“) (145)
For CIP / SIP cleaning, higher temperatures are permitted for limited
Threaded pipe DN 3 ... 40 40 -25 ... 130 °C
time periods; refer to the table titled "Maximum permissible cleaning
connection (1/10 ... 1 1/2“) (580) (-13 ... 266 °F)
temperature".
conforming to DIN
11851
JIS 10K-B2210 flange
DN 50, DN 80 16
(232) Nominal Material PN TS PS [bar]
(2“, 3“)
diameter
DN 65, DN 100 10 25 ... 100 Stainless steel 10 -25 ... 180 °C 10
(2 1/2“, 4“) (145) (1 ... 4") (-13 ... 356 °F) (145 psi)
Tri-Clamp DN 3 ... 50 16 -25 ... 121 °C
conforming to (1/10 ... 2“) (232) (-13 ... 250 °F)
DIN 32676 Wafer type design
DN 65 ... 100 10
(2 1/2 ... 4“) (145)
Tri-Clamp in acc. DN 3 ... 100 10 -25 ... 130 °C
with ASME BPE (1/10 ... 4“) (145) (-13 ... 266 °F)
External thread DN 3 ... 25 16 -25 ... 130 °C
ISO 228 / DIN 2999 (1/10 ... 1“) (232) (-13 ... 266 °F)
OD tubing DN 3 ... 50 10 -25 ... 130 °C
(1/10 ... 2“) (145) (-13 ... 266 °F)
1/8" sanitary DN 1 ... 2 10 -10 ... 120 °C
connectors (1/25 … 1/12“) (145) (-14 ... 248 °F)
DIN flange stainless steel to DN 100 (4")

PS PS
[bar] [psi]
45 652.5
40 580.0
PN 40
35 507.5
Fig. 89
30 435.0
25
PN 25
362.5
JIS 10K-B2210 wafer type design
20 290.0 Nominal Material PN TS PS [bar]
15
PN 16
217.5 diameter
10 145.0 DN 32 ... 100 1.4404 10 -25 ... 130 °C 10
PN 10
5 72.5 (1 1/4 ... 4") 1.4435 (-13 ... 266 °F) (145 psi)
0 0 1.4301
-30 -10 10 30 50 70 90 110 130 150 170 190 [°C]
TS
-22 14 50 86 122 158 194 230 266 302 338 374 [°F]
G00215
Fig. 87

15.1.7 Mechanical properties
Non-wetted parts
Wetted parts Standard Option
Part Standard Option Flange CrNi steel 1.4571 -
Lining PFA from DN 3 - (AISI 316Ti)
(1/10“)
PEEK DN 1 ... 2 Flowmeter sensor housing
(1/25 ... 1/12“)
Standard
Signal and CrNi steel 1.4539 CrNi steel 1.4571
grounding electrode (AISI 904L) (AISI 316Ti) Housing Deep-drawn housing
Hast. C-4 (2.4610) CrNi steel 1.4301 (AISI 304), 1.4308
Hast. B-3 (2.4600) Terminal box CrNi steel 1.4308 (AISI 304)
Titanium, tantalum, Meter tube Stainless steel
Platinum-iridium Cable gland Polyamide
Gaskets (for Weld EPDM (Ethylene- Silicone with FDA Stainless steel
stubs, threaded Propylene) with FDA approval (option, oil (in the case of hazardous area design
connection, Tri- approval, silicone or grease resistant) for ambient temperature of -40 °C
Clamp, external with FDA approval PTFE with FDA (40 °F))
threads) (CIP-resistant, no oils approval (DN 3 ... 8
or grease) (1/10 ... 5/16“))
Gasket for 1/8" PTFE Viton (only in
sanitary connectors combination with
PVC process
connection)
Process connection -
- Welded spuds, CrNi steel 1.4404 -
Tri-Clamp, etc. (AISI 316L)
- OD tubing CrNi steel 1.4435 -
(AISI 316L)

Appendix
16 Appendix
16.1 Return form
Statement on the contamination of devices and components

Repair and/or maintenance work will only be performed on devices and components if a statement form has been
completed and submitted.
Otherwise, the device/component returned may be rejected. This statement form may only be completed and
signed by authorized specialist personnel employed by the operator.
Customer details:
Company:
Address:
Contact person: Telephone:
Fax: Email:
Device details:
Type: Serial no.:
Reason for the return/description of the defect:
Was this device used in conjunction with substances which pose a threat or risk to health?
 Yes  No
If yes, which type of contamination (please place an X next to the applicable items)?
Biological  Corrosive/irritating  Combustible (slightly/extremely
combustible) 
Toxic  Explosive  Other Toxic substances 
Radioactive 
Which substances have come into contact with the device?

1.
2.
3.
We hereby state that the devices/components shipped have been cleaned and are free from any dangerous or
poisonous substances.
Town/city, date Signature and company stamp

Appendix
16.2 Overview of parameter settings (factory settings)

Sensor TAG Alphanumeric, max. 20 characters None
Sensor Location TAG Alphanumeric, max. 20 characters None
Qmax Depending on nominal diameter QmaxDN (see table in Section 6.6)
(see table in Section 6.6)
Q (Flowrate) Unit l/s; l/min; l/h; ml/s; ml/min; m3/s; m3/min; l/min
m3/h; m3/d; hl/h; g/s; g/min; g/h; kg/s;
kg/min; kg/h; kg/d; t/min; t/h; t/d
Totalizer/Pulse Unit m3; l; ml; hl; g; kg; t l
Pulses per Unit 1
Pulse Width 0,1 ... 2,000 ms 100 ms
Damping ( 1 Tau) 0,02 ... 60 sec. 1
DO1 Alarm Config Pulse F/Pulse R, Pulse F, General Alarm, Pulse F/Pulse R
Min. Flowrate Alarm, Max. Flowrate Alarm,
Empty Pipe, TFE, Only available for
FEP500 / FEH500 are: Gas Bubble,
Conductivity, Coating, Sensor Temp,
Signal
DO1 Drive Active, Passive Passive

DO2 Alarm Config F/R Signal, Pulse R, General Alarm, Min. F/R Signal
Flowrate Alarm, Max. Flowrate Alarm,
Empty Pipe, TFE, Only available for
Gas Bubble, Conductivity, Coating, Sensor
Temp, Signal
Digital Input DI No Function, Totalizer Reset(All), Flowrate Flowrate to Zero
to Zero, System Zero Adjust, Totalizer
Stop(All), Only available for
Switchover Dual Range, Start/Stop
Batching
Current Output 4 … 20 mA, 4 … 12 … 20 mA 4 … 20 mA
Iout at Alarm (in accordance with High alarm, adjustable to 21 … 23 mA or High alarm, 21.8 mA
NE43) Low alarm, adjustable to 3.5 … 3.6 mA For details refer to Section 9.2.
Iout at Flow >103% Off (no signaling, current output remains at Off
20.5 mA), high alarm, low alarm
Low Flow Cut Off 0 … 10 % 1%
Empty Pipe Detector On / Off Off
TFE Detector On / Off Off
16.2.1 For Profibus PA version

PA Addr. (BUS) 0 ... 126 126
Ident Nr. Selector 0 x 9700, 0 x 9740, 0 x 3430 0 x 3430

Appendix
16.3 Declaration of conformity
IMPORTANT (NOTE)
All documentation, declarations of conformity and certificates are available in ABB's download
area.
www.abb.com/flow
IMPORTANT (NOTE)
This is a class A device (industrial sector). This device can cause radio interferences in
residential areas. In this case, the operator may be required to take appropriate measures to
remedy the fault.

Notes
Notes

—
ABB Limited ABB Inc.
Measurement & Analytics Measurement & Analytics
Howard Road, St. Neots 125 E. County Line Road
Cambridgeshire, PE19 8EU Warminster, PA 18974
UK USA
Tel: +44 (0)870 600 6122 Tel: +1 215 674 6000
Fax: +44 (0)1480 213 339 Fax: +1 215 674 7183
Email: enquiries.mp.uk@gb.abb.com
ABB Engineering (Shanghai) Ltd.

Measurement & Analytics
No. 4528, Kangxin Highway, Pudong
New District
Shanghai, 201319,
P.R. China
Tel: +86(0) 21 6105 6666
Fax: +86(0) 21 6105 6677
Email: china.instrumentation@cn.abb.com
abb.com/flow
OI/FEX300/FEX500-EN Rev. J 02.2019
—
We reserve the right to make technical changes or modify the contents of this document
without prior notice. With regard to purchase orders, the agreed particulars shall prevail.
ABB does not accept any responsibility whatsoever for potential errors or possible lack of
information in this document.
We reserve all rights in this document and in the subject matter and illustrations contained
therein. Any reproduction, disclosure to third parties or utilization of its contents – in whole or
in parts – is forbidden without prior written consent of ABB.
© 2019 ABB
All rights reserved 3KXF231300R4201
Ex-FMU
(ABB)
SM/FEX300/FEX500/ATEX/IECEX-X1
ProcessMaster / HygienicMaster
FEX300, FEX500
ATEX / IECEx Zone 1, 2, 21, 22
Sicherheitshinweise für elektrische Betriebsmittel für

explosionsgefährdete Bereiche gemäß Richtlinie 94/9/EG
(ATEX) und IEC60079-0 (IECEx)
Magnetisch-induktiver Durchflussmesser
Safety instructions for electrical apparatus in potentially
explosive areas, in accordance with Directive 94/9/EC
(ATEX) and IEC60079-0 (IECEx)
Electromagnetic Flowmeter
Consignes de sécurité pour le matériel électrique en

atmosphère explosive selon la Directive 94/9/CE (ATEX) et
la norme CEI 60079-0 (IECEx)
Débitmètre électromagnétique
Instrucciones de seguridad para materiales eléctricos
utilizados en zonas potencialmente explosivas según la
Directiva 94/9/CE (ATEX) y IEC60079-0 (IECEx)
Medidor electromagnético de caudal
Sikkerhedsregler for elektrisk materiel til brug i
eksplosionsfarlige områder iht. direktiv 94/9/EF (ATEX) og
DS/EN 60079-0 (IECEx)
Magnetisk-induktiv flowmåler
Norme di sicurezza per mezzi di esercizio elettrici per zone
a rischio di deflagrazione secondo la direttiva 94/9/CE
(ATEX) e IEC60079-0 (IECEx)
Misuratore di portata elettromagnetico
Veiligheidsaanwijzingen voor elektrische bedrijfsmiddelen
voor explosiegevaarlijke bereiken, volgens richtlijn 94/9/EG
(ATEX) en IEC60079-0 (IECEx)
Elektromagnetische debietmeter
Instruções de segurança para equipamentos eléctricos em
áreas com perigo de explosão conforme a Directiva
94/9/CE (ATEX) e IEC60079-0 (IECEx)
Medidor de vazão mássica eletromagnético
Säkerhetsanvisningar för elektrisk utrustning för
explosionsfarliga områden enligt direktivet 94/9/EG (ATEX)
och IEC60079-0 (IECEx)
Induktiva flödesmätare
Räjähdysherkillä alueilla käytettävien sähköisten
käyttövälineiden turvallisuusohjeet direktiivien 94/9/EY
(ATEX) ja IEC60079-0 (IECEx) mukaan
Magneettinen virtausmittari
Contents
Important
This document forms an integral part of the following manuals:
• Operating Instruction OI/FEX300/FEX500
• Commissioning instruction CI/FEX300/FEX500
1 Safety ....................................................................................................................................................................4
1.1 Operator liability .............................................................................................................................................4
1.2 Technical limit values .....................................................................................................................................4
1.3 Safety information for electrical installation....................................................................................................4
1.4 Symbols and warnings ...................................................................................................................................5
2 Device designs ....................................................................................................................................................6
2.1 Model with compact design ............................................................................................................................6
2.1.1 ATEX/IEC Zone 1....................................................................................................................................6
2.1.2 ATEX/IEC Zone 2....................................................................................................................................7
2.2 Model with remount mount design .................................................................................................................7
2.2.1 ATEX/IEC Zone 1....................................................................................................................................7
2.2.2 ATEX/IEC Zone 2....................................................................................................................................9
2.3 Overview: The fast track to the device data .................................................................................................10
2.4 Name plate ...................................................................................................................................................11
2.4.1 Name plate for model with compact design ..........................................................................................11
2.4.2 Name plate for model with remote mount design .................................................................................12
2.4.3 Name plate for transmitter.....................................................................................................................13
3 Mounting ............................................................................................................................................................14
3.1 Information about opening and closing the housing ....................................................................................14
3.2 Cable entries ................................................................................................................................................15
3.3 High temperature version .............................................................................................................................16
3.4 Protection class IP 68...................................................................................................................................16
3.5 Rotating the transmitter housing ..................................................................................................................17
3.6 Information about using the device in areas with combustible dust.............................................................18
3.6.1 Maximum Allowable Surface Temperature ...........................................................................................18
3.6.2 Min. signal cable length.........................................................................................................................18
4 Ex relevant specifications for operation in Zones 1, 21, and 22 ..................................................................19
4.1 Electrical connection ....................................................................................................................................19
4.1.1 Models FEP315 / FEP515, FEH315 / FEH515, FEP325 / FEP525 and FET325 / FET525 in Zone 1
with HART protocol ...............................................................................................................................19
4.1.2 Models FEP315 / FEP515, FEH315 / FEH515, FEP325 / FEP525 and FET325 / FET525 in Zone 1
with PROFIBUS PA or FOUNDATION Fieldbus...................................................................................20
4.1.3 Models FEP325 / FEP525 in Zone 1 and transmitters FET325 / FET525 in Zone 2 or FET321 /
FET521 outside the hazardous area with HART protocol ....................................................................21
4.1.4 Models FEP325 / FEP525 in Zone 1 and transmitters FET325 / FET525 in Zone 2 or FET321 /
FET521 outside the hazardous area with PROFIBUS PA or FOUNDATION Fieldbus ........................22
4.2 Electrical data for operation in Zone 1 / Div. 1 .............................................................................................23
4.2.1 Devices with HART protocol .................................................................................................................23
4.2.2 Devices with PROFIBUS PA or FOUNDATION Fieldbus.....................................................................24
4.3 Temperature data for operation in Zone 1 / Div. 1 .......................................................................................25
5 Ex relevant specifications for operation in zones 2, 21 and 22....................................................................29
5.1 Electrical connection ....................................................................................................................................30
5.1.1 Models FEP315 / FEP515, FEP325 / FEP525, FEH315 / FEH515, FEH325 / FEH525, FET325 /
FET525 in Zone 2, FET321 / FET 521 outside the hazardous area with HART protocol ....................30
5.1.2 Models FEP315 / FEP515, FEP325 / FEP525, FEH315 / FEH515, FEH325 / FEH525, FET325 /
FET525 in Zone 2, FET321 / FET 521 outside the hazardous area with HART protocol ....................31
5.2 Electrical data for operation in Zone 2 / Div. 2 .............................................................................................32
5.2.1 Devices with HART protocol .................................................................................................................32
2 - EN FEX300, FEX500 SM/FEX300/FEX500/ATEX/IECEX-X1
Contents
5.2.2 Devices with PROFIBUS PA or FOUNDATION Fieldbus.....................................................................32
5.3 Temperature data for operation in Zone 2 / Div. 2 .......................................................................................33
6 Commissioning..................................................................................................................................................36
6.1 Preliminary checks prior to start-up..............................................................................................................36
6.2 Notes on combining the FEP325 flowmeter sensor with the FET325 transmitter or the FEP525 flowmeter
sensor with the FET525 transmitter .............................................................................................................36
6.3 Special features of version designed for operation in Ex zone 1 / Div. 1.....................................................37
6.3.1 Configuring the current output ..............................................................................................................37
6.3.2 Configuration of the digital outputs .......................................................................................................37
6.4 Changing the type of protection ...................................................................................................................39
7 Maintenance.......................................................................................................................................................40
7.1 General information......................................................................................................................................40
7.2 Replacing the transmitter or sensor .............................................................................................................41
7.2.1 Transmitter ............................................................................................................................................41
7.2.2 Flowmeter sensor..................................................................................................................................41
8 Spare parts list...................................................................................................................................................42
8.1 Fuses for transmitter electronics ..................................................................................................................42
8.2 Spare parts for the compact design .............................................................................................................42
8.3 Spare parts for remote design......................................................................................................................43
8.3.1 field-mount housing...............................................................................................................................43
8.3.2 Round field-mount housing ...................................................................................................................44
8.3.3 Flowmeter sensor (Zone 2/Div 2)..........................................................................................................44
8.3.4 Flowmeter sensor (Zone 1/Div 1)..........................................................................................................45
9 Appendix ............................................................................................................................................................46
9.1 Other applicable documents ........................................................................................................................46
9.2 Approvals and certifications .........................................................................................................................46
SM/FEX300/FEX500/ATEX/IECEX-X1 FEX300, FEX500 EN - 3

Safety
1 Safety
1.1 Operator liability
The operator must strictly observe the applicable national regulations with regard to installation,
function tests, repairs, and maintenance of electrical devices.
When operating the meter with combustible dusts, it is essential to comply with IEC 61241ff.
The safety instructions for electrical apparatus in potentially explosive areas must be complied
with, in accordance with Directive 94/9/EC (ATEX) and IEC60079-14 (Installation of equipment
in potentially explosive atmospheres).
To ensure safe operation, the requirements of EU Directive ATEX 118a (minimum requirements
concerning the protection of workers) must be met.
1.2 Technical limit values

Particular attention must be paid to the limit values listed in the sections relating to "ex relevant
specifications":
• The data for the signal inputs and outputs of the transmitter
• The permissible temperature data and limit values
1.3 Safety information for electrical installation

Never attempt electrical connection unless the power supply is switched off.
Ground the flowmeter sensor and transmitter housing. Make sure there is no risk of explosion.

Safety
1.4 Symbols and warnings
This symbol in conjunction with the signal word "Danger" indicates an imminent danger.
Failure to observe this safety information will result in death or severe injury.

This symbol in conjunction with the signal word "Danger" indicates an imminent electrical
hazard. Failure to observe this safety information will result in death or severe injury.

This symbol in conjunction with the signal word “Warning“ indicates a possibly dangerous
situation. Failure to observe this safety information may result in death or severe injury.
This symbol in conjunction with the signal word "Warning" indicates a potential electrical
hazard. Failure to observe this safety information may result in death or severe injury.
CAUTION – <Minor injury>

This symbol in conjunction with the signal word “Caution“ indicates a possibly dangerous
situation. Failure to observe this safety information may result in minor or moderate injury.
This may also be used for property damage warnings.
ATTENTION – <Property damage>!

The symbol indicates a potentially damaging situation.
Failure to observe this safety information may result in damage to or destruction of the product
and/or other system components.
IMPORTANT (NOTICE)
This symbol indicates operator tips, particularly useful information, or important information
about the product or its further uses. It does not indicate a dangerous or damaging situation.

Device designs
2 Device designs
The devices are available in two series. ProcessMaster 300 / HygienicMaster 300 with basic
functions and ProcessMaster 500 / HygienicMaster 500 with extended functions and options.
The series is identified by the fourth digit of the model number:
Model number / device series
FEP3... ProcessMaster 300 FEP5... ProcessMaster 500
FEH3... HygienicMaster 300 FEH5... HygienicMaster 500
Devices suitable for use in potentially explosive atmospheres feature the corresponding Ex
mark on their name plates.
The design intended for use in Ex Zones 2, 21, and 22 is identified by the letter "M" in the
model number, while the design intended for use in Zones 1 and 21 is identified by the letter
"L".
Example:
FEP315-100A1S1D2B0A1A0M1A1C1, FEP325-100A1S1D2B0A1A1M1A0Y1,
FET325-1A0M1A1C1
2.1 Model with compact design

The transmitter and the flowmeter sensor form a single mechanical entity.
Important
For further information about the instruments' explosion protection approval please refer to the
Ex test certificates (available on the product CD or under www.abb.com/flow).
2.1.1 ATEX / IEC Zone 1

ProcessMaster 300 / ProcessMaster 500 HygienicMaster 300 / HygienicMaster 500
FEP315.....L.... / FEP515.....L.... FEH315.....L.... / FEH515.....L....
Zone 1, 21 Zone 1, 21
G00886 G00883
ATEX ATEX
Certificate: FM08ATEX0080 Certificate: FM08ATEX0080
DN3-300: II 2G Ex d e ia ma IIC T6 … T2 II 2G Ex d e ia ma IIC T6 … T2
>DN300 : II 2G Ex d e ia IIC T6 … T2
II 2 D Ex tD iaD A21 IP6X T70°C … Tmedium II 2 D Ex tD iaD A21 IP6X T70°C … Tmedium
IEC IEC
Certificate: FME08.0004 Certificate: FME08.0004
DN3-300: Ex d e ia ma IIC T6 … T2 Gb Ex d e ia ma IIC T6 … T2 Gb
>DN300 : Ex d e ia IIC T6 … T2 Gb
Ex tD iaD A21 IP6X T70°C … Tmedium Ex tD iaD A21 IP6X T70°C … Tmedium

Device designs
FEP315.....M.... / FEP515.....M.... FEH315.....M.... / FEH515.....M....
Zones 2, 21, 22 Zones 2, 21, 22
ATEX ATEX
Certificate: FM08ATEX0038, FM08ATEX0080 Certificate: FM08ATEX0038, FM08ATEX0080
II 3 G Ex nA nC IIC T4 … T3 II 3 G Ex nA nC IIC T4 … T3
II 2 D Ex tD A21 IP6X T70 °C … Tmedium II 2 D Ex tD A21 IP6X T70 °C … Tmedium
IEC IEC
Ex nA nC IIC T4 … T3 Ex nA nC IIC T4 … T3
Ex tD A21 IP6X T70 °C … Tmedium Ex tD A21 IP6X T70 °C … Tmedium
2.2 Model with remount mount design

The transmitter is mounted in a separate location from the flowmeter sensor. The electrical
connection between the transmitter and flowmeter sensor may only be established using the
signal cable supplied.
Important
For further information about the instruments' explosion protection approval please refer to the
Ex test certificates (available on the product CD or under www.abb.com/flow).

Risk of explosion caused by incorrect transmitter installation
The FET321 / FET521 transmitter is not approved for hazardous areas.
The FET321 / FET521 transmitter must not be installed or operated in potentially explosive
atmospheres.
If the FEP325 flowmeter sensor is combined with the FET321 or FET325 transmitter (Zone 2),
the maximum permissible signal cable length is 50 m (164 ft) with a minimum conductivity of
5 µS/cm, without a pre-amplifier. The same is valid for the FEP525 flowmeter sensor with
FET521 or FET525 (Zone 2) transmitter.
If the FEP325 flowmeter sensor is combined with the FET325 transmitter (Zone 1), 10 m
(32.8 ft) signal cables are permanently connected to the transmitter. The same is valid for the
FEP525 flowmeter sensor with FET525 (Zone 1) transmitter.

Device designs
Flowmeter sensor
ProcessMaster 300 / ProcessMaster 500
FEP325.....L.... / FEP525.....L....
In Ex area, Zone 1, 21, 22
G00862
ATEX
Certificate: FM08ATEX0080
DN3-300: II 2G Ex e ia ma IIC T6 … T2
>DN300: II 2G Ex e ia IIC T6 … T2
II 2 D Ex tD iaD A21 IP6X T85 °C … Tmedium
IEC
Certificate: FME08.0004
DN3-300: Ex e ia ma IIC T6 … T2 Gb
>DN300 : Ex e ia IIC T6 … T2 Gb
Ex tD A21 IP6X T85 °C … Tmedium Gb
Transmitter
In Ex area, Zone 1, 21, 22 In Ex area, Zone 2, 21, 22 Outside the Ex area
FET325.....L.... / FET525.....L.... FET325.....M.... / FET525.....M.... FET321 / FET521
G00863
ATEX ATEX -
Certificate: FM08ATEX0038,
Certificate: FM08ATEX0080 No Ex approval!
FM08ATEX0080
II 2 (2) G Ex d e [ia] IIC T6 II 3 G Ex nA IIC T4
II 2 (2) D Ex tD [iaD] A21 IP6X T70°C II 2 D Ex tD A21 IP6X T70°C
IEC IEC
Ex d e [ia Gb] IIC T6 Gb Ex nA IIC T4
Ex tD [iaD] A21 IP6X T70°C Ex tD A21 IP6X T70°C

Device designs
Risk of explosion caused by incorrect transmitter installation
The FET321 / FET521 transmitter is not approved for hazardous areas.
The FET321 / FET521 transmitter must not be installed or operated in potentially explosive
atmospheres.
Without a pre-amplifier, the maximum permissible signal cable length is 50 m (164 ft) with a
minimum conductivity of 5 µS/cm.
With a pre-amplifier, the maximum permissible signal cable length is 200 m (656 ft).
Flowmeter sensor
FEP325.....M.... / FEP525.....M.... FEH325.....M.... / FEH525.....M....
In Ex area, Zone 2, 21, 22 In Ex area, Zone 2, 21, 22
ATEX ATEX
Certificate: FM08ATEX0038, FM08ATEX0080 Certificate: FM08ATEX0038, FM08ATEX0080
II 3 G Ex nA IIC T6 … T3 II 3 G Ex nA IIC T6 … T3
II 2 D Ex tD A21 IP6X T85 °C … Tmedium II 2 D Ex tD A21 IP6X T85 °C … Tmedium
IEC IEC
Ex nA IIC T6 … T3 Ex nA IIC T6 … T3
Ex tD A21 IP6X T85 °C … Tmedium Ex tD A21 IP6X T85 °C … Tmedium
Transmitter
(The flowmeter sensors illustrated above can be combined with the transmitters described
below)
In Ex area, Zone 2, 21, 22 Outside the Ex area
FET325.....M.... / FET525.....M.... FET321 / FET521
ATEX -
Certificate: FM08ATEX0038, FM08ATEX0080 No Ex approval!
II 3 G Ex nA IIC T4
II 2 D Ex tD A21 IP6X T70°C
IEC
Certificate: FME08.0004
Ex nA IIC T4
Ex tD A21 IP6X T70°C

Device designs
2.3 Overview: The fast track to the device data
These safety instructions related to explosion protection are valid in conjunction with the
following certificates:
Validity area Certificates

ATEX FM08ATEX0038, FM08ATEX0080
IEC FME08.0004
NEPSI Cert No. GYJ091345
GOST
Russia Ex certificate No. 8468478, GOST-R certificate No. 0634300
Kazakhstan Ex certificate No. 001032, GOST-K certificate No. 0025653
Ukraine Ex certificate No. 1093, DVSC certificate No. 1771
White Russia Ex certificate No. 05-687-2009, GGTN certificate No. 05-687-2009
Operation in Electrical connection Ex data

Model
zone Chapter
Zone1, 21 4.1.1 and 4.1.2 4.2 and 4.3
FEP315 or FEP515
ProcessMaster 300 / ProcessMaster 500
Zones 2, 21, 22 5.1.1 and 5.1.2 5.2 and 5.3
Zone1, 21 4.1.3 and 4.1.4 4.2 and 4.3

FEP325 + FET325
or
FEP525 + FET525
Zones 2, 21, 22 5.1.1 and 5.1.2 5.2 and 5.3
Zone1, 21 4.1.3 and 4.1.4 4.2 and 4.3

FEP325 + FET321
or
FEP525 + FET521 Zones 2, 21, 22 5.1.1 and 5.1.2 5.2 and 5.3
Zone1, 21 4.1.1 and 4.1.2 4.2 and 4.3

HygienicMaster 300 /
FEH315 or FEH515
HygienicMaster 500
Zones 2, 21, 22 5.1.1 and 5.1.2 5.2 and 5.3

FEH325 + FET325 Zone1, 21 4.1.3 and 4.1.4 4.2 and 4.3
or
FEH525 + FET525 Zones 2, 21, 22 5.1.1 and 5.1.2 5.2 and 5.3
FEH325 + FET321 Zone1, 21 4.1.3 and 4.1.4 4.2 and 4.3
or
FEH525 + FET521 Zones 2, 21, 22 5.1.1 and 5.1.2 5.2 and 5.3
Important
All documentation, declarations of conformity, and certificates are available in ABB's download
area.
www.abb.com/flow

Device designs
2.4 Name plate
2.4.1 Name plate for model with compact design
2
12
3
13
4 PN 16
14
5
15
6
16
7
17
8
18
9
19
10
20
11
21
G00629
Fig. 1: Integral mount design

1 Model number (for more detailed information about 17 Accuracy to which the unit was calibrated (e.g., 0.2%
the technical design, refer to the data sheet or the of rate)
order confirmation) 18 Version level (xx.xx.xx)
2 Order no. 19 Label indicating whether the unit is subject to the
3 Meter size and nominal pressure rating Pressure Equipment Directive (PED).
4 Material: Flange/lining/electrode Information on the relevant fluid group.
5 Tmed = maximum permissible fluid temperature Fluid group 1 = hazardous fluids, liquid, gaseous.
Tamb = maximum permissible ambient temperature (Pressure Equipment Directive = PED).
6 Calibration value Qmax DN
Pressure Equipment Directive 97/23/EC, it is
7 Calibration value Ss (span)
classified in accordance with SEP (= sound
Calibration value Sz (zero point)
engineering practice) as per Art. 3 Para. 3 of the PED.
8 Communications protocol of transmitter
If no such information is present, it means that the
9 Excitation frequency of sensor coils
device does not claim to comply with the requirements
10 Software version
of the Pressure Equipment Directive 97/23/EC. Water
11 Year of manufacture
supplies and connected equipment accessories are
12 CE mark
classed as an exception in accordance with guideline
13 Serial number for identification by the manufacturer
1/16 of Art. 1 Para. 3.2 of the Pressure Equipment
14 Client-specific TAG number (if specified)
Directive.
20 Ex mark according to ATEX (example)
16 Supplementary information: EE = grounding
21 Ex mark according to IECEx (example)
electrodes, TFE = partial filling electrode
Important

Device designs
2.4.2 Name plate for model with remote mount design
1
FEP325 11
2
12
3
4
5
6
13
7
14
8
9
15
10
16
17
18
G00630
Fig. 2: Remote mount design (external transmitter)

1 Model number (for more detailed information about 15 Excitation frequency of sensor coils
the technical design, refer to the data sheet or the 16 Label indicating whether the unit is subject to the
order confirmation) Pressure Equipment Directive (PED).
2 Order no. Information on the relevant fluid group.
3 Meter size and nominal pressure rating Fluid group 1 = hazardous fluids, liquid, gaseous.
4 Material: Flange/lining/electrode (Pressure Equipment Directive = PED).
5 Client-specific TAG number (if specified) If the pressure equipment is not subject to the
6 Tmed = maximum permissible fluid temperature Pressure Equipment Directive 97/23/EC, it is
Tamb = maximum permissible ambient temperature classified in accordance with SEP (= sound
engineering practice) as per Art. 3 Para. 3 of the PED.
If no such information is present, it means that the
8 Calibration value Qmax DN
device does not claim to comply with the requirements
9 Calibration value Ss (span)
of the Pressure Equipment Directive 97/23/EC. Water
Calibration value Sz (zero point)
supplies and connected equipment accessories are
10 Year of manufacture
classed as an exception in accordance with guideline
11 CE mark
1/16 of Art. 1 Para. 3.2 of the Pressure Equipment
12 Serial number for identification by the manufacturer
Directive.
13 Supplementary information: EE = grounding
17 Ex mark according to ATEX (example)
electrodes, TFE = partial filling electrode
18 Ex mark according to IECEx (example)
14 Accuracy to which the unit was calibrated
(e.g., 0.2% of rate)
Important

Device designs
2.4.3 Name plate for transmitter
4 9
G00864
Fig. 3: External transmitter, model: FET325 / FET525 for Zone 1

the technical design, refer to the data sheet or the 6 Supply voltage
order confirmation) 7 Communications protocol of transmitter
2 Order no. 8 Software version
3 Client-specific TAG number (if specified) 9 Version level (xx.xx.xx)
4 Tamb = maximum permissible ambient temperature 10 Ex mark according to ATEX (example)
4 9
6
10
7
G00632-01
Fig. 4: External transmitter, model FET325 / FET525 for Zone 2

the technical design, refer to the data sheet or the 6 Supply voltage
order confirmation) 7 Communications protocol of transmitter
2 Order no. 8 Software version
3 Client-specific TAG number (if specified) 9 Version level (xx.xx.xx)
4 Tamb = maximum permissible ambient temperature 10 Ex mark according to ATEX (example)

Mounting
3 Mounting
3.1 Information about opening and closing the housing
Risk of explosion!
When the housing cover is open, the explosion protection is suspended.
Before opening the housing switch off the power to all connection lines and wait at least 20
minutes.
Release the cover safety device by screwing in the Allen screw (1).
Before closing the housing make sure that the gasket (O-ring) for the housing cover is seated
correctly.
After closing the housing, lock the housing cover by unscrewing the Allen screw (1) to prevent
opening the cover accidentally.
1 1
G00758
Fig. 5

Mounting
3.2 Cable entries
1 2 3
G00759
Fig. 6
The cable glands (1) supplied are ATEX-/IECEx-certified.

