MaintGuideUSA PDF

The Maintenance Guide
Tips and reference information

to keep your installed base up and running
Because your success
is important to us…
As a shift of Endress+Hauser’s ‘Instrument Express’ concept, this
fully revised ‘Maintenance Guide’ aims at providing reference
information to your production, metrology and maintenance
teams. Elaborated on by our experts, it contains some reminders
of the measuring principles and gives answers to frequently asked
questions. And we have included lots of tips to help you make
better use of your installed base!
Keep a copy on your desk all year round!
How to deal with Endress+Hauser 3
Support 4
Tips & Advice 7 At your service 95
Level measurement 9 - 26 W@M - Life Cycle Management

Flow metering 27 - 44 for process automation 96
Liquid analysis 45 - 66 Commissioning 100
Pressure measurement 67 - 76 FieldCare® 101
Temperature measurement 77 - 82 Field Xpert 102
Recorders 83 - 86 Calibration services 104
Field communication 87 - 93 CompuCal™ 107
Maintenance services 108
Installed Base Audit 111
Training 114
How to get consumables, tools This small catalog contains the price lists
and spare parts? of electrodes, cables and various other
In addition to the Maintenance Guide, consumables, hardware, and software tools
Endress+Hauser issues ‘The Maintenance and of the most frequently ordered spare
Store’ on an annual basis. parts.
The Endress+Hauser Maintenance Guide

How to deal with
Endress+Hauser
Contacts list and links at a glance

Our support Our service offering (call 800-642-8737)
• Helpdesk Tel.: 800-642-8737 Option #3 • The W@M portal www.us.endress.com/W@M

Details on page 96
• Application support Tel.: 800-642-8737 Option #4
• Commissioning www.us.endress.com/start-up
• Field service Tel.: 800-642-8737 Option #2 Details on page 100
• Factory repairs Tel.: 800-642-8737 Option #1 • Plant Asset Management www.us.endress.com/fieldcare

To request a Return Authorization or download a Details on page 101
Declaration of decontamination:
www.us.endress.com/factoryrepair • Device configuration www.us.endress.com
Details on page 102
• Schedule training Tel.: 800-642-8737 Option #5
• On-site or factory Calibration www.us.endress.com/calibration
• Finding and ordering a spare part Details on page 104
Refer to ‘The Maintenance Store’ or W@M Portal
• Calibration Management www.us.endress.com/CompuCal
• Finding and ordering consumables Details on page 107
Refer to ‘The Maintenance Store’ or Online Shop:
www.us.endress.com/e-business • Maintenance services www.us.endress.com/contracts
Details on page 108
Details on pages 4 and 5
and on www.us.endress.com/services • Installed Base Audit www.us.endress.com/IBA
Details on page 111
• Training www.us.endress.com/training
Details on page 114
‘The Maintenance Store’: Documentation management

the easy way to find with W@M
the right spare part See page 5 See page 96

Information is periodically updated on www.us.endress.com/services
Total support throughout your plant life cycle

Our whole organization is geared towards helping you keep You can count on our experts to answer your requests for assistance
your plant up and running. This is of particular importance - our helpdesk, field service engineers and factory services are all
when troubleshooting or having an urgent need for a spare there to help, with different levels of support and response times to
part. match your needs.
Behind each local organization is also a logistical infrastructure

designed to support all regions with a flow of parts and
consumables, ensuring that all customers are served as their
situation demands.
Our Hotline - Real technical support
Our team of product specialists can help you put your sensors into By e-mail
operation and suggest the best solution in case of problems with an To send us your request by e-mail, send to:
application. Having analyzed the situation, they will provide advice techsupport@us.endress.com,
designed to: or complete the online form at:
• facilitate the diagnostic process www.us.endress.com/us_helpticket
• avoid the need for on-site visits wherever possible
• ensure your instruments and software are correctly installed For contact information and service information in other
• improve your maintenance countries
Visit www.endress.com/worldwide
You can contact us:*

By telephone
Monday through Friday, from 8:00 AM - 6:00 PM EST
800-642-8737
Emergency support provided 24 hrs/day, 7 days a week. *for customers in the USA. If in Canada or Mexico, see back cover.

Field Service - Always local, and available to help
Our team of dedicated troubleshooters are always on hand in
emergency situations for fast and efficient diagnosis and repair.
To arrange an on-site visit

By telephone
Our service coordinators will be happy to help you arrange an on-
site visit. Call them Mon. - Fri. 8:00 to 5:00 at
800-642-8737 Option #2.
By e-mail
To send us your request by e-mail, please complete and return the
form to: techsupport@us.endress.com
Factory Repair & Calibration -

Please provide the ‘Declaration of Decontamination’ with the returned
products
We always aim at keeping turn-around times as short as possible by handling your
repairs in a professional and safe manner.
As a certified company and, due to legal regulations, Endress+Hauser is obliged
to deal with all returned products which were in contact with the medium, in
a prescribed manner. When receiving returned products, we require certain
information from the ‘Declaration of Decontamination’ (Return Policy available
as download at www.us.endress.com/factoryrepair). You may also send an e-mail
to repair@us.endress.com. Please note that we can begin repairing or calibrating
returned products only upon receipt of the fully completed form.
Once the ‘Declaration of Decontamination’ is complete, please place it in a

prominent place on the outside of the package. Ensure that all goods are well packed
in order to protect the equipment during transport. Thank you in advance for
actively supporting us in protecting our personnel and the environment by following
the above procedure. We are convinced that this will help us to maintain our
technical equipment in good condition and guarantee our high standards of quality
and safety.
The Maintenance Store - consumables, spare parts and tools

always at hand
Quick delivery - an essential asset of our worldwide support.

Behind each local organization is a logistical infrastructure designed to
support all regions with a constant flow of parts and consumables, ensuring
that all customers are served as their situation demands.
As a complement to this Maintenance

Guide, please refer to ‘The
Maintenance Store’. This configurator
gives you a fast access to the most
frequently ordered consumables and
tools for maintenance. It also includes
a copy of the ‘Spare Part Finding Tool’
CD. This offline tool allows you to
select any Endress+Hauser spare part
from your computer.
You can also use our online tool:

www.us.endress.com

Maintenance Actions
A handy collection of information sheets dealing with a specific subject of direct

relevance to your day-to-day operations
Each sheet spells out your options(s) for immediate action. We publish several sheets each year.
Maintenance Today
A magazine for all instrument users and anyone

with responsibility for quality issues
Printed once or twice a year, it contains a selection of
in-depth articles, case studies and useful information.
‘Maintenance Today’ provides guidance on handling the
challenges and developments you are likely to meet, and on
choosing the tools and services best adapted to your needs.
e-Talkline subscription Online shop
Keep yourself informed of the latest developments in process The online shop is available round the clock and offers you the
instrumentation. We offer an electronic version, e-TALKLINE, opportunity to order standard products, services, consumables and
which is tailored to the interests that you have selected. You can spare parts with a personalized access point and in accordance
view or download a copy of Talkline direct from our site. with your conditions.
www.us.endress.com/etalkline
An intuitive navigation system allows you to directly compare the
products suitable for your application and with the help of the
configurator, you can select the options for the product, and then
Documentation online (download area) add them to your shopping cart. If you have standardized devices,
you can store them in personal product lists.
This application is available on our website, enables you to access • Constant access ensures a high level of flexibility
a wide range of documents (technical information, operating • Your price and delivery date available online
instructions, certificates, application sheets, safety instructions, www.us.endress.com/e-business
multimedia files) and you can access all of the installation and
update files required for Endress+Hauser software.
• Searching is easy and the results are very accurate Order tracking
• Access the desired documentation at any time
Accurate and up to date - delivery status
Track your order every step of the way.
If you want to install a device you have ordered or if you want to
perform maintenance on devices already installed, you will require
the delivery date of the material in order to plan these tasks. On
our Internet site you can trace the delivery of your orders around
the clock.
Together with our logistics provider, we supply you with tracking

information about the status of your shipment.
• Direct access to the delivery date
• Planning of installation and start-up/commissioning
www.us.endress.com/ordertracking

Tips & advice
Helping you to obtain
even higher availability from
installed instrumentation
Contents
Useful definitions 8
Level measurement 9
Flow metering 27
Liquid analysis 45
Pressure measurement 67
Temperature measurement 77
Recorders 83
Field communication 87
Installation Commissioning Operations Migration Re-engineering
Our contribution to your Time spent reading the chapters

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

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

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

Level measurement
Bob Collier
Expert in Level measurement
Endress+Hauser USA
“Installation is the key”

“ToF (Time of Flight) and capacitive Like in the other sections, we have also Each migration project has to be carefully
instruments are the most popular recapped the frequently asked questions. With examined.”
Endress+Hauser level devices. this information, you will be able to prevent or
resolve the vast majority of potential problems We also offer training sessions, in
ToF instruments share common concepts yourself! classroom and on-site. See ‘Training’ in
allowing simplified commissioning, the section ‘At your service’.
operation, and maintenance. Installation There is also plenty of useful information to
conditions are of utmost importance, help you get the best from your instruments Contents
especially regarding the nozzle. This is why throughout their life cycle.
we have decided to give you, in this guide, Basics 10
a reminder of these essential installation For those wanting to go further The chapter ‘Basics’ includes information
which is valid for all level measurement
conditions. in mastering this subject,
principles described hereafter. Thus you
Endress+Hauser has published should read it before any other chapter.
For capacitive level measurement the ‘Level Handbook’, a genuine
instruments, the situation is very different: level measurement bible. Level-radar 12
due to the physical principle, the key point is Guided level-radar 16
the connection to the ground, especially in Note: if you are intending to
Ultrasonic level measurement 19
case of a non-conductive tank. replace one of your capacitive devices, please
contact us. Capacitive level measurement 22
FAQ 25
For assistance selecting any new or replacement instrument, use the free Online selection
software, Applicator at www.us.endress.com/Applicator
For service on your gamma
products, please consult
Endress+Hauser at 317-642-8737
Basics
Level
Information common to all types of level measurement devices
The Time of Flight (ToF) All Endress+Hauser ToF Operation and Maintenance
principle level measurement devices
have the same display. Routine maintenance
• Emission of ultrasound- or The display of the process ToF devices include no wear
microwave-pulses value and the configuration parts thus require very little
• Reflection of the pulses from of the device occur locally maintenance. However,
the product surface by means of a large 4-line according to its criticality to
• Reception of the reflected alphanumeric display with plain the quality, some instruments
pulses text information. The guided need to be inspected and/or
• Measurement of the Time menu system with integrated calibrated periodically.
of Flight: calculation of the help text ensures quick and safe
distance between the device commissioning (see Fig. 3). Defining the right maintenance
and the product surface by To access the display, the cover frequency taking several
d = (c x t)/2 of the electronic compartment parameters into account is an
may be removed even in expert’s job. Endress+Hauser
Setup - Configuration of hazardous areas (IS and XP). can also help you with this task!
level instruments
The VU331 LC-Display can To test the 4 to 20 mA loop
General note: be removed to ease operation (see Fig. 4 and 5):
The respect of installation by simply pressing the snap-fit • The 2-wire, 4 to 20 mA with
Figure 1: The principle - Time of Flight conditions are of key (see Fig. 2). It is connected to HART® version includes test
importance for level the device by means of a 19.7” sockets for testing of the
measurement. Once this is (500 mm) cable. signal current
correctly done, the unit will • On the 4-wire versions
work. Nevertheless it is always The LC-Display VU331 allows (Levelflex and Prosonic),
necessary to configure the configuration via 3 keys directly there are two terminals
measuring point to achieve at the instrument. All device situated at the front of the
correct measurement. functions can be set through electronic module
a menu system. The menu
consists of function groups and Calibration (all devices)
LCD
functions. Within a function, Intrinsically our instruments
Order
ENDRES
MICROP
Code:
Ser.-No.:
Messbereich
Measuring
4...20
range
U 16...36
S+HAUS
ILOT
max.
II ER
20
(liquid crystal display) application parameters can be offer long-term stability
Maulburg
mA V DC m
IP
65
T
A >70°C
Made in Germany
: t
>85°C
read or adjusted. The user is and repeatability of your

Symbols
guided through a complete measurements. Nevertheless
configuration procedure. we recommend periodic
ENDRESS + HAUSER
calibration for the measurement

You can also configure your points which are critical to the
– + E
ToF instruments from your process and thus are important
3 keys
PC. Remote commissioning, to control the quality of your
including documentation of the product. From on-site to
snap-fit
measuring point and in-depth accredited services, you can be
analysis functions, is supported sure to find the right method
Figure 2: On-site operation with VU331 L00-FMxxxxxx-07-00-00-en-001
via FieldCare Setup. See by reaching the right balance
Headline Position indicator
presentation of FieldCare on between the device downtime
ENDRESS + HAUSER page 101. and the calibration uncertainty.
Our service team can set up any Calibration can be performed by

Symbol Main value Bargraph Unit Endress+Hauser level measurement Endress+Hauser either on-site or
– + E device for you and thus ensure you in our accredited laboratories
immediately get the best from your (see ‘Calibration’ in the ‘At your
Selection list
instrument. (see ‘Commissioning’ in service’ section).
the ‘At your service’ section)
Function groups -> Functions
HOME X F
F FG00 X F000 F001 F002 F003 F004 ...
FG01
O FG02
FG03
F F
O X Help text
FG04 S
S
FG05
FG06
X
FG07 Envelope
... curve
L00-FMRxxxxx-07-00-00-en-002
Figure 3: The ‘Basic Setup’ covers 95% of the situations
10 The Endress+Hauser Maintenance Guide