The black plugs (3) in the cable fittings are intended to provide protection during transport.
Any unused cable entry points must be sealed prior to commissioning, using the seals (2)
supplied; these can be found in the terminal box.
The use of standard cable fittings and seals is prohibited.
The outer diameter of the connecting cable must measure between 6 mm (0.24 in) and
12 mm (0.47 in) to ensure the necessary seal integrity.
Make sure that the cable fittings and seals are correctly and tightly installed.
Black cable fittings are installed by default when the device is supplied. If signal outputs are
connected to intrinsically safe circuits, we recommend that you replace the black caps on the
corresponding cable fittings with the blue ones supplied.
Important
In order to provide for the required temperature resistance, devices in low-temperature design
(optional, ambient temperature down to -40 °C (-40 °F) are delivered with a cable gland made
from metal.
When operating these devices on intrinsically safe current circuits, remove the metal cable
glands.

Mounting
3.3 High temperature version
The high temperature design allows for complete thermal insulation of the sensor, up to the
maximum illustrated device height.
The pipeline and sensor must be insulated after installing the unit according to the following
illustration.
The thermal resistance of the insulation must not exceed λ = 0.036 W/(mK); if it does, the
thickness of the insulation must be reduced accordingly.
G00654
Fig. 7
1 Insulation
The surface temperature depends on the fluid temperature.
Model name Maximum surface temperature

FEP325 / FEH325
T 85 °C (185 °F) ... Tmedium
FEP525 / FEH525
FEP315 / FEH315
T 70 °C (158 °F) ... Tmedium
FEP515 / FEH515
3.4 Protection class IP 68

For installation, see the commissioning instruction.

Mounting
3.5 Rotating the transmitter housing
3
2
3 G00761
Fig. 8
1. Loosen the Allen screws (3) on the front and back sides, but do not remove entirely.
2. Loosen screws (2) and rotate the transmitter housing (1) by 90° to the left or right.
3. Retighten screws (2) and Allen screws (3).
Risk of explosion!
When the screws for the transmitter housing are loosened, the explosion protection is
suspended.
Tighten all screws (2, 3) for the transmitter housing prior to commissioning.

Mounting
3.6 Information about using the device in areas with combustible dust
The device is approved for use in potentially explosive areas (gas and dust).
The Ex certification is provided on the name plate.
Risk of explosion!
The dust explosion protection is also provided by the housing.
Modifications to the housing are not allowed (e.g., removing or omitting parts).
3.6.1 Maximum Allowable Surface Temperature

Model name Maximum surface temperature
FEP325 / FEH325
T 85 °C (185 °F) ... Tmedium
FEP525 / FEH525
FEP315 / FEH315
T 70 °C (158 °F) ... Tmedium
FEP515 / FEH515
FET325 / FET525 T 70 °C (158 °F)
The maximum surface temperature is applicable to dust layers of up to 5 mm (0.20 inch) in

thickness. The minimum permissible ignition and smoldering temperatures of the dust
atmosphere should be calculated in accordance with IEC61241ff.
With thicker dust layers, the maximum permissible surface temperature must be reduced. The
dust can be conductive or non-conductive. IEC61241ff must be observed.
3.6.2 Min. signal cable length

In explosion protection areas, the signal cable cannot be shorter than 5 m (16.4 ft).

Ex relevant specifications for operation in Zones 1, 21, and 22
4 Ex relevant specifications for operation in Zones 1, 21, and 22
4.1 Electrical connection
Important
The housing for the transmitter and flowmeter sensor must be connected to the potential
equalization PA. The operator must ensure that when connecting the protective conductor
(PE) no potential differences can occur between protective conductor and potential
equalization (PA).
A temperature of 70 °C (158 °F) at the cable entry is assumed for the Ex calculations.
Therefore, the cables used for the supply power and the signal inputs and outputs must have a
minimum specification of 70 °C (158 °F).
4.1.1 Models FEP315 / FEP515, FEH315 / FEH515, FEP325 / FEP525 and FET325 / FET525 in Zone 1 with
HART protocol
FEP315 FEH315
FEP515 FEH515
A
24 V
6
1+ 2- + - + - + - + -
L N 31 32 51 52 81 82 41 42 M1 M2 D1 D2 3 2S E2 E1 1S SE
6
6
{
{
{
{
{
1 PE 2 3 4 5 FEP325 FET325
FEP525 FET525
7 8 9 10 11 12 13
6
M1 M2 D1 D2 3 E2 E1 SE
B
6 G00866-01
Fig. 9
A Transmitter 4 Digital input: (terminal 81/82)
B Flowmeter sensor Only available in conjunction with "passive" current output.
1 Supply power: Function can be configured locally using software: External output
See name plate switch-off, external totalizer reset, external totalizer stop, other
2 Current output (terminals 31/32) Data for the optocoupler: 16 V ≤ U ≤ 30 V, Ri = 2 kΩ
Dependent upon the device design, an "active" or a "passive" 5 Digital output DO2 (terminal 41/42)
output will be available. The output is always a "passive" output (optocoupler).
For devices designed for use in Ex Zone 1, the current output Data for the optocoupler: Umax = 30 V, Imax = 220 mA
cannot be reconfigured locally. Function can be configured locally as "Pulse Output" or "Digital
• Active: 4 ... 20 mA, HART protocol (standard), load: 250 Ω ≤ R ≤ Output" using software. Factory setting is "Digital Output", flow
300 Ω direction signaling.
• Passive: 4 ... 20 mA, HART protocol (standard), 6 Equipotential bonding
load: 250 Ω ≤ R ≤ 650 Ω, 7 Brown
Supply voltage for the current output: minimum 11 V, maximum 8 Red
30 V at terminals 31/32. 9 Orange
3 Digital output DO1 (terminal 51/52) 10 Yellow
The output is always a "passive" output (optocoupler). 11 Green
• Data for the optocoupler: Umax = 30 V, Imax = 220 mA, 12 Blue
Function can be configured locally as "Pulse Output" or "Digital 13 Violet
Output" using software. Factory setting is "Pulse Output".
• Configuration as pulse output. Maximum pulse frequency:
5,250 Hz, pulse width: 0.1 … 2,000 ms. The pulse factor and
pulse width are interdependent and are calculated dynamically.
• Configuration as contact output. Function: System alarm, empty
pipe alarm, max./min. alarm, flow direction signaling, other
All inputs and outputs are electrically isolated from each other and from the supply power.
The electrical specifications given are operating values.

4.1.2 Models FEP315 / FEP515, FEH315 / FEH515, FEP325 / FEP525 and FET325 / FET525 in Zone 1 with
PROFIBUS PA or FOUNDATION Fieldbus
FEP315 FEH315
FEP515 FEH515
A
FF+ FF- 6
1+ 2- PA+ PA- + -
L N 97 98 41 42 M1 M2 D1 D2 3 2S E2 E1 1S SE
6
6
{
{
{
{
{
1 PE 2 3 4 5 FEP325 FET325
FEP525 FET525
7 8 9 10 11 12 13
6
M1 M2 D1 D2 3 E2 E1 SE
B
6 G01019
Fig. 10
A Transmitter 5 Digital output DO2 (terminal 41/42)
B Flowmeter sensor The output is always a "passive" output (optocoupler).
1 Supply power: Data for the optocoupler: Umax = 30 V, Imax = 220 mA
See name plate Function can be configured locally as "Pulse Output" or "Digital
2 Digital communication (terminal 97 / 98) Output" using software. Factory setting is "Digital Output", flow
• PROFIBUS PA in acc. with IEC 61158-2 (PA+ / PA-) direction signaling.
U = 9 ... 32 v, I = 10 mA (normal operation), I = 13 mA (in the 6 Equipotential bonding
event of an error / FDE) 7 Brown
Bus connection with integrated protection against polarity 8 Red
reversal 9 Orange
The bus address can be set via the DIP switches in the device, 10 Yellow
the transmitter display or the fieldbus. 11 Green
or 12 Blue
• FOUNDATION Fieldbus in acc. with IEC 61158-2 (FF+ / FF-) 13 Violet
U = 9 ... 32 v, I = 10 mA (normal operation), I = 13 mA (in the
event of an error / FDE)
Bus connection with integrated protection against polarity
reversal
3 Not assigned
4 Not assigned
For devices with PROFIBUS PA or FOUNDATION Fieldbus the bus termination must conform to the FISCO model or the explosion protection
regulations, respectively.

4.1.3 Models FEP325 / FEP525 in Zone 1 and transmitters FET325 / FET525 in Zone 2 or FET321 / FET521
outside the hazardous area with HART protocol
FEP325 / FEP525 flowmeter sensor in the FET325 / FET525 transmitter FET321 / FET521 transmitter outside
hazardous area (Zone 1) in the hazardous area (Zone 2) the hazardous area
6a
A
24 V
1+ 2- + - + - + - + -
L N 31 32 51 52 81 82 41 42 M1 M2 D1 D2 3 2S E2 E1 1S SE
6 / 6a
{
{
{
{
{
1 PE 2 3 4 5
7 8 9 10 11 12 13
M1 M2 D1 D2 3 E2 E1 SE
B
6 G00867
Fig. 11
B Flowmeter sensor Function can be configured locally using software: External output
1 Supply power: switch-off, external totalizer reset, external totalizer stop, other
See name plate Data for the optocoupler: 16 V ≤ U ≤ 30 V, Ri = 2 kΩ
2 Current output (terminals 31/32) 5 Digital output DO2 (terminal 41/42)
The current output can be configured locally as an "active" or The output is always a "passive" output (optocoupler).
"passive" output. Data for the optocoupler: Umax = 30 V, Imax = 220 mA,
• Active: 4 ... 20 mA, HART protocol (standard), fmax ≤ 5250 Hz,
load: 250 Ω ≤ R ≤ 650 Ω Function can be configured locally as "Pulse Output" or "Digital
• Passive: 4 ... 20 mA, HART protocol (standard), Output" using software. Factory setting is "Digital Output", flow
load: 250 Ω ≤ R ≤ 650 Ω, direction signaling.
Supply voltage for the current output: minimum 11 V, maximum 6 Equipotential bonding
30 V at terminals 31/32. 6a Functional ground (only with flowmeter sensor FET321 outside
3 Digital output DO1 (terminal 51/52) the hazardous area)
The digital output can be configured locally as an "active" or 7 Brown
"passive" output. 8 red
• Active: U = 19 ... 21 V. Imax = 220 mA, fmax ≤ 5250 Hz 9 Orange
• Passive: Umax = 30 V, Imax = 220 mA, fmax ≤ 5250 Hz 10 yellow
Function can be configured locally as "Pulse Output" or "Digital 11 Green
Output" using software. Factory setting is "Pulse Output". 12 blue
• Configuration as pulse output. Maximum pulse frequency: 13 Violet

4.1.4 Models FEP325 / FEP525 in Zone 1 and transmitters FET325 / FET525 in Zone 2 or FET321 / FET521
outside the hazardous area with PROFIBUS PA or FOUNDATION Fieldbus
FEP325 / FEP525 flowmeter sensor in the FET325 / FET525 transmitter FET321 / FET521 transmitter outside
hazardous area (Zone 1) in the hazardous area (Zone 2) the hazardous area
6a
A
FF+ FF-
1+ 2- PA+ PA- + -
L N 97 98 41 42 M1 M2 D1 D2 3 2S E2 E1 1S SE
6 / 6a
{
{
{
{
{
1 PE 2 3 4 5
7 8 9 10 11 12 13
M1 M2 D1 D2 3 E2 E1 SE
B
6 G01006
Fig. 12
1 Supply power: Data for the optocoupler: Umax = 30 V, Imax = 220 mA
See name plate Function can be configured locally as "Pulse Output" or "Digital
2 Digital communication (terminal 97 / 98) Output" using software. Factory setting is "Digital Output", flow
• PROFIBUS PA in acc. with IEC 61158-2 (PA+ / PA-) direction signaling.
U = 9 ... 32 v, I = 10 mA (normal operation), I = 13 mA (in the 6 Equipotential bonding
event of an error / FDE) 7 Brown
Bus connection with integrated protection against polarity 8 Red
reversal 9 Orange
The bus address can be set via the DIP switches in the device, 10 Yellow
the transmitter display or the fieldbus. 11 Green
or 12 Blue
• FOUNDATION Fieldbus in acc. with IEC 61158-2 (FF+ / FF-) 13 Violet
U = 9 ... 32 v, I = 10 mA (normal operation), I = 13 mA (in the
event of an error / FDE)
Bus connection with integrated protection against polarity
reversal
3 Not assigned
4 Not assigned
For devices with PROFIBUS PA or FOUNDATION Fieldbus the bus termination must conform to the FISCO model or the explosion protection
regulations, respectively.

4.2 Electrical data for operation in Zone 1 / Div. 1
When operating in potentially explosive areas, observe the following electrical data for the signal inputs and outputs of the transmitter. For the
correct current output design (active/passive), see the marking contained in the device's terminal box.
Model: FEP315, FEH315 / FEP515, FEH515 or FET325 / FET525

Operating values Ex data
Explosion protection type Ex i, IS
Inputs and UN IN UO IO PO CO COPA LO
outputs [V] [mA] [V] [mA] [mW] [nF] [nF] [mH]
Active current 20 100 500 210 195 6
output UI II PI CI CIPA LI
Terminal 31/32 30 30
[V] [mA] [mW] [nF] [nF] [mH]
60 425 4) 2000 4) 8,4 24 0,065
Passive current UI II PI CI CIPA LI
output 30 30 [V] [mA] [mW] [nF] [nF] [nH]
Terminal 31/32 60 500 4) 2000 4) 8,4 24 170
Passive digital UI II PI CI CIPA LI
output DO2 [V] [mA] [mW] [nF] [nF] [nH]
Terminal 41/42 30 220
4251) 4)
60 2000 4) 3,6 3,6 170
5002) 4)
Passive digital
4251) 4)
output DO1 30 220 60 2000 4) 3,6 3,6 170
5002) 4)
Terminal 51/52
Passive digital
input DI 3) 30 10 60 500 4) 2000 4) 3,6 3,6 170
Terminal 81/82
1) For "active" current output

2) For "passive" current output
3) Only available in conjunction with passive current output
4) Intrinsically safe single-channel or multi-channel barriers (supply isolators) with resistance characteristic must be used.
Special connection conditions:
The output circuits are designed in such a way that they can be connected to both intrinsically-safe and non-intrinsically-safe circuits. It is not
permitted to combine intrinsically safe and non-intrinsically safe circuits. On intrinsically safe circuits, equipotential bonding must be in place
along the entire length of the cable used for the current outputs.
The rated voltage of the non-intrinsically safe circuits is UM = 60 V.
Provided that rated voltage UM = 60 V is not exceeded if connections are established to non-intrinsically safe external circuits, intrinsic safety is
still guaranteed.
If the installation is changed from type of protection "e" to "i" or vice versa, the device must be checked in accordance with the instructions
contained in section 6.4 "Changing the type of protection".

4.2.2 Devices with PROFIBUS PA or FOUNDATION Fieldbus
correct design (PROFIBUS PA or FOUNDATION Fieldbus), see the marking contained in the device's terminal box.

The fieldbus (terminal 97 / 98) and the digital output (terminal 41 / 42) can be connected in Zone 1 / Div. 1 in three different variants.
Variant 1 Intrinsically safe fieldbus connection in acc. with FISCO, intrinsically safe connection of the digital output

Explosion protection type Ex i, IS and FISCO
Inputs and UN IN Ui Ii Pi Ci CiPA Li
outputs [V] [mA] [V] [mA] [mW] [nF] [nF] [µH]
Passive digital
output DO2 30 220 60 200 1) 5000 1) 3.6 3.6 0.17
Terminal 41/42
Fieldbus
Terminal 97/98 32 30 17 380 5320 1 1 5
Variant 2 Intrinsically safe fieldbus connection (not in acc. with FISCO!), intrinsically safe connection of the digital output

Explosion protection type Ex i, IS
Passive digital
output DO2 30 220 60 200 1) 5000 1) 3.6 3.6 0.17
Terminal 41/42
Fieldbus
Terminal 97/98 32 30 60 500 5000 1 1 5
Variant 3 Fieldbus connection in acc. with FNICO (Zone 2, Div. 2), connection of digital output (Zone 2, Div. 2)

Explosion protection type Ex n, NI and FNICO
Passive digital
output DO2 30 220 - - - - - -
Terminal 41/42
Fieldbus
Terminal 97/98 32 30 60 500 1) 5000 1) 1 1 5
1) Single-channel or multi-channel barriers (supply isolators) with resistance characteristic must be used.
Special connection conditions:
The output circuits are designed in such a way that they can be connected to both intrinsically-safe and non-intrinsically-safe circuits. It is not
permitted to combine intrinsically safe and non-intrinsically safe circuits. On intrinsically safe circuits, equipotential bonding must be in place
along the entire length of the cable used for the signal outputs.
The rated voltage of the non-intrinsically safe circuits is UM = 60 V.
Provided that rated voltage UM = 60 V is not exceeded if connections are established to non-intrinsically safe external circuits, intrinsic safety is
still given.
If the installation is changed from type of protection "e" to "i" or vice versa, the device must be checked in accordance with the instructions
contained in section 6.4 "Changing the type of protection".

4.3 Temperature data for operation in Zone 1 / Div. 1
Model name Surface temperature
FEP315 / FEH315 70 °C (158 °F)
FEP515 / FEH515
FEP325 / FEP525 85 °C (185 °F)
FET325 / FET525 70 °C (158 °F)

With increasing fluid temperature > 70 °C (158 °F) or > 85 °C (185 °F) the surface temperature also increases to the level of the fluid
temperature.
Important
The maximum permissible fluid temperature depends on the lining and flange material, and is limited by the operating
values in Table 1 and the explosion protection specifications in Tables 2 ... n.
Table 1: Fluid temperature as a function of lining and flange material

Models FEP315 / FEP325, FEP515 / FEP525
Materials Fluid temperature (operating values)
Lining Flange Minimum Maximum
90 °C (194 °F)
Hard rubber Steel -10 °C (14 °F)
80 °C (176 °F) 1)
90 °C (194 °F)
Hard rubber Stainless steel -15 °C (5 °F)
80 °C (176 °F) 1)
Soft rubber Steel -10 °C (14 °F) 60 °C (140 °F)
Soft rubber Stainless steel -15 °C (5 °F) 60 °C (140 °F)
PTFE Steel -10 °C (14 °F) 130 °C (266 °F)
PTFE Stainless steel -25 °C (-13 °F) 130 °C (266 °F)
PFA Steel -10 °C (14 °F) 180 °C (356 °F)
PFA Stainless steel -25 °C (-13 °F) 180 °C (356 °F)
Thick PTFE Steel -10 °C (14 °F) 180 °C (356 °F)
Thick PTFE Stainless steel -25 °C (-13 °F) 180 °C (356 °F)
ETFE Steel -10 °C (14 °F) 130 °C (266 °F)
ETFE Stainless steel -25 °C (-13 °F) 130 °C (266 °F)
1) Only China production site (under preparation)
Models FEH315, FEH515

Lining Process connection Material Fluid temperature (operating values)
Minimum Maximum
PFA Flange Stainless steel -25 °C (-13 °F) 180 °C (356 °F)
PFA Wafer type - -25 °C (-13 °F) 130 °C (266 °F)
PFA Variable process connection Stainless steel -25 °C (-13 °F) 130 °C (266 °F)

Table 2: Fluid temperature (Ex data) for ProcessMaster models FEP315, FEP515
Ambient temperature
Nominal diameter
Temperature (- 40 °C)1) - 20 °C ... + 40 °C (- 40 °C)1) - 20 °C ... + 50 °C (- 40 °C)1) - 20 °C ... + 60 °C

Design
class
Not thermally Thermally Not thermally Thermally Not thermally Thermally
insulated insulated insulated insulated insulated insulated
Gas & Gas & Gas & Gas & Gas & Gas &
Gas Gas Gas Gas Gas Gas
dust dust dust dust dust dust
NT 130 °C 90 °C 30 °C 80 °C 40 °C
T1
HT 180 °C 120 °C 20 °C 120 °C 20 °C
NT 130 °C 90 °C 30 °C 80 °C 40 °C
T2
HT 180 °C 120 °C 20 °C 120 °C 20 °C
DN 3 ... DN 100
NT 130 °C 90 °C 30 °C 80 °C 40 °C
T3
HT 180 °C 120 °C 20 °C 120 °C 20 °C
NT 120 °C 90 °C 30 °C 80 °C 40 °C
T4
HT 120 °C 120 °C 20 °C 120 °C 20 °C
NT 85 °C 70 °C 30 °C 80 °C 40 °C
T5
HT 85 °C 85 °C 20 °C 85 °C 20 °C
NT 70 °C 70 °C 30 °C 70 °C 40 °C
T6
HT 70 °C 70 °C 20 °CC 70 °C 20 °C
NT 130 °C 90 °C 30 °C 80 °C 40 °C
T1
HT 180 °C 120 °C 20 °C 120 °C 20 °C
NT 130 °C 90 °C 30 °C 80 °C 40 °C
T2
DN 125 ... DN 2000
HT 180 °C 120 °C 20 °C 120 °C 20 °C

NT 130 °C 90 °C 30 °C 80 °C 40 °C
T3
HT 180 °C 120 °C 20 °C 120 °C 20 °C
NT 125 °C 90 °C 30 °C 80 °C 40 °C
T4
HT 125 °C 120 °C 20 °C 120 °C 20 °C
NT 90 °C 90 °C 30 °C 80 °C 40 °C
T5
HT 90 °C 90 °C 20 °C 90 °C 20 °C
NT 75 °C 75 °C 30 °C 75 °C 40 °C
T6
HT 75 °C 75 °C 20 °C 75 °C 20 °C
1) Low-temperature version (option)
NT standard version, Tmedium maximum 130 °C (266 °F)

HT high-temperature version, Tmedium maximum 180 °C (356 °F)
Not thermally insulated: The flowmeter sensor is not surrounded by pipe insulation material.
Thermally insulated: The flowmeter sensor is surrounded by pipe insulation material.
Important
The standard version includes explosion protection for gases and dust.
• If the installation location for the device is classified as a potentially explosive area for gases and dust, the
temperature data in the "Gas & dust" columns in the table must be taken into consideration.
• If the installation location for the device is classified as a potentially explosive area for gases only, the temperature
data in the "Gas" columns in the table must be taken into consideration.

Table 3: Fluid temperature (Ex data) for ProcessMaster models FEP325, FEP525
Ambient temperature
Nominal diameter

Design
class
NT 130 °C 110 °C 110 °C 110 °C 110 °C
T1
HT 180 °C 160 °C 150 °C 160 °C 150 °C
NT 130 °C 110 °C 110 °C 110 °C 110 °C
T2
HT 180 °C 160 °C 150 °C 160 °C 150 °C
DN 3 ... DN 100
NT 130 °C 110 °C 110 °C 110 °C 110 °C

T3
HT 180 °C 160 °C 150 °C 160 °C 150 °C
NT 120 °C 110 °C 110 °C 110 °C 110 °C
T4
HT 120 °C 120 °C 120 °C 120 °C 120 °C
NT 85 °C 85 °C 85 °C 85 °C 85 °C
T5
HT 85 °C 85 °C 85 °C 85 °C 85 °C
NT 70 °C 70 °C 70 °C 70 °C 70 °C
T6
HT 70 °C 70 °C 70 °C 70 °C 70 °C
NT 130 °C 110 °C 110 °C 110 °C 110 °C
T1
HT 180 °C 160 °C 150 °C 160 °C 150 °C
NT 130 °C 110 °C 110 °C 110 °C 110 °C
T2
DN 125 ... DN 2000
HT 180 °C 160 °C 150 °C 160 °C 150 °C

NT 130 °C 110 °C 110 °C 110 °C 110 °C
T3
HT 180 °C 160 °C 150 °C 160 °C 150 °C
NT 125 °C 110 °C 110 °C 110 °C 110 °C
T4
HT 125 °C 125 °C 125 °C 125 °C 125 °C
NT 90 °C 90 °C 90 °C 90 °C 90 °C
T5
HT 90 °C 90 °C 90 °C 90 °C 90 °C
NT 75 °C 75 °C 75 °C 75 °C 75 °C
T6
HT 75 °C 75 °C 75 °C 75 °C 75 °C
NT standard version, Tmedium maximum 130 °C (266 °F).

HT high temperature version, Tmedium maximum 180 °C (356 °F).
Important

Table 4: Fluid temperature (Ex data) for HygienicMaster models FEH315, FEH515
Ambient temperature
Nominal diameter

Design
class
NT 130 °C 110 °C 20 °C 80 °C 40 °C
T1
HT 180 °C 120 °C 20 °C 120 °C 20 °C
NT 130 °C 110 °C 20 °C 80 °C 40 °C
T2
HT 180 °C 120 °C 20 °C 120 °C 20 °C
DN 3 ... DN 100
NT 130 °C 110 °C 20 °C 80 °C 40 °C
T3
HT 180 °C 120 °C 20 °C 120 °C 20 °C
NT 120 °C 110 °C 20 °C 80 °C 40 °C
T4
HT 120 °C 120 °C 20 °C 120 °C 20 °C
NT 85 °C 85 °C 20 °C 80 °C 40 °C
T5
HT 85 °C 85 °C 20 °C 85 °C 20 °C
NT 70 °C 70 °C 20 °C 70 °C 40 °C
T6
HT 70 °C 70 °C 20 °C 70 °C 20 °C
NT standard version, Tmedium maximum 130 °C (266 °F).