Level
Check of the measurement Maintenance planning Corrective maintenance Instrument and
(all devices) - spare parts spare parts availability
Configuration of the level Do you know exactly which part of The more critical your You will find detailed
measurement instrument your installed instrumentation base instrument is to your process, information in the next sections
is often undertaken during is critical to the operation of the the shorter the acceptable (Level-radar, ultrasonic level
plant and how you could maintain or
the commissioning phase. In calibrate it more efficiently? Are you
repair time. measurement, etc.)
the majority of cases this is sure that your present actions are • Thanks to the ToF concept,
sufficient. minimizing the risks of unplanned most parts can be easily Migration
In some cases it is useful to breakdowns? Are you sure that replaced by the user (also
your present actions are the most
make additional checks of your cost effective?
for Ex) thus allowing quick You will find detailed
level measurement in order to: repair: display, electronic information in the next sections
• Validate the measured value With Endress+Hauser’s Installed Base module, antenna (Level-radar, ultrasonic level
related to the real level in the Audit, our service consultant will • Tags on each component
help you to quickly find an answer to measurement, etc.)
tank these questions and move forward in
allow easy identification of
• Eliminate interference echoes a controlled manner to a maintenance spares
emitted by the installations plan which improves plant reliability • An installation manual is Re-engineering
in an empty tank (for ToF while reducing costs… provided with every spare part
(see ‘Installed Base Audit’ in the See our advice in the next
devices) ‘At your service’ section).
In case of a highly critical sections. See also our online
If level measurement instrument, you might consider Applicator tool.
instruments are to be Maintenance performing stocking a complete new
recalibrated following an instrument.
operational phase, this is often If you do not have the time or the
done by gauging the capacity of right tools to efficiently perform
your maintenance, an Endress+Hauser
a container in liters, so there is service contract can provide you the
no need to remove the device appropriate level of maintenance support
from the process. We can you require.
provide you with specific advice
We provide regular checks on your DC AC / DC
on this. equipment and warranty extensions power display unit, power
alternatively recorder, PCS
providing you with complete peace of
mind and cost control. Commubox
alternatively
FXA191/195
communication
DXR375
resistor Commubox
From regular support to partnership (> 250 W) communication FXA191/195
resistor DXR375
agreements, we offer four distinct levels (> 250 W)
of service… (see ‘Service Contracts’
in the ‘At your service’ section). 4...20 mA 4...20mA
test sockets for testing

of the signal current
plant
1 2 3 4 ground 5 6 1 2
plant
ground
L- L+ I+ I- I+ I- L1/L+ N/L-
Figure 4: Terminal assignment - 2-wire, L00-FMxxxxxx-04-00-00-en-015

Figure 5: Terminal assignment - 4-wire, L00-FMxxxxxx-04-00-00-en-011
4 to 20 mA with HART AC/DC power, 4 to 20 mA with HART
The Endress+Hauser Maintenance Guide 11

Level-radar
Level
Micropilot series
For several years, Micropilot M instrumentation has been the product of choice for level-radar
measurement. FMR230 (horn antenna) and 231 (rod antenna) instruments use 6 GHz waves,
while FMR240 (horn antenna), 244 (horn antenna encapsulated in PTFE), 245 (flat antenna)
and 250 (level-radar measurement on solids) use 26 GHz waves.
In this section, you will find essential information and advice that will help you
to perform the optimum follow-up of your Micropilot M instruments throughout
their life cycle.
Measuring principle flange:

reference point of
measurement
The Micropilot is a ‘downward- 20 mA flange:
looking’ measuring system, 100%
reference point of
measurement
operating based on the Time
of Flight method. It measures
the distance from the reference
D threaded
point (process connection) to the connection
1 ½” BSPT (R 1½”)
E
“90% of the product surface. Radar impulses or 1½ NPT:
reference point of
are emitted by an antenna, F measurement
success of the setup reflected off the product surface inactive
depends on proper and received again by the radar

L
length
system.
installation”
Input (see Fig. 1) 4 mA
The reflected radar impulses are 0%
max.level
received by the antenna and Figure 1: Measuring principle
L00-FMR2xxxx-15-00-00-en-001
transmitted into the electronics.

A microprocessor evaluates the
signal and identifies the level Installation conditions Tank
echo caused by the reflection of installations (see Fig.
the radar impulse at the product Because most problems reported 3)
surface. The unambiguous signal by the users are due to incorrect • Avoid any installations (1),
identification is accomplished installation and/or initial like limit switches,
by the PulseMaster® eXact calibration, we would like to temperature sensors, etc.,
software, based on many years remind you of the essential inside the signal beam
of experience with Time of points that must be considered. • Symmetrical installations (2),
Flight technology. i.e. vacuum rings, heating
The distance D to the product Orientation (see Fig. 2) coils, baffles, etc., can
surface is proportional to the • Recommended distance (1) also interfere with the
time of flight t of the impulse: wall – outer edge of nozzle:
measurement
D = c · t/2, ~1/6 of tank diameter.
with c being the speed of light. Nevertheless the device Optimization options
should not be installed
Based on the known empty • Antenna size: the bigger the antenna,
closer than 11.8” (30 cm) the smaller the beam angle, the less
distance E, the level L is (FMR230/231) or 5.9” interference echoes
calculated: (15 cm) (FMR240/244/245) • Mapping: the measurement can be
L=E–D to the tank wall. optimized by means of electronic
Refer to Figure 1 for the • Not in the center (3), suppression of interference echoes
reference point for E. • Antenna alignment: refer to ‘optimum
interference can cause signal mounting position’
The Micropilot is equipped loss • Stilling well: a stilling well can always be
with functions to suppress • Not above the fill stream (4) used to avoid interference
interference echoes. The user • It is recommended to • Metallic screens (3) mounted at a
slope spread the radar signals and can,
can activate these functions. use a weather protection therefore, reduce interference echoes
They ensure that interference cover (2) in order to protect Please contact Endress+Hauser for
echoes (i.e. from edges and weld the transmitter from direct further information.
seams) are not interpreted as sun or rain. Assembly and
level echo. disassembly is simply done by
L00-FMR2xxxx-17-00-00-xx-001
Figure 2: Orientation means of a tension clamp.
Level
Commissioning of two Micropilot M
Installation in tank (free • Align marker towards tank Figure 3: Tank installations
space) FMR230 - Optimum wall (the marker is always L00-FMR2xxxx-17-00-00-xx-002
mounting position (see Fig. 4) exactly in the middle between

• Observe installation two bolt-holes in the flange)
instructions described above • After mounting, the housing
• Align marker towards tank can be turned 350° in order to
wall (the marker is always simplify access to the display
nozzle
exactly in the middle between and the terminal compartment H
two bolt-holes in the flange) • For optimum measurement,

• After mounting, the housing the horn antenna should
can be turned 350° to simplify extend below the nozzle.
ØD
access to the display and the Select version with 4”

terminal compartment (100 mm) antenna extension L00-FMR230xx-17-00-00-en-002
• The horn antenna must if necessary. Figure 4: Optimum mounting position FMR230
L00-FMR230xx-17-00-00-en-001
extend below the nozzle,

Note!
otherwise use antenna Please contact Endress+Hauser for
extension FAR10 application with higher nozzle.
• Align horn antenna vertically • The horn antenna must be aligned
vertically. The maximum range may
be reduced, if the horn antenna is not
Installation in tank (free vertically aligned.
space) FMR231 - Optimum
mounting position (see Fig. 5) Standard installation
• Observe installation FMR244
instructions described above (see Fig. 7 on next page)
• Align marker towards tank • Observe installation
wall (the marker is always instructions described above
exactly in the middle between • Align marker towards
two bolt-holes in the flange) tank wall L00-FMR231xx-17-00-00-en-001
1
• Use spring washers (1) • Install the device using the
Note! threaded boss (AF 60) only. H
spring washers
H
It is recommended to retighten the Observe the max. torque of
flange bolts periodically, depending 14.75 lbf-ft (20 Nm).
on process temperature and pressure.
Recommended torque: 44.25 to 73.75
• After mounting, the housing inactive length
beam launched
inactive length
can be turned 350° in order
here
lbf-ft. (60 to 100 Nm). beam launched

here
• After mounting, the housing can to simplify access to the

be turned 350° in order to simplify display and the terminal
access to the display and the
compartment
L00-FMR231xx-17-00-00-en-002
terminal compartment Figure 5: Optimum mounting position FMR231

• The inactive part of the rod antenna • For optimum measurement,
must extend below the nozzle the tip of the antenna should
• The rod antenna must be aligned extend below the nozzle.
vertically
Nozzle heights up to 19.7”
(500 mm) can be accepted
Installation in tank (free if this should not be possible
marker at instrument flange
or threaded boss
space) FMR240, FMR244, due to mechanical reasons.

°
90°
90
FMR245 - Optimum 90
° H
mounting position (see Fig. Note! 1½” BSPT (R 1½”),
6) Please contact Endress+Hauser for 90

°
DN50 DN80…150
G 1½" (FMR 244)
or
1½ NPT
application with higher nozzle. ANSI 2” ANSI 3…6”
• Observe installation
90
°
ØD
• The antenna must be aligned vertically

instructions described above L00-FMR240xx-17-00-00-en-001
Figure 6: Installation in a tank - optimum mounting position

L00-FMR240xx-17-00-00-de-002
Standard installation • Do not weld through the pipe wall. The
Level
spring washers
FMR245 (see Fig. 8) inside of the stilling well must remain

1
smooth. In case of unintentional welding
• Observe installation through the pipe, the weld seam and any
H instructions described above unevenness on the inside needs to be
H
• Align marker towards carefully removed and smoothed. Otherwise,
ØD
ØD
tank wall strong interference echoes will be generated
and material buildup will be promoted.
L00-FMR245xx-17-00-00-de-002
• The marker is always exactly • Particularly on smaller nominal widths it
L00-FMR244xx-17-00-00-de-002
in the middle between two needs to be observed that flanges are welded
Figure 7: Standard Figure 8: Standard installation FMR245
bolt-holes in the flange to the pipe such that they allow for correct
installation FMR244 orientation (marker aligned toward slots)
• Use spring washers (1)
Note! Installation in bypass FMR230,
It is recommended to retighten the
FMR240, FMR245 (see Fig. 10)
flange bolts periodically, depending
marker at instrument flange
on process temperature and pressure. • Align marker perpendicular (90°)
or threaded boss
Recommended torque: 44.25 to 73.75 to tank connectors
lbs-ft. (60 to 100 Nm). • The marker is always exactly in
°
90
• After mounting, the housing can

the middle between two bolt-
be turned 350° in order to simplify
access to the display and the holes in the flange
1½” BSPT (R 1½”), terminal compartment • After mounting, the housing
G 1½" (FMR 244)
DN50 DN80…150 or • The antenna must be aligned vertically can be turned 350° in order to
1½ NPT Caution! The maximum range may be
ANSI 2” ANSI 3…6”
simplify access to the display and
reduced, if the antenna is not vertically
L00-FMR230xx-17-00-00-en-006 aligned. the terminal compartment
Figure 9: Installation in stilling well - optimum mounting position Note! Please contact Endress+Hauser for • The horn must be aligned
application with higher nozzle. vertically
• Measurements can be performed
Installation in stilling well through an open full bore ball
FMR230, FMR240, FMR244, valve without any problems
FMR245 (see Fig. 9) • Additional installation instructions
• Align marker toward slots described above
• The marker is always exactly
in the middle between two Recommendations for the bypass pipe
bolt-holes in the flange • Metal (no plastic or enamel coating)
• After mounting, the housing • Constant diameter
• Select horn antenna as big as possible. For
can be turned 350° in order intermediate sizes (i.e. 3.74”/95 mm) select
to simplify access to the next larger antenna and adapt it mechanically
display and the terminal (FMR230/FMR240 only).
compartment • At any transition (i.e. when using a ball valve
or mending pipe segments), no gap may be
• Measurements can be created exceeding 0.04” (1 mm)
Figure 10: Installation in bypass - optimum mounting position performed through an open
L00-FMR230xx-17-00-00-en-007
• In the area of the tank connections (~ ±20

full bore ball valve without cm / 7.87”) a reduced accuracy of the
any problems measurement has to be expected
• Additional installation
instructions on page 20 Installation in vessel FMR250
with horn antenna (see Fig. 11)
Recommendations for the stilling well • Observe installation instructions
marker at instrument
• Metal (no enamel coating, plastic on described above
flange or threaded boss 1) request)
• Align marker towards vessel wall
• Constant diameter
• Diameter of stilling well not larger (the marker is always exactly in the
°
90°
90
90
° than antenna diameter middle between two bolt-holes in
• Weld seam as smooth as possible and the flange)
on the same axis as the slots
1½” BSPT (R 1½”) • After mounting, the housing
• Slots offset 180° (not 90°)
90
°
DN80…200
or
1½ NPT • Slot width respectively diameter of can be turned 350° in order to
90
°
ANSI 3…8”
holes max. 1/10 of pipe diameter, simplify access to the display and
de-burred. Length and number the terminal compartment
do not have any influence on the
1) at version with top target positioner, the marker is at the housing adapter
• The horn antenna should protrude
(opposite the air purge connection) measurement.
• Select horn antenna as big as possible. from the nozzle. If this is not
possible for mechanical reasons,
L00-FMR250xx-17-00-00-en-009
For intermediate sizes (i.e. 7”/180 mm)

Figure 11 (above and right): Installation select next larger antenna and adapt it larger nozzle heights can be
in vessel FMR250 - optimum mounting mechanically (FMR230/FMR240 only).
position
accepted.
• At any transition (i.e. when using a
ball valve or mending pipe segments),
no gap may be created exceeding 1
H mm (0.04”)
• The stilling well must be smooth on
the inside (average roughness Rz ≤ 6.3
μm). Use extruded or parallel welded
stainless steel pipe. An extension of the
pipe is possible with welded flanges or
ØD
pipe sleeves. Flange and pipe have to
be properly aligned at the inside.
L00-FMR250xx-17-00-00-en-004

Note! Operation and Maintenance Instrument and
Level
• Please contact Endress+Hauser for
application with higher nozzle
spare parts availability
• Ideally, the horn antenna should See ‘Basics’ (page 10).
be installed vertically. To avoid Your Spare parts New
interference reflections or for optimum Note for FMR250: In extremely instrument availability generation
alignment within the vessel, the dusty applications, the
FMR250 with optional top target
positioner can be swiveled by 15° in integrated air purge connection Micropilot II/FMR230V NO - stopped 09/2005 Micropilot M
all directions. can prevent clogging of the
antenna (see Fig. 12). Pulsed Micropilot II/FMR231E NO - stopped 09/2005 Micropilot M
operation is recommended.
Setup - Configuration • Pulsed operation: max.
pressure of purge air: 87 psia (6 If you want to get more information
about spare parts availability, please
See ‘Basics’. bar abs.) call our hotline 317-642-8737.
• Permanent operation:
recommended pressure range air purge connection:
The ‘Basic setup’ menu NPT ¼
of the purge air: 2.9 to 7.25 Re-engineering
or
enables a quick and simple G ¼ (max. torque 3.5 Nm)
psi (200 to 500 mbar)
commissioning. The software
Caution! Make sure to use dry Instruments that operate at
helps the user to enter the main
purge air. 26 GHz used to be selected
parameters which cover 95% of
the cases. By entering the data for storage applications.
Calibration However, thanks to the recent Figure 12: FMR250 integrated air purge
carefully, you will avoid many connection
L00-FMR250xx-17-00-00-en-010
See ‘Basics’ (page 10). redevelopment, from software

problems.
version1.05.xx, the new 26 GHz
Corrective maintenance instruments can now be used
Note for FMR244/245: Please
- Spare parts on process applications. Please
take a blocking distance of
See ‘Basics’ (page 11). consult us.
7.87” (0.2 m) into account. (See
details on the blocking distance
Note for all radar devices: Instruments that operate at
in chapter Ultrasonic level
The replacement of either 6 GHz, whose cost is higher,
measurement - page 19).
the electronic module or still used on demanding
the HF module requires a processes (with turbulent
Our service team can set up any
Endress+Hauser device for you and
reprogramming. Some of the surface or foam formation).
thus ensure you immediately get the default parameters have to
best from your instrument be modified. The relevant See also our online Applicator
(see ‘Commissioning’ in the ‘At your procedure is delivered with the
service’ section). tool.
new module.
Note for
FMR240/244/245/250: The
replacement of the electronic
module requires specific attention.
If it contains software with
versions 1.02.xx or 1.04.xx,
you need to also replace the
HF module.