HT high temperature version, Tmedium maximum 180 °C (356 °F).
Important

Ex relevant specifications for operation in zones 2, 21 and 22
5 Ex relevant specifications for operation in zones 2, 21 and 22
A temperature of 70 °C (158 °F) at the cable entry is assumed for the Ex calculations.
Therefore, the cables used for the supply power and the signal inputs and outputs must have a
minimum specification of 70 °C (158 °F).
For devices with remote mount design for use in FM / cFM Div. 1 or FM / cFM Div. 2 the signal
cable between the flowmeter sensor and the transmitter must have a minimum length of 5 m
(16.4 ft).

5.1 Electrical connection
5.1.1 Models FEP315 / FEP515, FEP325 / FEP525, FEH315 / FEH515, FEH325 / FEH525, FET325 / FET525
in Zone 2, FET321 / FET 521 outside the hazardous area with HART protocol
FEP315 / FEP515, FEH315 / FEH515, FEP325 / FEP525, FEH325 / FEH525 flowmeter FET321 / FET521 transmitter outside the
sensors and FET325 / FET525 transmitters in the hazardous area (Zone 2) hazardous area
FEP315 / FEP515 FEP325 / FEP525 FET321 / FET521
FEH325 / FEH525
6
6
6a
FEH315 / FEH515 FEP325 / FEP525 FET325 / FET525
FEH325 / FEH525
6
6
6
A
24 V
1+ 2- + - + - + - + -
L N 31 32 51 52 81 82 41 42 M1 M2 D1 D2 3 2S E2 E1 1S SE
6 / 6a
{
{
{
{
{
1 PE 2 3 4 5
7 8 9 10 11 12 13
M1 M2 D1 D2 3 E2 E1 SE
B
6 G00873-01
Fig. 13
B Flowmeter sensor Function can be configured locally using software: External output
1 Supply power: switch-off, external totalizer reset, external totalizer stop, other
See name plate Data for the optocoupler: 16 V ≤ U ≤ 30 V, Ri = 2 kΩ
2 Current output (terminals 31/32) 5 Digital output DO2 (terminal 41/42)
The current output can be configured locally as an "active" or The output is always a "passive" output (optocoupler).
"passive" output. Data for the optocoupler: Umax = 30 V, Imax = 220 mA, fmax ≤ 5250
• Active: 4 ... 20 mA, HART protocol (standard), load: 250 Ω ≤ R ≤ Hz
650 Ω Function can be configured locally as "Pulse Output" or "Digital
• Passive: 4 ... 20 mA, HART protocol (standard), Output" using software. Factory setting is "Digital Output", flow
load: 250 Ω ≤ R ≤ 650 Ω direction signaling.
Supply voltage for the current output: minimum 11 V, maximum 6 Equipotential bonding
30 V at terminals 31/32. 6a Functional ground (only with transmitter FET321 outside the
3 Digital output DO1 (terminal 51/52) hazardous area)
The digital output can be configured locally as an "active" or 7 Brown
"passive" output. 8 red
• Active: U = 19 ... 21 V. Imax = 220 mA, fmax ≤ 5250 Hz 9 Orange
• Passive: Umax = 30 V, Imax = 220 mA, fmax ≤ 5250 Hz 10 yellow
Function can be configured locally as "Pulse Output" or "Digital 11 Green
Output" using software. Factory setting is "Pulse Output". 12 blue
• Configuration as pulse output. Maximum pulse frequency: 13 Violet

5.1.2 Models FEP315 / FEP515, FEP325 / FEP525, FEH315 / FEH515, FEH325 / FEH525, FET325 / FET525
in Zone 2, FET321 / FET 521 outside the hazardous area with HART protocol
FEP315 / FEP515, FEH315 / FEH515, FEP325 / FEP525, FEH325 / FEH525 flowmeter FET321 / FET521 transmitter outside the
sensors and FET325 / FET525 transmitters in the hazardous area (Zone 2) hazardous area
FEP315 / FEP515 FEP325 / FEP525 FET321 / FET521
FEH325 / FEH525
6
6
6a
FEH315 / FEH515 FEP325 / FEP525 FET325 / FET525
FEH325/ FEH525
6
6
6
A
FF+ FF-
1+ 2- PA+ PA- + -
L N 97 98 41 42 M1 M2 D1 D2 3 2S E2 E1 1S SE
6 / 6a
{
{
{
{
{
1 PE 2 3 4 5
7 8 9 10 11 12 13
M1 M2 D1 D2 3 2S E2 E1 1S SE
B
6 G01020
Fig. 14
1 Supply power: Data for the optocoupler: Umax = 30 V, Imax = 220 mA,
See name plate fmax ≤ 5250 Hz,
2 Digital communication (terminal 97 / 98) Function can be configured locally as "Pulse Output" or "Digital
• PROFIBUS PA in acc. with IEC 61158-2 (PA+ / PA-) Output" using software. Factory setting is "Digital Output", flow
U = 9 ... 32 v, I = 10 mA (normal operation), I = 13 mA (in the direction signaling.
event of an error / FDE) 6 Equipotential bonding
Bus connection with integrated protection against polarity 6a Functional ground (only with flowmeter sensor FET321 outside
reversal the hazardous area)
The bus address can be set via the DIP switches in the device, 7 Brown
the transmitter display or the fieldbus. 8 red
or 9 Orange
• FOUNDATION Fieldbus in acc. with IEC 61158-2 (FF+ / FF-) 10 yellow
U = 9 ... 32 v, I = 10 mA (normal operation), I = 13 mA (in the 11 Green
event of an error / FDE) 12 blue
Bus connection with integrated protection against polarity 13 Violet
reversal
3 Not assigned
4 Not assigned
For devices with PROFIBUS PA or FOUNDATION Fieldbus in Zone 2 / Div 2 the bus termination must conform to the FNICO model or the
explosion protection regulations, respectively.

5.2 Electrical data for operation in Zone 2 / Div. 2
correct current output design (active/passive), see the marking contained in the device's terminal box.

Ex data Operating values
Ex n/NI
Signal inputs and outputs Ui [V] Ii [mA] Ui [V] Ii [mA]
Current output
30 30 30 30
Active/passive Terminal 31/32
Digital output DO1
30 220 30 220
Active/passive Terminal 51/52
Digital output DO2
30 220 30 220
passive Terminal 41/42
Digital input DI
30 10 30 10
Terminal 81/82
5.2.2 Devices with PROFIBUS PA or FOUNDATION Fieldbus

correct design (PROFIBUS PA or FOUNDATION Fieldbus), see the marking contained in the device's terminal box.

Explosion protection type Ex n, NI and FNICO
Passive digital
output DO2 30 220 - - - - - -
Terminal 41/42
Fieldbus
Terminal 97/98 32 30 32 500 1) 7000 1) 1 1 5
1) Single-channel or multi-channel barriers (supply isolators) with resistance characteristic must be used.

5.3 Temperature data for operation in Zone 2 / Div. 2
Model name Surface temperature
FEP315 / FEH315 70 °C (158 °F)
FEP515 / FEH515
FEP325 / FEH325 85 °C (185 °F)
FEP525 / FEH525
FET325 / FET525 70 °C (158 °F)

With increasing fluid temperature > 70 °C (> 158 °F) or > 85 °C (> 185 °F) the surface temperature also increases to the level of the fluid
temperature.
Important
The maximum permissible fluid temperature depends on the lining and flange material, and is limited by the operating
values in Table 1 and the explosion protection specifications in Tables 2 ... n.
Table 1: Fluid temperature as a function of lining and flange material

Models FEP315 / FEP325, FEP515 / FEP525
Materials Fluid temperature (operating values)
Lining Flange Minimum Maximum
90 °C (194 °F)
Hard rubber Steel -10 °C (14 °F)
80 °C (176 °F) 1)
90 °C (194 °F)
Hard rubber Stainless steel -15 °C (5 °F)
80 °C (176 °F) 1)
Soft rubber Steel -10 °C (14 °F) 60 °C (140 °F)
Soft rubber Stainless steel -15 °C (5 °F) 60 °C (140 °F)
PTFE Steel -10 °C (14 °F) 130 °C (266 °F)
PTFE Stainless steel -25 °C (-13 °F) 130 °C (266 °F)
PFA Steel -10 °C (14 °F) 180 °C (356 °F)
PFA Stainless steel -25 °C (-13 °F) 180 °C (356 °F)
Thick PTFE Steel -10 °C (14 °F) 180 °C (356 °F)
Thick PTFE Stainless steel -25 °C (-13 °F) 180 °C (356 °F)
ETFE Steel -10 °C (14 °F) 130 °C (266 °F)
ETFE Stainless steel -25 °C (-13 °F) 130 °C (266 °F)
1) Only China production site (under preparation)
Models FEH315 / FEH325, FEH515 / FEH525

Lining Process connection Material Fluid temperature (operating values)
Minimum Maximum
PFA Flange Stainless steel -25 °C (-13 °F) 180 °C (356 °F)
PFA Wafer type - -25 °C (-13 °F) 130 °C (266 °F)
PFA Variable process connection Stainless steel -25 °C (-13 °F) 130 °C (266 °F)

Table 2: Fluid temperature (Ex data) for ProcessMaster models FEP315, FEP515 and HygienicMaster models FEH315,
FEH515
Ambient temperature
Nominal diameter
- 20 °C ... + 40 °C - 20 °C ... + 50 °C - 20 °C ... + 60 °C

Temperature
- 40 °C ... + 40 °C 1) - 40 °C ... + 50 °C 1) - 40 °C ... + 60 °C 1)

Design
class

100 °C 2)
NT 130 °C 130 °C --- --- 130 °C --- --- 80 °C 40 °C --- ---
ProcessMaster DN 3 ... DN 2000
HygienicMaster DN 3 ... DN 100
T1 110 °C 3)
HT 180 °C 180 °C 180 °C 180 °C 180 °C 180 °C 180 °C 180 °C 180 °C 40 °C 180 °C 40 °C
100 °C 2)
NT 130 °C 130 °C --- --- 130 °C --- --- 80 °C 40 °C --- ---
T2 110 °C 3)
HT 180 °C 180 °C 180 °C 180 °C 180 °C 180 °C 180 °C 180 °C 180 °C 40 °C 180 °C 40 °C
100 °C 2)
NT 130 °C 130 °C --- --- 130 °C --- --- 80 °C 40 °C --- ---
T3 110 °C 3)
HT 180 °C 180 °C 180 °C 180 °C 180 °C 180 °C 180 °C 180 °C 180 °C 40 °C 180 °C 40 °C
100 °C 2)
NT 130 °C 130 °C --- --- 130 °C --- --- 80 °C 40 °C --- ---
T4 110 °C 3)
HT 130 °C 130 °C 130 °C 130 °C 130 °C 130 °C 130 °C 130 °C 130 °C 40 °C 130 °C 40 °C

2) Temperature values for ProcessMaster
3) Temperature values for HygienicMaster

Important

Table 3: Fluid temperature (Ex data) for ProcessMaster models FEP325, FEP525 and HygienicMaster models FEH325,
FEH525
Ambient temperature
Nominal diameter
- 20 °C ... + 40 °C - 20 °C ... + 50 °C - 20 °C ... + 60 °C

Temperature
- 40 °C ... + 40 °C 1) - 40 °C ... + 50 °C 1) - 40 °C ... + 60 °C 1)

Design
class

110 °C 2)
NT 130 °C 130 °C --- --- 130 °C 130 °C --- --- 110 °C --- ---
T1 120 °C 3)
HT 180 °C 180 °C 180 °C 180 °C 180 °C 180 °C 180 °C 180 °C 180 °C 180 °C 180 °C 180 °C
ProcessMaster DN 3 ... DN 2000
HygienicMaster DN 3 ... DN 100
110 °C 2)
NT 130 °C 130 °C --- --- 130 °C 130 °C --- --- 110 °C --- ---
T2 120 °C 3)
HT 180 °C 180 °C 180 °C 180 °C 180 °C 180 °C 180 °C 180 °C 180 °C 180 °C 180 °C 180 °C
110 °C 2)
NT 130 °C 130 °C --- --- 130 °C 130 °C --- --- 110 °C --- ---
T3 120 °C 3)
HT 180 °C 180 °C 180 °C 180 °C 180 °C 180 °C 180 °C 180 °C 180 °C 180 °C 180 °C 180 °C
110 °C 2)
NT 130 °C 130 °C --- --- 130 °C 130 °C --- --- 110 °C --- ---
T4 120 °C 3)
HT 130 °C 130 °C 130 °C 130 °C 130 °C 130 °C 130 °C 130 °C 130 °C 130 °C 130 °C 130 °C
NT 95 °C 95 °C --- --- 95 °C 95 °C --- --- 95 °C 95 °C --- ---
T5
HT 95 °C 95 °C 95 °C 95 °C 95 °C 95 °C 95 °C 95 °C 95 °C 95 °C 95 °C 95 °C
NT 80 °C 80 °C --- --- 80 °C 80 °C --- --- 80 °C 80 °C --- ---
T6
HT 80 °C 80 °C 80 °C 80 °C 80 °C 80 °C 80 °C 80 °C 80 °C 80 °C 80 °C 80 °C

2) Temperature values for ProcessMaster
3) Temperature values for HygienicMaster

Important

Commissioning
6 Commissioning
6.1 Preliminary checks prior to start-up
The following points must be checked before commissioning:
• The supply power must be switched off.
• The supply power must match information on the name plate.
• The pin assignment must correspond to the connection diagram.
• Sensor and transmitter must be grounded properly.
• The temperature limits must be observed.
• The sensor must be installed at a largely vibration-free location.
• The housing cover and its safety locking device must be sealed before switching on the
supply power.
• For devices with remote mount design and an accuracy of 0.2 % of rate make sure that the
flowmeter sensor and the transmitter match correctly.
For this purpose, the final characters X1, X2, etc. are printed on the name plates of the
flowmeter sensors, whereas the transmitters are identified by the final characters Y1, Y2,
etc.
Devices with the end characters X1 / Y1 or X2 / Y2, etc. fit with each other.
• Any unused connections must be sealed in accordance with IEC 60079 prior to
commissioning using the plugs supplied.
Important
Commissioning and operation must be performed in accordance with ATEX 137 or BetrSichV
(EN60079-14). Only properly trained personnel are authorized to carry out commissioning in
Ex areas.
6.2 Notes on combining the FEP325 flowmeter sensor with the FET325 transmitter or the FEP525
flowmeter sensor with the FET525 transmitter
G00875
Fig. 15
When combining the FEP325 flowmeter sensor with the FET325 transmitter, you must ensure
that the flowmeter sensor is assigned to the transmitter correctly.
The same is valid for combining the FEP525 flowmeter sensor with the FET525 transmitter.
The flowmeter sensor is identified by means of the suffix (X01, X02, etc.) that forms part of the
order number on the name plate.
The associated transmitter is identified by means of the suffix (Y01, Y02, etc.) that forms part of
the order number on the name plate.

Commissioning
6.3 Special features of version designed for operation in Ex zone 1 / Div. 1
6.3.1 Configuring the current output
For devices designed for use in Ex Zone 1 / Div.1, the current output cannot be reconfigured
subsequently.
The configuration required for the current output (active/passive) must be specified when the
order is placed.
For the correct current output design (active/passive), see the marking contained in the device's
terminal box.
6.3.2 Configuration of the digital outputs

For version designed for operation in Ex zone 1 / Div. 1, the digital outputs DO1 (51/52) and
DO2 (41/42) can be configured on a NAMUR switching amplifier. On leaving the factory, the
device is configured with the standard wiring (non-NAMUR).
Devices with PROFIBUS PA or FOUNDATION Fieldbus only have the digital output
DO2 (41 / 42).
Important
The outputs' type of protection remains unaffected by this. The devices connected to these
outputs must conform to the applicable regulations for explosion protection.

Commissioning
The jumpers are located on the backplane in the transmitter housing.
4
2 3
BR902 BR901 BR902
1 2 1 2 1 2
3 G00874-01
HART protocol PROFIBUS PA

FOUNDATION Fieldbus
Fig. 16
BR902 for digital output DO1 BR901 for digital output DO2
BR902 in position 1: Standard (non-NAMUR) BR901 in position 1: Standard (non-NAMUR)
BR902 in position 2: NAMUR BR901 in position 2: NAMUR
Configure the digital outputs as described:

1. Switch off the supply power and wait at least 20 minutes before the next step.
2. Open the cover safety device (4) and housing cover (1).
3. Loosen screws (3) and pull out transmitter plug-in (2).
4. Insert the jumpers in the required positions.
5. Put the transmitter plug-in (2) back into the housing and retighten the screws (3).
6. Close the housing cover (1) and lock the cover by unscrewing the screw (4).

Commissioning
6.4 Changing the type of protection
Models FEP315 / FEP515, FEH315 / FEH515, FEP325 / FEP525, FET325 / FET525 can
provide various types of protection during operation:
• When connected to an intrinsically safe circuit in Zone 1, operated as an intrinsically safe
device (Ex ia)
• When connected to a non-intrinsically safe circuit in Zone 1, operated as a device with a
flameproof enclosure (Ex d)
• When connected to a non-intrinsically safe circuit in Zone 2, operated as a non-sparking
device (Ex nA)
If a device which is already operational is required to provide a different type of protection, the
following measures must be implemented/insulation checks must be performed in accordance
with IEC 60079-ff.
A subsequent change of the type of protection is the sole responsibility of the operator.
No. 1. Type of protection 2. Type of protection Required step/check

1 Zone 1: Zone 1: • Switch off supply power.
Ex d, non-intrinsically safe Intrinsically safe circuits Use 500 VAC or 710 VDC to take the following
circuits measurements for one minute:
Jumper terminals 31/32, 41/42, 51/52, 81/82.
Then measure all jumpers (A,B,C,D) against one
another.
31 32 41 42 51 52 81 82
A B C D
G00884
• Switch off supply power.

Use 500 VAC or 710 VDC to take the following
measurements for one minute:
Jumper terminals 31/32, 41/42, 51/52, 81/82.
Then measure against the housing.
31 32 41 42 51 52 81 82
G00885
• Visual inspection
Zone 2: • Special precautions/checks are not necessary.
Non-sparking (nA)
2 Zone 1: Zone 1: • Visual inspection (no damage to the threads of
Intrinsically safe circuits Ex d, non-intrinsically the cover or the cable fittings)
safe circuits
Zone 2: • Special precautions/checks are not necessary.
Non-sparking (nA)
3 Zone 2: Zone 1: • Perform the checks described under No. 1.
Non-sparking (nA) Intrinsically safe circuits
Zone 1: • Visual inspection (no damage to the threads of
Ex d, non-intrinsically the cover or the cable fittings)
safe circuits

Maintenance
7 Maintenance
7.1 General information
Repair and maintenance activities may only be performed by authorized customer service
personnel.
When replacing or repairing individual components, original spare parts must be used.
Risk of explosion!
When the housing cover is open, the explosion protection is suspended.
Before opening the housing switch off the power to all connection lines and wait at least 20
minutes.
Warning – Electrical voltage risk!

When the housing is open, EMC protection is impaired and protection against contact is
suspended.
Before opening the housing, switch off power to all connecting cables for the device.
Warning - Potential damage to parts

The electronic components of the printed circuit board can be damaged by static electricity
(observe ESD guidelines).
Make sure that the static electricity in your body is discharged before touching electronic
components.
Important
Users must also observe the information in the operating and commissioning instruction for
the device.

Maintenance
7.2 Replacing the transmitter or sensor
Important
After replacing the transmitter, the system data must be reimported according to information in
the operating instruction (see the chapter "Downloading the system data").
7.2.1 Transmitter
1 2 3
4 3
G00689
G00689-01
Fig. 17
Replace the transmitter plug-in as follows:
2. Release the cover safety device (4) and housing cover (1).
3. Loosen screws (3) and pull out transmitter plug-in (2).
4. Replace transmitter plug-in and retighten screws (3).
7.2.2 Flowmeter sensor
1 2
G00698
G00698-01
Fig. 18
Replace the flowmeter sensor as follows:
2. Open the cover safety device (4) and housing cover (1).
3. Disconnect the signal cable (if necessary, remove the sealing compound).
4. Install the new sensor according to the installation instructions.
5. Complete the electrical connection according to the connection diagram.

Spare parts list
8 Spare parts list
8.1 Fuses for transmitter electronics
1 2
1
G00690-01
Fig. 19
1 Fuse (1.0 A) for power supply, suitable for all devices D151B003U05
2 Fuse (0.25 A) for the coil circuit in the field housing, suitable for D151B003U02
all devices
8.2 Spare parts for the compact design
G00878
Fig. 20
1 Cable gland without explosion protection, plastic, gray, M20 x 1.5 D150A008U15
Cable gland for Zone 2 / Div. 2, plastic, gray, M20 x 1.5 D150A008U23
Seal plug for Zone 2 / Div. 2, plastic, M20 x 1.5 D150Z007U09
Cable gland for Zone 1 / Div. 1, plastic, black, M20 x 1.5 D150A004U15
Cable gland for Zone 1 / Div. 1, plastic, blue, M20 x 1.5 D150A008U13
2 O-ring 118 x 3.7 (covered) D101A034U05

Spare parts list
8.3 Spare parts for remote design
8.3.1 Field-mount housing
1+2
1+2
4
G00879
Fig. 21
1 Screw D004G108AU01
2 Spring washer D085D020AU20
3 Contact board assy D682A016U01
5 Cover for supply power connection (not shown) D355H303U01

Spare parts list
8.3.2 Round field-mount housing
G00876
Fig. 22
Cable gland for Zone 1 / Div. 1, plastic, black, M20 x 1.5 D150A004U15
Cable gland for Zone 1 / Div. 1, plastic, blue, M20 x 1.5 D150A008U13
2 O-ring 118 x 3.7 (covered) D101A034U05
8.3.3 Flowmeter sensor (Zone 2/Div 2)
1 2
3
G00880
Fig. 23
for FEH model for FEP model
1 O-ring D101A034U06 D101A034U06
2 Connection board (without preamplifier) D685A1090U01 D685A1090U01
Connection board (with preamplifier) D685A1089U01 D685A1089U01
3 Cable gland for Zone 2 / Div. 2, plastic, gray, D150A008U23 D150A008U23
M20 x 1.5

Spare parts list
8.3.4 Flowmeter sensor (Zone 1/Div 1)
G00877
Fig. 24
1 O-ring D101A034U06
2 Cable gland for Zone 1 / Div. 1, plastic, black, M20 x 1.5 D150A004U15

Appendix
9 Appendix
9.1 Other applicable documents
• Data Sheet for ProcessMaster (DS/FEP300, DS/FEP500)
• Data Sheet for HygienicMaster (DS/FEH300, DS/FEH500)
• Operating Instruction (OI/FEX300/FEX500)
• Commissioning instruction (CI/FEX300/FEX500)
• HART interface description (COM/FEX300/FEX500/HART)
• PROFIBUS PA interface description (COM/FEX300/FEX500/PB)
• FOUNDATION Fieldbus interface description (COM/FEX300/FEX500/FF)
9.2 Approvals and certifications
The version of the meter in your possession meets the requirements of the
CE mark
following European directives:
- EMC directive 2004/108/EC
- Low voltage directive 2006/95/EC
- Pressure equipment directive (PED) 97/23/EC
- ATEX directive 94/9/EC
Explosion Identification for intended use in potentially explosive atmospheres according
Protection to:
- ATEX directive (marking in addition to CE marking)
- IEC standards
- FM Approvals (US)
- cFM Approvals (Canada)
- NEPSI (China)
- GOST
Important
All documentation, declarations of conformity, and certificates are available in ABB's download
area.
www.abb.com/flow

T-STRAINER
(WOOSUNG)
WOOSUNG FLOWTEC Co.,Ltd
Head office / Factory
1461-1, Songjung-dong, Gangseo-gu, Busan, Korea
Installation, Operation &
Tel : +82-51-831-1533 Fax : +82-51-831-1534 Maintenance Manual
Branch Office(Seoul)
2F, Soojung B/D, #225-2 Seokchon-dong, Songpa-gu, Seoul, Korea Tee Strainers
Tel : +82-2-412-6822 Fax : +82-2-412-6823 Straight Flow Type (M/N:TS1/2)
Web : www.woosungflowtec.com
<Product install direction>

1
2 VERTICAL TYPE HORIZONTAL TYPE
FLOW
FLOW
FLOW FLOW
FLOW
FLOW
5 TV5 TV6 TH9
HORIZONTAL TYPE
8
FLOW FLOW FLOW FLOW FLOW FLOW
9 TH10 TH11 TH12
7 ◈Operation◈
■ Prior to the system operation, open the outlet of the strainer
and a valve, which is close by, and then gradually open the i-
4 nlet of the strainer and a valve, which is close by, after opera-
ting the system. At this time, it is important to open a valve
gradually to prevent the damage of the filter(8).
■ If a pressure difference between the strainer front and near is
6 increased, the filter(8) should be cleaned because there is a f-
oreign substance.
5
◈Maintenance and Repair◈
■ The water leak inspection should be executed periodically an-
d at a proper time, the filter(8) should be cleaned and repla-
ced.
■ When the filter(8) is blocked by a foreign substance , it will
ITEM ITEM be the reason of a potential damage to the connected equip-
DESCRIPTION DESCRIPTION ment by occurring the pressure difference between the strai-
NO. NO.
ner front and near therefore when the pressure between the
BODY INLET front and the near is increased, the filter should be cleaned.
1 6 STUD BOLT
FLANGE
BODY OUTLET
2 7 COVER ◈Filter cleaning and Replacement◈
FLANGE
■ Block a flow of a fluid by closing a front and a rear valve of
3 BODY 8 FILTER the strainer. (If a valve is not installed, block a inflow of a fluid.)
■ Gradually open the drain plug(4) and completely discharge a
4 DRAIN PLUG 9 COVER GASKET pressure and fluid which is inside. At this time, if the operat-
ing oil contains a fluid except of a water or a operation tem-
5 NUT perature is over 120℉(48.9℃), a fluid should be discharged
to the safety space which is away from a operator. A operator
◈Installation◈ should wear a safety equipment.
■ Check the gasket to be inserted between the flange of the pi- ■ Release the nut(5) and then dismantle the cover(7).
pe line and the flange of the strainer extremity. If the strainer ■ Remove a foreign substance after taking out the filter(8).
and the pipe line are connected by welding, rust and other u- ■ Confirm the filter(8) whether it is damaged or not. If it is da-
nknown material have to be removed. maged, replace it. Change a cover gasket(9).
■ When the strainer is installed, the flow direction of the fluid ■ Remove a foreign substance which is inside of the strainer.
and the flow direction(Arrow) which is marked on the product ■ Assemble in reverse order of a dismantlement. When the filt-
should be in line and should be installed to be able to chan- er(8) is assembled, assemble with considering a inflow directi-
ge and clean the filter(8). At this time, horizontality and vert- on of a fluid and the shape of the filter such as the picture
icality of the strainer, which is connected with the pipe line, which is on the left side.
should be checked.
21
WOOSUNG FLOWTEC Co.
Head office / Factory
1461-1, Songjung-dong, Gangseo-gu, Busan, Korea
Installation, Operation &
Tel : +82-51-831-1533 Fax : +82-51-831-1534 Maintenance Manual
Branch Office(Seoul)
2F, Soojung B/D, #225-2 Seokchon-dong, Songpa-gu, Seoul, Korea Tee Strainers
Tel : +82-2-412-6822 Fax : +82-2-412-6823 Angle Flow Type (M/N:TA1/2)
Web : www.woosungflowtec.com
2 <Product install direction>

VERTICAL TYPE
FLOW
FLOW
1 FLOW FLOW FLOW FLOW
FLOW
FLOW
TV1 TV2 TV3 TV4
5
HORIZONTAL TYPE
FLOW
FLOW FLOW FLOW FLOW
FLOW
8
TH1 TH2 TH3 TH4
FLOW
FLOW FLOW FLOW FLOW
9
FLOW
7
TH5 TH6 TH7 TH8
◈Operation◈
4 ■ Prior to the system operation, open the outlet of the strainer
and a valve, which is close by, and then gradually open the i-
nlet of the strainer and a valve, which is close by, after opera-
ting the system. At this time, it is important to open a valve
6 gradually to prevent the damage of the filter(8).
■ If a pressure difference between the strainer front and near is
increased, the filter(8) should be cleaned because there is a f-
oreign substance.
5
◈Maintenance and Repair◈

■ The water leak inspection should be executed periodically an-
ITEM ITEM d at a proper time, the filter(8) should be cleaned and repla-
DESCRIPTION DESCRIPTION ced.
NO. NO.
■ When the filter(8) is blocked by a foreign substance , it will
BODY INLET be the reason of a potential damage to the connected equip-
1 6 STUD BOLT ment by occurring the pressure difference between the strai-
FLANGE
BODY OUTLET ner front and near therefore when the pressure between the
2 7 COVER front and the near is increased, the filter should be cleaned.
FLANGE
3 BODY 8 FILTER
4 DRAIN PLUG 9 COVER GASKET ◈Filter cleaning and Replacement◈

■ Block a flow of a fluid by closing a front and a rear valve of
5 NUT the strainer. (If a valve is not installed, block a inflow of a fluid.)
■ Gradually open the drain plug(4) and completely discharge a
◈Installation◈ pressure and fluid which is inside. At this time, if the operat-
■ Check the gasket to be inserted between the flange of the pi- ing oil contains a fluid except of a water or a operation tem-
pe line and the flange of the strainer extremity. If the strainer perature is over 120℉(48.9℃), a fluid should be discharged
and the pipe line are connected by welding, rust and other u- to the safety space which is away from a operator. A operator
nknown material have to be removed. should wear a safety equipment.
■ When the strainer is installed, the flow direction of the fluid ■ Release the nut(5) and then dismantle the cover(7).
and the flow direction(Arrow) which is marked on the product ■ Remove a foreign substance after taking out the filter(8).
should be in line and should be installed to be able to chan- ■ Confirm the filter(8) whether it is damaged or not. If it is da-
ge and clean the filter(8). At this time, horizontality and vert- maged, replace it. Change a cover gasket(9).
icality of the strainer, which is connected with the pipe line, ■ Remove a foreign substance which is inside of the strainer.
should be checked. ■ Assemble in reverse order of a dismantlement.
20
Mixing pump
(DESMI)
OPERATION AND MAINTENANCE INSTRUCTIONS
DESMI vertical "in-line" centrifugal pump

ESL Monobloc
DESMI Pumping Technology A/S

Tagholm 1, DK-9400 Nørresundby, Denmark
Tel.: +45 96 32 81 11
Fax: +45 98 17 54 99
E-mail: desmi@desmi.com
Internet: www.desmi.com
Manual: Language: Revision:

T1515 English N(11/19)
Special pump No. ...............................................