Guided level-radar
Level
Levelflex series
The current guided level-radar range includes Levelflex M:

• FMP40 for general applications in liquids and solids
• FMP41C for corrosive liquids and for high hygienic requirements
• FMP45 mainly in liquids with pressures up to 5801.5 psi (400 bar) and
temperatures from -328 to +752°F (-200 to +400°C)
• New FMP43 (from 01/07/07) for pharma requirements
With this section we aim at providing efficient help to Levelflex M users throughout
the life cycle.
Measuring principle flange:

reference point of
measurement
The Levelflex is a ‘downward- 20 mA

100%
looking’ measuring system that
functions according to the ToF
method (ToF = Time of Flight).
D
The distance from the reference
E
point (process connection of probe length LN
“Consider blocking the measuring device) to the F
product surface is measured.

distances and pay High-frequency pulses are L
attention to the nozzle” injected to a probe and led
4 mA
along the probe. The pulses are 0%
reflected by the product surface,
received by the electronic
evaluation unit and converted
into level information.
Figure 1: Measuring principle L00-FMP4xxxx-15-00-00-en-002
This method is also known

as TDR (Time Domain
Reflectometry).
Input (see Fig. 1) The Levelflex comes with
The reflected pulses are functions to suppress
transmitted from the probe interference echoes (e.g.
to the electronics. There, a internals and struts).
microprocessor analyzes the
reference point of
measurement signals and identifies the level
echo, which was generated Installation conditions
UB
by the reflection of the high-
100%
frequency pulses at the product Upper blocking distance
max. 20 m /67 ft surface. This clear signal finding (see Fig. 2)
benefits from the more than The upper blocking distance
E 30 years of experience with (UB) is the minimum distance
LN
F pulse Time of Flight procedures from the reference point of the
remote display that have been integrated measurement (mounting flange)
FHX 40
into the development of the to the maximum level. Within
PulseMaster® Software. the blocking distance, a reliable
0%
measurement can not be
Distance D to the product guaranteed (see table p.17).
surface is proportional to the
Time of Flight t of the impulse: Lower blocking distance
B D = c · t/2, At the lowest part of the
with c being the speed of light. probe an exact measurement
Figure 2: Upper blocking distance L00-FMP4xxxx-17-00-00-en-006 Based on the known empty is not possible. The following
F = measuring span distance E, level L is calculated: measuring error is present in
E = empty distance (= zero)
UB = upper blocking distance
L=E–D the vicinity of the probe end:
LN = probe length Reference point for E see Fig. 1. (see Fig. 3)
B = minimum distance of the probe to the container wall

Blocking distance and measuring range:
Level
FMP40 LN ft (m) UB inches (mm)
min max
Cable probe 3.3 (1) 115 (35) (1) 7.9 (8) (2)
6 mm rod probe 1.0 (0.3) 6.5 (2) 7.9 (8) (2)
16 mm rod robe 1.0 (0.3) 13 (4) 7.9 (8) (2)
Coax probe 1.0 (0.3) 13 (4) 0/0
(1) Larger measuring range available on request.
(2) The indicated blocking distances are predetermined. Media with DK > 7, the upper
blocking distance UB can be reduced for rod and cable probes to 4” (100 mm). The
upper blocking distance UB can be entered manually.
LBD [m] if DC>7 if DC<7

Cable probe 0.02 0.25
Check of a Levelflex at a chemical plant
Rod or coax probe 0.02 0.05
If εr (dielectric coefficient) Type of probe installation
Rod probe and coax probe Cable probe
value is less than 7 for cable (see Fig. 5) Sum of non-linearity, Sum of non-linearity,
probes, then measurement is • Probes are mounted to the non-repeatability, and

hysteresis in inches (mm)
non-repeatability, and
hysteresis in inches (mm)
not possible in the area of the process connection with 3.15 (80) 3.15 (80)
2.36 (60)
straining weight (0 to 9.84”/0 threaded connections or DC = 2 2.36 (60)
DC > 7
1.57 (40)
to 250 mm from end of probe; flanges and are usually also 0.79 (20)
DC > 7
1.57 (40)
0.79 (20)
lower blocking distance) (see secured with these. If during 0 0
table). this installation there is -0.79 (-20) -0.79 (-20)
the danger that the probe -1.57 (-40) -1.57 (-40)
General installation end moves so much that it -2.36 (-60) -2.36 (-60)
instructions touches the tank floor or cone -3.15 (-80) -3.15 (-80)
0 1.97 3.94 5.91 7.87 9.84 11.8 0 1.97 3.94 5.91 7.87 9.84 11.8
(for bulk solids + fluids) at times, the probe must, if (50) (100) (150) (200) (250) (300) (50) (100) (150) (200) (250) (300)
Let’s review some very necessary, be shortened and Distance from probe end in inches (mm) Distance from probe end in inches (mm)
important instructions (see Fig. secured. The easiest way to fix Figure 3: Measuring error in the vicinityDCof= Dielectric
the probe Constant
end
4): the cable probes is to screw
• Do not mount rod or cable them to the internal thread on 1 2
probes in the filling curtain (2) the lower end of the weight.
• Mount rod and cable probes • The ideal installation is
away from the wall (B) at such mounting in a screwed joint
a distance that, in the event / screw-in sleeve which
of buildup on the wall, there is internally flush with the
is still a minimum distance of container ceiling B
3.94” (100 mm) between the • If installation takes place in
probe and the buildup a nozzle, the nozzle should
• In the case of bulk solids in be 1.97” to 5.9” (50 to
concrete silos, a large distance 150 mm) in diameter and
(B) should be observed should not be more than 5.9”
between the probe and the (150 mm) high. Installation
concrete wall, if possible adapters are available for
≥ 3.28 ft (1 m), but at least other dimensions. C
1.64 ft. (0.5 m) • Installation with welding boss
• In metal and plastic silos, is strongly recommended
the probe can be mounted when the product εr
very close to the wall (0.66 (dielectric coefficient) is
Figure 4: General installation conditions
ft/0.2m), but ensure that the low. “90% of the problems 1 = correct installation L00-FMP4xxxx-17-00-00-xx-003
probe does not touch the wall encountered in case of a low

• Minimum distance of probe εr are due to a bad nozzle”
end to the container floor (C): installation with welding boss installation in nozzle
– Cable probe: 5.9” (150 mm) Installation in concrete silos

– Rod probe: 1.97” (50 mm) (see Fig. 6)
– Coax probe: 0.39” (10 mm) Installation, for example, into
• If the product becomes a thick concrete ceiling should < 150 mm
highly electrostatically be made flush with the lower (< 4")
charged during processing, edge. Alternatively, the probe

a grounding chain should be can also be installed into a pipe diameter nozzle:
< DN150 (< 6”)
mounted in the filling curtain that must not protrude over the
or the end of the probe lower edge of the silo ceiling.
should be grounded The pipe should be kept at a
Figure 5: Type of probe installation
L00-FMP4xxxx-17-00-00-en-017

minimum length. Installation in a ≥ 2” (DN50) metal flange, Our service team can set up any
Level
suggestions see diagram. or a metal sheet with diameter Endress+Hauser device for you and Re-engineering
The centering disk should be of ≥ 7.87” (200 mm) must be thus ensure you immediately get the
used for tube diameter > 5.9” mounted under the screw-in best from your instrument FMP45, which is more robust,
(see ‘Commissioning’ in the ‘At your
(150 mm) to prevent buildup in piece. service’ section).
can replace a FMP40.
the inner part of the tube.
Installation in plastic Setup - Configuration

containers (see Fig. 7) Operation and Maintenance
Please note that the ‘guided See ‘Basics’.
level-radar’ measuring principle Maintenance
requires a metal surface at the The ‘Basic setup’ menu See ‘Basics’ (page 11).
process connection! When enables a quick and simple
installing the rod and cable commissioning. The software Calibration
probes in plastic silos, whose helps the user to enter the main See ‘Basics’ (page 10).
silo cover is also made of plastic parameters which cover 95%
or silos with wood cover, the of the cases. By entering the Corrective maintenance
probes must either be mounted data carefully, you will avoid - Spare parts
many problems. See ‘Basics’ (page 11)
Note for all radar devices:

the replacement of either
the electronic module or
4” 4”
(100 mm) (100 mm) the HF module requires
reprogramming. Some of the
default parameters have to
be modified. The relevant
procedure is delivered with the
new module.
Instrument and
3.15” to 5.91”
Your Spare parts New
(80 to 150 mm) instrument availability generation
Levelflex FMP232E NO - stopped 10/2005 FMP40
Levelflex FMP332E NO - stopped 10/2005 FMP40

Figure 6: Installation in concrete silos
If you want to get more information

metal sheet or metal flange about spare parts availability, please
call our hotline 800-642-8737.
silo roof of plastic

or wood
Figure 7: Installation in plastic containers

metal sheet or metal flange
Wall thickness for GFK/PP

< 15 mm
L00-FMP4xxxx-17-00-00-en-018

Ultrasonic level measurement
Level
Prosonic series
The current ultrasonic range of transmitters includes the Prosonic M

FMU40/41/42/43/44 and Prosonic S FMU90.
With this section we aim to:

• provide efficient help to Prosonic M users throughout the life cycle
• answer the most frequently asked questions by the users of Prosonic S FMU86x,
and give key information to successfully migrate to FMU90
Measuring principle
BD
Time of Flight method 20 mA
100%
The Prosonic M sensor emits
ultrasonic pulses in the direction D
of the product surface. There,
they are reflected back and E F
received by the sensor. The

“The installation of Prosonic M measures the time t
between pulse emission and L
the sensor and the reception. The instrument
presence of foam uses time t (and the velocity of 4 mA
0%
sound c) to calculate distance D
or bubbles have a between the sensor membrane
L00-
strong impact on and the product surface:

D = c · t/2
the measurement” As the device knows the empty
Figure 1: Measuring principle
F = span (full distance)
distance E from a user entry, E = empty distance
it can calculate the level as D = distance from sensor membrane to the product surface
BD = blocking distance
follows: L = level
L=E-D
An integrated temperature
sensor compensates changes in Interference echo ensures that interference
the velocity of sound caused by suppression echoes (e.g. from edges, welded
temperature changes. The interference echo joints and installations) are not
suppression feature of Prosonic M interpreted as level echoes.
Tip: why is there a blocking distance?
Waves are emitted at the surface of the sensor membrane. The device
is either emitting or receiving but cannot do both at the same time. In 0
case of an obstacle located within the area between positions 1 and 2,
1
the resulting echo would be surrounded by the residual vibration and
could not be differentiated. 2 3 4
As it is impossible to differentiate the echo within this area, the level
to be measured must not approach the membrane.
3 6 9 Duration (ms)
This distance is named blocking distance.
1.6’ 3.3’ 4.9’ Distance in ft (m)
(0.5) (1) (1.5)
Figure 2 T2: the residual membrane vibration is weakened enough to reflect an echo
T0: Start of the emitted impulsion. An alternating current which frequency and to differentiate it.
corresponds to the system’s resonance, makes crystals oscillate. T3: the echo comes back after 6 ms meaning the total distance represents
T1: End of the emitted impulsion. Membrane continues to vibrate during 1ms 2 m. Therefore the product surface is located 3.3 ft. (1m) under the probe.
and then switches to the receiving position. T4: Double reflection echo or numerous reflections can sometimes be observed.

Adjustment Blocking distance, nozzle
Level
Enter the empty distance E and installation (see Fig. 5 and
the span F to adjust the device Table 2)
(see Fig. 1). Install the Prosonic M at a
height so that the blocking
Blocking distance distance BD is not exceeded,
Span F may not extend even at maximum fill level.
into blocking distance BD. Use a pipe nozzle if you cannot
Level echoes from the maintain the blocking distance
blocking distance cannot be in any other way. The interior
evaluated due to the transient of the nozzle must be smooth
characteristics of the sensor. and may not contain any edges
or welded joints. In particular,
Influence of foam and there should be no burr on the
bubbles on the level inside of the tank side nozzle Surface 1 Surface 2 Surface 3 Surface 4
measurement on liquids end. Note the specified limits for
Figure 3: Reflection of ultrasonic waves on liquids
(see Fig. 3) nozzle diameter and length. To Surface 1: ideal conditions
The occasional presence of foam minimize disturbing factors, we Surface 2: very light foam with big bubbles in very thin layers
or the presence of a disparate recommend an angled socket Surface 3: light foam in thick layer
Surface 4: very dense foam, small bubbles, compact
foam layer at the liquid’s surface edge (ideally 45°).
has a weak impact on ultrasonic
measurement. However a per- If the blocking distance is
manent thick foam layer absorbs undershot, it may cause device
ultrasonic waves and stops their malfunction. In order to notice 2 3 4
reflection at the liquid’s surface. if the level approaches the

If the foam is quite dense, its blocking distance, you can 7
own surface may often become specify a safety distance (SD). 1

5
a reflector. If the level is within this safety 1/6D
distance, the Prosonic M outputs D

Installation conditions a warning or alarm message. 6 α
L
The essentials (see Fig. 4) Setup - Configuration

• Do not install the sensor in r
the middle of the tank (3). See ‘Basics’.
We recommend leaving a L00-FMU4xxxx-17-00-00-de-005
distance between the sensor The ‘Basic setup’ menu Figure 4: General installation conditions
and the tank wall (1) of 1/6 enables a quick and simple
of the tank diameter. commissioning. The software
• Use a protective cover, in helps the user to enter the main
order to protect the device parameters which cover 95% of Sensor a Lmax rmax
from direct sun or rain (2) the cases. By entering the data FMU40 11° 16 ft / 5 m 1.6 ft / 0.48 m
• Avoid measurements through carefully, you will avoid many
FMU41 11° 26 ft / 8 m 2.5 ft / 0.77 m
the filling curtain (4) problems.
• Make sure that equipment FMU42 11° 33 ft / 10 m 3.1 ft / 0.96 m
(5) such as limit switches, Our service team can set up any FMU43 6° 50 ft / 15 m 2.6 ft / 0.79 m
temperature sensors, etc. Endress+Hauser device for you and
are not located within thus ensure you immediately get the FMU44 11° 65 ft / 20 m 6.3 ft / 1.93 m
the emitting angle a. In best from your instrument
(see ‘Commissioning’ in the Table 1
particular, symmetrical ‘At your service’ section).
equipment (6) such as FMU 43
heating coils, baffles, etc. can FMU 40/41 FMU 42/44
influence measurement. Operation and Maintenance BD

• Align the sensor so that it SD
is vertical to the product Maintenance

surface (7) See ‘Basics’ (page 11).
• Never install two ultrasonic E F
L
measuring devices in a tank, We recommend a periodical L
L
as the two signals may affect inspection of the membrane
D
each other and the use of a piece of cloth D
D
• To estimate the detection to wipe it down if necessary.
range, use the 3 dB emitting L00-FMU4xxxx-17-00-00-en-004
Figure 5: Blocking distance, nozzle installation

angle a (see Table 1) Calibration BD: blocking distance; SD: safety distance; E: empty calibration; F: full calibration
See ‘Basics’ (page 10). (span); D: nozzle diameter; L: nozzle length
Corrective maintenance
- Spare parts
See ‘Basics’ (page 11)
Instrument and • An installation on a mast can Prosonic BD Max. Max. Nozzle Max. nozzle
Level
spare parts availability be reused. On the contrary, M family range range bulk diameter length
See table to the right. you will need to drill again in liquids materials
case of wall mounting. 2” / 50 mm ~ 3.15”/80 mm
• FMU90 transmitters are FMU40
0.8 ft / 16 ft /
6.5 ft / 2 m 3” / 80 mm ~ 9.45”/240 mm
available as field housing or 0.25 m 5m
4” / 100 mm ~ 11.8”/300 mm
call our hotline 800-642-8737. cabinet housing (mounting on
DIN rail) 1.1 ft / 26 ft / 11.5 ft/ 3” / 80 mm ~ 9.45”/240 mm
FMU41
• Because ISO Venturi channels 0.35 m 8m 3.5 m 4” / 100 mm ~ 11.8”/300 mm
Migration
were not preconfigured 1.3 ft / 33 ft / 3” / 80 mm ~ 9.8”/250 mm
in the FMU861 (ISO415 FMU42 16 ft / 5 m
S range: FMU860 (1-channel 0.4 m 10 m 4” / 100 mm ~ 11.8”/300 mm
level measurement), 861 (flow to ISO480), many users
FMU43 2 ft / 50 ft / 23 ft / 7 m min. 4” / 100 ~ 11.8”/300 mm
measurement) and 862 (2 have asked us about the
0.6 m 15 m mm
-channel level measurement) curves and about the way to
FMU44 1.6 ft / 66 ft / 33 ft / min. 6” / 150 ~ 15.7”/400 mm
have been phased-out. program them in the device.
0.5 m 20 m 10 m mm
The new FMU90 transmitters These channels are not
Table 2
associated with FDU9X sensors preconfigured in the FMU90.
replace FMU86x transmitters • Matrix programming has
been replaced by a simplified Your Spare parts New
and FDU8x sensors. instrument availability generation
The new FMU90 transmitter and user-friendly program-
is fully compatible with the ming concept on the new
Prosonic S FMU90 FMU2380 NO - stopped 12/2002 FMU4x*
FDU8x transmitters and can
be used in association with • The maximum distance FMU2480 NO - stopped 12/2002 FMU4x*
FDU8x sensors. between the transmitter and
Warning: The sensors the sensor is 954 ft. (300 m) FMU2680 NO - stopped 12/2002 FMU4x*
FDU83/84/85/86 with an as was the case with the old
ATEX, FM or CSA certificate generation FMU280 NO - stopped 12/2002 FMU4x*
are not certified for connection FMU130E/A NO - stopped 10/2005 FMU4x*
to the FMU90 transmitter. Re-engineering
On the other hand, the new FMU131E/A NO - stopped 10/2005 FMU4x*
FDU9x sensors cannot be used The 2-channel version of
with FMU86x transmitters. FMU90 is quite polyvalent: FMU232 YES - until 11/2008 FMU4x*
each channel can be affected
Advantages either to flow measurement FMU2780 NO - stopped 12/2002 FMU90
• FMU90 offers full or to level measurement thus
compatibility with the allowing three combinations: FMU86x YES - until 03/2012 FMU90
equivalent FMU86x version level + level, level + flow and
flow + flow. FDU8x YES - until 12/2013 FDU9x
e.g. the 1-channel level
measurement FMU90 is 100% FDU41C YES - until 12/2010 FMU44
compatible with FMU860
FDU60Z NO - stopped 10/2006 FMU44
FDU61Z NO - stopped 10/2006 FMU44
* Partly compatible

Capacitive level measurement
Level
Liquicap series
The current Endress+Hauser range of capacitive sensors includes

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

• provide a concise reminder of the main guidelines for optimal use of capacitive
sensors
• provide efficient help to Liquicap M users throughout the life cycle
Measuring principle 1 2 3
The principle of capacitive level

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

“Ensure good
R
(conductive material). When
the probe is in air (1), a low
connection to the
L00-FMI5xxxx-15-05-xx-xx-001
Figure 1: Measuring principle
initial capacitance is measured. R: Conductivity of liquid
ground in any case” When the container is filled, C: Capacitance of liquid
the capacitance of the capacitor CA: Initial capacitance (probe not covered)
CE: Final capacitance (probe covered): change in capacitance
increases the more the probe ΔC: Change in capacitance
is covered (2), (3). As of a
conductivity of 100 μs/cm, the
measurement is independent
of the value for the dielectric
constant (DK) of the liquid. As Phase-selective Thus, Liquicap M has buildup
a result, fluctuations in the DK measurement compensation.
value do not affect the measured The electronic evaluation of the
value display. Furthermore, the container capacitance works General installation
system also prevents the effect of along with the principle of conditions
medium buildup or condensate phase-selective measurement.
near the process connection for In this process, the amount • The probe may not come into
probes with an inactive length. of alternating current and the contact with the container
phase shift between the voltage wall! Do not install probes in
Note! A ground tube is used as a and current is measured. the area of the filling curtain!
counter electrode for containers With these two characteristic • When using in agitating
made of non-conductive quantities, the capacitive idle tanks, make sure you install
materials. current can be calculated by at a safe distance from the
the medium capacitor and the agitator
Function real current by the medium • Rod probes with a ground
The selected electronic insert resistance. Conductive buildup tube should be used in the
of the probe (e.g. FEI50H 4 to stuck to the probe rod/cable event of severe lateral load
20 mA HART) converts the acts like additional medium • When mounting, ensure
measured change in capacitance resistance and causes an error there is a good electrically
of the liquid into a signal in in measurement. As the size conductive connection
proportion to the level (e.g. of the medium resistance can between the process
4 to 20 mA) and thus makes it be determined with phase- connection and the tank
possible to measure the level. selective measurement, an e.g. use an electrically
algorithm is used to compensate conductive sealing band
the buildup on the probe.
Level
For containers that conduct Note! A fully insulated rod
electricity e.g. steel tanks, probe may neither be shortened
see Fig. 2. nor extended.
For containers that do not Damaged insulation probe
conduct electricity e.g. plastic results in an incorrect
tanks, use a probe with measurement result.
ground tube and ensure proper
grounding (see Fig. 3). On non-conductive tanks
(plastic tanks)
When installing in a nozzle, use Always use a probe with ground
a rod probe with ground tube tube (see Fig. 6).
and inactive length (see Fig. 4).
Tensioning weight (see Fig.
As a general rule, the probe 7)
L00-FMI5xxxx-11-06-xx-x
Figure 2: Installation on Figure 3: Installation on containers

should neither be shortened nor The end of the probe needs
containers that conduct electricity that do not conduct electricity
lengthened. Only on Liquicap T to be secured when the probe
FMI21, Liquicap M FMI52 / could touch the silo wall or
FTI52 and Minicap FTC262 another part in the tank. This is
the probe may be shortened by what the internal thread in the
means of a special kit. probe weight is intended for.
The bracing can be conductive
Specific installation or insulating to the tank wall.
conditions for rod probes We strongly recommend to
secure the end of the probe in
The probes are ‘plug and play’ case of high tank or silo and also
where the conductivity is in case of agitated liquid.
higher than 100 µS/cm. To minimize the pull force on
Reported measurement errors a cable that is tied down, leave
are generally due to: a small amount of slack on the
• A bad connection to the cable. The maximum tensile L00-FMI5xxxx-11-06-xx-xx-007
ground load may not exceed 14.75 lbf-ft Figure 4: Installation in a nozzle Figure 5: Installation of rod probes on
conductive tanks
• The absence of a counter (200 Nm).
electrode or a ground tube
in case of containers made of Setup - Configuration
non-conductive material
• Customer’s specific Calibration is necessary only at
constraints startup. There will be no drift
afterwards.
On conductive tanks
(metal tanks) Liquicap M FMIxx
If the process connection of For conductive liquids
the probe is insulated from (>100 µS/cm), the probe is
the metal tank (e.g. through calibrated at the factory to the
seal material), the ground probe length ordered (0% to
connection at the probe 100%). For non-conductive
housing must be connected to liquids (<1 µS/cm), 0%
Figure 6: Installation of rod probes on

the tank by means of a short calibration is performed at non-conductive tanks Figure 7: Tensioning weight
cable. (see Fig. 5) the factory. Only the 100%

calibration has to be carried out Remote operation with
Level
on-site. FieldCare
FieldCare is described on page
Liquicap M FTIxx and 101.
Solicap M FTIxx
Calibration at the detection point Maintenance
has to be carried out on-site. No maintenance is necessary.
You may use the 4 to 20 mA
Liquicap T current pick-off, e.g. for
For conductive liquids full/empty calibration with L00-FMI5xxxx-07-05-xx-xx-000
Figure 8: Local operation directly on the electronic insert
(> 30 µS/cm), the probe is multimeter. (No need to • Green LED ( operational status)
calibrated at the factory to the disconnect circuit!) • Red LED ( fault message)
• Key (-)
probe length ordered (0% to
• Key (+)
100%). For non-conductive Adjustment • Mode switch
liquids (< 1 µS/cm), 0% An adjustment is necessary: 1 : Operation 5 : Measuring range
calibration is performed at • for non-conductive liquids 2 : Empty calibration 6 : Self-test
the factory. Only the 100% • if the er of the medium has 3 : Full calibration 7 : Reset (factory settings)
4 : Measuring modes 8 : Upload sensor EEPROM
calibration has to be carried out changed • 4 to 20 mA current pick-off, e.g. for full/empty calibration with multimeter
on-site. (No need to disconnect circuit!)
Instrument and • Display connection
Other probes (T12892, spare parts availability
T12894, 11500Z) See table at the right Label
Calibration of the remote
Measure Value
transmitter at the detection point If you want to get more information
64.50
Measure Value
has to be carried out on-site. 64.50
call our hotline 800-642-8737. % %
+
Minicap
Our serviceand Nivector
team can set up any Softkeys
Nothing to bedevice
Endress+Hauser carried out.and
for you Migration Value Bargraph Unit
thus ensure you immediately get the
Position
best from your instrument
(see ‘Commissioning’ in the ‘At your Multicap is phased-out. CX001
main menu
service’ section). Please consult us. output
Picklist device properties
Re-engineering basic setup
Operation and Maintenance

Please consult us. Figure 9: Local operation with the display
Local operation directly
on the electronic insert
(FEI50H) (see Fig. 8)
Local operation with the instrument availability generation
display (see Fig. 9)
The display can be used Multicap family YES - until 12/2010 Consult us
to configure directly at the
device via 3 keys. All device
functions can be set via menu
operation. The menu consists of
function groups and functions.
Application parameters can be
read or set in the functions.