OPERATION AND MAINTENANCE INSTRUCTIONS ............................................................................................ 1
1. PRODUCT DESCRIPTION ............................................................................................................................. 3
1.1 DELIVERY ................................................................................................................................................ 3
2. TECHNICAL DATA ....................................................................................................................................... 3
2.1 EXPLANATION OF THE TYPE NUMBER ............................................................................................ 3
2.2 TECHNICAL DESCRIPTION .................................................................................................................. 4
3. INSTALLATION ........................................................................................................................................... 5
3.1 MOUNTING/FASTENING ....................................................................................................................... 5
3.2 WIRING ..................................................................................................................................................... 6
4. TRANSPORT/STORAGE .............................................................................................................................. 6
5. DISMANTLING ........................................................................................................................................... 7
5.1 DISMANTLING OF ESL25/40/50/80/100-180 ...................................................................................... 8
5.2 DISMANTLING OF ESL40/50/80/100-180N, ESL65-180M .............................................................. 10
5.3 INSPECTION .......................................................................................................................................... 11
6. ASSEMBLING ........................................................................................................................................... 12
6.1 FITTING SEALING RINGS (Not applicable for ESL25-180 and ESL40/50-180N) ........................ 12
6.2 FITTING SHAFT ..................................................................................................................................... 12
6.3 FITTING SHAFT SEAL .......................................................................................................................... 12
6.4 FITTING IMPELLER .............................................................................................................................. 12
6.5 FITTING CASING COVER OR MOTOR BRACKET ......................................................................... 12
6.6 FITTING MOTOR FOR ESL40/50/80/100-180N AND ESL65-180M ............................................... 12
6.7 SHAFT ..................................................................................................................................................... 13
7. FROST PROTECTION ................................................................................................................................. 14
8. START-UP ................................................................................................................................................ 14
8.1 START-UP .............................................................................................................................................. 14
9. SYSTEM BALANCING ................................................................................................................................ 15
10. INSPECTION AND MAINTENANCE............................................................................................................. 16
10.1 DRAINING THE PUMP ....................................................................................................................... 16
11. REPAIRS................................................................................................................................................... 16
11.1 ORDERING SPARE PARTS .............................................................................................................. 16
11.2 REPLACING THE IMPELLER ............................................................................................................ 16
11.3 REPLACING WEAR RINGS ............................................................................................................... 16
11.4 REPLACING SHAFT SEAL (22) ........................................................................................................ 16
11.5 REPLACING BALL BEARINGS IN MOTOR..................................................................................... 17
12. OPERATING DATA .................................................................................................................................... 18
13. EU DECLARATION OF CONFORMITY ......................................................................................................... 19
14. INFORMATION RELEVANT FOR DISASSEMBLY OR DISPOSAL AT END-OF-LIFE ............................................. 20
15. ASSEMBLY DRAWING ESL25-180/-12-COMB. ........................................................................................... 21
19. ASSEMBLY DRAWING ESL80-180/-12 & ESL80-180B/-12 &ESL80-180E/-12 -COMB. ................................. 25
20. ASSEMBLY DRAWING ESL100-180/-12-COMB. ......................................................................................... 26
DESMI Pumping Technology A/S 2
www.desmi.com
Tagholm 1
9400 Nørresundby – Denmark
Tel: +45 96 32 81 11 Fax: +45 98 17 54 99
21. ASSEMBLY DRAWING ESL40/50-18N/-12-COMB ...................................................................................... 27
22. ASSEMBLY DRAWING ESL80/100-180N/-12 & ESL65-180M/-12-COMB .................................................... 28
23. DIMENSIONAL SKETCH ESL ...................................................................................................................... 29

www.desmi.com
Tagholm 1
Tel: +45 96 32 81 11 Fax: +45 98 17 54 99
1. PRODUCT DESCRIPTION
These operation and maintenance instructions apply to the DESMI ESL Monobloc pump.
The pump is a single-stage vertical "in-line" centrifugal pump (i.e. horizontal inlet and outlet on
the same line) equipped with stainless steel shaft, mechanical shaft seal, and closed impeller.
The impeller is mounted on the motor shaft at a shaft extension. The pumps are equipped with
a mechanical seal shaft and have holes in the bracket for inspection of leaks.
1.1 DELIVERY
- Check on delivery that the shipment is complete and undamaged.
- Defects and damages, if any, to be reported to the carrier and the supplier
immediately in order that a claim can be advanced.
2. TECHNICAL DATA
The pumps are manufactured in various material combinations which appear from the type
number on the name plate. See below.
2.1 EXPLANATION OF THE TYPE NUMBER

All the ESL pumps are provided with a name plate. The type number indicated on the name
plate is built up as follows:
ESLXXX-YYY-MR-Z
XXX: Pressure branch diameter, YYY: Standard impeller diameter

M: The material combination of the pump.
R: The assembly combination of the pump.
Z: Other variants
M may be the following:

A: Casing and cover : Cast iron+cast iron alloy. Impeller and sealing rings: Bronze
B: Casing and cover : Cast iron + cast iron alloy. Impeller and sealing rings: Stainless
C: All cast iron
D: Casing and shaft seal cover: Bronze. Impeller and sealing rings: Bronze
S: Casing, shaft seal cover, impeller and sealing rings: SAF2507 and stainless steel alloy
E: Special materials
U: Nonmagnetic material
The pumps can be delivered in other material combinations according to agreement with the
supplier.
R may be the following:

02: Monobloc, with bearing in the pump
12: Monobloc, without bearing in the pump
13: Spacer, light bearing housing
14: Spacer, heavy bearing housing
15: Spacer, heavy bearing housing and heavy motor bracket (special motor bracket)

www.desmi.com
Tagholm 1
Tel: +45 96 32 81 11 Fax: +45 98 17 54 99
Z may be the following:
i : PN16 flanges
j : PN25 flanges
k : Special flange
l : Other stuffing box
m : BS flanges
n : ANSI flanges
o : Shockproof design
p : Other design
q : JIS flanges
Any use of the pump is to be evaluated on the basis of the materials used in the pump. In case
of doubt, contact the supplier.
Pumps in material combinations A and C are primarily used for fresh water.
Pumps in material combination D are primarily used for seawater.
If the pumps are designed for special purposes the following is to be indicated:
Pump No. :
Pump type :
Application :
Comment :
2.2 TECHNICAL DESCRIPTION

The noise level indicated is the airborne noise including the motor. The noise depends on the
motor type supplied, as the noise from the pump can be calculated as the noise level of the
motor + 2dB(A). The noise level is for pumps with electric motors.
The capacity of the pump appears from the name plate on the pump. If the pump has been
delivered without motor, the pump capacity is to be indicated on the plate when mounting the
motor.
The permissible loads on the flanges appear from the following table. The values apply to
standard pumps in bronze (Rg5) and cast iron
(GG20). As to pumps in SG iron (GGG40), NiAlBz
or stainless steel the values are to be increased by
a factor 1.5.

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DN Forces (N) Torques (Nm)
Piping
F M
mm FY Fz FX My Mz Mx
Horizontal pipeline 25 250 320 250 480 300 150 260 420
at right angles to the 40 400 500 400 750 400 200 300 550
shaft 50 500 600 550 1000 450 250 350 600
Suction and pressure 65 650 840 750 1340 510 310 380 700
flanges above level 80 800 950 850 1500 550 350 400 750
of installation 100 1000 1250 1150 2000 650 400 500 900
In connection with the permissible loads on the flanges the following is to be observed:
2 2
 F   
 calculated     M calculated  2
F  M 
 Max. permissibl e   Max. permissibl e 
where index “calc” is the values calculated by the user.

At the same time none of the forces or moments may exceed the indicated figure multiplied
by 1.4.
3. INSTALLATION
3.1 MOUNTING/FASTENING
Insert the pump in the pipeline in the same way as a valve. The pump can be inserted in both
horizontal and vertical pipes, but not in a horizontal pipe if the motor is placed below horizontal
level. The max. loads on the flanges appear from the technical description.
When installing the pump check that it is earthed to avoid an electrical potential in the pump.

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The max. permissible loads on the flanges stated in paragraph 2.2 are to be
observed.
At installations pumping hot or very cold liquids, the operator must be aware that it is
dangerous to touch the pump surface and, consequently, he must take the
necessary safety measures.
3.2 WIRING
Wiring to be carried out by authorised skilled workmen according to the rules and
regulations in force.
4. TRANSPORT/STORAGE
The weights of the pumps in A and D combination (without motor) are stated in the following
table, and the pumps are to be lifted as shown below.
Weight in kg A12 / D12

Pump comb. Incl. base plate
ESL25-180 30/32
ESL40-180N 35/38
ESL40-180 37/40
ESL50-180N 42/44
ESL50-180 41/44
ESL65-180M 63/70
ESL65-180 62/69
ESL80-180N 67/74
ESL80-180 64/71
ESL80-180B 64/71
ESL80-180E 65/73
ESL100-180N 78/87
ESL100-180 76/87
The pump is to be stored in a dry area.

Before shipment the pump is to be fastened securely on pallets or the like.
The pump is to be lifted in the following way:

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The lifting straps must not bear against sharp edges and corners.
5. DISMANTLING
Before dismantling the pump make sure that it has stopped. Empty the pump of
liquid before it is dismantled from the piping system. If the pump has been
pumping dangerous liquids you are to be aware of this and take the necessary
safety measures.
If the pump has been pumping hot liquids, take great care that it is drained before it is
removed from the piping system.

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5.1 DISMANTLING OF ESL25/40/50/80/100-180
Before dismantling 1. Remove nut (15) and 2. Remove screw (20) and
stud (14); washer (23);

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3. Remove the impeller 4. Remove set screw (10) 5. Remove pointed screw (24),
(7)/(2)/(5) and the key (19) pull casing cover (4) and stop
ring(21) and shaft seal(22) and
motor with shaft apart;
6. Press out the seat (22); 7. If necessary, remove

pointed screw (11) to pull
off the shaft;

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5.2 DISMANTLING OF ESL40/50/80/100-180N, ESL65-180M
Before dismantling 1. Remove the flush pipe (29) only 2. Remove nut (15) and stud
forESL40/50-180N, remove venting (14);
plug (5), muff (9) and sleeve (21) for
ESL80/100-180N and ESL65-180M
3. Remove screw (20, 24 in 4. Remove the impeller (2, 5 in 5. Remove shaft seal (22, 522 in
ESL40/50-180N) and washer ESL40/50-180N) and the key (19) ESL40/50-180N) and rear cover
(23, 25 in ESL40/50-180N); (4, 7 in ESL40/50-180N);

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6. Remove set screw 7. Remove motor bracket 8. If necessary, remove
(10, 810 in ESL40/50-180N) (7, 104 in ESL40/50-180N) pointed screw (11, 311 in
ESL40/50-180N) to pull off
the coupling
5.3 INSPECTION
When the pump has been dismantled, check the following parts for wear and damage:
- Sealing ring/impeller: Max. clearance 0.3-0.6 mm measured in radius.

- Shaft seal/shaft seal cover: Check the seat for flatness and cracks.
Check the rubber parts for elasticity.

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6. ASSEMBLING
Refer to the reverse process of dismantling.
6.1 FITTING SEALING RINGS (Not applicable for ESL25-180 and ESL40/50-180N)
When fitted the wear ring (17) (not applicable for ESL40-180) is to bear against the
shoulder of the pump casing (1). When fitted the wear ring (16) is to bear against the
shoulder of the casing cover (4).
6.2 FITTING SHAFT

For ESL25/40/50/65/80/100-180, fit the shaft flange (8) (Not applicable for ESL25-180) and
the shaft (6) in the motor, then fit the pointed screw (11).
6.3 FITTING SHAFT SEAL

Before fitting the seat, clean the recess in the shaft seal cover (ESL 25-180) or the motor
bracket or rear cover (ESL 40/50/80/100-180N, ESL65-180M). When fitting the seat, remove
the protective coating without scratching the lapped surface. Dip the outer rubber ring of the
seat into soapy water. Now press the seat into place with the fingers and check that all parts
are correctly imbedded.
If it is necessary to use tools for assembling, then protect the sliding surface of the seat to
prevent it from being scratched or cut. Lubricate the inner surface of the slide ring rubber
bellows with soapy water and push it over the shaft. The use of a conical fitting bush as
shown on the assembly drawing is recommended to avoid that the rubber bellows is cut.
Push the slide ring over the shaft with the hand. If the rubber bellows is tight, use a fitting
tool and take care that the slide ring is not damaged. If the carbon ring is not fixed, it is
important to check that it is fitted correctly, i.e. the chamfered/lapped side is to face the seat.
The carbon ring can be held by a little grease.
When using soapy water on the shaft, the bellows will settle and seat in abt. 15 minutes, and
until then tightness should not be expected. After start, check by viewing the leak hole that
there are no leaks.
6.4 FITTING IMPELLER

Fit the key in the shaft and lead the impeller towards the shoulder of the shaft. Fit the stop
ring (21) before the impeller, (2)/(7)/(5). Take care that the ring at the end of the shaft seal
spring locates in the recess of the impeller. Secure the impeller with washers (23) and a
nut/screw (20, for ESL40/50-180N is 24).
6.5 FITTING CASING COVER OR MOTOR BRACKET

Place the O-ring (3, for ESL40/50-180N is 703) (or gasket in ESL25-180 12) between pump
casing and motor bracket (or casing cover in ESL25-180 12 combination or rear cover in
ESL40/50/80/100-180N and ESL65-180M) in the O-ring groove and hold it with a little
grease. However, check the material of the O-ring first. As standard the material is nitrile,
but it might be EPDM which will be damaged by mineral grease. Use soft soap or silicone
grease for EPDM. Fit and fasten shaft seal cover or motor bracket, mounted with the
electric motor, in the pump casing. Screw the pointed screws back into the shaft seal cover
before tightening. Fit circulation pipe (29) in ESL40/50-180N.
6.6 FITTING MOTOR FOR ESL40/50/80/100-180N AND ESL65-180M

Fit the motor coupling (8, 108 in ESL40/50-180N) to motor shaft and tighten the pointed screw
(11, 311 in ESL40/50-180N) slightly, place motor onto bracket (7, 104 in ESL40/50-180N) and
tighten the set screw (10, 810 in ESL40/50-180).Add 2 shims (301) between motor coupling
(8,108 in ESL40/50-180N) and pump shaft flange (6, 206 in ESL40/50-180N), adjust the
motor coupling to make it resist on the shims to ensure it is at the right axial position. Tighten
the pointed screw (11, 311 in ESL40/50-180) and remove the shims (301). Tighten the set
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screw (25, 17 in ESL40/50-180N) to lift up the impeller to a right position.
Regarding the tightening torque of pointed screw (11, 311 in ESL40/50-180N)
Dimension Point Torque Pointed

Motor Size
Screws Screws
71/80 M6 10Nm
90/100/112/132/160 M8 24Nm
6.7 SHAFT
When the pump has been assembled, check that the shaft rotates freely. In case the shaft
has been dismantled in the combination, tap the shaft towards the shaft end of the electric
motor by means of a plastic hammer, and fasten the pointed screws (first the middle screw)
according to the below table. Check that the wobble, measured as close to the shaft end as
possible, is within the limits indicated in the table.
Dimension Point Torque Pointed

Motor Size Max.Wobble
Screws Screws
71 M6 10Nm 70um
80 M6 10Nm 70um
90 M8 24Nm 70um
100/112 M8 24Nm 70um
132 M10 40Nm 70um
160 M12 75Nm 70um

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7. FROST PROTECTION
Pumps which are not in operation during frost periods are to be drained to avoid frost
damage. Remove the plug at the bottom to empty the pump. Alternatively, it is possible to
use anti-freeze liquids in normal constructions.
8. START-UP
A centrifugal pump will not function until it has been filled with liquid between the foot
valve and somewhat above the impeller of the pump.
The liquid also serves as coolant for the shaft seal. In order to protect the shaft seal
the pump must not run dry.
ATTENTION
For safety reasons the pump is only allowed to operate against closed discharge valve for a
short time (max. 5 minutes and at a max. temperature of 80°C for standard pumps).
Otherwise there is a risk of damage to the pump and, at worst, of a steam explosion. If the
pump is not monitored, the installation of a safety device is recommended.
8.1 START-UP
Before starting the pump check that:
- the shaft rotates freely without jarring sounds.

- the pump casing and the suction line are filled with liquid.
Start the pump for a moment to check the direction of rotation. If the direction is correct (i.e.
in the direction of the arrow) the pump may be started.
In order to protect the shaft seal the pump must never run dry.
If there is a positive suction lift, open the valve on the suction side of the pump and evacuate
the air through the vent plug (5, 25 in rear cover in ESL40/50-180N). If there is no positive
suction lift, the plant must be equipped with a foot valve or a non-return valve on the suction
side.
Prime the pump while the vent plug (5, 25 in rear cover in ESL40/50-180N) is kept open.
When the pump has been filled with water, and the air has been evacuated, the system
can be started. Check the direction of rotation. If the direction is incorrect interchange 2 of
the power cords. The direction of rotation is indicated by an arrow. Make sure the bearings
are running correctly and that they do not become warm.

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9. SYSTEM BALANCING
It is often difficult to calculate a manometric delivery head in advance. It is, however,

decisively important to the quantity of liquid delivered.
A considerably smaller delivery head than expected will increase the quantity of liquid
delivered, causing increased power consumption and perhaps cavitation in pump and piping.
In the pump the impeller may show signs of heavy erosion caused by cavitation (corrosion)
which may at times render an impeller unfit for use in a very short time. Not unusually do
similar erosions occur in pipe bends and valves elsewhere in the piping system.
Therefore, after start-up, it is necessary to check either the quantity of liquid delivered or the
power consumption of the pump e.g. by measuring the current intensity of the connected
motor. Together with a reading of the differential pressure the quantity of water delivered can
be determined against the characteristics of the pump.
Should the pump not function as intended, please proceed according to the fault-finding list.
Bear in mind, though, that the pump was carefully checked and tested at the factory and that
the majority of faults stem from the piping system
FAULT CAUSE REMEDY
The pump has no 1. Wrong direction of rotation Change direction of rotation to

or too low capacity clockwise when viewed from
shaft end (the direction of the
arrow)
2. Piping system choked Clean or replace
3. The pump is choked Clean the pump
4. Suction line leaks Find the leakage, repair the fault,
Pump takes air non-return valve not submerged
5. Suction lift too high Check data sheet Q/H curve and
6. Pump and piping system NPSH or contact DESMI
wrongly dimensioned As 5
The pump uses too 1. Counter-pressure too low Insert orifice plate or check
much power 2. The liquid is heavier valve/Contact DESMI
than water Contact DESMI
3. Foreign body in pump
Dismantle the pump, remove the
4. Electric motor is cause
running on 2 phases Check fuses, cable connection,
and cable
The pump makes 1. Cavitation in pump Suction lift too high/ Suction line
noise wrongly dimensioned/Liquid
temperature too high

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10. INSPECTION AND MAINTENANCE
Inspect the shaft seal for leaks at regular intervals.
- Before inspection of a pump without guard check that the pump cannot be started
unintentionally.
- The system is to be without pressure and drained of liquid.
- The repairman must be familiar with the type of liquid which has been pumped as well
as the safety measures he is to take when handling the liquid.
10.1 DRAINING THE PUMP

When the piping system has been drained, note that there is still liquid in the pump. Remove
the liquid by dismantling the pipe plug (18) at the bottom of the pump.
11. REPAIRS
11.1 ORDERING SPARE PARTS

When ordering spare parts please always state pump type, serial No. (appears on the name
plate of the pump), position No. on the assembly drawing and designation on the spare parts
list.
The following parts are exposed to wear: Shaft seal (22,522 in ESL40/50-180N), impeller
(2)/(7)/(5), wear rings (16)and (17) (not including in ESL25-180 and ESL40/50-180N)and the
ball bearings of the motor.
11.2 REPLACING THE IMPELLER

Close the valves on both sides of the pump. Dismantle pipe (29) in ESL40/50-180N and loosen
the nuts (15) and dismantle the top piece from the pump casing. Remove the screw (20, for
ESL40/50-180N is 24) and take off the impeller (2)/(7)/(5),. Fit the new impeller.
11.3 REPLACING WEAR RINGS

(Not applicable for ESL 25-180 and ESL40/50-180N. And ESL40-180 only has a wear
ring in the motor bracket)
When motor and pump have been separated, the wear ring (17) in the pump casing (1) can
be pulled out.
In order to replace the upper wear ring (16) it is necessary first to dismantle the impeller. Press
the new seal rings into place with an even push all over the face of the ring. Normal diameter
difference between seal ring and impeller 0.3-0.4 mm.
11.4 REPLACING SHAFT SEAL (22)

Dismantling as described in paragraph 5.1 or 5.2.
When the impeller has been dismantled, remove the key (19) and then the stop ring (21) (Not
applicable for ESL 25-180 and ESL40/50/80/100-180N, ESL65-180M) which is locked with a
pointed screw. The sealing element itself can now be pulled off the shaft.
Remove the seat ring from the top piece by pressing with a pair of screwdrivers or the like
under the collar off the seat. If the seat cannot be removed, dismantle the top piece from the
motor to permit pressing from the back.

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Clean the bore for seat and shaft thoroughly of dirt and rust. Remove persistent coatings, if
any, by grinding the shaft lightly with very fine emery cloth.
Grease the new seat ring and the inserted 0-ring well with glycerine – not oil – and press it
into place in the casing. Check that the seat is fitted correctly by knocking lightly with a piece
of wood. The seat ring is to be treated very carefully to prevent the sliding surface from being
scratched.
It is necessary to use a conical bush as shown below to prevent the rubber bellows from being
damaged during mounting.
Grease the back of the carbon ring with glycerine to ensure that it stays in its correct place
during the mounting. Grease the shaft, the conical bush and the rubber bellows amply with
glycerine.
Press the shaft seal on to the shaft until it resists. Press the driving ring only.
Finally place the stop ring (21) (Not applicable for ESL 25-180 and
ESL40/50-180N) on the shaft and lock it with the pointed screw.
When the pump has been mounted, ventilate the pump casing carefully before putting the
pump into operation.
When the pump has been running for 1-2 min., ventilate it again, after which it can start normal
operation.
Do not forget to check the direction of rotation if there is a risk that the power cords to motor
have been exchanged.
11.5 REPLACING BALL BEARINGS IN MOTOR
The ball bearing in the front bearing of the motor can be replaced without disassembling the
pump.
If the ball bearing in the rear bearing of the motor is to be replaced, it is necessary to
disassemble the pump and dismantle the pump shaft (as described in paragraph 5.1):
Dismantle the top piece from the motor. Remove the pointed screws (11, 311 in ESL40/50-
180N) in the pump shaft (6,206 in ESL40/50-180N). The pump shaft can now be pulled off the
motor shaft.
When assembling the pump again, check the motor shaft for damages in the form of marks,
burrs, or upsetting of the shaft end.
Damages, if any, are to be remedied by means of a file and fine emery cloth. This work has to
be done very carefully, especially on new motors, the shaft ends of which are often damaged
during transport. If this is not done carefully, the throw will be bigger than permitted and/or the
pump shaft will scratch the motor shaft when fitted.
Normally, the pump shaft is to go relatively smoothly on the motor shaft (manually or by means
of light strokes with a plastic hammer).
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Tighten the pointed screws (the one in the middle first) in accordance with the torque indicated
in the table and finally check that the throw stays within the indicated limits by means of an
indicator clock.
12. OPERATING DATA
The following working pressures (pressure in piping incl. the pressure increase caused by the
pump) and number of revolutions are allowed in standard pumps.
Max. Max.
working working pressure[bar]
Pump Max.RPM
pressure[bar] Bronze SG-iron
ESL25-180 /Cast
16iron 30 3600
ESL40-180N 16 30 3600
ESL40-180 16 30 3600
ESL50-180N 16 30 3600
ESL50-180 16 30 3600
ESL65-180M 10 16 3600
ESL65-180 10 16 3600
ESL80-180N 10 16 3600
ESL80-180 10 20 3600
ESL80-180B 10 20 3600
ESL80-180E 10 16 3600
ESL100-180N 10 16 3600
ESL100-180 10 16 3600
The max. working pressure for NiAlBz and stainless steel pumps is 1.5 times max. working
pressure for bronze (RG5).
The above-mentioned max. working pressure is a design value – delivered pumps are
pressure tested according to actual application requirements and actual flange standards.
For instance the above-mentioned max. working pressure is NOT valid for pumps approved
by a classification society. Pumps approved by classification societies have been pressure
tested according to the requirements of these societies, i.e. a test pressure of 1.5 x the
permissible working pressure. The test pressure is stated in the test certificate and stamped
into the discharge flange of the pump.
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13. EU DECLARATION OF CONFORMITY
DESMI Pumping Technology A/S, hereby declare that our pumps of the ESL Monobloc type
are manufactured in conformity with the following essential safety and health requirements in
the COUNCIL DIRECTIVE 2006/42/EC on machines, Annex 1.
The following harmonized standards have been used:
EN/ISO 13857:2008 Safety of machinery. Safety distances to prevent

danger zones being reached by the upper limbs
EN 809:1998 + A1:2009 Pumps and pump units for liquids – Common
safety requirements
EN12162:2001+A1:2009 Liquid pumps – Safety requirements – Procedure
for hydrostatic testing
EN 60204-1:2006/A1:2009 Safety of machinery – Electrical equipment of
machines (item 4, General requirements)
Ecodesign Directive (2009/125/EC). Water pumps:
Commission Regulation No 547/2012.
Applies only to water pumps marked with the
minimum efficiency
index MEI. See pump nameplate.
Pumps delivered by us connected with prime movers are CE-marked and comply with the
above requirements.
Pumps delivered by us without prime movers (as partly completed machinery) must only be
used when the prime mover and the connection between prime mover and pump comply with
the above requirements.
Nørresundby, March 05 2019
Henrik Mørkholt Sørensen

Managing Director
DESMI Pumping Technology A/S

Tagholm 1
9400 Nørresundby

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14. INFORMATION RELEVANT FOR DISASSEMBLY OR DISPOSAL AT END-OF-LIFE
No damage materials are used in DESMI pumps – please refer to DESMI Green Passport (can be sent on
request – contact a DESMI sales office) – i.e. common recycling companies can handle the disposal at
end-of-life. Alternatively the pump and motor can be returned to DESMI at end-of-life for safe
recycling.