Frequently asked questions
Level
Micropilot: How can I adjust the LCD contrast? Prosonic FMU86X: Alignment values cannot be entered, the
Press ‘+ ‘ and ‘E’ or ‘-’ and ‘E’ simultaneously. values keep going back to alignment empty 32.8 ft (10 m)
and alignment full 29.5 ft (9 m).
Micropilot: How can I unlock the hardware? No sensor has been selected yet. Select sensor and confirm with ‘E’!
No configuration is possible if the device is locked. To unlock the
hardware via the Display, enter the following code: Press ‘+’, ‘-’ and Prosonic FMU86X: Although a different endpoint of the
‘E’ simultaneously. scaling has been entered in V2H7, the device keeps
indicating in the former units in VOHO.
Levelflex M: The filling level indicated by the device is After changing the endpoint in V2H7, the value entered in V2HO
too high. What can be done? must be confirmed with ‘E’.
• Check the setting of the medium property and correct,
if necessary Prosonic FMU86X: How to shift the decimal dot?
• Carry out mapping Press ‘+’ and ‘->’ simultaneously.
(Cable probes: mapping range 6.6 ft (2 m),
Rod probes: Define the total probe length as mapping range) Prosonic FMU86X: Error E641 “Echo lost”. Is there a
Attention: During mapping, the filling level must be below the troubleshooting?
mapping range. Remove the sensor and cable it directly to the transmitter. Then aim
at the ground so that the membrane is approximately 3.3 ft (1 m)
Prosonic S/M and Micropilot M: The level indicated by the above the ground. If E641 disappears, it means the device is OK.
device is too high. What can be done?
Carry out mapping. Attention: During mapping, the filling level Prosonic: How can I adjust the 0% level of the tank?
must be below the mapping range. As the tank is empty, read the value displayed in V0H8 and type the
same value in V0H1.
Levelflex M, Prosonic S/M and Micropilot M: The device
indicates the correct value on-site, but keeps on showing Prosonic: Is there any equivalence between the parameters
4 mA at the output. What can be done? for FMU86X and for FMU90?
Presumably a HART address was assigned and the device works in No. The approach is different.
the Multidrop mode. Set the HART address to 0!
Prosonic FMU90: the sensor is not recognized…
Check which type of sensor is connected. In case this is the old
FDU8x sensor, the sensor has to be selected manually.
Capacitive measurement: I get an incorrect measured value

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

Your instruments tuned to perfection.
Just as a piano needs to be tuned to ensure a perfect pitch so do critical process measurement instruments. Calibration services from
Endress+Hauser deliver the skills and tools necessary to ensure your quality, safety, or environmental measurement devices are tuned to
perfection. Calibration from Endress+Hauser – let us help you stay in tune.
www.us.endress.com/calibration
Endress+Hauser, Inc
2350 Endress Place
Greenwood, IN 46143 Sales: 888-ENDRESS
26 inquiry@us.endress.com Service: 800-642-8737 The Endress+Hauser Maintenance Guide
www.us.endress.com Fax: 317-535-8498
Flow metering
Kyle Shipps
Expert in Flow metering
Endress+Hauser USA
“Installation and setup require particular care”
“Flowmeters are so reliable that users main questions that you ask us. With this Contents
refer to us primarily during installation information, you will be able to prevent
and commissioning; very often it is not for or resolve the vast majority of potential Basics 28
several years that users come back to us. problems yourself! The chapter ‘Basics’ includes information
It is true that there are certain problems which is valid for all flow metering
due to aging, but others can be resolved by There is also plenty of useful information to principles described hereafter. Thus you
should read it before any other chapter.
recalibration. From time to time we also help you get the best from your instruments
find that the flowmeter has been used for throughout their life cycle… and prepare Maintenance of
an application other than that for which for renewing your equipment gradually.” ‘Proline’ flowmeters 30
it had been selected, at the risk of it being Electromagnetic flowmeters 32
unsuited to this application, and creating a For those wanting to go
long term reliability problem… Finally, we further in mastering this Mass flowmeters 35
observe that many apparently maintenance- subject, Endress+Hauser Vortex flowmeters 38
related problems prove to be installation has published the ‘Flow
and setup problems. Handbook’, a genuine flow Ultrasonic flowmeters 40
measurement bible. Thermal mass flowmeters 42
That is why we have decided to give you in FAQ 44
this guide a reminder of the few operating We also offer training sessions, in classroom
constraints and installation conditions for and on-site. See ‘Training’ in the section ‘At
flowmeters. We have also recapped the your service’.
For assistance selecting any new or replacement instrument, use the free Online selection software, Applicator at
www.us.endress.com/Applicator

Basics
Flow
Information common to any type of flowmeter
Electromagnetic Mass Vortex Ultrasonic Thermal mass

flowmeters flowmeters flowmeters flowmeters flowmeters
Specific information p. 32 Specific information p. 35 Specific information p. 38 Specific information p. 40 Specific information p. 42
Installation requirements Installation in a siphon Setup - Configuration

overview It sometimes can’t be ensured
that the pipe is always full (i.e. General note:
The specification of ANY wastewater pipes). This could If the installation and wiring
flowmeter is based on an lead to measuring errors or conditions have been observed
ideal installation. Installation situations where the flowmeter initially, you can be certain of
guidelines for all technologies will not work at all. getting correct measurements
exist. They should be viewed as • The flowmeter should then be from the instrument’s first
“Compliance with MINIMUM requirements: installed in a siphon (Fig. 2) activation. Configuration will
• If solids are carried with the only serve to optimize the
installation requirements The flowmeter must remain fluid it is recommended to operating parameters of the
would avoid most completely full at all times. plan a cleaning access. A U- quantities measured (current
This is of utmost importance tube or a sloping pipe might output setup, etc.)
reported errors!” for filling or dosing applications, be simple solutions.
since many flowmeters (except Since 2007, all
mass flowmeters) measure the Advice: the ideal mount Endress+Hauser flowmeters
fluid’s velocity, assuming that for a flowmeter is in a fluid belong to the Proline family
the whole section is full of riser vertical pipe (Fig. 3) and thus offer a QUICK
liquid. Measuring errors might • The meter must be installed SETUP.
flow direction
be particularly important if this with sufficient straight pipe QUICK SETUP enables quick
is not the case. Please note that upstream and easy configuration of the
this rule applies even to mass • See technology-specific device’s main functions (units,
flowmeters. installation conditions for outputs…).
further details (mainly vortex,
Figure 1 Installation at the highest ultrasonic and thermal mass You can also configure your
point of pipe work flowmeter) flowmeters from your PC.
F06-5xxxxxxx-11-00-00-xx-000
• Installation at the top of a See presentation of FieldCare

piping system causes a risk Wiring on page 101.
that air will collect and Take care with the instrument
negatively influence the wiring, especially when Our service organization can set up
performance (Fig.1) the transmitter is mounted any Endress+Hauser flowmeter for
you and thus ensure you immediately
• Avoid installing directly remotely. get the best from your instrument
Figure 2: Installation in a siphon upstream of a free pipe outlet
F06-5xxxxxxx-11-00-00-xx-002
(see ‘Commissioning’ in the
in a vertical pipe as air is Ensure correct tightening of the ‘At your service’ section).
potentially rising up through wires and cable glands. In case
the flowmeter causing of humid atmosphere, check
flow direction
measuring errors that no water drop may get into

• The flowmeter should be the flowmeter.
installed in a lower part of
the pipe work. This ensures Further requirements may apply
Figure 3: Ideal mount for a flowmeter enough head pressure to for one particular technology.
avoid cavitation and the Please check specific
F06-5xxxxxxx-11-00-00-xx-004
meter will always remain full. installation conditions for

EMF*, mass flowmeters,
etc. in the next sections.
…
*EMF: Electromagnetic flowmeter

Flow
Inspection of the
flowmeter pipe
Functional check of a flowmeter using the FieldCare software associated with Flowmeters mounted in a fluid riser vertical pipe
the FieldCheck tool (small right picture)
Operation and Maintenance Calibration and output function of the Maintenance planning
Intrinsically our flowmeters transmitter
Do you know exactly which part of
In most applications, when offer long-term stability • They may be checked using
your installed instrumentation base
correctly selected and installed, and repeatability of your a flow simulator in the field is critical to the operation of the
Endress+Hauser flowmeters measurements. Nevertheless so that problems can be plant and how you could maintain
(except mechanical) require we recommend periodic identified. For any flowmeter or calibrate it more efficiently? Are
you sure that your present actions are
very little maintenance as calibration for the measurement belonging to the Proline
minimizing the risks of unplanned
they are designed without points which are critical to family (see next page) we breakdowns? Are you sure that your
any moving mechanical parts. the process and thus are recommend the use of our present actions are the most cost
Nevertheless, according to its important to control the quality FieldCheck® smart signal effective?
criticality to the quality, some of your product. From on-site simulator which facilitates
With Endress+Hauser’s Installed Base
flowmeters need to be inspected to accredited services, you on-site verification. Audit, our service consultant will help
and/or calibrated periodically. can be sure to find the right The user may effect either you to quickly find an answer to these
Defining the right maintenance method by finding the right a manual simulation of the three questions and move forward in
a controlled manner to a maintenance
frequency taking several balance between the flowmeter flowmeter functions or a full
plan which improves plant reliability
parameters into account is an downtime and the calibration check of the flowmeter, of its while reducing costs… (see ‘Installed
expert’s job. Endress+Hauser uncertainty. electronics only or of its sensor Base Audit’ in the ‘At your service’
can also help you with this task! only. The tool incorporates section).
Calibration can be performed by
Endress+Hauser either on-site or
procedures for automatically
Periodic inspection to assure in our accredited laboratories checking all the electronic Maintenance
reliability of the application (see ‘Calibration’ in the ‘At your operations (linearity of the
After a flowmeter has been service’ section). amplifier, the analog outputs If you do not have the time or the
operating for a period of time, and frequency) on the one right tools to efficiently perform
the user may think that just Inspection of seals hand, and all the sensor service contract can provide you the
because the flowmeter signal and gaskets operations on the other appropriate level of maintenance support
is stable it is correct – but this In some processes, operational (magnetic field and measuring you require.
might not be the case. Even an needs necessitate the use of electrode integrity). With
We provide regular checks on your
indicated flow that appears to be frequent cleaning or sterilization FieldCare software, the user equipment and warranty extensions
within acceptable limits may be in place (CIP or SIP). The can upload the test results providing you with complete peace of
inaccurate and may then affect flowmeter seals and gaskets to a PC, incorporate them in mind and cost control.
the quality of the final product. should then be carefully chosen a certificate, print them or
From regular support to partnership
and frequently replaced to avoid archive them, thus meeting agreements, we offer four distinct
Pipeline inspections risks of leakage, contamination the requirements of quality levels of service…
• Deposits in the pipe can cause and even process failure. procedures. (see ‘Service Contracts’ in the
a slow drift of measured ‘At your service’ section).
values at meter output that is Routine maintenance Moreover, this solution
not detected and rectified The need for routine combined with calibration Corrective maintenance
• According to the type of maintenance is defined could allow to reduce the The more critical your
flowmeter, anything that according to the importance of calibration frequencies and instrument is to your process,
alters the shape or diameter the flowmeter in the process. by this way reduce your the shorter the acceptable time
of a pipeline upstream of the maintenance costs. for repairing is.
measurement point will cause Flowmeters can be checked in a Thanks to the Proline concept
errors in the readings variety of ways: FieldCheck is presented on page 31. (see next page), flowmeters
• The most common offer a modular design; one of
Due to the effects of sedimenta- maintenance seems to be the the outcomes is that most parts
tion or deposition, a periodical use of electrical devices for can be easily replaced thus
cleaning of the flowmeter pipe simple checking of the input allowing quick repair. …
might be necessary.

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

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

Instrument and spare parts minimize storage and replaces FieldTool and
spare parts availability Electromagnetic
costs ToFTool. flowmeters
You will find detailed • Time-saving by easily • Promag 10
information in the next sections replaceable components • Better plant availability on • Promag 23
(EMF, Mass flowmeters, etc.) without recalibration account of self-diagnosis • Promag 50
• Promag 53
• Multi-option control with functions, data backup • Promag 55
local display or configuration (S-DAT, T-DAT), standardize
software (such as FieldCare), spare parts concept, etc. Mass flowmeters
• Promass 40
locally through the service • ‘Quick Setups’ and
• Promass 80
interface or by digital standardized configuration • Promass 83
communication from a routines for user convenience • Promass 84
control center. Note that • FieldCheck for testing
Vortex flowmeters
FieldCare is now the standard flowmeters in-line
• Prowirl 72
• Prowirl 73
Ultrasonic flowmeters
• Prosonic Flow 90
• Prosonic Flow 92F
Permanent self-diagnosis
All Proline flowmeters have continuous
Thermal mass flowmeters
self-diagnosis during operation. Faults, if
• T-mass 65
they occur, are unambiguously classified.
So you have maximized process
dependability.
Data storage /
data transfer
All device parameters
and settings are securely
stored on these data
memory modules in the
form of:
• T-DAT for
transmitter data
(at Promag 53,
Promass 83 and
Prosonic Flow 93)
• S-DAT for sensor data
(all devices)

FieldCheck® How does it work?
Flow
FieldCheck® includes a signal
generator, connector cables
Smart signal simulator and ‘Simubox’ adapters for
connection to the various types
of flowmeters (see picture).
With FieldCheck®, meter verification can be carried out
without the removal of the Proline flowmeter from the pipe. The user may affect:
Where ISO 9000 requires frequent test cycles, FieldCheck® • A manual simulation of
is an economical alternative to calibration. the flowmeter functions.
The generator simulates a
flow based on several freely
Modular concept Designed especially for Main advantages programmable profiles. This
flowmeter verification*, • All Endress+Hauser PROline allows the user to check the
All Endress+Hauser flowmeters FieldCheck® simulates sensor flowmeters can be tested behavior of the outs towards
are based on unified electronics signals to test and evaluate directly on-site, without the device, or the supervision
and operating concepts. The the behavior of a piece of removal of the instrument system, without any actual flow
modular Proline device concept equipment. It can also, thanks • Simultaneous verification in the pipe.
provides the user with obvious to its checking procedures, test of process outputs (current, or
advantages, e.g. in service proper flowmeter functioning frequency) • A full check of the flowmeter,
situations: – be it to meet in-house criteria • Large, clear, multivariable of its electronics only, or of its
or regulatory requirements. The displays sensor only (see photo). The
• Minimization of spare parts check and test results obtained • Expanded functionality tool incorporates procedures
costs through standardized with FieldCheck® can then be with the FieldCare® for automatically checking
components stored in a database and printed software program: reading all the electronic operations
• Time-saving with easily out for subsequent use, e.g. in and printing of test results (linearity of the amplifier, the
replaceable meter electronics, connection with certification by (verification certificates) analog outputs and frequency)
without the need of audit organizations. on the one hand, and all the
recalibration sensor operations on the other
• Individual retrofitting of (magnetic field and measuring
flowmeters for application- Outputs electrode integrity).
specific modifications
We can provide checks on your
Service Proline flowmeters as on-site
interface service for your installed devices.
Our specialist staff will carry out
all the test functions directly in the
installation.
Your benefits:
• Cost savings by providing the
inspection equipment
On-site connections • No familiarization required by
operating personnel
Workshop
• Test certificate as record and proof
connection
of the simulation and verification
Simubox
FieldCare is presented on page 101.
Time-saving ‘Quick Setups’
The Quick Setup menus