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15. ASSEMBLY DRAWING ESL25-180/-12-COMB.
1 Pump casing
2 Impeller
02 Plug
3 Gasket
4 Motor bracket
5 Vent plug
6 Shaft
10 Set screw
11 Pointed screw
14 Stud
15 Nut
19 Key
20 Nut
Mechanical
22
shaft seal
23 Washer
25 Cover
26 Plug
27 Washer
28 Guard
96 Manometer
97 Nipple
98 Sleeve
100 Base plate
200 Screw

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1 Pump casing
2 Plug
3 O-ring
4 Casing cover
5 Vent plug
6 Shaft
7 Impeller
8 Shaft flange
10 Set screw
11 Pointed screw
14 Stud
15 Nut
16 Wear ring
18 Plug
19 Key
20 Screw
21 Stop ring
Mechanical
22
shaft seal
23 Washer
24 Pointed screw
51 Base plate
52 Screw
96 Manometer
97 Nipple
98 Sleeve

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1 Pump casing
2 Plug
3 O-ring
4 Casing cover
5 Vent plug
6 Shaft
7 Impeller
8 Shaft flange
10 Set screw
11 Pointed screw
14 Stud
15 Nut
16 Wear ring
17 Wear ring
18 Plug
19 Key
20 Screw
21 Stop ring
Mechanical
22
shaft seal
23 Washer
24 Pointed screw
51 Base plate
52 Screw
96 Manometer
97 Nipple
98 Sleeve

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1 Pump casing
2 Plug
3 O-ring
4 Casing cover
5 Vent plug
6 Shaft
7 Impeller
8 Shaft flange
10 Set screw
11 Pointed screw
14 Stud
15 Nut
16 Wear ring
17 Wear ring
18 Plug
19 Key
20 Screw
21 Stop ring
Mechanical
22
shaft seal
23 Washer
24 Pointed screw
96 Manometer
97 Nipple
98 Sleeve
100 Base plate
200 Screw

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19. ASSEMBLY DRAWING ESL80-180/-12 & ESL80-180B/-12 &ESL80-180E/-12 -COMB.
1 Pump casing
2 Plug
3 O-ring
4 Casing cover
5 Vent plug
6 Shaft
7 Impeller
8 Shaft flange
10 Set screw
11 Pointed screw
14 Stud
15 Nut
16 Wear ring
17 Wear ring
18 Plug
19 Key
20 Screw
21 Stop ring
Mechanical
22
shaft seal
23 Washer
24 Pointed screw
96 Manometer
97 Nipple
98 Sleeve
100 Base plate
200 Screw

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1 Pump casing
2 Plug
3 O-ring
4 Casing cover
5 Vent plug
6 Shaft
7 Impeller
8 Shaft flange
10 Set screw
11 Pointed screw
14 Stud
15 Nut
16 Wear ring
17 Wear ring
18 Plug
19 Key
20 Screw
21 Stop ring
Mechanical
22
shaft seal
23 Washer
24 Pointed screw
96 Manometer
97 Nipple
98 Sleeve
100 Base plate
200 Screw

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21.ASSEMBLY DRAWING ESL40/50-18N/-12-COMB
1 Pump casing
5 Impeller
7 Rear cover
14 Stud
15 Nut
16 Washer
17 Set screw
18 Plug
19 Key
23 Washer
24 Screw
25 Plug
26 Nipple
28 Nipple
29 Pipe
51 Base plate
52 Screw
96 Manometer
97 Nipple
98 Sleeve
104 Motor bracket
108 Motor coupling
206 Shaft W. Flange
311 Pointed screw
522 Shaft seal
703 O-ring
810 Set screw
811 BH-Screw
812 Guard

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22.ASSEMBLY DRAWING ESL80/100-180N/-12 & ESL65-180M/-12-COMB
1 Pump casing
2 Impeller
3 O-ring
4 Rear cover
5 Venting plug
6 Shaft W. Flange
7 Motor bracket
8 Motor coupling
9 Muff
10 Set screw
11 Pointed screw
14 Stud
15 Nut
16 Wear ring
17 Wear ring
18 Plug
19 Key
20 Set screw
21 Sleeve
22 Shaft seal
23 Washer
24 Washer
25 Set screw
96 Manometer
97 Nipple
98 Sleeve
100 Base plate
200 Screw
201 Inter. flange
202 Set screw
811 BH-Screw
812 Guard

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23.DIMENSIONAL SKETCH ESL
D DA DB DC H HA HB HF I J K KA KB L LA LB N x M
Type TN Flange Max. Max. Min. Max. Max.
mm mm mm mm mm mm mm mm mm mm mm mm mm mm mm mm mm
1"
1 ESL25- 180 10 25 115 68 85 754 644 110 60 240 275 220 110 110 300 150 150 4xø14
25 mm
1½"
2 ESL40-180N 10 40 150 90 110 878 778 100 60 285 320 244 116 128 360 180 180 4xø18
40 mm
1½"
3 ESL40- 180 10 40 150 90 110 960 840 120 60 285 320 253 118 135 350 175 175 4xø18
40 mm
4 2"
ESL50-180N 10 50 165 102 125 878 780 98 60 285 320 260 123 137 400 200 200 4xø18
50 mm
2"
5 ESL50- 180 10 50 165 102 125 935 830 105 60 285 320 267 145 122 400 200 200 4xø18
50 mm
2½"
6 ESL65- 180 10 65 185 122 145 878 828 155 100 285 320 295 137 158 440 220 220 4xø18
65 mm
7 2½"
ESL65- 180M 10 65 185 122 145 878 828 155 100 285 320 295 137 158 440 220 220 4xø18
65 mm
3"
8 ESL80- 180 10 80 200 138 160 966 830 136 120 285 320 320 150 170 480 240 240 8xø18
80 mm
9 3"
ESL80- 180N 10 80 200 138 160 990 830 160 120 285 320 310 140 170 480 240 240 8xø18
80 mm
10 3"
ESL80- 180B 10 80 200 138 160 966 830 136 120 285 320 320 150 170 480 240 240 8xø18
80 mm
11 3"
ESL80- 180E 10 80 200 138 160 990 830 160 120 285 320 310 140 170 480 240 240 8xø18
80 mm
12 4”
ESL100- 180 10 100mm 100 220 158 180 1003 833 170 140 285 320 350 160 190 540 270 270 8xø18
13 4”
ESL100- 180N 10 100mm 100 220 158 180 1003 833 170 140 285 320 350 160 190 540 270 270 8xø18
Table with thread sizes of manometer, drain and vent plug hole (if any) on the next page.

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Type Manometer Drain Air vent
1 ESL25-180 1/4” 1/8” 1/8”
2 ESL40-180N 1/4” 3/8” 1/4”
3 ESL40-180 1/4” 3/8” 1/8”
4 ESL50-180N 1/4” 3/8” 1/4”
5 ESL50-180 1/4” 3/8” 1/8”
6 ESL65-180 1/4” 3/8” 1/8”
7 ESL65-180M 1/4” 3/8” 1/8”
8 ESL80-180 1/4” 3/8” 1/8”
9 ESL80-180N 1/4” 3/8” 1/8”
10 ESL80-180B 1/4” 3/8” 1/8”
11 ESL80-180E 1/4” 3/8” 1/8”
12 ESL100-180 1/4” 3/8” 1/8”
13 ESL100-180N 1/4” 3/8” 1/8”

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FCV
(EMERSON-V3)
Reference Manual
Version: RM 8000-100-01 Ed 01
Release: July, 2020
Damcos™ Local Power Unit

Manual
The content of this publication are presented for information purposes only, and while effort has been made to ensure their accuracy, they are not to be construed
as warranties or guarantees, expressed or implied, regarding the products or services described herein or their use or applicability. All sales are governed by our
terms and conditions, which are available upon request. We reserve the right to modify or improve the designs or specifications of our products at any time with-
out notice. Damcos A/S accepts no responsibility for any errors that may appear in this publication.
As each system may be configured for each delivery, the content and illustrations in this manual may differ from your system.
Copyright © Damcos A/S, 2020

Reference Manual for LPU in English
Damcos LPU: Table of Contents Reference Manual
July 2020 RM 8000-100-01 Ed 01
Table of Contents
Abbreviation and Denomination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Warning Levels Used in Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Handling and Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Service Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Mounting Recommendations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Bleeder Valve Positions on LPU. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Use with other Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
More Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Electrical Product Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Cable Connection Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Encapsulation Top Cover - Internal Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
PCB, Printed Circuit Board - Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Cable Glands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
General Service Instructions for LPU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

General Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
LPU and Optional Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Detailed Product Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Overview LPU-D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Hydraulic Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Operating LPU-D 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Emergency Operation LPU-D Version 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

LPU-D, Options for Double Acting Actuator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Emergency Operations with hand pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Emergency Operations with Firmly Mounted hand pump . . . . . . . . . . . . . . . . . . . . . . 57
Overview LPU-S . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Hydraulic Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Operating LPU-S . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Emergency Operation LPU-S Version 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

LPU-S, Options for Single Acting Actuators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Emergency Operations with hand pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Emergency Operations with Firmly Mounted hand pump . . . . . . . . . . . . . . . . . . . . . . 73
1
Reference Manual Damcos LPU: Table of Contents
RM 8000-100-01 Ed 01 July 2020
Actuator Speed Adjustment on LPU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

Pump Pressure Adjustment for LPU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Measuring Oil Level in LPU Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Emptying Oil from LPU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Refill of Oil in LPU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Replace Pump in LPU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Replace Hydraulic Block in LPU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Replace DPI in LPU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Replace Motor in LPU. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Replace Motor Capacitor in LPU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
Replace Solenoid Valve Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
Replace Printed Circuit Board (PCB) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
Replace 250 ml Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
Replace 250 ml Level Tank (with Switch). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
Replace 1000 ml Level Tank (with Switch) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
Troubleshooting Guide LPU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .143

Trouble Shooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .155
2
Damcos LPU: Abbreviation and Denomination Reference Manual
July 2020 RM 8000-100-01 Ed 01
Abbreviation and Denomination
DI Digital In
DO Digital Out
DPI Direct Position Indicator
ESD Emergency Shut Down
FC Fail Close
FO Fail Open
HP Hand Pump
ICMS Integrated Control and Monitoring System
ISC Integrated Ship Control
LPU Local Power Unit
LPU-D LPU for double-acting actuator
LPU-S LPU for single-acting spring actuator
LPU-Ex LPU approved for mounting in hazardous area
PCB Printed Circuit Board
PLC Programmable Logic Controller
BB-VPI Bulkhead mounted Volumetric Position Indicator
VPI Volumetric Position Indicator
3
Reference Manual Damcos LPU: Abbreviation and Denomination
RM 8000-100-01 Ed 01 July 2020
4
Damcos LPU: Handling Reference Manual
July 2020 RM 8000-100-01 Ed 01
Handling
A description of issues concerning
personal safety and how to handle the Local Power Unit
at delivery, Installation and operation
5
Reference Manual Damcos LPU: Handling
RM 8000-100-01 Ed 01 July 2020
6
Damcos LPU: Warning Levels Used in Manuals Reference Manual
July 2020 RM 8000-100-01 Ed 01
Warning Levels Used in Manuals

The following warning levels are used in the documentation of Damcos A/S for the safety of people and equip-
ment.
Warning! Indicates a potentially hazardous situation which, if not avoided, could result in death or seri-
ous injury.
Caution! Indicates a potentially hazardous situation which, if not avoided, may result in property damage.
Note! Indicates important information regarding the product.
Warnings
All personnel that handles Damcos LPU shall take part of and understand the following information prior to han-
dling the system. See warnings on next page.
7
Reference Manual Damcos LPU: Safety
RM 8000-100-01 Ed 01 July 2020
Safety
8
Damcos LPU: Handling and Storage Reference Manual
July 2020 RM 8000-100-01 Ed 01
Handling and Storage
Storage before Installation

The system equipment must be stored under shelter in their original shipping boxes with protection for rain, pref-
erable in dry indoor place, not directly exposed to wind, rain, sand, dirt, etc.
The equipments with packing should be kept from the possibility of physical damage and protected against envi-
ronmental dust.
All ports and covers must be correctly mounted during storage to avoid moisture and dust to enter the LPU.
Moist conditions should be avoided.
The equipments should be stored in an easily accessible place where they can be easily brought out for rigging
work.
Transport and Storage

Use proper lifting facilities and transportation equipment.
In case of lifting, take care not to damage any painting. Scratches or damage of a coated area can cause galvanic
corrosion. If scratched repair before equipment is finally installed.
As weight of LPU is about 14 kg it can be lifted simply by holding around tank, motor or electrical housing.
If LPU is mounted on actuator with no valve mounted, it can be lifted by hand (small actuators) or by lifting eye
bolt at the actuator (larger actuators). If LPU is mounted on actuator and valve lifting of the assembled unit must
be done using lifting facilities at valve. Lifting eye bolt on actuator is not dimensioned for valve lifting and should
be removed immediately when actuator is mounted on valve.
Handling after Installation prior to Service Operation

After installation the equipment should be covered with strong heat shrinkable plastic cover, as thoroughly as
possible using humidity absorbers inside the plastic cover.
Be careful to protect the coated and plastic surfaces, and particularly avoid hard and sharp items in contact with
the equipment.
Secure the equipment to prevent it from tipping over.
Check the equipment regularly, especially for damages on the shrinkable plastic cover and also check the condi-
tion of the humidity absorbers.
9
Reference Manual Damcos LPU: Commissioning
RM 8000-100-01 Ed 01 July 2020
Commissioning
Qualified commissioning is crucial for the service life and functional safety of the hydraulic system.
Note! LPU-Ex has it’s own User Manual placed inside the electrical housing.
Please read this manual carefully before installing LPU Ex.
Preparation Instruction
Before first time starting up the system, LPU, actuator and possible hydraulic piping must be fully de-aired.
All electrical cables to LPU must to be connected.
Note! If the LPU is connected with hydraulic piping, please note the following:
This will influence the required tank size and the system performance, due to compressibility of the oil in
piping and pressure drop in piping.
Several other parameters influence the system; Temperature, Flow, Valve torque, Actuator type.
It may be required to use larger diameter piping for some LPU, or adjust the valve speed to be quite low.
In case you have trouble with the LPU system performance, please consult Emerson.
Before installation check pipe length from LPU to actuator. Check below if maximum pipe length and LPU tank
capacity match. The values below are for piping ID 8 mm. for larger pipe diameter, max pipe length must be
reduced accordingly to keep the same pipe volume
BRC BRC BRC BRC BRC BRC BRC BRC

Tank size (ml)
125 250 500 1000 2000 4000 8000 16000
Standard; 250 ml tank 15 15 15 15 14 13 11 7
250 ml tank w switch 24 24 24 24 23 22 20 17
1000 ml tank w switch 85 85 85 85 85 85 85 81
BRCF BRCF BRCF BRCF BRCF BRCF BRCF BRCF

Tank size (ml)
125 250 500 1000 2000 4000 8000 16000
Standard; 250 ml tank 30 30 30 30 29 27 23 15
250 ml tank w switch 49 49 49 48 47 45 41 34
1000 ml tank w switch 85 85 85 85 85 85 85 85
KF+KF KF+KFR
Tank size (ml) KC 65 KC 125 KC 250 KC 325 KC 400 KF 65
R 125 250
Standard; 250 ml tank 15 14 12 7 0.6 30 30 29
250 ml tank w switch 24 24 21 16 10 49 49 47
1000 ml tank w switch 85 85 85 84 77 85 85 85
10
Damcos LPU: Commissioning Reference Manual
July 2020 RM 8000-100-01 Ed 01
Commissioning Procedure
1. First check the power supply to the substation that controls the LPU. Voltage must correspond to LPU.
(Please be aware, that switching power to an LPU-Power will make the LPU run for 7 seconds. If on/off relays
has been used, all LPU-Power will run 7 seconds or more simultaneously after switching power to substation).
Check cable entry in cable glands and that cables are fastened in the glands. Minimum bending radius for
cable must be OK.
2. If refill is required, refill with a hydraulic oil, as specified for the system if required. The LPU is normally pre-
filled with Shell Tellus S2V32 (earlier Tellus T 32), for deck mounting Shell Tellus S4VX (earlier Tellus Arctic
32).
See “Refill of Oil in LPU” on page 89.
3. Open valve.
If the valve has not started opening within 10 seconds, open bypass valve at actuator for 5 seconds and close
firmly again. If the valve still doesn’t start opening within 10 seconds, start trouble shooting.
4. At fully open position, the pressure will rise to 150 bar and the LPU will run at that pressure for an individual
extra time, depending partly on the valve operating time. If it doesn’t stop, check position indicator sig-
nal, pressure switch signal and electrical connection. For bulkhead mounted units check oil level again. If oil
level is low the system is not properly de-aired.
5. Check position indication while the valve is fully open.
6. Close the valve again. If LPU becomes noisy (more than by pressure rise) during opening while the actuator
stops moving before full opened position, check oil level again.
7. Check position indication while the valve is fully closed. If position indication has to be adjusted, adjust in
closed position and check in open position. If continuous position indication has to be adjusted at circuit
board (Power Control), adjust in closed position first, then in open position.
8. Open / close the valve several times checking opening/closing speed.
9. Check for external oil leakage.
10.After 1 week or after operating valve several times, check for external oil leakage.
Bulkhead mounted LPU

Even if a proper de-airing of the pipes has been carried out, there may be small amounts of air in the piping. This
air may return to the LPU within several days or at open/close cycles. Frequently check oil level the first week after
operating the valve (see next page). Stop the LPU if the desired position has not been reached within normal
time.
At start up check that:
• LPU is filled up with oil
• Quick connection cap has been mounted – 100% tight
• Look for possible visual leakage, e.g. flange between LPU and actuator.
• After mounting of cable in the LPU, the Cable Connection cover shall be mounted correct, secured and tight-
ened. Make sure the O-ring in the cover is correctly placed before mounting Cable Connection cover.
• Cable is mounted tight into cable gland and cannot be moved
• There is no unwanted noise during open/close operation
• LPU does not make any unwanted noise during continually running or stuck during operation, if so then stop
and check.
11
Reference Manual Damcos LPU: Commissioning
RM 8000-100-01 Ed 01 July 2020
LPU Tank with Switch
• Oil level is controlled by measuring the distance from cap to piston with closed or fully opened actuator, see
picture above.
Oil level must be 30-32 mm for 250 tank and 27-29 mm for 1000 tank.
• If oil refill is required, close the valve, connect pressure connection from hand pump to B-quick connection
for LPU.
Note! See “Measuring Oil Level in LPU Level Tank” on page 81for complete instruction on how to measure
the oil level.
12
Damcos LPU: Commissioning Reference Manual
July 2020 RM 8000-100-01 Ed 01
LPU Setup for Not Configured LPU (type0)

Standard Procedure with new, not configured LPU (type 0)
Step LED output Comment

1. The LPU is in remote mode. Steady Blue Motor and solenoid valve can be acti-
vated with magnetic input OPEN and
CLOSE.
2. Fill the LPU with oil and perform See “Refill of Oil in LPU” on page 89.
the de-airing.
3. Set the valve in Closed position.
Note! Fail-Open actuators must be set in CLOSED position, and the solenoid valve kept activated while
leaving the mode with blue LED, by activating magnetic input LOCAL once. LED turns steady white.
Solenoid valve stays activated.
4. Activate the ADJUST mode and See Adjust Mode in User Manual.
the position indicator is adjusted
in closed valve position.
Note! ADJUST may not be needed when a PCB has been replaced without changing or adjusting the posi-
tion indicator.
5. ADJUST procedure is subse- Fail-Open Actuator will go to OPEN posi-

quently terminated by magnet tion.
input LOCAL.
6. LEARN is activated to configure See Learn Mode in User Manual.
the LPU.
7. The LPU setup will normally be
finished.
13
Reference Manual Damcos LPU: Service Area
RM 8000-100-01 Ed 01 July 2020
Service Area
There should be enough space around the actuators to ensure easily access and service.
To be able to perform emergency operation by emergency key or hand pump there must also be enough space
around the actuator enabling this operation.
Service Area for LPU with 250 ml Tank
All Measurements in mm
14
Damcos LPU: Service Area Reference Manual
July 2020 RM 8000-100-01 Ed 01
Service Area for LPU 250 ml Tank with Switch
Service Area for LPU 1000 ml Tank with switch
15
Reference Manual Damcos LPU: Service Area
RM 8000-100-01 Ed 01 July 2020
16
Damcos LPU: Mounting Recommendations Reference Manual
July 2020 RM 8000-100-01 Ed 01
Mounting Recommendations
The LPU is especially developed for mounting directly at Damcos valve actuators types BRC 125-16000, BRCF
125-16000, KC 65-400, KF 65-250 and KFR 125-250. Mounting at actuator types BRC 32000, KC 600 and BRCF
HT is possible, but not recommended due to runtime capabilities.
Before direct mounting at small pipes the strength of pipes should be considered. Alternatively the LPU could be
bulkhead mounted instead of mounted directly on actuator.
LPU can be placed at almost all environment onboard a ship, but attention must be paid to hazardous areas and
submersion. The LPU can be short time flooded (3 bar for 24 hours or 1,5 bar for 72 hours), but permanent sub-
mersion must be avoided.
For LPU placed on deck or in very corrosive environments a special coating must be applied to LPU and actuator.
Environmental temperature for LPU is normally -5°C to +70°C and with special oil -25°C to +70°C. Oil viscosity
must be considered depending on environmental temperatures.
LPU mounted with BRC / BRCF

LPU and actuators BRC and BRCF can be oriented in all directions, but placing actuator with horizontal valve spin-
dle and LPU placed below actuator is not recommended due to more difficult de-airing of actuator and servicing
the LPU.
LPU mounted with KC / KF

LPU and actuators KC and KF can be oriented in all directions, but placing actuator with horizontal valve spindle is
not recommended due to globe valve construction that requires valve spindle to be as vertical as possible.
LPU mounted with KFR

Actuators type KFR can only be placed with vertical valve spindle and actuator on top of valve.
17
Reference Manual Damcos LPU: Bleeder Valve Positions on LPU
RM 8000-100-01 Ed 01 July 2020
Bleeder Valve Positions on LPU
Valve bleed positions on the LPU. The lower pictures shows the bleed valve position on the hydraulic block.
LPU Version 3 are equipped with an automatic bleeder valve function. The automatic bleeder function enables
the LPU to be installed in all directions without disabling the unit. This will ease the installation and reduce the
number of opening points and hence minimize the risk of introducing dirt into the system.
Due to this new tank bleed design the LPU bleed valve is placed at fixed location and is not to be relocated
depending on actuator and LPU orientation.
Exceptions
Bleed valve position at highest

point on BRCF actuator.
For horizontal placed BRCF actuator the bleed valve at top of BRCF should be placed at top position, see picture
above.
18
Damcos LPU: Bleeder Valve Positions on LPU Reference Manual
July 2020 RM 8000-100-01 Ed 01
If you have an LPU of older design (version 1 or 2), then it is extremely important that bleeder valve position is cor-
rectly chosen when mounting LPU with actuator on pipe. Other positions are plugged when not used! This is nor-
mally done at installation.
Note! LPU version 3 has automatic bleeder function and the position of the bleeder valve will be the same
regardless to position of the LPU.
For KC/KF/KFR bleed valve on top of actuator has no connection to LPU tank and must always be pres-
ent!
19
Reference Manual Damcos LPU: Use with other Equipment
RM 8000-100-01 Ed 01 July 2020
Use with other Equipment
Portable Hand Pump

The LPU system can be locally and emergency operated by use of portable hand pump or
firmly mounted LPU hand pump.
Portable hand pump can simply be connected to quick connectors at LPU. Usage instruc-
tions are shown at tag at LPU.
Caution!
When using the portable hand pump with a double acting LPU the pipe pressure must be
released before remote operation.
For a single acting LPU there is no restriction.
Usage of Portable Hand Pump where LPU is Hydraulically Connected via Pipes
There are cases where the portable hand pump must be connected remotely to the LPU via pipes (block). This
implicates that the access to the LPU is difficult and that there will be no local feedback. See pictures below.
In these cases pipe connectors including stop and quick connectors are recommended to be added to the LPU.
Important notes for operating portable hand pump

Pipe Length < 5 meters:
– release the pipe pressure before remote operation
Pipe Length < 100 meters:
– release the pipe pressure before remote operation.
Minimum release time is 20 seconds!
DPI inside
Firmly Mounted Hand Pump

Firmly mounted hand pump will work best using Damcos HP-LPU.
The HP-LPU is placed between LPU and actuator or between LPU
and bulkhead block.
20
Damcos LPU: Use with other Equipment Reference Manual
July 2020 RM 8000-100-01 Ed 01
Bulkhead Mounted
If valve and actuator are placed in a way so mounting LPU directly on actuator is not possible (due to narrow space
for LPU or actuator placed in hazardous or submerged area etc.) LPU can be bulkhead mounted on a B-block, and
hydraulically connected to actuator with pipes.
If the position indicator is located at the actuator (DPI or NAMUR type) with electrical cable to LPU. A cable is then
connected between position indicator and LPU.
If a Volumetric Position Indicator is used, a BB-VPI block is used, serving both as B-block and VPI.
By default the BB-VPI has internal wire connection to LPU, so no external cables are added.
When using VPI with LPU, pipe length should be no more than 30 meters each, since no compensation blocks can
be used.
Mounting on Actuator
LPU can be placed directly at Damcos actuators type BRC, BRCF, KC, KF and KFR and Bettis actuators type BHH,
BHHF, BL, BLF and BLFR. Other actuators can be operated using B-block or special mounting block placed at actu-
ator or bulkhead, but please be aware of flow, pressure and maximum runtimes.
21
Reference Manual Damcos LPU: Use with other Equipment
RM 8000-100-01 Ed 01 July 2020
22
Damcos LPU: General Description Reference Manual
July 2020 RM 8000-100-01 Ed 01
General Description
A short description
of the LPU and
the system
21
Reference Manual Damcos LPU: General Description
RM 8000-100-01 Ed 01 July 2020
22
Damcos LPU: Description Reference Manual
July 2020 RM 8000-100-01 Ed 01
Description
The LPU - (Local Power Unit) - is an integrated electro-hydraulic system for remote control of valves and actuators
and are especially developed for bulkhead mounting or direct on valve actuators, primarily onboard ships. The
LPU consists of a hydraulic pump which is driven by an asynchronous capacitor motor and several valve functions.
The LPU offers installation in both safe and hazardous area in two basic versions:
• LPU-S (fail safe) for single acting actuator
• LPU-D (fail set) for double acting actuator
The LPU offer is further expanded with six different electrical standard versions all equipped with different levels of
functions and possibilities:
– LPU Basic
– LPU Plus
– LPU Elite
– LPU P-NET
– LPU Power
– LPU Ex
The LPU program offers installation both on the actuator and for separate installation on the bulkhead in safe and
hazardous area and can control both single and double acting actuators.
23
Reference Manual Damcos LPU: More Information
RM 8000-100-01 Ed 01 July 2020
More Information
Installation, Service, Maintenance, Operation and Technical Data can be found in the following documentation:
Data Sheets
• Damcos Local Power Unit - General – SD 1507-2EXX
• LPU-D - Hydraulic Data for Double-Acting Operated Actuator – SD 1502-2EXX
• LPU-S - Hydraulic Data for Single-Acting Spring Operated Actuator – SD 1501-2EXX
• Power Controlled LPU – SD 1503-2EXX
• P-NET Controlled LPU System – SD 1506-2EXX
• LPU Basic, Plus and Elite Controlled System – SD 1507-2EXX
• LPU-S-Ex-d-IIC – SD 1510-2EXX
• LPU-D-Ex-d-IIC – SD 1511-2EXX
Manuals
• Reference Manual LPU – RM 8000-100-01
• User Manual LPU – UM 8000-100-02
• User Manual Aperio – UM 9000-30-001
Contact Information
Emerson Automation Solutions
Damcos A/S
Aaderupvej 41
DK-4700 Naestved
T +45 5578 7200
F +45 5578 7272
www.Emerson.com/marine
24
Damcos LPU: Electrical Product Connection Reference Manual
July 2020 RM 8000-100-01 Ed 01
Electrical Product Connection

Overview of the cable connections,
wiring diagrams
and power
25
Reference Manual Damcos LPU: Electrical Product Connection
RM 8000-100-01 Ed 01 July 2020
26
Damcos LPU: Cable Connection Cover Reference Manual
July 2020 RM 8000-100-01 Ed 01
Cable Connection Cover

Customer Cable Connection
LPU Basic, Plus and Elite P-NET controlled LPU Power controlled LPU
controlled system
Examples of Cable Connection Cover for different systems.To the left the numbered connections as explained in the dia-
gram below.
Terminal 1 2 3 4 5 6 7 8 9 10 11 12
Basic 24 0 DI DI DO DO Close
VDC VDC Open Close Open
Plus 24 0 DI DI DI AUX DO DO Close

Elite 24 0 DI DI DI AUX DO DO Close DO AUX

(AI) (AO)
Power Motor N Sole Pos. Pos. ← OR→ DO DO Close DO

noid 4-20 4-20 Open or or POT COM or
POT high low POT mid
P-NET Pos. DO DO Close DO

4-20 Open COM
Terminal X1 X2 X3 X4 X5 X6 X7
Basic PE/Ground N(AC) 230 VAC
Plus PE/Ground N(AC) 230 VAC
Elite PE/Ground N(AC) 230 VAC
Power PE/Ground
P-NET PE/Ground N(AC) 230 VAC 24 VDC 0 VDC A B
27
Reference Manual Damcos LPU: Cable Connection Cover
RM 8000-100-01 Ed 01 July 2020
Internal Connections – Terminal to Terminal
Examples of Cable Connection Cover

for different systems.
To the right the numbered connections
as explained in the diagram below.
Terminal 1 2 3 4 5 6 7 8 9 10 11 12 J1
Basic Y3 Y2 Y1 Y1
Plus Y3 Y2 Y1 Y1
Elite Y3 Y2 Y1 Y1
Power Y1 Y1
P-NET Y3 Y2 Y1 Y4 Y5 Y6 Y7 Y1
Connection Example for Chain/Loop Power

24 V Signal: 5 to 8 wires
Simple I/O
230 V Power:
(chain/loop)
Note! Maximum 6 LPU:s in a loop and total 13 A.
28
Damcos LPU: Cable Connection Cover Reference Manual
July 2020 RM 8000-100-01 Ed 01
Connection Layout
The connection layout for Basic, Plus and Elite are the same for both double and single acting valve.
LPU for Actuators Controlled by 24 VDC Signals
LPU for Actuators Controlled P-NET FieldBus
29
Reference Manual Damcos LPU: Cable Connection Cover
RM 8000-100-01 Ed 01 July 2020
LPU for Actuators Power Controlled
30
Damcos LPU: Encapsulation Top Cover - Internal Wiring Reference Manual
July 2020 RM 8000-100-01 Ed 01
Encapsulation Top Cover - Internal Wiring
1 2 3 4 5 6 7 8 9 10 11 12
Basic 230 VAC N N/C J1 24 VDC 0 VDC DI DI DI DO DO DO

Red Blue Black Green Open Close AUX Open Closed AUX
Y1/Gn Purple Grey Brown Orange Yellow White
Plus 230 VAC N N/C J1 24 VDC 0 VDC DI DI DI DO DO DO

Y1/Gn Purple Grey Brown Orange Yellow White
Elite 230 VAC N N/C J1 24 VDC 0 VDC DI DI DI DO DO DO

Y1/Gn AI+ Grey Brown AO+ Yellow White
Purple Orange
Power Motor N Sole- J1 NC NC AO AO N/C DO DO DO

Red Blue noid Black Green pos pos Open Closed COM
Brown Y1/Gn Purple Grey Orange Yellow White
P-NET 230 VAC N N/C J1 24 VDC 0 VDC A B AO+ DO DO DO

Bus Red Blue Black Green Purple Grey pos Open Closed COM
Y1/Gn Brown Orange Yellow White
31
Reference Manual Damcos LPU: PCB, Printed Circuit Board - Wiring
RM 8000-100-01 Ed 01 July 2020
PCB, Printed Circuit Board - Wiring
LPU Basic, Plus and Elite Controlled System
32
Damcos LPU: PCB, Printed Circuit Board - Wiring Reference Manual
July 2020 RM 8000-100-01 Ed 01
P-Net Controlled LPU System
33
Reference Manual Damcos LPU: PCB, Printed Circuit Board - Wiring
RM 8000-100-01 Ed 01 July 2020
Power Controlled LPU
Note! Power PCB can be of Analog or ON/OFF!
34
Damcos LPU: Cable Glands Reference Manual
July 2020 RM 8000-100-01 Ed 01
Cable Glands
Cable Glands sizes and numbers are decided at order.
There are room for two M20x1.5 and two M25x1.5 on the Cable Connection Cover.
Not used cable entrances will be plugged!
Note! Cable Gland for P-Net must be screened!
IP Class requirement IP68. For more technical data about cable glands and cables please read the data sheets for
the specific system (see “Data Sheets” on page 24).
35
Reference Manual Damcos LPU: Cable Glands
RM 8000-100-01 Ed 01 July 2020
36
Damcos LPU: General Service Instructions for LPU Reference Manual
July 2020 RM 8000-100-01 Ed 01
General Service Instructions for LPU

This chapter describes the general requirements
and service recommendations for the LPU
37
Reference Manual Damcos LPU: General Service Instructions for LPU
RM 8000-100-01 Ed 01 July 2020
38
July 2020 RM 8000-100-01 Ed 01
General Considerations
Important notes on LPU equipment and systems:
• use original spare parts and tools
• use lifting facilities and transport equipment - see “Handling and Storage” on page 9
• use handling instructions
• electrical cables are only to be connected by qualified personnel
Note! Read Safety chapter before handling any equipment!
39
RM 8000-100-01 Ed 01 July 2020
Maintenance
As LPU is designed for limited running capabilities and has a closed oil reservoir regular maintenance work is not
required. However, if running in major temperature variations the recommendation is to change the oil every 5th
year. Furthermore, if the LPU is used with a BRCF it is recommended to change the oil in case of a breakdown in
the spring housing. In that case the suction filter should be changed as well. LPU Basic, Plus and Elite will raise a
maintenance flag after 7000 operations as a reminder.
A hydraulic oil, as specified for the system (32 cSt40°C, Viscosity Index (VI) > 140, for temperature below -5°C VI >
300) has to be used. The LPU is normally pre-filled with Shell Tellus S2V32 and for deck mounting (on request)
Shell Tellus S4VX. If other oil brand is to be used it must be compatible with above mentioned Shell oil to ensure
proper function of LPU as there normally will be a rest of the old oil in small parts of LPU.
Suction filter is designed to last for a long time, so regular exchange is not required, but at breakdown the oil
could be contaminated and for this reason the suction filter should be exchanged as well.
Note! If green oil is specified, please order the LPUs with Panolin Atlantis. Exchanging mineral oil to green oil
is troublesome, since the LPU cannot be properly emptied without dismantling the LPU.
40
July 2020 RM 8000-100-01 Ed 01
LPU and Optional Equipment

The LPU can be equipped with additional equipment, such as switches, indicators etc. Further more the LPU can
be bulkhead mounted, mounted with blocks or otherwise mounted in respect to customer requirements and sys-
tem. Always check your specific system drawings and documents for correct information. This manual is a guide
on how to perform the installation, operation and service of your system. For further information please contact
Emerson service engineer or appointed agent.
41
RM 8000-100-01 Ed 01 July 2020
42
Damcos LPU: Detailed Product Overview Reference Manual
July 2020 RM 8000-100-01 Ed 01
Detailed Product Overview

Overview of the LPUs and step by step
procedures for replacement of parts
43
Reference Manual Damcos LPU: Detailed Product Overview
RM 8000-100-01 Ed 01 July 2020
44
Damcos LPU: Overview LPU-D Reference Manual
February 2017 RM 8000-100-01 Ed 01
Overview LPU-D
Cable Glands Cable Connection Cover
Encapsulation
Top Part Sight Glass
for LED 1000 ml Tank
w switch
Solenoid PCB
Encapsulation Control
Base Part Block D 250 ml Tank
Capacitor w switch
Motor Small
or Large
250 ml Tank
Pump Cover Base Hydraulic

Block D External
Feedback
DPI
The LPU-D is designed for the control of double-acting actuators requiring hydraulic pressure for operation in
both opening and closing the valve. The LPU-D can be mounted either directly on actuator or remotely on bulk-
head.
In the modular design of the LPU the Base Hydraulic Block acts as the rack and the Control Block as the heart of
the hydraulic function. For LPU-D these blocks are named Base Hydraulic Block D and Control Block D.
The LPU standard versions comes with several electrical alternatives with different levels of possibilities and func-
tions, such as LPU Basic, Plus, Elite and P-NET.
For further information about the different versions, please see separate PDS.
45
Reference Manual Damcos LPU: Overview LPU-D
RM 8000-100-01 Ed 01 February 2017
Base Hydraulic Block D (D)
A and B
Pump
Quick Connection for
Open/Close
emergency operation
Speed adjustment
B to T
Tank filling valve
DPI
Plug for adjusting
Position Indicator and
easy exchange of DPI
Control Block D
SV Solenoid Valve
Pressure Switch D2 Pressure Switch D3
Control Block D (D1) Control Block D with Control Block D with

Pressure Switch (D2) Pressure Switch
Elite Power/P-net Version (D3)
(spare parts only)
46
Damcos LPU: Overview LPU-D Reference Manual
February 2017 RM 8000-100-01 Ed 01
Tank Level Switch (Elite and Plus only)

LPU may be ordered with Tank Level Switch (Level tank, P2 or P4).
When LPU is equipped with tank level switch, it works like this:
If the hydraulic oil level in LPU is too low at any time, the LPU will then set an error, displayed continuously with
LED, with Bluetooth, and as common error, (which will cause the AUX OUT to be set, in case it is configured to show
errors).
When tank level is low, LPU will still execute any command, since execution of the valve control has top priority,
and since low oil level will be indicated while there is still enough oil in LPU to run normally and without problems.
Only AutoCorrection will not be executed when oil level is low, since it may cause damage to the LPU.
47
Reference Manual Damcos LPU: Hydraulic Functions
RM 8000-100-01 Ed 01 February 2017
Hydraulic Functions
Control Block Function

Background
The control block ensures proper remote and emergency functions for opening and closing of valve and especially
the fail-set function.
Solution
When activating motor and solenoid valve the actuator/valve will open. When valve is fully opened motor will be
stopped and a few seconds later solenoid valve will be de-activated. When activating motor without activating
solenoid valve the valve will close. When valve is fully closed motor will be stopped.
When motor is de-activated the valve will be kept in position by means of hydraulic lock.
When emergency opening or closing by hand pump the oil will be pumped from hand pump to actuator opening
port and return oil from actuator will be led back to hand pump tank so no oil is added to LPU system during
emergency operation. When hand pump is not activated any longer the position will be kept by means of hydrau-
lic lock.
When closing valve after emergency opening this can be done in 2 ways: Turn portable hand pump direction valve
to close and pump to close or by remotely closing the valve.
Small BRC actuators can alternatively be emergency operated by means of handle to turn shaft directly after
opening of by-pass valve.
Benefits
• Remote operation by activating/deactivating motor and solenoid valve
• Emergency operating by use of firmly mounted hand pump or portable hand pump
• Remote control after hand pump operation will automatically be engaged
• No risk of oil emptying due to wrong handling of emergency operation
• Possibility of pressure switch to ensure “keep-closed function”
• Release valves to avoid major pressure increase due to heating of oil
48
Damcos LPU: Hydraulic Functions Reference Manual
February 2017 RM 8000-100-01 Ed 01
Feedback Adjustment Function
Background
It will be of advantage to adjust position feedback without opening the electrical compartment.
Solution
Activating the ADJUST function the internal LED will help adjusting position indicator by use of a combination of
LED light and blinking. Position indicator can thus be mechanically adjusted to the right level.
Benefits
Easy adjustment of position indicator without opening cover of LPU.
49
RM 8000-100-01 Ed 01 February 2017
Safe Hand Pump Function
Background
The LPU is developed with several safety functions and equipment to secure a smooth and safe use at all times,
following regulations and handling instructions.
A firmly mounted hand pump is used for emergency operation.
A portable hand pump is used for emergency operation or filling of oil into LPU and Actuator.
Solution
All LPUs are provided with quick connections for connection of a portable hand pump for emergency operation of
the valve.
Benefits
• Quick connections on front of the LPU for the portable hand pump
• The firmly mounted HP-LPU can be used with all double-acting Damcos actuators such as BRC and KC actua-
tors
• The firmly mounted hand pump offers fast emergency operation without need of any other remote facilities
• Safe operating of hand pump without risk of draining oil out of the unit
• Portable hand pump can be used for filling of oil into LPU and Actuator
• LPU Elite offers a possibility to set LPU into Local mode prior to manual operation - thus issuing a warning to
the remote system, and blocking the remote control.
50
Damcos LPU: Operating LPU-D 3 Reference Manual
July 2020 RM 8000-100-01 Ed 01
Operating LPU-D 3
1. Tank for hydraulic oil
2. Suction filter
3. Electrical motor
4. Pump safety valve
5. Solenoid valve
6. Double pilot operated check valve, opening
side
7. Tank filling valve
8. Actuator relief valve, opening side
9. In-line filter
10.Quick connection for hand pump opening
with filter
11.Double-acting actuator
12.Quick connection for hand pump closing
with filter
13.In-line filter
14.Actuator relief valve, closing side
15.Double pilot operated check valve, closing
side
16.Pressure switch (D2 or D3)
17.Variable displacement pump
Hydraulic Diagram LPU-D
To Open Valve
When the motor and solenoid valve are activated the oil is sucked from tank through the suction filter to the
pump and pumped through the solenoid valve and the pilot operated check valve (6) to the actuator port B. This
causes the actuator to open the valve. The oil from actuator port A flows back through the pilot operated check
valve (15) (which is opened by the pressure in the B-line) and returns through the solenoid valve to the tank.
When the valve is fully open, the pressure rises to 150 bar, which causes the pump safety valve to open so that the
oil flows back to tank. The motor and the solenoid valve are then de-energized.
The actuator is now hydraulically locked in position by the pilot operated check valves.
Safety/Actuator Relief Valve

In case of a major rise in temperature, the pressure may rise. This will not cause any problems because of the actu-
ator relief valve (8) and (14), which will open at approx. 225 bar.
Close Valve
Closing the valve follows exact the same procedure, except that the solenoid valve is not activated which causes
the ports A and B to be reversed.
When the motor is running the direction of oil- flow is solely determined by the activation of the solenoid valve.
51
Reference Manual Damcos LPU: Operating LPU-D 3
RM 8000-100-01 Ed 01 July 2020
52
Damcos LPU: Emergency Operation LPU-D Version 3 Reference Manual
July 2020 RM 8000-100-01 Ed 01
Emergency Operation LPU-D Version 3
53
Reference Manual Damcos LPU: LPU-D, Options for Double Acting Actuator
RM 8000-100-01 Ed 01 July 2020
LPU-D, Options for Double Acting Actuator

Note! Small BRC actuators (size 125 – 500 Nm) can alternatively be emergency operated by means of a man-
ual key after opening the bypass valve manually.
All LPU-D are equipped with quick connections for Emergency operation by Portable hand pump.
All Plus and Elite units can, if magnets are ordered, be locally operated by magnets whenever power to
the unit is intact 230 VAC and 24 VDC.
There is no option to have a separate hand pump bulkhead mounted (HP should always be mounted
either with Actuator or with LPU).
Direct Mounted LPU-D with Hand Pump

DPI Feedback
Direct mounted LPU (BA) with LPU hand pump permanently mounted at actuator BRC or KC for emergency oper-
ation with DPI feedback. See below.
54
Damcos LPU: LPU-D, Options for Double Acting Actuator Reference Manual
July 2020 RM 8000-100-01 Ed 01
Bulkhead Mounted LPU with Hand Pump

The bulkhead mounted LPU (BB) and LPU hand pump with pipe connection to actuator BRC or KC can be emer-
gency operated with the below options.
Bulkhead mounted LPU with HP and VPI feedback (left) and external (DPI) feedback at actuator (right).
55
Reference Manual Damcos LPU: Emergency Operations with Hand Pump
RM 8000-100-01 Ed 01 July 2020
Emergency Operations with Hand Pump
Emergency Opening
1. Connect hand pump P-line to B port on LPU-D.
2. Connect hand pump T-line to A port on LPU-D.
3. Pump to open.
4. Disconnect hand pumphand pump.
Emergency Closing
1. Connect hand pump P-line to port A on LPU-D.
2. Connect hand pump T-line to port B on LPU-D.
3. Pump to close.
4. Disconnect hand pump.
Alternative for BRC 125, 250 and 500
1. Open by-pass valve at actuator

2. Use the Emergency Operator Key to turn the actuator to open (counterclockwise) / close (clockwise).
3. After operation close by-pass valve.
56
Damcos LPU: Emergency Operations with Firmly Mounted Hand PumpReference Manual
July 2020 RM 8000-100-01 Ed 01
Emergency Operations with Firmly Mounted Hand Pump
Emergency Opening of Actuator

1. Turn the directional valve at the hand pump to position “OPEN”
2. Operate hand pump until the valve has reached the desired position.
3. After hand pump operation directional valve must be turned to "REMOTE" to engage remote control again.
The valve will now stay in position until operated with hand pump again or by remote control.
Emergency Closing of a Double Acting Actuator

1. Turn the directional valve at the hand pump to position “CLOSE”
Note! LPU Elite offers a possibility to set LPU into Local mode prior to manual operation – thus issuing a warn-
ing to the remote system, and blocking the remote control.
57
Reference ManualDamcos LPU: Emergency Operations with Firmly Mounted Hand Pump
RM 8000-100-01 Ed 01 July 2020
58
Damcos LPU: Overview LPU-S Reference Manual
July 2020 RM 8000-100-01 Ed 01
Overview LPU-S
Cable Connection Cover

Cable Glands
Encapsulation
Top Part 1000 ml Tank
Sight Glass with switch
for LED
Bracket
Solenoid for PCB
Encapsulation Control 250 ml Tank

Base Part Block S with switch
Capacitor
Motor Small
or Large 250 ml Tank
Base Hydraulic
Block S
Pump Cover External
Feedback
DPI
The LPU-S is designed to control spring closing or spring opening actuators by mounting either directly on actua-
tor or remotely on bulkhead. Oil pressure is used for opening the valve by pressing the springs together. Closing
valve by means of mechanical springs.
In the modular design of the LPU the Base Hydraulic Block acts as the rack and the Control Block as the heart of
the hydraulic function. For LPU-S these blocks are named Base Hydraulic Block S and Control Block S.
The LPU standard versions comes with several electrical alternatives with different levels of possibilities and func-
tions, such as LPU Basic, Plus, Elite and P-NET. For further information about the different versions, please see sep-
arate PDS.
Note! The LPU-S has a built-in quick closing function and therefore does not need an external QC-Block.
For fast closing of LPU-S, see section about Quick Closing Function.
61
Reference Manual Damcos LPU: Overview LPU-S
RM 8000-100-01 Ed 01 July 2020
Base Hydraulic Block S (S)

A and B
Quick Connection for
Closing speed emergency operation
adjustment
B to T
Tank filling or
Pump spring release
Opening
Speed adjustment
DPI
Plug for adjusting
Position Indicator and
easy exchange of DPI
Control Block S
SV Solenoid Valve
Pressure Switch S2 including Pressure Switch S3

easy detection
Control Block S (S1) Control Block S with Control Block S with

Pressure Switch (S2) Pressure Switch (S3)
Elite P-NET
62
Damcos LPU: Overview LPU-S Reference Manual
July 2020 RM 8000-100-01 Ed 01
Tank Level Switch (Elite and Plus only)

LPU may be ordered with Tank Level Switch (Level tank, P2 or P4).
When LPU is equipped with tank level switch, it works like this:
If the hydraulic oil level in LPU is too low at any time, the LPU will then set an error, displayed continuously with
LED, with Bluetooth, and as common error, (which will cause the AUX OUT to be set, in case it is configured to show
errors).
When tank level is low, LPU will still execute any command, since execution of the valve control has top priority,
and since low oil level will be indicated while there is still enough oil in LPU to run normally and without problems.
Only AutoCorrection will not be executed when oil level is low, since it may cause damage to the LPU.
63
RM 8000-100-01 Ed 01 July 2020
Hydraulic Functions
LPU-S Quick Closing Function

Background
A fast closing is demanded in case of power loss or ESD.
Solution
The built-in quick closing function is used to block flow back to the LPU tank during closing and to control oil flow
directly back to actuators A-port.
Benefits
• Better control of oil flow within the LPU-S due to the blocking function of oil back to the actuator during clos-
ing
• Faster and safer closing due to a larger closing oil flow feasibility and hence speed and safety is increased
64
July 2020 RM 8000-100-01 Ed 01
Control Block Function

Background
The control block ensures proper remote and emergency functions for opening and closing of valve and especially the fail-
close function.
Solution
The control block is equipped with functions to ensure remote control and emergency handling. Contains quick
closing function to allow faster closing of valves.
When activating motor and solenoid valve the actuator/valve will open. When valve is fully opened motor will be
stopped, but solenoid valve is still activated to keep valve in open position. When de-activating solenoid valve the
valve will close due to internal springs in actuator.
When emergency operating by hand pump the passage to solenoid valve is blocked and opening of actuator by
means of hand pump will then be possible. Return oil from actuator will be led back to hand pump, so no oil is
added to LPU system during emergency operation.
When closing valve after emergency opening this can be done in 3 ways: Turn portable hand pump direction valve
to close or open by-pass valve at actuator or LPU or start remote opening for few seconds and then remotely close
the valve.
Contains quick closing function to allow faster closing of valves.
Benefits
• Remote operation by activating/deactivating motor and solenoid valve.
• Emergency opening by use of firmly mounted hand pump or portable hand pump
• Valve closing after emergency opening by use of hand pump, by-pass valve or remote operation
• No risk of oil emptying due to incorrect handling of emergency operation
• Possibility of pressure switch to ensure “keep-open function” or “keep-close function”
• Release valve to avoid major pressure increase due to heating of oil
65
RM 8000-100-01 Ed 01 July 2020
Feedback Adjustment Function
Background
It will be of advantage to adjust position feedback without opening the electrical compartment.
Solution
Activating the ADJUST function the internal LED will help adjusting position indicator by use of a combination of
LED light and blinking. Position indicator can thus be adjusted to the right level.
Benefits
Easy adjustment of position indicator without opening cover of LPU. Simply by means of a magnet and an 8mm
Allen key, you can mechanically adjust the position indicator - On/OFF or Analogue. No electrical connections to
be made, no exposure to water or dirt.
66
July 2020 RM 8000-100-01 Ed 01
Safe Hand Pump Function
Background
The LPU is developed with several safety functions and equipment to secure a smooth and safe use at all times,
following regulations and handling instructions.
A firmly mounted hand pump is used for emergency operation.
A portable hand pump is used for emergency operation or filling of oil into LPU and Actuator.
Solution
All LPUs are provided with quick connections for connection of a portable hand pump for emergency operation of
the valve.
Benefits
• Quick connections on front of the LPU for the portable hand pump
• The firmly mounted HP-LPU can be used with all single-acting Damcos actuators such as BRCF and KF actua-
tors
• The firmly mounted hand pump offers fast emergency operation without need of any other remote facilities
• Safe operating of portable hand pump without draining the LPU for oil
• Portable hand pump can be used for filling oil into LPU and Actuator
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RM 8000-100-01 Ed 01 July 2020
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Damcos LPU: Operating LPU-S Reference Manual
July 2020 RM 8000-100-01 Ed 01
Operating LPU-S
1. Tank for hydraulic oil
2. Suction filter
3. Electrical motor
4. Pump safety valve
5. Non-return valve
6. Pressure switch (S2 or S3)
7. Shuttle valve
8. In-line filter
9. Quick connection for hand pump,
opening with filter
10.Fail safe actuator, single-acting
11.By-pass / tank filling valve
12.Quick connection for hand pump suction
13.Non-return valve
14.Actuator relief valve
15.Solenoid valve
16.Throttle valve / closing speed adjustment
17.Pilot operated non return valve
18.Variable displacement pump
Hydraulic Diagram LPU-S
To open Valve
To move the valve towards open, the motor (3) is activated.
The oil is led from tank through the pump and through the non-return valve (5), directly to the actuator B port. To
prevent the oil from flowing back to tank, the solenoid valve (15) must be energized. When the valve is fully open,
the pressure rises to 150 bar which causes the pump safety valve (4) to open and the oil flows back to tank. The
motor is de-energized.
The actuator is now hydraulically locked in position by the solenoid valve.
Safety/Actuator Relief Valve

In case of a major increase of temperature, the pressure may rise. This will not cause any problems because of the
safety valve (14) which will open at approximately 225 bar.
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Reference Manual Damcos LPU: Operating LPU-S
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To Stop Valve in Intermediate Position

The valve can be stopped (and hydraulically locked) in any intermediate position simply by de-energizing the
motor.
If the pressure drops while valve is fully open - due to a minor leakage in the solenoid valve or due to temperature
variations -, the pressure switch (6) will detect this. The motor may then be activated for some seconds in order to
keep up the pressure, and prevent the valve from leaving the open position. - This may take place automatically.
If no pressure switch is present, the LPU will conduct AutoCorrection based on the valve position (Positive Pres-
sure function).
Close Valve
To move the valve towards closed, the solenoid valve is de-energized. The springs then move the actuator, press-
ing the oil back from the actuator B port, through the throttle valve (16) and the solenoid valve (15) to the LPU
tank.
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Damcos LPU: Emergency Operation LPU-S Version 3 Reference Manual
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Emergency Operation LPU-S Version 3
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Reference Manual Damcos LPU: LPU-S, Options for Single Acting Actuators
RM 8000-100-01 Ed 01 July 2020
LPU-S, Options for Single Acting Actuators

Note! All LPU-S are equipped with quick connections for Emergency operation by Portable hand pump.
All spring loaded actuators can be emergency operated to set the valve in safe position by opening the
actuator bypass valve manually, releasing the spring package.
All Plus and Elite units can, if magnets are ordered, be locally operated by magnets whenever power to
the unit is intact 230 VAC and 24 VDC.
There is no option to have a separate hand pump bulkhead mounted (HP should always be mounted
either with Actuator or with LPU).
Direct Mounted LPU with Hand Pump

DPI Feedback
Direct mounted LPU (BA) with LPU hand pump permanently mounted at actuator BRCF or KF for emergency oper-
ation with DPI feedback. See below.
Direct mounted LPU (BA) permanently mounted at actuator KF for emergency operation with DPI feedback. See
above to the right.
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July 2020 RM 8000-100-01 Ed 01
Bulkhead Mounted LPU with Hand Pump

The bulkhead mounted LPU (BB) and LPU hand pump with pipe connection to actuator BRCF or KF can be emer-
gency operated with the below options.
Bulkhead mounted LPU with HP and VPI feedback (left) and external (DPI) feedback at actuator (right).
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Reference Manual Damcos LPU: Emergency Operations with Hand Pump
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Emergency Operations with Hand Pump
Emergency Opening
1. Connect hand pump P-line to B port on LPU-S.
2. Connect hand pump T-line to A port on LPU-S.
3. Pump to open.
Emergency Closing if Emergency Opened

1. Connect hand pump P-line to B port on LPU-S.
2. Switch handle on hand pump to release pressure from B.
3. Actuator will close by springs.
If Emergency or Remote Opened

1. Open by-pass valve at actuator.
2. Actuator will close by springs.
3. After operation close by-pass valve.
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July 2020 RM 8000-100-01 Ed 01
Emergency Operations with Firmly Mounted Hand Pump

Emergency Open a Fail-Open LPU
1. Open by-pass at the actuator or at the firmly mounted hand pump until the valve has reached the desired
position. Then close by-pass valve again.
2. If the actuator has been closed by remote control and power is still on “the keep closed” function is activated
and the LPU may start up trying to keep the actuator closed. You have to disconnect power or remove close-
command before manual operation is started.
Note! This will only apply to fully open valve.

If intermediate positions is wanted the bypass valve must be closed and a few stroke by hand pump to
close position must be applied.
Emergency Closing a Fail-Close Actuator

1. Open by-pass at the actuator or at the firmly mounted hand pump until the valve has reached the desired
position. Then close by-pass valve again.
2. If the actuator has been opened by remote control and power is still on, “the keep open” function is activated
and the LPU may start up trying to keep the actuator open. You have to disconnect power or remove open-
command before manual operation is started.
Note! This will only apply to fully closed valve.

If intermediate positions is wanted the bypass valve must be opened and a few stroke by hand pump to
open position must be applied.
Emergency Closing a Fail-Open LPU

1. Turn the directional valve at the hand pump to position “CLOSE”
Emergency Opening a Fail-Close LPU

1. Turn the directional valve at the hand pump to position “OPEN”
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Reference ManualDamcos LPU: Emergency Operations with Firmly Mounted Hand Pump
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Damcos LPU: Actuator Speed Adjustment on LPU Reference Manual
July 2020 RM 8000-100-01 Ed 01
Actuator Speed Adjustment on LPU
LPU-D
Speed adjustment for double acting actuators
Tools
• 4 mm Allen Key
Actuator to run slower
Use the Allen key to turn the screw clockwise

(fasten screw).
Note! To run the actuator at minimum

speed then just tighten the screw
slightly (maximum 1.5 Nm).
Actuator to run faster

Use the Allen key to turn the screw counter-
clockwise (loosen screw).
Note! To run the actuator at maximum

speed then just loosen the screw
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Reference Manual Damcos LPU: Actuator Speed Adjustment on LPU
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LPU-S
Open speed adjustment for single acting actuators
Tools
• 4 mm Allen Key
Actuator to open slower

(fasten screw).
Note! To run the actuator at minimum

opening speed then just tighten the
screw slightly (maximum 1.5 Nm).
Actuator to open faster

Note! To run the actuator at maximum

opening speed then just loosen the
screw slightly (maximum 1.5 Nm).
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Damcos LPU: Actuator Speed Adjustment on LPU Reference Manual
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Closing Speed adjustment for single acting actuators
Tools
• 4 mm Allen Key
• 11 mm Wrench
Loosen the counter-nut

Use the wrench to loosen the counter-nut as
shown in the picture.
Actuator to close slower

(fasten screw).
Note! To close the actuator at minimum

speed then just tighten the screw
Actuator to close faster

Note! To close the actuator at maximum

speed then just loosen the screw
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Reference Manual Damcos LPU: Actuator Speed Adjustment on LPU
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Fasten the counter nut

When required adjustment speed is obtained
then fasten the counter-nut as shown in the
picture.
Note! It is recommended to run a LEARN or TIME procedure after speed adjustment of LPU. These procedures
are found in the User Manual.
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Damcos LPU: Pump Pressure Adjustment for LPU Reference Manual
July 2020 RM 8000-100-01 Ed 01
Pump Pressure Adjustment for LPU

Note! The pump pressure for LPU is set at factory and adjustment will normally not be required. However it is
possible to readjust pump pressure if required.
Pump pressure adjustment for LPU
Tools
• 5 mm Allen Key with ball head
The key most be long enough to reach
down to hexagon in Base Hydraulic block,
see picture next page.
• Pressure Gauge with adapter.
1. Pressure gauge to be mounted at Port P

on LPU using an adapter.
Caution! The pump pressure adjustment

must be performed with Actuator
mounted!
2. Remove the Cable Connection cover.
3. Remove the nut as marked on the pictures

to the right.
Note that the LPU is turned around in this
picture!
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Reference Manual Damcos LPU: Pump Pressure Adjustment for LPU
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4. Insert the 5 mm Allen key with the ball

head all the way down to the hexagon for
adjustment.
Note! The pressure is normally set to 150

bar. As there are some tolerances in
the system, the pressure might be
varying, that is why the pressure is
set to 150 bar to assure a running
pressure of 135 bar at the actuator.
5. If a pressure of less than 150 bar is required

the adjustment screw is loosened slightly.
6. Access cover is then placed on top of LPU

again and pump is started.
When actuator is in end position the pump
pressure can be seen at pressure gauge.
7. Repeat step 2 to 6 until the desired pump
pressure is reached.
Caution! Pump pressure must be in the range of 90-150 bar. Adjustment beyond this range is possible for
testing purposes, but is not allowed for working actuators.
8. After final adjustment the pressure gauge

is dismounted and the plug is fastened in
the Encapsulation top part.
9. Check that O-ring for Cable Connection
cover is placed correct in groove. Then
remount the Cable Connection cover.
Note! If major oil spillage has occurred

when connecting and disconnect-
ing the pressure gauge the tank
must be filled using hand pump, see
special instruction for this
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Damcos LPU: Measuring Oil Level in LPU Level Tank Reference Manual
July 2020 RM 8000-100-01 Ed 01
Measuring Oil Level in LPU Level Tank

Tools
• Hand pump
To be connected to B port
• Allen key - 4 mm
To open valve B to T
• Wrench
To remove the Bleeder valve (level tank)
• Level meter, such as a caliper
To measure oil level in the LPU tank
Note! Just measuring the oil level in standard tank is not possible. A portable hand pump must be used, and
the tank is re-filled according to the description in “Refill of Oil in LPU” on page 89.
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Reference Manual Damcos LPU: Measuring Oil Level in LPU Level Tank
RM 8000-100-01 Ed 01 July 2020
Measure level of oil in LPU tank with switch using portable hand pump
1. Release pressure in hydraulic system by

opening by-pass valve at actuator or BB-
Block (B to T).
Use a 4 mm Allen key to open valve B to T.
2. Close by-pass valve again.
3. Remove Bleed valve on level tank using a

wrench.
The tank with switch can be of 250 ml or

1000 ml, the example used here is a 250
ml tank.
4. Measure the distance as shown in the pic-

ture.
Note! If distance is maximum 32 mm for

250 tank or maximum 29 mm for
1000 tank oil level is OK.
Distance for empty tank will be

approximately 67 mm for 250 ml
tank 157 ml for 1000 ml tank
If oil level is too low then go to “Refill of Oil in

LPU” on page 89.
If oil level is OK then continue to next step in
this flow.
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Damcos LPU: Measuring Oil Level in LPU Level Tank Reference Manual
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5. Remount the bleed valve.
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Reference Manual Damcos LPU: Measuring Oil Level in LPU Level Tank
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Damcos LPU: Emptying Oil from LPU Reference Manual
March 2019 RM 8000-100-01 Ed 01
Emptying Oil from LPU

If any hydraulic repair is to be made at LPU it is important to note that LPU has a closed tank system and oil in LPU
may be at a few bar overpressure. For this reason it is required to ensure that no overpressure is present in the sys-
tem and for environmental reasons that oil is not spilled on the deck during repair.
Tools
• Hand pump
• Wrench
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Reference Manual Damcos LPU: Emptying Oil from LPU
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Emptying oil from LPU-D
1. Actuator must be closed before emptying

oil from LPU.
2. Connect portable hand pump to Quick
Connection A and B.
Preferable use Damcos Portable hand
pump to attach to quick connection B.
3. Open bypass valve B to T.