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

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

Electromagnetic flowmeters
Flow
Promag series
The current Endress+Hauser range of electromagnetic

flowmeters includes Proline Promag 50, 53 and 55.
In this section, you will find essential information and advice

that will help you to perform the optimum follow-up of your
Promag electromagnetic flowmeters throughout their life
cycle.
Measuring principle
To measure flow based on

Faraday’s law of induction an
alternating magnetic field is
produced with coils of copper
wire. A controlled coil current
ensures that the magnetic field
“The meter must strength remains constant during
the measurement. The length
remain completely of the conductor (the distance
full at all times.” between the two measuring
electrodes at the internal
diameter of the measuring tube)
is also a constant value. The only
variable in Faraday’s equation is
the flow velocity of the passing
fluid. The generated voltage is
exactly proportional and linear When installed a short distance at the highest point of the pipe
to the velocity of the fluid. An from a profile disturbance an and will function correctly. In
EMF* does not measure volume EMF will suffer measuring applications where a partly filled
but velocity. The induced voltage errors due to the disturbed flow pipe is unlikely the orientation of
of a general purpose EMF from profile entering the meter. The the electrodes doesn’t matter.
Endress+Hauser equals approx. flowmeter should therefore
300 µV per m/s velocity. be installed according to the The grounding of the EMF
installation recommendation must be according to the
Installation conditions with sufficient straight pipe guidelines (see FAQs). For
F06-5xxxxxxx-11-00-00-xx-005
up- and downstream. The further information please refer
In addition to installation recommended straight lengths to the corresponding chapter in
Figure 1: Recommended straight lengths
guidelines for all technologies are measured from the center the Operating Manual.
(see ‘Basics’), the particular of the flowmeter. This means
installation requirements of an in small diameter there is often Setup - Configuration
EMF are: enough straight length within
the device itself. All Proline flowmeters propose a
Inlet and outlet runs ‘Quick Setup’ program to make
The meter must be installed If the Empty Pipe Detection standard commissioning easy.
with sufficient straight pipe is used the correct sensor
up-stream. orientation must be considered Our service team can set up any
F06-5xxxxxxx-11-00-xx-xx-000 If possible, install the sensor well (see Figure 2). Endress+Hauser flowmeter for you
clear of fittings such as valves, T- The empty pipe detection and thus ensure you immediately get
the best from your instrument
pieces, elbows, etc. Compliance electrode must be at the highest (see ‘Commissioning’ in the ‘At your
with the following requirements point of a horizontally installed service’ section).
for the inlet and outlet runs is EMF. If the EMF must be
necessary in order to ensure installed in a horizontal pipe the
measuring accuracy : F06-5xxxxxxx-11-00-xx-xx-000
transmitter/terminal housing
Figure 2: Orientation in case of Empty • Inlet run ≥ 5 x DN must be located on top of the
Pipe Detection (1) • Outlet run ≥ 2 x DN pipe. Then the EPD electrode is
* EMF: Electromagnetic Flowmeter

Flow
EMF mounted
horizontally
EMF mounted
in a siphon
EMF mounted vertically EMF with remote electronics
Operation and Maintenance be obtained by means of • These calibration recommen-

comparison with an ultrasound dations are no substitute for
Preventive maintenance device. This is in no way a the maintenance operations
How can you minimize the calibration. required to keep the device in
risks of failure or drift of your perfect working condition
measurement point? Calibration
Having no moving parts, EMFs Calibration frequency should Calibration of flowmeters can be
performed by Endress+Hauser either
require very little preventive be in line with the operating
on-site or in our accredited laboratories
maintenance. conditions. Device calibration (see ‘Calibration’ in the ‘At your
Process conditions may affect procedures and intervals service’ section).
your flowmeters’ lifetime or depend on:
accuracy: abrasive products, • the precision required for
soiling of the electrodes, effects leakage flow monitoring, Instrument and
from high temperatures or high • its criticality to the process, spare parts availability
temperature cycles (e.g. CIP), the legislative constraints
vibration, aggressive chemical imposed. Your Spare parts New
products, etc. So it is important to define the instrument availability generation
If you face one of those calibration intervals and the
situations, you can drastically maximum permissible error of a Promag 30/33 YES - until 12/2007 Promag 50/53
decrease the risk of process measurement point.
downtime by planning The main factors influencing Promag 39F/H NO - stopped 09/2007 Promag 50/53
periodical checks and flowmeter drift are:
calibrations. Another topic • the process conditions (fluid Dosimag A YES - until 12/2010 Dosimag 5BH
requires particular attention: type, product temperature, etc.)
the seals on H sensors (hygienic • the ambient conditions in Promag 35S YES - until 12/2010 Promag 55S
or small diameter) which are which the sensors are fitted
exposed to repeated cleaning (ambient temperature,
or sterilization (CIP/SIP) may moisture). If you want to get more information
quickly deteriorate. Ensure that call our hotline 800-642-8737.
they are regularly replaced. In knowing that calibration
frequencies should be
To control the functional integrity optimized over time in line Spare parts stock
of the Promag we use special with the operating histories, For any flowmeter belonging to
tools which provide very you need to set an initial the Proline family, we suggest
complete checks of the internal frequency. Hereafter you will stocking a full set of electronic
parameters of the electronics find a table of recommendations inserts.
including elements of the to help you define this
sensor (See full description of frequency, taking into account
FieldCheck® on page 31). the process conditions and
ambient conditions:
Our service contracts can include
such verifications – once a year Note:
is recommended (see ‘Service
Contracts’ in the ‘At your service’
• For abrasive or corrosive
section). fluids, the calibration
frequency must be lowered
Note: a measurement according to the wear
consistency check may

Migration For a more in-depth analysis of your
Oil, Hydrocarbons
Flow
0.05 µS/cm Ultra pure water
current installed base, we can help Water
Promag 5X series is you with our ‘Installed Base Audit’
1 µS/cm Pure water
service (see the ‘Services’ section). Min. Conductivity
Endress+Hauser’s new
for EMFs
generation of electromagnetic 10 µS/cm
Industrial water
flowmeters. These new Re-engineering
instruments offer new ways 100 µS/cm
Potable water
to carry out preventive You wish to apply an EMF to 1 mS/cm
verification (see FieldCheck a different application than Food Beer
on page 31). They can replace the one for which it had been 10 mS/cm
Milk
Orange juice
all Endress+Hauser’s previous selected? Please take the Apple juice
instruments. following advice into account. 100 mS/cm Tomato juice
Process Phosphoric acid
Sulphuric acid
The old generation included No or low conductivity 1000 mS/cm
Hydrochloric acid
primarily the Promag 30, If a fluid has a rather low Caustic soda
Promag 33 and Promag 35. As conductivity, an EMF cannot

of December 2007, the parts for be used. The following
the Promag 30 and 33 are no liquids can NOT be measured
longer available. because their conductivity is
too low: vegetable or mineral
• With which device should oil, de-mineralized water,
you replace your Promag 30? hydrocarbons/solvents, etc. (see
For identical applications, graphics)
with the Promag 10, which However, if these liquids are
is much more user-friendly mixed with even a low quantity The effect of buildup
and easy to use. In addition, on the electrodes
of a conductive liquid, an EMF
you will only need to stock a might be used.
single electronics board. To apply an EMF successfully Temperature range Measuring range
• With which device should the fluid must have a minimum All available liner materials are You also need to check that the
you replace your Promag 33? conductivity of: >5 µS/cm for isolating plastics or rubbers with flowmeter’s measuring range
For standard applications: Promag 50/53/55 (55 also for a limited operating temperature. is adequate for the application.
with its designated successor, water) >20 µS/cm for water This is the limiting factor for the In case of a different pipe
which is the Promag 50. applications in general >50µS/ applicability of EMF’s. diameter, a certain flow rate
For special applications: the cm for Promag 23/10. is required at minimum flow
Promag 53 offers a broader Buildup / ECC so that the flowmeter operates
range of options and better Solid Content in a fluid While an EMF is very tolerant with the expected accuracy. The
measurement uncertainty. Since the influence of solids regarding buildup on the Applicator software allows you
Promag 53 also includes is very much dependent on measuring tube, there are to check the device’s accuracy
passive or active pulse output, concentration, mixture, particle limitations. A layer on the over the measuring range.
like Promag 33. characteristics and other electrodes will eventually lead
• With which device should parameters, expert knowledge to a reduced flow signal and the Again consider proper
you replace your Promag 35? is required to select and size the device might stop functioning. installation and setup.
With the Promag 55, typically best fitting model and options.
for applications involving Two typical influences must be If the buildup is conductive
high-load fluids (paper mill, considered: (e.g. magnetic in heating water
mining extraction, etc.) • Excessive signal noise due systems), it is possible to use
Please call our sales force (888- to solids requires a high an electronic solution: ECC
ENDRESS) for more information performing transmitter (electrode clean circuit) keeps
about replacement. (Promag 55) the measuring electrodes clean
• For abrasive slurries suitable and free from buildup.
liners and electrode designs/
materials must be chosen

Mass flowmeters
Flow
Promass series
The current Endress+Hauser range of mass flowmeters

includes Proline Promass 80, 83 and 40.

Promass flowmeters throughout their life cycle.
Measuring principle
The measuring principle

is based on the controlled
generation of Coriolis forces.
These forces are always present
when both translational and
rotational movements are
“Ensure that cavitation superimposed.
does not occur!” FC = 2 � ∆m (v � w)

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

Flow
Commissioning and
configuration with
FieldCare
Mobile flow rig for

on-site calibration
Mass flowmeters mounted vertically
Installation conditions • For gas measurement the following rules apply:

– Flow velocity in the measuring tubes should not be more than
In addition to installation guidelines for all technologies (see ‘Basics’), half the sonic velocity (0.5 Mach)
here are the specific installation requirements for a mass flowmeter: – The maximum mass flow depends on the density of the gas:
formula shown below
When using a bent measuring tube and horizontal installation, the
position of the sensor has to be matched to the fluid properties! Measuring ranges for gases
The full scale values depend on the density of the gas. Use the
formula below to calculate the full scale values:
mmax(G) = mmax(F) � rG) / 160 [kg/m3]
mmax(G) = max. full scale value for gas [kg/h]
mmax(F) = max. full scale value for liquid [kg/h]
r(G) = Gas density in [kg/m3] at operating conditions
Here, mmax(G) can never be greater than mmax(F).
Mounting location
F06-xxxxxxxx-11-00-00-xx-003
No special precautions need to be taken for fittings which create
turbulence (valves, elbows, T-pieces, etc.), as long as no cavitation
Horizontal installation for sensors with a bent measuring tube occurs. Entrained air or gas bubbles in the measuring tube can result
1 Not suitable for fluids with entrained solids. Risk of solids accumulating.
2 Not suitable for outgassing fluids. Risk of air accumulating.
in an increase in measuring errors. Therefore, avoid the following
mounting locations in the pipe installation:
System pressure • Highest point of a pipeline. Risk of air accumulating
It is important to ensure that cavitation does not occur, because it • Directly upstream of a free pipe outlet in a vertical pipeline
would influence the oscillation of the measuring tube. No special
measures need to be taken for fluids which have properties similar to
water under normal conditions.
In the case of liquids with a low boiling point (hydrocarbons, solvents,
liquified gases) or in suction lines, it is important to ensure that
pressure does not drop below the vapor pressure and that the liquid
does not start to boil. It is also important to ensure that the gases that
occur naturally in many liquids do not outgas. Such effects can be
prevented when system pressure is sufficiently high.
Therefore, the following locations should be preferred for installation: F06-xxxxxxxx-11-00-00-xx-004
• Downstream from pumps (no danger of vacuum)

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

Operation and maintenance Calibration
Flow
See ‘Basics’ (page 29) and also page 33 for information regarding
Preventive maintenance calibration.
Having no moving parts, mass flowmeters require very little
Calibration can be performed by Endress+Hauser either on-site or in our accredited
preventive maintenance. Though many process conditions may laboratories (see ‘Calibration’ in the ‘At your service’ section).
affect your Promass’ lifetime and accuracy: corrosive and abrasive
mediums, high temperature on the electronic and stress by
vibrations for the whole device. Furthermore the accuracy of Instrument and spare parts availability
the measurement may be affected by: deposit of medium in the
measured pipe, inhomogeneous mediums, gas bubbles and solids. Your Spare parts New
Are you faced by one of those situations? By planning periodical instrument availability generation
checks you will drastically decrease the risk of process downtime.
Promass 60F/M/I YES - until 12/2008 Promass 80M
There are two simple ways to check a mass flowmeter:
Promass 63MT/MP YES - until 12/2010 Promass 83M
1 - Zero point adjustment
All measuring devices are calibrated to state-of-the-art technology. Promass 63F YES - until 12/2010 Promass 83F
The zero point determined in this way is imprinted on the nameplate.
Promass 64F/M YES - until 12/2010 Promass 84F/M
Calibration takes place under reference conditions. Therefore, a zero
point adjustment is generally not required!
Experience shows that the zero point adjustment is advisable only in
special cases: If you want to get more information about spare parts availability, please call our
• When the highest measuring accuracy is required and the flow hotline 317-642-8737.
rates are very low
• Under extreme process or operating conditions (e.g. very high Spare parts stock
process temperatures or very high viscosity fluids) For any flowmeter belonging to the Proline family, we suggest
stocking a full set of electronic inserts.
How to check the zero point?
• First you have to set the low flow cutoff to 0 and close the pipe Migration
• Then check the zero-point in the display, while the flow in the pipe From the Promass 60 and 63, the sensor may in any case be
is definitely 0. In this state, the display has to show ‘0.00’ and has replaced by the new version. The electronic board must be
to be stable. changed at the same time (for Rackbus and DZL363 devices,
please consult us). Endress+Hauser provides upgrade kits including
2 - Compare the displayed and real densities mechanical parts and a new type plate.
You only have to know the density of the medium which is in the
pipe (e.g. d water = 0.998 kg/dm3 at 68°F/20°C). You mustn´t Re-engineering
stop the flow. Compare the displayed density to the density of the Pressure loss has to be considered before using a mass flowmeter
medium. The displayed value has to be stable and accurate in the in a new application. Pressure loss depends on the fluid properties
possible tolerance threshold. and on the flow rate. Please refer to the Operating Instructions to
If one of these two methods gives a wrong result, please contact us. calculate pressure loss.
Note: To get a good result with these two methods, it is necessary to
have no air or gas bubbles in the liquid.
To control the functional integrity of the Promass we use

special tools which provide very complete checks of the internal
parameters of the electronics including elements of the sensor
(See full description of FieldCheck® on page 31)
Our service contracts can include such verifications – once a year is recommended
(see ‘Service Contracts’ in the ‘At your service’ section).

Vortex flowmeters
Flow
Prowirl series
The current Endress+Hauser range of vortex flowmeters

includes Proline Prowirl 72 and 73.

Prowirl vortex flowmeters throughout their life cycle.
Measuring principle
Vortex shedding flowmeters

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

Flow
The use of the remote
version is recommended
for cryogenic applications
Use the remote version in case of low accessibility to the sensor Orientation for applications
with hot water
• Orientations B and D are Perfect centering Preventive maintenance Spare parts stock
recommended for very cold The centering rings supplied with The device does not contain For any flowmeter belonging to
fluid (e.g. liquid nitrogen) the wafer style meters are used to any moving parts and requires the Proline family, we suggest
mount and center the instrument. no particular maintenance. stocking a full set of electronic
The arrow indicated on the We recommend the periodic inserts.
device must always point in Setup - Configuration checking of the instrument
the direction of flow in all by means of the FieldCheck Migration
mounting orientations. All Proline flowmeters propose a simulator. (See full description
‘Quick Setup’ program to make of FieldCheck® on page 31). Prowirl 72 is fully compatible
Caution! standard commissioning easy. with Prowirl 77. Please consult
• If fluid temperature is ≥ 392°F In case of vortex flowmeters, Our service contracts can include us in case of a migration from
(200°C), orientation B is the Quick Setup can configure such verifications – once a year Prowirl 70H.
not permitted for the wafer the device according to the Contracts’ in the ‘At your service’
version (Prowirl 72 W) with application (liquid, gas, steam). section). Re-engineering
a nominal diameter of 4” (DN
100) and 6” (DN 150). Our service team can set up any When thinking about using a
• In case of vertical orientation Endress+Hauser flowmeter for you Calibration vortex flowmeter for a new
and thus ensure you immediately get
and downward flowing liquid, See ‘Basics’ (page 29) and application, the following
the piping always has to be (see ‘Commissioning’ in the ‘At your also page 33 for information limitations have to be taken
completely filled service’ section). regarding calibration. into account, to avoid future
problems :
Inlet and outlet runs Calibration of flowmeters can be • Pulsating flow and swirl
As a minimum, the inlet and Operation and Maintenance performed by Endress+Hauser either have a detrimental effect on
outlet runs shown below must on-site or in our accredited laboratories measuring accuracy
(see ‘Calibration’ in the ‘At your
be observed to achieve the The measuring range depends • Long inlet and outlet runs are
service’ section).
specified accuracy of the device. on the fluid and the nominal necessary, depending on the
The longest inlet run shown diameter. Do not work outside type of fitting upstream
must be observed if two or more the measuring range. Note: On-site calibration is • Vortex is not adapted for
flow disturbances are present. possible for liquid applications highly viscous liquids
Note: A specially designed If temperature and pressure only. Factory calibration also • Measurement with low flow
perforated plate flow conditioner vary during the process, you uses only water as fluid. velocities is not possible
can be installed if it is not possible need to use a calculator to take (Re < 4000)
to observe the inlet runs required. in account simultaneously the Instrument and
volume flow delivered by the spare parts availability
Piping insulation vortex flowmeter, the pressure
When insulating, please ensure and/or the temperature. Your Spare parts New
that a sufficiently large area of instrument availability generation
the housing support is exposed. In steam pipes, it is essential
The uncovered part serves to avoid any steam, water or Prowirl 70F/W/D YES - until 12/2008 Prowirl 72F/W/D
as a radiator and protects the pressure shock on the meter.
electronics from overheating (or The effects of such shocks Prowirl 70H YES - until 12/2009 Prowirl 72F
undercooling). would be irreparable.
Measurement with low flow Prowirl 77 YES - until 12/2008 Prowirl 72
The maximum insulation height
permitted is illustrated in the velocities (Re < 4000) is not
diagrams. These apply equally possible.
to both the compact version and
the sensor in the remote version.

Ultrasonic flowmeters
Flow
Prosonic Flow series
The current Endress+Hauser range of ultrasonic flowmeters includes:

• Proline Prosonic Flow 90 and 93 in both ‘clamp on’ (non-contact measurement technique)
and insertion versions
• New Prosonic Flow 92 Inline whose installation requirements are similar to those of the
electromagnetic flowmeters
• Prosonic Flow 92 portable ‘clamp on’ flowmeters
In this section, you will find essential information and advice to obtain the best from ‘clamp on’
ultrasonic devices throughout their life cycle.
Measuring principle
Prosonic Flow operates on

the principle of transit time
difference.
An acoustic (ultrasonic) signal
is transmitted in both directions
from one measuring sensor
“Note the type of to the other. As the signal
propagation velocity of the
fluid and the pipe waves is less when the waves
material” travel against the direction of
flow than along the direction of
flow, a transit time difference
occurs. This difference is directly
proportional to the flow velocity.
Prosonic Flow calculates the
flow from the pipe cross-
sectional area and the measured Recommended materials: Compliance with the following
transit time difference. • Cast iron, with or without requirements for the inlet and
cement coating outlet runs is recommended
flow
v ~ ∆t • Stainless steel in order to ensure measuring
direction
Q=v�A • Carbon steel accuracy (see Figure 2).
• PVC
F06-5xxxxxxx-11-00-00-xx-006
v = flow velocity
• PE Orientation
∆t = transit time difference
v = volume flow • GRP (composite material) See Figure 3.
A = pipe cross-sectional area • Fibrocement
Note: If the pipe material does Coupling medium
Figure 1: Mounting location In addition to the volume flow, not conduct sound waves A coupling medium is required
the system measures the sound (e.g. granular concrete), use to ensure the acoustic coupling
velocity in the liquid. The insertion sensors instead of between the sensor and the
sound velocity can be used to clamp on sensors. piping. This is applied to
distinguish different liquids or the sensor surface during
as a measure of product quality. Mounting location commissioning. Periodic
Correct measurement is replacement of the coupling
Limitations: possible only if the pipe is full. medium is usually not required.
• Pipes from ½” to 16” (DN 15 Avoid the following locations Prosonic Flow 93 offers a
to 4000) (see Fig. 1) : coupling medium monitoring
• Liquids should not be heavily • Highest point of a pipeline. function as part of its ‘Extended
contaminated with solids or gas
F06-9xxxxxxx-11-05-00-xx-010
Risk of air accumulating. Diagnostics’ software package.

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

Flow
Prosonic Flow 92 used
for the measurement
consistency check of
an electromagnetic
flowmeter
(see page 27)
Standard horizontal installation Installation of coated pipes Installation in highly

corrosive environment
Setup - Configuration of both sensors as well as the

electronic functionality.
All Proline flowmeters propose a
‘Quick Setup’ program to make Our service contracts can include
standard commissioning easy. In such verifications – once a year
F06-9xxxxxxx-11-05-00-xx-004
case of ultrasonic flowmeters, Contracts’ in the ‘At your service’
you need to know precisely the section).
pipe material, the pipe external
diameter, the pipe thickness and Figure 3: Orientation
View A shows the recommended orientation with upward direction of flow.
the type of fluid. Calibration
View B shows the recommended installation range (C ≤ 120°) in a horizontal installation
See ‘Basics’ (page 29) and position
Some fluids have already been also page 33 for information
programmed. For others, the regarding calibration.
sound velocity in the fluid is
requested. The Quick Setup According to quality constraints,
will then help you configure the you may wish to periodically
transmitter and will give you the calibrate your instrument.
F06-9xxxxxxx-11-00-05-xx-008
exact positioning of the sensors. Ultrasonic flowmeters can be
calibrated on a flow rig. Please
Operation and Maintenance note that the conditions are
Figure 4: Sensor replacement in the insertion version
different from the process 1 = Sensor section in contact with fluid (screwed in), 2 = Sensor element (active sec-
Take care of the sensor cable: if conditions. tion), 3 = Connector holder, 4 = Sensor cover, 5 = Sensor connector
it gets twisted or wounded, the
measurement will be impacted Calibration of flowmeters can be
and the replacement is relatively performed by Endress+Hauser either
on-site or in our accredited laboratories
expensive. (see ‘Calibration’ in the ‘At your
Preventive maintenance Your Spare parts New
• Check periodically the correct instrument availability generation
tightening of the connectors Instrument and
• Ensure that the sensors’ posi- spare parts availability DMU93 NO - stopped 12/2007 DMU90/91/93
tion is kept constant See table to the right.
• Coupling medium should be
periodically changed in the Spare parts stock
following situations: For any flowmeter belonging to
- important variation of the Proline family, we suggest
temperature stocking a full set of electronic
- ambient moisture or inserts and sensors.
streaming on the pipe Note: changing the sensor does
- outside application exposed not affect the electronics; no
to wind, sand or dust recalibration is necessary.
On-site verification is possible Sensor replacement in the

with the FieldCheck simulator insertion version (see Fig. 4)
(described on page 31). The active part of the sensor
The ‘service’ test block offers a can be exchanged without
simple way to test the function interrupting the process.

Thermal mass flowmeters
Flow
t-mass series
The current Endress+Hauser range of thermal mass

flowmeters includes Proline t-mass 65.

thermal mass flowmeters throughout their life cycle.
t-mass insertion version mounted on
a low pressure air pipe
Measuring principle
The thermal principle operates

by monitoring the cooling effect
of a gas stream as it passes over
a heated transducer (Pt100).
Gas flowing through the
sensing section passes over two
“Ensure the sensor Pt100 RTD transducers one of
which is used conventionally
is mounted at as a temperature sensing
90 degrees to the device, while the other is used
as a heater. The temperature
flow direction and sensor monitors the actual
avoid condensation” process values while the heater
is maintained at a constant
differential temperature above Pipework requirements
this by varying the power Good installation practice
consumed by the sensor. The should be followed at all times:
greater the mass flow, the • Clean pipe and flange welded
greater the cooling effect and joints
power required to maintain • Correctly sized gaskets
the differential temperature. • Correctly aligned flanges and
The measured heater power is gaskets
therefore a measure of the gas • The use of seamless pipe
mass flow rate. immediately upstream of the
flowmeter
These devices need to be • The use of pipe work with a
programmed for a certain gas matching internal diameter
or gas mixture. In the factory, to that of the flowmeter
calibration is performed on to ensure that no step
air, using a highly accurate disturbance greater than
and repeatable flow rig, and 0.04” (1 mm) can occur at
a dynamic sensor and gas the meter inlet or outlet,
property calculator model ‘Gas 0.12” (3 mm) for diameters >
Engine’ determines mass flow 8” (DN 200).
for the application gas.
As a general comment,
Installation conditions anything that disturbs the
smoothness of the internal
Like Vortex flowmeters, thermal pipe wall should be eliminated;
mass flowmeters require a fully the goal should be a smooth
developed flow profile as a uninterrupted internal surface.
Figure 1: Minimum inlet and outlet runs
prerequisite for correct volume For further information please
a0005113
A = Inlet run 3 = 90° elbow or T-piece