4. Pump low pressure to quick connection A
until oil starts flowing from quick connec-
tion B to hand pump.
5. When oil stops flowing open bypass valve
at actuator or bulkhead block.
6. Let the rest of oil flow to hand pump.
7. Oil is now at 0 pressure in LPU.

Level tank is now emptied from oil.
Suction tank will still be full of oil. Place a
bucket below suction tank and empty it
completely by unscrewing the M6 screws
at tank and lift tank from main block to let
oil flow out.
Note! When emptying a suction tank the

seal at tank must be checked before
remounting the tank.
8. Hydraulic repairs can now be performed.
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Damcos LPU: Emptying Oil from LPU Reference Manual
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Emptying oil from LPU-S
1. Actuator must be closed before emptying

oil from LPU.
2. Unscrew plug P and mount draining device
at port P.
Draining device could be hand pump or
tubing into a bucket.
3. Open bypass valve B to T.

4. Oil starts flowing from port P to hand
pump or bucket.
5. When oil stops flowing open bypass valve
at actuator or bulkhead block.
6. Let the rest of oil flow to hand pump.
7. Oil is now at 0 pressure in LPU.

Level tank is now emptied from oil.
Suction tank will still be full of oil. Place a
bucket below suction tank and empty it
completely by unscrewing the M6 screws
at tank and lift tank from main block to let
oil flow out.
Note! When emptying a suction tank the

seal at tank must be checked before
remounting the tank.
8. Hydraulic repairs can now be performed.
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Reference Manual Damcos LPU: Emptying Oil from LPU
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Damcos LPU: Refill of Oil in LPU Reference Manual
July 2020 RM 8000-100-01 Ed 01
Refill of Oil in LPU

At delivery from Damcos the LPU is mounted on actuator and filled with oil. However the refilling of oil is neces-
sary if:
• oil leakage at LPU is detected
• parts are changed in LPU
• LPU starts to make special noises during operation
Note! Oil refilling is preferably done with no pressure in system.

This means that BRC and KC should preferably be in intermediate position and BRCF, KF and KFR should
preferably be closed in safe (released) position.
Alternatively bypass valve at actuator or B-block can be opened before oil filling.
Recommended refill oil

Use a hydraulic oil, as specified for the system. The LPU is normally pre-filled with Shell Tellus T S2 V 32, for deck
mounting Shell Tellus S4 VX.
Caution! The cleanliness class of the oil must be of NAS 9 or better. Make sure that no dirt or foreign particles
can enter the system when refilling oil into the system. Keep caps on quick connections mounted in
order to keep out dirt from the oil in the system.
Tools
• Hand pump
• Wrench
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Reference Manual Damcos LPU: Refill of Oil in LPU
RM 8000-100-01 Ed 01 July 2020
Refill oil in LPU with 250 ml tank (standard) using portable hand pump
1. Connect hand pump to Quick Connection

B.
pump to attach to quick connection B.
2. Open bypass valve B to T. Use a 4 mm Allen

key to open valve B to T.
3. At low pressure (maximum 10 bar) pump

oil to quick connection B until oil flows out
of bleed valve at end of suction tank.
4. Close stop valve B to T and remove hand
pump from quick connection B.
5. First time LPU is running a small amount of
oil may leak from Bleed valve. This is nor-
mal, but if this continues then a leakage
check must be performed.
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Damcos LPU: Refill of Oil in LPU Reference Manual
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Refill oil in LPU with tank with switch using portable hand pump
1. Connect hand pump to Quick Connection

B.
pump to attach to quick connection B..
2. Open bypass valve B to T. Use a 4 mm Allen

key to open valve B to T.
3. Remove Bleed valve on level tank using a

wrench.
The tank with switch can be of 250 ml or

1000 ml, the example used here is a 250
ml tank.
4. Measure the distance as shown in the pic-

ture.
Note! If distance is maximum 32 mm for

250 tank or maximum 29 mm for
1000 tank the oil tank is full.
Distance for empty tank will be

approximately 67 mm for 250 ml
tank 157 ml for 1000 ml tank.
If oil level is too low then go to step 5.

If oil level is OK then go to step 7.
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Reference Manual Damcos LPU: Refill of Oil in LPU
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5. Start pumping oil using the hand pump

(that is connected to the quick connection
B at LPU). Note that bypass B to T must
remain open.
Maximum pressure is 10 bar.
6. Pump until the oil level is 30 - 32 mm for
250 tank or 27 - 29 mm for 1000 tank oil.
7. Close bypass valve B to T and disconnect

hand pump from quick connection B.
8. Remount the bleed valve and activate the

LPU a few times and check the oil level
again.
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Damcos LPU: Replace Pump in LPU Reference Manual
July 2020 RM 8000-100-01 Ed 01
Replace Pump in LPU

There are two sizes of the LPU pump. The difference is the number of pistons. The pump must be replaced by
pump of same size (same number of pistons).
Warning! Disconnect the Power from the LPU before continue replacing the pump!
Note! This procedure requires the LPU tank to be emptied from oil.
Tools
• Hand pump
• Allen key
• Wrenches
To remove screws and Bleeder valve (level tank)
• Level meter
• Blunt tool
To break the cover on the spare pump
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Reference Manual Damcos LPU: Replace Pump in LPU
RM 8000-100-01 Ed 01 July 2020
Replace LPU Pump
1. Empty tank from oil, see instruction“Emp-

tying Oil from LPU” on page 87. Note! Tank must be empty before continue replacing
pump.
2. Remove the motor starting with removing

the screws at Base Hydraulic Block.
3. Remove the motor.

If required remove electrical wires to
motor first.
The motor must be rotated and tilted to
get clear of electrical housing.
4. Remove coupling and pump cover.
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July 2020 RM 8000-100-01 Ed 01
5. Remove shaft for pump and if possible

rotor.
If it is not possible to remove rotor it will be
removed when stator is removed.
6. Remove plug in front of Base Hydraulic

Block between pump adjustment and
quick connection.
7. Remove screw using a 2 mm allen key. 7a
7b
8. Remove stator.
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RM 8000-100-01 Ed 01 July 2020
9. Remove two O-rings. Be careful not to

make any scratches to the housing.
Also check for dirt, dust and other irregu-
larities in the cavity and ball bearing.
10.Take out the new spare pump and remove

the plastic cover. There should be two new
O-rings with the spare.
11.Lubricate the O-rings before placing them

in the block.
12.Place the new O-rings in the block hous-

ing.
Note! The O-rings are of different sizes and

should be placed as shown in the
picture.
13.Lubricate the free end of stator keeping

the stator in the tool.
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July 2020 RM 8000-100-01 Ed 01
14.Stator with tool to be positioned with

marking arrow at end of tool pointing up
towards the electrical housing.
Check also that the positioning hole in the
stator is directed for the M4 screw to be
inserted correctly (see step 7).
15.Slowly push tool with stator all the way

into the block until it stops. You might
need to turn the tool back and forth until it
reach all the way in.
16.Place the allen key in the hole for the M4

screw and turn stator slightly back and
forth with help of tool to make sure the
placement hole is coincident with the M4
threaded hole.
When done remove the allen key.
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RM 8000-100-01 Ed 01 July 2020
17.Insert the M4 screw and push it in the

block with help of the allen key.
Turn the stator back and forth until it locks
the screw into place. When the stator can-
not be moved back and forth anymore the
screw is in place.
18.Now remove the mounting tool by break-

ing it with a blunt tool while rotor is held
back in place.
Pull out the mounting tool while keeping
the rotor in place.
19.Remount the plug.
20.Remount the shaft.

Be careful not to damage the sealing sur-
face or other surfaces around the pump.
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July 2020 RM 8000-100-01 Ed 01
21.Lubricate the O-ring on the pump cover

and mount the pump cover with the O-
ring.
Then mount the coupling locking the
pump cover into the housing.
22.Align the groove on the pump coupling

with the motor coupling by turning it, pref-
erably both horizontal or both vertical.
23.Remount the motor.

Position the groove in the motor shaft to
fit the coupling.
Gently push wires into cable duct in main
block.
Note! See that the motor flange can be fit

tight to the block by hand, before
tightening the screws.
Caution! Check that no wires are trapped

and that O-rings are in place
before remounting each part!
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RM 8000-100-01 Ed 01 July 2020
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Damcos LPU: Replace Hydraulic Block in LPU Reference Manual
July 2020 RM 8000-100-01 Ed 01
Replace Hydraulic Block in LPU

Warning! Disconnect the Power from the LPU before continue replacing the hydraulic block!
Tools
• Hand pump
• Allen keys
To open valve B to T and for open and close LPU cover
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Reference Manual Damcos LPU: Replace Hydraulic Block in LPU
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Replace Hydraulic Block
1. Empty tank from oil, see instruction “Emp-

pump.
Warning! Disconnect the Power from the LPU before continue disassemble the unit!
2. Remove the Cable Connection Cover.
3. Remove the Encapsulation Top part with

bracket and circuit board from the LPU.
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July 2020 RM 8000-100-01 Ed 01
4. Use clean cloths to plug the holes for wires

from motor and position indicator.
5. Disconnect wires from solenoid valve coil

and, if present, pressure switch.
6. Remove the screws from the Control block

and then remove the Control block.
For LPU-D the block consists of two parts;
the Control block and the Solenoid valve.
Remove both parts.
LPU-D LPU-S
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RM 8000-100-01 Ed 01 July 2020
7. Check and replace the 7 (seven) O-rings in

the bottom of the Encapsulation Base Part.
For LPU-D also replace the 4 (four) O-rings
between Control block and Solenoid valve.
Note! Always lubricate O-rings before

assembly.
8. Take out the new Control Block (spare

part). Note that the control blocks are dif-
ferent depending on LPU model (D or S)
and if your model includes pressure
switch(es) or not.
Control Block D Control Block S
9. Ensure that all O-rings are in place before

mounting the new control block.
Fasten the screws by 9 Nm.
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July 2020 RM 8000-100-01 Ed 01
10.Remove any excess oil in encapsulation

and remove the clothes in the holes for
wires. (See step 4.)
11.Connect wire to solenoid valve coil and
also, if used, the pressure switch.
12.Connect the wires for the circuit board in

the Encapsulation Top part.
13.Lubricate the O-ring between encapsula-
tion parts and check that it is in place and
intact.
14.Mount the Encapsulation Top Part.
Check that no wires are trapped between
parts before mounting.
15.Fasten the 7 (seven) screws by 7 Nm.
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RM 8000-100-01 Ed 01 July 2020
16.Check that O-ring in Cable Connection

Cover is lubricated and in place.
17.Mount the Cable Connection Cover by

hand.
Ensure that it is properly mounted and fas-
tened 6 (six) screws by 7 Nm.
18.Fill the LPU with Oil as described in “Refill

of Oil in LPU” on page 89.
19.Open and close valve by remote and by
hand pump to make sure the hydraulic
block is working properly.
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Damcos LPU: Replace DPI in LPU Reference Manual
July 2020 RM 8000-100-01 Ed 01
Replace DPI in LPU

Before replacing the Direct Position Indicator, please read the section about adjusting and calibrating the DPI in
the User Manual.
Caution! When mounting DPI, please leave the DPI adjusting screw protruding 1-2 mm from the block.
If the adjusting screw is tightened too far, the DPI will be crushed!
Tools
• 8 mm Allen keys with ball head (Pin wrench and 3 mm Allen Key for painted LPU)
To remove the DPI plug
• Pliers or tool with 2 mm Screw

To remove DPI from LPU
• Magnets
To run the LPU locally and initiate Adjust and Calibrate procedures as required
Can be ordered from Damcos
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Reference Manual Damcos LPU: Replace DPI in LPU
RM 8000-100-01 Ed 01 July 2020
Replace Direct Position Indicator
1. .Start with removing the plug for the DPI.
2. Then use the Pliers or a special tool with

M2 screw to carefully lift out the Direct
Position Indicator.
Caution! Be careful not to pull or yank the

wires out of place.
3. Unplug the DPI from the LPU without pull-

ing the wires.
Gently separate the two wire plugs from
each other and remove the old DPI.
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July 2020 RM 8000-100-01 Ed 01
4. It is important that the spring is mounted

in the bore before the DPI is mounted.
If the spring on the old DPI remains in the
LPU when removing old DPI, then remove
the spring from the new DPI and use the
one that is still inside the LPU.
Caution! It is important that the spring is

used and mounted as described
above.
5. Remove the old DPI and replace with the

new.
Place it in the LPU and push it in to a posi-
tion where the contact can be connected.
6. Plug in the contact and be careful with the
wires not get stuck or tangled.
Make sure the wires are placed in the
groove of the DPI.
7. Push the DPI carefully all the way in until
you feel the DPI moving back and forth
with the spring when you push gently and
release.
8. Remount the DPI plug - leave the plug

approximately 2 mm protruding from the
block - do not tighten more.
Caution! If the adjusting screw is tightened

too far, the DPI will be crushed.
After adjustment (see below),
normally the screw will be flush
with the block ±1 mm.
9. The new DPI will need to be adjusted

mechanically.
The adjustments are described on the fol-
lowing pages.
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RM 8000-100-01 Ed 01 July 2020
Mechanically Adjusting the DPI

For more information about the Adjust mode please see “ADJUST mode” in the User Manual.
Adjust Direct Position Indicator Mechanically
1. The actuator must be in CLOSED VALVE

position.
2. Enter the Adjust mode by placing the
magnet on the LOCAL grove on the LPU
and hold it there.
3. Keep the magnet on the LOCAL until the
LED on the LPU starts flashing RED. Then
release the magnet.
This will take 35 seconds and go through
flashing blue (depending on model) and
flashing white before flashing red.
Note! Remove the magnet as soon as the

light starts flashing red!
You are now in the ADJUST mode!
4. In the Adjust mode. Turn the DPI plug as

the picture shows using the allen key.
5. Turn the allen key slowly and stop when
the LED starts flashing Red.
Caution! If the adjusting screw is tightened

too far, the DPI will be crushed.
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July 2020 RM 8000-100-01 Ed 01
6. Then turn the DPI adjustment plug:

DPI-E
– For DPI-E:
Turn the adjust plug the same way
around for 1/3 turn.
The LED remains flashing RED.
– For DPI-C:
Turn the other way around for 1/2 turn.
The LED will be steady RED.
Now the DPI is adjusted correctly!
DPI-C
7. Exit the ADJUST mode by placing and

releasing the magnet on the LOCAL groove
on the LPU.
Release the magnet as soon as the LED
starts flashing Green.
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RM 8000-100-01 Ed 01 July 2020
Calibrating the DPI-C

For more information about calibrating the DPI, please see “Calibrating Analog Position Indicators” in the User
Manual.
Calibrate Direct Position Indicator DPI-C
1. First be sure that the Actuator is in closed

position.
Note! If the actuator is not in closed posi-

tion then set the actuator into
closed position!
2. Set the LPU in the Calibration mode by

placing one magnet on the CLOSE and one
magnet on the OPEN groove on the LPU.
3. Hold the magnet on these spots until the
LED start flashing between Red and Green
lights.
Then remove the magnets.
4. Place the magnet on the CLOSE and hold it

there until the LED starts flashing Green,
then remove the magnet.
This position is now defined as 0%.
After 3 green flashes, the LED will turn
RED, indicating that the valve is closed,
position < 3% .
Note! This is now defined as the closed

position by the DPI!
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July 2020 RM 8000-100-01 Ed 01
5. Open the valve by shortly placing the mag-

nets on the LOCAL and OPEN groove on
the LPU or use remote control to open
valve.
The valve should now move to fully open.
6. Wait until the Actuator is in fully open posi-

tion and stops moving, then place the
magnets on CLOSE and OPEN and hold
them there until the LED starts flashing
Red and Green. Then remove the magnets.
7. Place the magnet on the OPEN and hold it

there until the LED starts flashing Green,
then remove the magnet.
This position is now defined as 100%.
LED will be steady GREEN to indicate OPEN
VALVE position (position > 97%).
Note! This is now defined as the open posi-

tion by the DPI!
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RM 8000-100-01 Ed 01 July 2020
114
Damcos LPU: Replace Motor in LPU Reference Manual
July 2020 RM 8000-100-01 Ed 01
Replace Motor in LPU

Warning! Disconnect the Power from the LPU before continue replacing the motor block!
Tools
• Hand pump
• Allen keys
Caution! Please be aware that if other ID number of motor is used, capacitor might be required to be
exchanged as well!
To replace capacitor please see “Replace Motor Capacitor in LPU” on page 123.
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Reference Manual Damcos LPU: Replace Motor in LPU
RM 8000-100-01 Ed 01 July 2020
Replace LPU Motor
1. Empty tank from oil, see instruction“Emp-

motor.

Note! Be careful with the wirings con-

nected to the circuit board!
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July 2020 RM 8000-100-01 Ed 01
4. On the circuit board remove the socket

with wires connected to the motor.
The picture is an example of how the
board might look. If you are unsure check
your specific drawings for the connections.
5. Locate the wires from the motor, you will

find them as indicated in the picture.
Wires are placed in the cable duct hole.
6. Disconnect the wires from the socket.
Note! For P-NET version, a special dis-

mounting tool is required, and
motor wires must be equipped with
Molex Mini-fit bushings.
7. Place a bucket below the LPU motor (in

case pump cover loosen due to a minor
overpressure in tank).
8. Unscrew 4 screws and remove motor.
9. Carefully pull wires out of the cable duct

hole for cables at block facing the motor.
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RM 8000-100-01 Ed 01 July 2020
10.Take out the coupling placed on the pump

cover and use grease on the coupling place
on the block.
Then put it back in place aligning the
groove.
11.Align direction of coupling for the spare

motor with the coupling on the pump,
preferably both horizontal or both vertical.
12.Gently push wires into cable duct in main

block. Possibly push at motor side and pull
gently from encapsulation side.
13.Mount the new motor.

Fasten the 4 screws by 7 Nm.
Caution! Check that no wires are trapped

and that O-rings are in place
before remounting each part!
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July 2020 RM 8000-100-01 Ed 01
14.Connect the wires for the circuit board in

the socket and then connect the socket to
the circuit board in the Encapsulation Top
part.
15.If required lubricate the O-ring between

encapsulation parts and check that it is in
place and intact.
Note! If the motor capacitor is to be

changed it is recommended to do
that before closing the Encapsula-
tion Top part.
16.Mount the Encapsulation Top Part by

hand.
ten the 7 screws by 7 Nm and check that
no wires are trapped between parts before
mounting.
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RM 8000-100-01 Ed 01 July 2020


hand.
ten the 6 screws by 7 Nm.
19.Fill the LPU with Oil as described in “Refill

of Oil in LPU” on page 91.
20.Open and close valve by remote and by
hand pump to make sure the hydraulic
block is working properly.
122
Damcos LPU: Replace Motor Capacitor in LPU Reference Manual
July 2020 RM 8000-100-01 Ed 01
Replace Motor Capacitor in LPU

Warning! Disconnect the Power from the LPU before continue replacing the motor capacitor!
Tools
• Allen keys
Caution! Please be aware that different types of capacitors for LPU exist, so check that new capacitor has
same ID number or description as the one to be replaced.
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Reference Manual Damcos LPU: Replace Motor Capacitor in LPU
RM 8000-100-01 Ed 01 July 2020
Replace LPU Motor Capacitor

3. Disconnect capacitor wires from connec-

tor.
4. Cut the cable straps to hold the capacitor
in place and remove capacitor.
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Damcos LPU: Replace Motor Capacitor in LPU Reference Manual
July 2020 RM 8000-100-01 Ed 01
5. Before mounting the new capacitor, please

check that the ID number or description is
the same as the one that is to be replaced.
If the ID match then fasten new capacitor
using 2 cable straps of max 6.4 mm Strap
width.
6. Connect wires to capacitor.
7. Connect the connector to the PCB in the
Encapsulation Top part.
8. Lubricate the O-ring between encapsula-

tion parts and check that it is in place and
intact.
9. Mount the Encapsulation Top Part by hand.

ten the 7 screws by 7 Nm and check that
no wires are trapped between parts before
mounting.

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Reference Manual Damcos LPU: Replace Motor Capacitor in LPU
RM 8000-100-01 Ed 01 July 2020

hand.
ten the 6 screws by 7 Nm.
12.Open and close valve by remote to make

sure the capacitor is working properly.
126
Damcos LPU: Replace Solenoid Valve Coil Reference Manual
July 2020 RM 8000-100-01 Ed 01
Replace Solenoid Valve Coil

Warning! Disconnect the Power from the LPU before continue replacing the Solenoid Valve Coil!
Tools
• Hand pump
• Allen keys
125
Reference Manual Damcos LPU: Replace Solenoid Valve Coil
RM 8000-100-01 Ed 01 July 2020
Replace Solenoid Valve Coil

3. Disconnect wires for Solenoid Valve coil.
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Damcos LPU: Replace Solenoid Valve Coil Reference Manual
July 2020 RM 8000-100-01 Ed 01
4. Unscrew the outer knob of the Solenoid

Valve.
5. Pull out the Solenoid Valve.
6. Replace the Solenoid Valve and push the

new solenoid valve in place in the block.
Then screw the outer knob into place.
7. Connect the wires for the Solenoid Valve.
8. If necessary lubricate the O-ring between

encapsulation parts and check that it is in
place and intact.
9. Mount the Encapsulation Top Part.
Check that all connectors are in place and
that no wires are trapped between parts
before mounting.
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Reference Manual Damcos LPU: Replace Solenoid Valve Coil
RM 8000-100-01 Ed 01 July 2020
10.Fasten the screws by 7 Nm.


hand.
ten screws by 7 Nm.
13.Open and close valve by remote control to

make sure the hydraulic block is working
properly.
128
Damcos LPU: Replace Printed Circuit Board (PCB) Reference Manual
July 2020 RM 8000-100-01 Ed 01
Replace Printed Circuit Board (PCB)

Warning! Disconnect the Power from the LPU before continue replacing the Printed Circuit Board!
Tools
• Allen keys
To open LPU cover
131
Reference Manual Damcos LPU: Replace Printed Circuit Board (PCB)
RM 8000-100-01 Ed 01 July 2020
Replace PCB
2. Remove the Encapsulation Top part from

the LPU.
Disconnect all connectors and remove the
Encapsulation Top part including the cir-
cuit board.
Leave the connectors for wires that are
internal in the Encapsulation Top part.
3. Remove the old PCB.

Dismount the red plastic bushings from
the bracket and then dismount the bracket
(2 x M4 screws).
4. Mount the new PCB.
Exchange PCB in the bracket (4 x M3
screws).
Remount the bracket in top-part
Remount the plastic bushings.
5. Connect wires to the new PCB
For more information about the wiring
connection please check with your specific
drawings and.“Electrical Product Connec-
tion” on page 27.
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Damcos LPU: Replace Printed Circuit Board (PCB) Reference Manual
July 2020 RM 8000-100-01 Ed 01
6. If necessary lubricate the O-rings and

mount the Top Encapsulation part with the
new PCB card.
Check that no wiring is caught between
the flanges and that the O-rings are in
place.
7. Mount the Cable Connection Cover by

hand.
ten 6 (six) screws by 7 Nm.
8. Setup the new PCB.

For Basic/Plus and Elite see section about
magnet control.
For Power, in case of an analog position
indicator (DPI), the potentiometer will
need to be adjusted before the top cover is
closed.
P-NET LPU is configured via P-NET.
Note! It is recommended to run ADJUST, LEARN or TIME procedure after installation of the new PCB card.
These procedures are found in the User Manual.
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Reference Manual Damcos LPU: Replace Printed Circuit Board (PCB)
RM 8000-100-01 Ed 01 July 2020
134
Damcos LPU: Replace 250 ml Tank Reference Manual
July 2020 RM 8000-100-01 Ed 01
Replace 250 ml Tank

Warning! Disconnect the Power from the LPU before continue replacing the tank!
Replacing LPU Tank Scenarios

There are three scenarios for replacing the LPU tank:
1. Replacing to similar tank type
(250 ml tank to 250 ml tank)
2. Replacing from 250 ml tank to tank with switch
3. Replacing from tank with switch to 250 ml tank.
Tools
• Allen keys
To open tank and tank parts.
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Reference Manual Damcos LPU: Replace 250 ml Tank
RM 8000-100-01 Ed 01 July 2020
Replace to similar LPU Tank

tank.
2. Unscrew the four screws and remove the

tank.
3. Make sure that the O-ring is in place for the

new tank.
4. Mount the new tank by hand.

Ensure that it is properly mounted and that
the O-ring is not trapped.
5. Then fasten the four screws by 7 Nm.
6. Refill oil in the LPU as described in “Refill of

Oil in LPU” on page 91.
7. Check for external leakages at tank.
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July 2020 RM 8000-100-01 Ed 01
Replace from 250 ml tank to tank with switch

tank.

tank.
3. Unscrew the three screws and remove the

Suction pipe.
4. Remove plug from main hydraulic block.
5. Take connector from underneath plug in

main block and connect to connector at
level tank.
6. Make sure that the two O-rings are in place
and lubricated on the level tank before
mounting tank.
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RM 8000-100-01 Ed 01 July 2020
7. Mount tank by hand ensuring that electri-

cal wires are pushed into cable duct and
that hydraulic filter is in place.
8. Ensure that all is properly mounted (O-ring
must not be trapped) and fasten the four
screws by 7 Nm.

10.Check for external leakages at tank.
11.Update circuit board configuration (by
running the self-learning, see User Manual
for more information) to setup the level
switch.
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July 2020 RM 8000-100-01 Ed 01
Replace from tank with switch to 250 ml tank

tank.

tank.
3. Disconnect wires for level switch.
4. Place connector and wires for level switch

into the drilled hole at main hydraulic
block and close by means of plug.
5. Ensure that filter is in place, check and

lubricate O-ring at Suction pipe and mount
Suction pipe and fasten the three screws.
6. Make sure that O-ring is in place and lubri-

cated for 250 ml tank.
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RM 8000-100-01 Ed 01 July 2020
7. Mount tank by hand ensuring that O-ring

is in place (O-ring must not be trapped).
Fasten the four screws by 7 Nm.

10.Update circuit board (self-learning, see
User Manual for more information) to
setup for no level switch.
140
Damcos LPU: Replace 250 ml Level Tank (with Switch) Reference Manual
July 2020 RM 8000-100-01 Ed 01
Replace 250 ml Level Tank (with Switch)


(level tank to level tank)
2. Replacing from 250 ml tank to level tank
Please see “Replace from 250 ml tank to tank with switch” on page 137.
3. Replacing from level tank to 250 ml tank.
Please see “Replace from tank with switch to 250 ml tank” on page 139.
Tools
• Allen keys
139
Reference Manual Damcos LPU: Replace 250 ml Level Tank (with Switch)
RM 8000-100-01 Ed 01 July 2020

tank.

tank.
4. Connect the wires to the new level tank.

mounting tank.

cal wires are pushed into drilling and that
hydraulic filter is in place.
screws by 7 Nm.

140
Damcos LPU: Replace 1000 ml Level Tank (with Switch) Reference Manual
July 2020 RM 8000-100-01 Ed 01
Replace 1000 ml Level Tank (with Switch)


(level tank to level tank)
2. Replacing from 250 ml tank to level tank
Please see “Replace from 250 ml tank to tank with switch” on page 137.
3. Replacing from level tank to 250 ml tank.
Please see “Replace from tank with switch to 250 ml tank” on page 139.
Tools
• Allen keys
141
Reference Manual Damcos LPU: Replace 1000 ml Level Tank (with Switch)
RM 8000-100-01 Ed 01 July 2020

tank.

tank.
4. Connect the wires to the new level tank.

mounting tank.

cal wires are pushed into drilling and that
hydraulic filter is in place.
screws by 7 Nm.

142
Damcos LPU: Troubleshooting Guide LPU Reference Manual
July 2020 RM 8000-100-01 Ed 01
Troubleshooting Guide LPU

This chapter describes how to identify
and correct minor problems for LPU
143
Reference Manual Damcos LPU:
RM 8000-100-01 Ed 01 July 2020
144
Damcos LPU: Trouble Shooting Reference Manual
July 2020 RM 8000-100-01 Ed 01
Trouble Shooting
Problem Possible Cause Correction Additional Data
Valve/Actuator/LPU Bypass valve at actuator, Check all bypass valves and make
don't move after block or LPU open. sure they are closed!
receiving remote
command. AUX in is activated. Make sure that the valve can be
operated, then turn OFF AUX IN.
LPU is in LOCAL mode. Make sure that the valve may be See Setting and Con-
operated, then turn OFF LOCAL trolling LPU in LOCAL
mode. mode in User Man-
ual.
No electrical power or too Find reason for no power and See “Commissioning
low voltage (AC or DC). connect power to LPU. Procedure” on
page 11.
LPU firmware halted (dis- Disconnect DC supply for one

played by LED). second.
No hydraulic oil. Check oil level in tank and possi- See “Measuring Oil
bly refill. Level in LPU Level
Look for leakage. Tank” on page 81.
PCB defective. Change PCB. See “Replace Printed

Circuit Board (PCB)”
on page 131.
Electrical motor is defec- Change Motor. See “Replace Motor

tive. in LPU” on page 117.
Solenoid valve defect, not Check power to solenoid valve, See “Replace Sole-
activated or not de-acti- possibly change coil or complete noid Valve Coil” on
vated. valve. page 125.
See “Change Sole-
noid Valve”.
Pump defective or having Exchange pump. See “Replace Pump

leakage. in LPU” on page 95.
Hydraulic block defective. Change hydraulic block. See “Replace Hydrau-

lic Block in LPU” on
page 101.
Actuator defective. Change actuator.
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Reference Manual Damcos LPU: Trouble Shooting
RM 8000-100-01 Ed 01 July 2020
Valve/Actuator/LPU Bypass valve at actuator, Check all bypass valves and make
don't move after block or LPU open. sure they are closed!
receiving local com-
mand (magnet) AUX in is activated. Make sure that the valve is opera-
ble, then turn OFF AUX IN.
Local control not available Check LPU specifications

for this version of LPU. whether local control is available.
No electrical power or too Find reason for no power and See “Commissioning
low voltage (AC or DC). connect power to LPU. Procedure” on
page 11.
LPU firmware halted (dis- Disconnect DC supply for one

played by LED). second.
No hydraulic oil. Check oil level in tank and possi- See “Refill of Oil in
bly refill. Look for leakage. LPU” on page 89.
PCB defective. Change PCB. See “Replace Printed

Circuit Board (PCB)”
on page 131.
Electrical motor is defec- Change Motor. See “Replace Motor

tive. in LPU” on page 117.
Solenoid valve defect, not Check power to solenoid valve, See “Replace Sole-
activated or not de-acti- possibly change coil or complete noid Valve Coil” on
vated. valve. page 125.
Pump defective or having Exchange pump. See “Replace Pump

leakage. in LPU” on page 95.

page 101.
Actuator/LPU is LPU firmware halted (dis- Disconnect DC supply for one

running, but no played by LED. second.
valve movement is
seen from remote Position feedback needs Adjust position indicator. See Adjust proce-
or LED adjustment. dure in User Manual.
Incorrect setup of LPU to Ensure that setup of the LPU cor-

match the current type of responds to actual type of posi-
position indicator. tion indicator.
Wiring for position indica- Check wiring and fix defective

tor defective. wire/connector.
Position indicator defec- Change position indicator. See “Replace DPI in

tive. LPU” on page 107.
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July 2020 RM 8000-100-01 Ed 01
Double acting Quick connector not firmly Check that quick connectors are See “Emergency
Actuator/LPU Emer- mounted. clean and fasten cap. Operation LPU-D Ver-
gency operation is sion 3” on page 53.
not working
Bypass valve at actuator, Check all bypass valves and make
block or LPU open. sure they are closed.
No hydraulic oil in hand Refill hand pump with clean oil of

pump. correct specification.

page 101.
Single acting Actu- Quick connector not firmly Check that quick connectors are See “Emergency
ator/LPU Emer- mounted. clean and fasten cap. Operation LPU-S Ver-
gency operation is sion 3” on page 69.
not working
Bypass valve at actuator, Check all bypass valves and make
block or LPU open. sure they are closed.
Remaining pressure in Open bypass valve in actuator to

hydraulic system release pressure, close bypass
valve again and retry emergency
operation.
No hydraulic oil in hand Refill hand pump with clean oil of

pump. correct specification.

page 101.
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RM 8000-100-01 Ed 01 July 2020
Oil leaking from From BRCF spring cham- Check if piping corresponds to See “Commission-
bleed valve ber: wrong pipe dimen- dimensioning rules. ing” on page 10.
sioning.
Hydraulic system not prop- Check de-airing of system, espe-

erly de-aired. cially if pipes are present in sys-
tem or linear actuators are used.
Leakage from bleed valve Release the pressure from tank, See “Refill of Oil in
in main block: Oil filling has then fill at lower pressure. LPU” on page 89.
taken place with too high
pressure.
Bleed valve defective. For level tank change bleed See “Replace 250 ml
valve, for suction tank change Tank” on page 135.
tank.
Wrong setup of pipe Check rules for pipe mounted See “Commission-
mounted hand pump. hand pump. ing” on page 10.
Hydraulic system over- Release a little oil from system See “Bleeder Valve
filled. and check again. The purpose of Positions on LPU” on
bleed valve is to release excess oil page 18.
to avoid too high internal pres-
sure in case of heating, decom-
pression etc.
Need for repeated Leakage from BRCF spring Check if piping corresponds to See “Commission-
oil filling chamber: wrong pipe dimensioning rules. ing” on page 10.
dimensioning.
Wrong setup of pipe Check rules for pipe mounted See “Commission-
mounted hand pump. hand pump. ing” on page 10.
Other external leakage in Find reason for leakage and

system repair.
Hydraulic system not prop- Check de-airing of system, espe-

erly de-aired. cially if pipes are present in sys-
tem or linear actuators are used.
Hydraulic system over- See “Bleeder Valve

filled (actually no need for Positions on LPU” on
filling). page 18.
Bleed valve defective. For level tank change bleed See “Replace 250 ml
valve, for suction tank change Tank” on page 135.
tank.
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July 2020 RM 8000-100-01 Ed 01
Noise from pump Natural noise due to pres- Please be aware that sudden
surization of hydraulic oil. change of oil pressure that
always happen in a hydraulic
pump will make noise.
Compare with other LPU.
Low oil level. Check oil level and refill. See “Measuring Oil
Level in LPU Level
Tank” on page 81.
Contaminated oil filter. Exchange oil filter.
Pump piston sticking. Clean area for pump and replace See “Replace Pump
pump. in LPU” on page 95.
Ball bearing defective. Clean area for pump and See “Replace Pump
replaced bearing. Check if pump in LPU” on page 95.
should be replaced too due to
contamination of parts.
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RM 8000-100-01 Ed 01 July 2020
Actuator/LPU is Wrong speed adjustment. Adjust opening and closing See “Actuator Speed
moving too slow speed (see MaxTimeError as Adjustment on LPU”
well). on page 75.
Bypass valve not firmly Check that bypass valves are

closed. firmly closed.
High running torque of Due to automatic reduction of

valve, especially for BRCF. pump displacement at high pres-
sure the valve/actuator will move
slowly if a high running torque is
demanded. This will especially be
remarkable at BRCF that need a
high pressure to compress
springs.
Specified runtimes are calculated
for a running torque of 10% of
nominal actuator torque (for
BRCF 4000 it will be 400 Nm, for
BRCF 250 it will be 25 Nm).
Internal leakage in hydrau- Repair or change actuator.

lic actuator.
Internal leakage in hydrau- Change hydraulic block. See “Replace Hydrau-

lic block. lic Block in LPU” on
page 101.
Leakage in pump. Change pump. See “Replace Pump

in LPU” on page 95.
Too low oil level. Check oil level and refill tank. See “Measuring Oil
Level in LPU Level
Tank” on page 81.
Oil filter or suction pipe Check suction pipe and replace

contaminated. suction filter.
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July 2020 RM 8000-100-01 Ed 01
Damcos APP or AUX-Out Serial Warnings
Motor overload error Motor Duty/cycle is too high Move valve less often when
to be continued continu- in regular use.
ously or motor has run too
long compared to the nomi- Check oil level. See “Measuring Oil
nal runtime. Level in LPU Level
Tank” on page 81.
Check LPU function.
Check and adjust actual See TIME procedure

runtimes (see MaxTime in User Manual.
error) and run TIME proce-
dure.
Position error Setpoint and actual position Check LPU functions, adjust See ADJUST proce-
differ more than accepted position indicator. dure in User Manual
and possibly calibrate
analog position indi-
cator.
Max time Error Operation time (opening or Check LPU functions. See TIME procedure
closing) > max time limit. in User Manual.
See “Actuator Speed
Adjustment on LPU”
on page 75.
Check oil level. See “Measuring Oil

Level in LPU Level
Tank” on page 81.
Repositioning error Failed to stay in correct posi- Check LPU functions.

tion or maintain full pressure,
without correcting too often. Check for leakages.
Check oil level. See “Measuring Oil

Level in LPU Level
Tank” on page 81.
Low AC voltage 230 VAC below limit. Reestablish correct power

supply, check voltage while
LPU is running.
Check power supply and

LPU functions.
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RM 8000-100-01 Ed 01 July 2020
Motor high current Too high motor or pump Reestablish correct power
error torque, defective motor or supply, check voltage while
capacitor, too high AC Volt- LPU is running.
age.
Check power supply and See “Commissioning
LPU functions. Procedure” on
page 11.
Oil level low alarm by Low oil level in the LPU tank! Refill oil tank. See “Refill of Oil in
level tank indicator. LPU” on page 89.
Low DC voltage 24 VDC supply voltage below Reestablish correct power See Local Operation
limit. supply, check voltage at and Feedback in User
LPU. Manual.
Pressure error Pressure not achieved or has Check LPU system for: See Local Operation
fallen -and cannot be rebuilt – tightness and Feedback in User
by AutoCorrection. – bypass valves closed Manual.
– oil level
– de-airing
– pressure switch function
– sufficient ExtraTime
Humidity high Humidity inside encapsula- Check all external sealings,

tion high. including DPI plug.
Temperature high LPU temperature above high Check external temperature

limit inside encapsulation. and valve / flange tempera-
ture.
Check LPU function See Local Operation

and Feedback in User
Manual.
Temperature low LPU temperature below low Consider changing to Arctic See “Maintenance”
limit inside encapsulation. oil. Avoiding repeated alarm on page 40.
requires changed factory
setting of minimum tem-
perature
Maintenance recom- Maintenance interval Call for Emerson service See “Reset Mainte-
mended exceeded (operation count). engineer to check all LPU nance Flag” in User
and reset the indicator. Manual.
Min time error Operation time < minimum Check oil level, possibly See “Measuring Oil
time limit. refill and de-air LPU. Level in LPU Level
Tank” on page 81.
Readjust the actual run- See TIME procedure

time(s) and/or run the TIME in User Manual.
procedure.
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July 2020 RM 8000-100-01 Ed 01
Position indicator Position indicator electrical Adjust the position indica- See ADJUST proce-
error warning. (analog signal level tor. dure in User Manual.
is out of range or OPEN and
CLOSED switches are both Subsequently calibrate ana- See Calibrating Ana-
closed). log position indicator. logue Position Indica-
tors in User Manual.
Check the wiring if the error

persists.
Replace the position indica- See “Replace DPI in

tor. LPU” on page 107.
Pressure switch error Pressure switch does not go Check the pressure switch See “Replace Hydrau-
OFF at low pressure, or the connections and the resis- lic Block in LPU” on
switch cannot be detected by tance of the switch (2K2 page 101.
means of the internal resis- when OPEN).
tor.
Incorrect hydraulic connec-

tion of pressure switch.
Analog input error Analog 4-20 mA output out Check the control output
of range or bad connection. signal through LPU <20V.
Check the connections.
Check the voltage over the

LPU AI (OPEN) to "0.
Analog output error 4-20 mA current loop error. Check the output current.
Check the connections.
Check the voltage over the

analog input.
Oil level sensor error Oil level switch signal level Check connections.
not in range (disconnected).
Replace the level tank. See “Replace 250 ml
Tank” on page 135.
Sensor error Climate chip communication Disconnect DC power for See “Replace Printed
(RH and T) error. one second. Circuit Board (PCB)”
If the error persists on page 131.
exchange the PCB.
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154
Damcos LPU: Index Reference Manual
February 2017 RM 8000-100-01 Ed 01
Index
A HP-LPU ................................................................ 20
Actuator speed adjustment ................................. 75 Hydraulic Block replacement in LPU ........... 101, 107
Hydraulic Functions
LPU-D ............................................................ 48
B
LPU-S............................................................. 62
Base Hydraulic Block D ........................................ 46
Base Hydraulic Block S ......................................... 60
Bettis actuators ................................................... 20 I
Bleeder valve positions ........................................ 18 Internal Connections – Terminal to Terminal ....... 28
Bulkhead mounting............................................. 20
L
C LPU and Optional Equipment ............................... 41
Cable Connection Cover ...................................... 27 LPU Setup for Not Configured LPU (type0) ........... 13
Cable Glands ....................................................... 35 LPU-D .................................................................. 45
Check of oil level....................................... 82, 87, 91 LPU-S ................................................................... 59
Commissioning ................................................... 10
Contact Information............................................ 24 M
Control Block D ................................................... 46 Maintenance........................................................ 40
Control Block Function Motor Capacitor replacement in LPU ................. 121
LPU-D ........................................................... 48 Motor replacement in LPU ................................. 115
LPU-S ............................................................ 63 Mounting on actuator.......................................... 20
Control Block S .................................................... 60 Mounting Recommendations .............................. 17
Customer Cable Connection................................ 27
N
D NAMUR................................................................ 20
Damcos actuators ............................................... 20
Description.......................................................... 23
O
DPI ...................................................................... 20
Oil and refilling instruction................................... 89
Oil in LPU ............................................................. 89
E Oil level check.......................................... 82, 87, 91
Emergency Operation of LPU-D ........................... 53 Operating LPU-D.................................................. 51
Emergency Operation of LPU-S............................ 69 Operating LPU-S .................................................. 67
Empty LPU of oil .................................................. 85 Overview
Encapsulation Top Cover - Internal Wiring ........... 31 LPU-S............................................................. 59
Overview of LPU-D ............................................... 45
F
Feedback Adjustment Function P
LPU-D ........................................................... 49 PCB replacement ............................................... 129
LPU-S ............................................................ 64 Printed Circuit Board - Wiring............................... 32
Pump pressure adjustment for LPU ...................... 79
G Pump replacement in LPU .................................... 93
General Considerations ....................................... 39
Q
H Quick Closing Function LPU-S .............................. 62
Handling instruction.............................................. 9
Hand pump ......................................................... 20
155
Reference Manual Damcos LPU: Index
RM 8000-100-01 Ed 01 February 2017
R
Recommended refill oil........................................ 89
Refill of Oil ........................................................... 89
Refill of Oil in LPU................................................. 89
Replace 1000 ml Level Tank (Pressure Tank) ...... 141
Replace 250 ml Level Tank (Pressure Tank) ........ 139
Replace 250 ml Tank (Pressureless) ................... 133
Replace Hydraulic Block in LPU .................. 101, 107
Replace Motor Capacitor in LPU ......................... 121
Replace Motorin LPU ......................................... 115
Replace Printed Circuit Board ............................ 129
Replace Pump in LPU ........................................... 93
Replace Solenoid Valve Coil ............................... 125
S
Safe hand pump Function
LPU-D............................................................ 50
LPU-S ............................................................ 65
Service Area......................................................... 14
Solenoid Valve Coil replacement ....................... 125
Speed adjustment on LPU.................................... 75
Storage instruction................................................ 9
T
Tank Level Switch
LPU-D............................................................ 47
LPU-S ............................................................ 61
Tank replacement.............................. 133, 139, 141
Transport instruction............................................. 9
Troubleshooting Guide...................................... 143
W
Warning Levels ...................................................... 7
Warning messages ................................................ 7
156
Emerson Automation Solutions © 2020 Emerson. All rights reserved.
Damcos A/S
The Emerson logo is a trademark and service mark of Emerson Electric Co. Damcos and the
Aaderupvej 41 Damcos logotype are trademarks of Damcos A/S, Rosemount and the Rosemount logotype
DK-4700 Naestved are registered trademarks of Rosemount Inc. Damcos A/S is a member of the Emerson Process
T +45 5578 7200 Management family of companies. All other marks are the property of their respective owners.
F +45 5578 7272
www.Emerson.com/marine The contents of this publication are presented for information purposes only, and while effort
has been made to ensure their accuracy, they are not to be construed as warranties or guaran-
tees, expressed or implied, regarding the products or services described herein or their use or
applicability. Standard Terms and Conditions of Sale can be issued by contacting Damcos A/S.
We reserve the right to modify or improve the designs and specifications of our products at
any time without notice.
Damcos A/S accepts no responsibility for any errors that may appear in this publication.
※ Actuators that can be opened by emergency operation actuator : BRC125 - BRC500
1. Open the crossover valve by turning counter clockwise.
2. Use the emergency operation key on the actuator.
3. Open crossover valve at the actuator and turn the key counter clockwise to open valve an clockwise
to close valve.
4. After emergency operation by key the cross-over valve is closed.

Portable TRO colorimeter
(TECHCROSS)
2020-10-14 TC31-20-PTS-001 Rev.2
Park, Jihun Lee, Gwangho Kwon, Kyungahn
Pocket TRO Sensor Manual Technical document
Pocket TRO Sensor
Manual
Techcross
Confidential Document
i
i 페이지 11/30/2020
2020-10-14 TC31-20-PTS-001 Rev.2
Park, Jihun Lee, Gwangho Kwon, Kyungahn
Pocket TRO Sensor Manual Technical document
Table of contents
1. Overview ....................................................................................................................... 3
1.1. Revision History ............................................................................................................ 3
2. Product specification .................................................................................................... 3
2.1. Specification of Reagent .............................................................................................. 4
2.2. Drawing ......................................................................................................................... 4
3. Safety ............................................................................................................................ 4
3.1. Safety information labelling ......................................................................................... 5
4. Product component ...................................................................................................... 5
4.1. Keypad .......................................................................................................................... 6
4.2. Display ........................................................................................................................... 7
5. Measuring principle ...................................................................................................... 7
5.1. Analytical method ......................................................................................................... 7
5.2. Measurement method .................................................................................................. 7
5.3. Self-test ......................................................................................................................... 8
5.4. Calibration ..................................................................................................................... 8
6. Maintenance ................................................................................................................. 8
6.1. Clean the instrument .................................................................................................... 8
6.2. Clean the measurement cell ........................................................................................ 8
7. Troubleshooting ............................................................................................................ 9
Confidential Document
ii
ii 페이지 11/30/2020
2020-10-14 TC31-20-PTS-001 Rev.2
1. Overview
This manual explains Pocket TRO Sensor (Hereafter, referred to as ‘PTS’) that measures TRO(total residual oxidant)
content in the water. The manual’s contents are correct by thorough inspection or repair. However, they can be a
little bit different from the product if it is improved.
1.1. Revision History

Version Date Progress Prepared by Remarks
Rev.0 2019-12-13 First prepared Park, Jihun
Rev.1 2020-09-08 Add product component and instructions Ha, Kyunguk
Rev.2 2020-10-13 Review Document. Park, Jihun
Rev.3 2020-11-25 Add product component and instructions Ha, Kyunguk
2. Product specification
Table 1. Product specification
No. Specification Details Remarks
1 Measuring range 0 ~ 15 mg/L
2 Accuracy ±10% or 0.1 mg/L, whichever is greater
3 Resolution 0.01 mg/L
4 Display OLED 128 x 64
5 Rated voltage 6V (AAA x 4EA)
6 Sample Temperature 1℃ to 40℃
7 Weight about 260g
8 Dimension (W x H x D) 70 x 155 x 66.3 mm
9 Storage temperature -10 ~ 60 ℃
10 Operation temperature 0 ~ 55 ℃
11 Humidity 0~95% Relative Humidity (Non-Condensing)
Confidential Document - 3 - 3/9

2020-10-14 TC31-20-PTS-001 Rev.2
2.1. Specification of Reagent

- Number of reagent : 100 packs
- Part No. : 2105669-KR
- Maker : HACH
2.2. Drawing
3. Safety
This manual explains the basic guidelines that must generally be implemented in the product including the
installation, operation, and maintenance. Please make sure to read all the contents of the manual before unpacking,
installing, or operating the product. Please make sure to pay attention to all kinds of danger and warnings. Please
be informed that noncompliance may result in user or equipment damage.

2020-10-14 TC31-20-PTS-001 Rev.2
3.1. Safety information labelling

Please refer to the marks attached to this equipment. If you will not follow the indicated guidelines, you may get
injured or equipment may be damaged.
Caution : Potential risk that may cause slight or serious injuries
4. Product component
Product components consist as below.
1) Storage case
2) Main body

2020-10-14 TC31-20-PTS-001 Rev.2
3) Pack of reagents 4) Measurement cell
4.1. Keypad
1
3
Key Contents
 Set zero value before a measurement.
1. Zero key  Push and hold for 2 seconds to enter or exit menu mode.
 In menu mode and selected menu, scrolls down.
2. Power key  Set the power to on and off.
 Start a sample measurement.
3. Measurement key  In menu mode, selects menu option shown.
 In selected menu, scrolls up or selects option.

2020-10-14 TC31-20-PTS-001 Rev.2
4.2. Display
2 3 4
1) Numeric display: Display the measured value and error message

2) Status icon: Display the status such as standby, measurement.
3) Progress bar: Display the measurement progress.
4) Battery icon: Display the battery power level.
5) Button icon: Guide the location of the button.
5. Measuring principle
5.1. Analytical method
PTS is equipment that measures TRO in the water. It uses the DPD colorimetric method that does DPD(N,N-diethyl-
p-phenylenediamine sulfate) reagent. When a pack of reagent is mixed with a sample water, they are changed to
red in proportion to concentration of TRO in the water. It measures and digitizes the concentration by using
LED(Sources of light) and inform users of them. TRO concentrations are calculated by differences in absorbance.
5.2. Measurement method

1) Power on PTS.
2) Clean the measurement cell and cap with no-lint cloth.
3) Insert the measurement cell into the cell holder.
4) Close the cap on the main body over the measurement cell.
5) Push ZERO button. The display shows “0.00”.
6) Remove the measurement cell from the cell holder.
7) Add one 10-mL reagent powder pillow.
8) Close the measurement cell. Joggle the measurement cell for about 20 seconds to dissolve the reagent.
Undissolved powder will not affect accuracy. A red color will show if chlorine is in the sample water.
9) Within 1 minute of the reagent addition, insert the prepared sample into the cell holder.
10) Close the cap on the main body over the measurement cell.
11) Push MEASURE button. Results show in mg/L.
12) Remove the measurement cell from the cell holder.
13) Immediately empty and rinse the measurement cell and cap three times with the deionised water.

2020-10-14 TC31-20-PTS-001 Rev.2
5.3. Self-test
Check the LED, Photosensor status before calibration.
1) In menu, enter the 3. Self-test.

2) If you want to test, selects yes.
3) Do calibration according to test result.
Note: If the result is Need calibration, do 5.4. Calibration. If the result is Good status, just use it as it is.
5.4. Calibration
If you want to calibrate, do 5.3. Self-test first.
1) In menu, enter the 4. Calibration.

2) If you want to calibrate, selects yes.
3) If you select yes, a blinking operation will be performed.
4) When the blinking operation is finished, calibration is complete.
6. Maintenance
6.1. Clean the instrument
Clean the exterior of the instrument with moist and soft cloth and then wipe the instrument dry as necessary.
6.2. Clean the measurement cell

Clean the interior and exterior of the measurement cell a few times with deionised water and then let the
measurement cell air dry. In order to maintain transparent for a long time, it must be washed immediately after
measurement.
Note: Take care to avoid scratches on the interior and exterior surface of the measurement cell.

2020-10-14 TC31-20-PTS-001 Rev.2
7. Troubleshooting
Error Description Solution
There is ambient light in the cell holder. Identify the cap fully
E-00 Ambient light error
installed into the cell holder.
The zero measurement is too low. Check the degree of
E-01 Zero-measurement error
turbidity. If it is not clear, fill clean water again.
E-02 No Zero error Measure a blank solution to set the zero.
Identify if there is blockage in the cell. If present, clean the
E-03 Blockage error
cell holder. If there is not any blockage factor, test again.
The reading is less than minimum range of the instrument.
E-04 Low range error
Check sample water and measurement cell and test again.
The reading is more than maximum range of the instrument.
E-05 High range error
Check sample water and measurement cell and test again.
E-06 Low battery power The voltage of battery is too low. Replace the batteries.

(Ecs Manual - Appendix - Ver.c) Ms Sophie (2022.02.23)

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ECS MANUAL [APPENDIXⅡ]

NO. EQUIPMENT NAME MAKER

2 ANU Metering pump IWAKI

TRO Sensor TECHCROSS (DTS)

Ex- TRO Sensor HF SCIENTIFIC, INC. (CLX)

SOLENOID VALVE ASSY PARKER

WATER SEPERATOR (Ex-TRO Sensor Air line) MISUMI

4 CSU ENDRESS + HAUSER

8 Ex- FMU ABB

10 Mixing pump DESMI

11 FCV Actuator & Spanner EMERSON(V3)

12 Portable TRO colorimeter TECHCROSS (PTS)

Binconet Marine Solutions Co., Ltd Issued Date :

Human-Computer Interface 2016-02-11

31, Cheonggangro 91beongil, Gijang-Eup, Gijang-Gun

Ver 1.0 English HOME PAGE : http://www.binconet.co.kr

Panel PC ARA-15iXTS-MPPC USER’S MANUAL

Display : 15” TFT LCD 1024 x 768 dots

Storage Humidity : 5 ~ 90% RH, non-condensing

Weight Net : 6.7 kg

2.3 Display Specification

Display Size : 15” TFT Color LCD

2.4 Touch Screen Specification

3.1 Mother Board Layout

4.1 Bottom I/O view

Cutting Size : 357 x 299 mm

6. BIOS Setup & Software Driver Setup

9-1. Set up and General Handling Precaution

9-2. Operating Precaution

9-3. Cleaning of the equipment and management

Installation ......................... ............................................................ 16

1. Notes on Installation ............................................. 17

Operation .......................... ............................................................ 27

1. Preparation for Operation ...................................... 28

● The symbols on this instruction manual have the following meanings:

Nonobservance or misapplication of “Warning” sec-

Nonobservance or misapplication of “Caution” sec-

Indicates an important action or procedure which must be performed or carried out

● For specified application only

● Operating site must be free of water and humidity

● Specified power only

● Do not run the pump dry

● Do not wet or dampen

● Do not damage or change power cable

● Install an earth leakage breaker

● Handling of power cable

● Follow the instruction manual

● Limited operating site and storage

● Disposal of used pump

2. Operating Principle ............................. 6

3. Identification Code .............................. 7

6. Operating Function ........................... 11

7. Display and Keys .............................. 13

After unpacking the goods, check the following

(1) Do the model, voltage, etc., shown on the

(1) Series name EH Series

PVC : Polyvinyl chloride (Transparent)

(5) Voltage symbol

(7) Controller E : E type

(9) Special configuration

Points to be noted in handling

Pump body Control unit

● Memory back-up function