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

Flow
Endress+Hauser‘s new
gas calibration flow rig
t-mass being calibrated on a gas t-mass measuring Air injection regulation

calibration flow rig N2 consumption in the pond of aeration
(wastewater)
Inlet and outlet runs requested before delivery. Thus In practice, a certain drift can Spare parts stock
If possible, install the sensor well commissioning is quite simple. also be noted when the process For any flowmeter belonging to
clear of fittings such as valves, T- temperature is higher than the Proline family, we suggest
pieces, elbows, etc. Compliance Requested information: 122°F (50°C). In that case, we stocking a full set of electronic
with the following requirements • Gas type if not air recommend to have the device inserts.
for the inlet and outlet runs (composition if more than calibrated once a year.
is recommended in order to one gas in % Mole) Migration
ensure measuring accuracy (see • Gas pressure The t-mass flowmeters are
Figure 1). It is recommended • Gas temperature designed to support in-situ Thermal mass flowmeter t-
to install a perforated plate flow • Line size - internal diameter calibration using a reference mass AT70 is no longer sold.
conditioner if the recommended • 20 mA range required meter signal (mobile rig), With brand new 65F/I series,
inlet runs are not available. • Flow engineering units thus saving time and cost by Endress+Hauser offers full
(kg/h etc.) reducing the need for factory re- interchangeability.
Orientation calibration. An adjustment may What about the interchangeability
The device can generally be ‘DELIVERY SETTINGS’ are the complete the calibration work. with existing sensors?
installed in any position in the programmed parameters (factory Please discuss your specific From the mechanical side:
piping. In the case of wet/dirty settings plus customer specific requirements with your • The t-mass 65I available
gases, upward flow is preferred settings) originally delivered Endress+Hauser service process connections are G 1”
in vertical pipes to minimize with the device. representative. and NPT 1”
condensation/contamination • The t-mass 65F flange length
on or around the sensing The Quick Setup menu contains For higher precision, t-mass 65 is identical to the AT70
element. In particular, where the default settings that are flowmeters can be calibrated From the electrical side: the
free condensation can occur adequate for commissioning. with an ISO/IEC 17025 65F/I series can be supplied
(e.g. Biogas) the sensor should You may use the Quick Setup accredited specific gas flow rig. with 24 VDC, allowing total
be mounted to prevent water in order to change parameters interchangeability with AT70.
collecting on or around the or to use the device on another Calibration of flowmeters can be
sensing elements (e.g. do not application. performed by Endress+Hauser either Re-engineering
install the sensor at a low point on-site or in our accredited laboratories
(see ‘Calibration’ in the ‘At your
in the installation without Operation and Maintenance service’ section).
Besides the utilities, t-mass
adequate drainage). 65F/I series is ideally suited
Make sure that the direction Preventive maintenance for the air injection regulation
arrow on the sensor matches Full compatibility with Corrective maintenance in the pond of aeration of a
the direction of flow (direction FieldCheck® (see page 31) will See ‘Basics’ (page 29). wastewater treatment plant.
of fluid flow through the pipe). allow on-site checking (when You can change the sensor and See Installation conditions
Note: The best accuracy is the specific SimuBox will be the transmitter on-site. Thanks before you decide to change the
obtained only if the gas is dry available). to S-DAT and T-DAT, no further device’s application.
and clean. programming is necessary. Use Gas Engine software to
Calibration change the gas mixture.
Setup - Configuration See ‘Basics’. Instrument and
The sensor is provided fully The sensor’s aging directly
calibrated with an S-DAT. impacts the measurement.
Each meter is programmed to Aging may be sped up in case of Your Spare parts New
individual requirements, i.e. in buildup due to solids deposit, of instrument availability generation
particular the gas type or gas shock on any of the transducers
composition and calibrated with or of abrasion due to the t-mass AT70 YES t-mass 65
air. The necessary information is presence of impurities in the gas.

Flow
How to achieve proper potential equalization? What to do when faced with measurement drift over time?
Perfect measurement requires the medium and the sensor have • Remove the measuring tube and clean it
the same electrical potential. Most Promag sensors have a standard • Return it to the factory so that it can undergo the calibration
installed reference electrode which guarantees the required bench procedure
connection and makes additional potential matching measures
unnecessary. Coil current fault?
Special cases are mentioned in the Operating Manual. In particular • Make sure that all the connectors are correctly clipped onto the
the case of plastic pipes and isolating lined pipes. electronics boards
In exceptional cases it is possible that, due • If so: Return the complete device to the factory
to the grounding plan of a system, large The instrument counts at zero flow. What should I do?
matching currents flow over the reference • Probable cause: air transit
electrodes. This can lead to destruction of • Calibrate DPP with tube empty and tube full
the sensor. In such cases, e.g. for fiberglass or • Activate ‘product presence detection’ function.
PVC piping, it is recommended that you use Note: See ‘Process Parameters Menu’ in the Operating Instructions.
F06-5xxxxxxx-04-xx-xx-xx-004
additional ground disks for potential matching.

The measurement exhibits peaks or fluctuating values.
Grounding should be ensured at first installation; nevertheless in The measurement is unstable. What should I do?
some cases it may be corrected later. • Check the installation conditions
• Make sure that the pipe is completely filled (no air in the unit)
How to connect a flowmeter to an automaton (PLC) and • High or low fluid load?
then make them talk to each other? • Make sure there are no air bubbles
• Correct electrical wiring. Use a specific cable to connect the • Electrical connection: if electronics separate: ground connection?
sensor to the transmitter (Please read carefully ‘4.1 Wiring Synthetic pipe?
– Connecting the remote version’ in the Promag 50 Operation
Manual). With the Profibus® version, are different values displayed on
• Ensure full compatibility between the emitter and the receiver the display and the automaton?
by a proper parametrization of the Pulse/Frequency output • Go to the communication menu
according to your automaton’s settings. • Validate the ‘set unit to bus’ box.
Go to the program matrix at level ‘(4207) Output signal‘ and Note: this is also valid after any programming alteration.
select:
0 = PASSIVE - POSITIVE How do I test the pulse output?
1 = PASSIVE - NEGATIVE • For the test, set a pulse period of 1 second
2 = ACTIVE - POSITIVE • Connect a diode mode multimeter to the unwired (+) and (-)
3 = ACTIVE - NEGATIVE terminals
Factory setting: PASSIVE-POSITIVE • The value changes can be seen on the multimeter
See also the Proline Promag 53 operating manual, p.68 for more (one step = 1 s): Equipment OK
explanation.
How do I test the current output?
What is the unlocking code for my instrument? • Connect a milliammeter to the unwired terminals 26 (+)
Name of device: e.g. ‘0050’ or ‘50’ for Promag 50 and 27 (-)
• Go to the ‘current output’ menu
How do I set the end of the 4-20 mA output scale? • Activate the ‘current simulation’ box
• Go to the ‘current output’ menu • Define the current to be simulated in the ‘sim. curr. value’ box
• Go to the ‘20 mA end of scale’ box
There is a high measurement error. What should I do?
How do I set the Pulse output? • Check the installation conditions
• Go to the ‘pulse output/frequency’ menu • Make sure that the pipe is completely filled (no air in the unit)
• Go to the ‘pulse value’ box • Is the setup correct?
How do I wire the pulse output on a Promag 50? The Promass shows Error#587 but the tubes do not oscillate.
• Connect the 24 V DC to the + terminal of the pulse output What is the reason for that?
• Retrieve the signal on terminal 25 (Input/Output terminal Perhaps the pipe is only partly filled or there is a too low pressure
numbers) and gas bubbles are in the medium. Please check:
• Is the pipe completely filled?
• Are there gas bubbles in the medium?

Liquid analysis
Don Spriggs
Expert in Liquid Analysis
Endress+Hauser USA
“We help you in all situations!”
“Analysis devices typically require more You will also find some recommendations Contents
maintenance than the other measurement related to maintenance intervals to help you
principles. As a consequence, the keep your instruments fit! pH and ORP measurement 46
maintenance staff that takes care of a plant Conductivity measurement 51
generally knows exactly what has to be done. In addition to this, we have included expert
approaches to diagnosis and frequently Turbidity measurement 54
Another consequence is that most asked questions to help you make the right Chlorine measurement 57
reported questions concern either the diagnosis and actions in case of trouble.
use of an Endress+Hauser device itself Oxygen measurement 60
or troubleshooting (generally due to the As experts, we also offer training sessions, Analyzers 63
application). in classroom and on-site. We would be glad FAQ 66
to meet with you and help you go one step
That is why we have decided to give you further. See ‘Training’ in the section ‘At
in this guide a reminder of the different your service’.”
principles used in liquid analysis.

pH and ORP measurement
Liquid analysis
Electrodes and transmitters
A complete pH or ORP measuring system includes:

• an analog or a digital electrode
• a transmitter
• a special measuring cable
• an immersion, flow or retractable assembly
In this section, you will find essential information and advice to obtain the best from
pH and ORP measuring systems throughout their life cycle.
pH measurement -
Measuring principle
The pH value is used as a

unit of measurement for the
acidity or alkalinity of a liquid
medium. The membrane
glass of the electrode supplies
“You can solve many an electrochemical potential
which is dependent upon the
problems yourself” pH value of the medium. This
potential is generated by the
selective penetration of H+ions
through the outer layer of the
membrane. An electrochemical
boundary layer with an electric
potential forms at this point. An
integrated Ag/AgCl reference
system serves as reference Figure 1: Example of a complete
C07-CPM2x3xx-14-06-00-xx-001.eps
6 Retractable assembly Cleanfit W
electrode. measuring system CPA450
Transmitter
1 Flow assembly CPA250 7 Electrode, e.g. Orbisint CPS11
The transmitter converts 2 Junction box VBA 8 Immersion assembly CPA111
the measured voltage into 3 Liquisys M CPM253 transmitter 9 Extension cable
Electrode Reference
the corresponding pH value 4 Measuring cable e.g. CPK9 Options: extension cable, junction box
electrode according to the Nernst 5 Liquisys M CPM223 transmitter VBA or VBM
equation.
The influences
Figure 2: The principle of pH/ORP on pH measurement
measurement • Temperature influences at two • Electrical phenomena ORP measurement -
levels. First on the electrode • Dissimilar media measuring principle
slope sensitivity. Temperature • Soiling
compensation serves to bring • Aggressive chemical products The ORP potential is a unit of
back this sensitivity from measurement for the state of
its value at the operating The Endress+Hauser range equilibria between oxidizing
temperature to its value at The current range of and reducing components
the reference temperature pH measurement equipment of a medium. ORP potential
(77°F/25°C). Secondly includes: is measured similarly to the
temperature influences on • a wide range of pH pH value. A platinum or gold
pH: the pH of a fluid will electrodes, analog and digital electrode is used instead of
not be the same at 194°F with Memosens technology pH-sensitive membrane glass.
(90°C) as at 59°F (15°C). • Liquisys M CPM223/253, Analog to the pH measurement,
With Liquiline and Mycom S, Mycom S CPM153 an integrated Ag/AgCl reference
a0003686
Figure 3: Electrode installation;

inclination angle min. 15° from you can compensate the and Liquiline M CM42 system is used as a reference
the horizontal medium’s temperature. transmitters electrode.
• Contamination of the • their accessories
reference element (cables and assemblies)

Liquid analysis
The Endress+Hauser range ORP) or use Memosens • Cable and connection check
The current range of ORP technology • Calibration and adjustment
measurement equipment • The cabling should not
includes: be interrupted (avoid any Cleaning glass pH
• a wide range of ORP temporary connection). If an and ORP electrodes
electrodes, analog and digital extension is necessary, use There are 5 levels of cleaning:
with Memosens technology a High Impedance junction • Level 1: use water + sponge
• Liquisys M CPM223/253, box (VBM). • Level 2: use water + soap
Mycom S CPM153 and (presence of grease) Figure 4A: Asymmetrical connection
Liquiline M CM42 transmitters Connecting pH and ORP • Level 3 (ORP only): carefully
• their accessories (cables and sensors (see Fig. 4A and 4B) clean the metal pins or
mounting assemblies) The pH and ORP analog surfaces mechanically (polish
sensors can be connected under water using ultra fine
Installation conditions both symmetrically and abrasive paper or grit free
asymmetrically. polishing compound)
Do not install the electrode • Level 4: use diluted
upside down (see Fig. 3). Advantages of symmetrical hydrochloric acid HCl
The inclination angle must be measurement: (3 to 5%) and rinse with
at least 15° from the horizontal. • No leakage current since both clean water
A smaller inclination angle is not the reference and pH/ORP Note! After chemical cleaning,
permitted as such an inclination measuring electrodes are the ORP sensor can require Figure 4B: Symmetrical connection
results in air cushion forming. connected with a high several hours conditioning
This might impair the contact of impedance amplifier time. Therefore check the
reference and metal lead. • Safe measurement under calibration after a day.
Caution! difficult process conditions • Level 5: use specific products Cable and connection check
• Make sure that the assembly’s (strong flowing and/or highly to clean contamination (see • Check cables and connections
threaded connection for resistant media, partially list below) for moisture, cuts or kinks
the electrode is clean and soiled reference diaphragm) • Check electrical continuity:
working properly before • Oily and greasy films: establish a short-circuit
Clean with detergent and water or
installing the electrode Advantages of asymmetrical between 2 wires at one end
any grease dissolvers such as alcohol,
• Hand tighten the measurement: acetone. of the cable (e.g. between
electrode (2.2 lbf-ft/3 • Use of assemblies without • Inorganic layers: ‘Measure’ and ‘Ref’).
Nm)! (Given value only potential matching possible Immerse the electrode for 15 min in Measure the resistance with
diluted hydrochloric acid or sodium
applies to installation in an ohmmeter at the other
hydroxide (max 5%).
Endress+Hauser assemblies.) Caution! In the case of a • Lime and metal hydroxide layers: end (should be 0.1Ω/m).
• Make sure to follow the symmetrical connection, Dissolve layers with diluted • Detection of insulation
installation instructions in the the potential matching pin hydrochloric or acetic acid (vinegar) default: disconnect both
(max 10%).
operating instructions of the (solution ground) must ends of the cable and
• Layers containing sulphide:
used assembly be connected and always Use mixture of hydrochloric acid (max measure the impedance
immersed in the medium 10%) saturated with urea. between the different wires
Cabling (even during calibration). • Layers containing proteins: with an insulation meter
Immerse the electrode in a mixture of
• Cable should be no longer that measures with 1000 V
hydrochloric acid (max 10%) saturated
than 164 ft/50 m (CPK7, Operation and Maintenance with pepsin (8500 units) at 98.6°F (should be R = ∞)
CPK9, CYK71); for higher (37°C).
distances use an electrode Maintenance work at the Note! Always rinse carefully with
plenty of clear water and wipe with
fitted with a preamplifier transmitter includes: a soft cloth.
(CPF81 for pH, CPF82 for • Cleaning of assembly …
and sensor

Calibration the potential matching pin • Keep the electrode terminal (+ the ‘PA’ terminal
Liquid analysis
Use the CAL key to access the must be connected and immersed until the in case of a symmetrical
‘calibration’ function group. always immersed in the reading stabilizes connection). As the pH-meter
Use this function group to medium before you validate the input has a potential of 0 mV,
calibrate the sensor. The • Enter the actual buffer measurement the display should indicate the
calibration can take place in a value in the transmitter (at 3) Enter the actual buffer value Zero value of the last calibration
number of ways: current temperature) in the transmitter (at current (i.e. around pH7).
• By measuring in two • Keep the electrode temperature) You need a pH simulator if you
buffer solutions with known immersed until the 4) Rinse the electrode with wish to test the whole scale.
pH value reading stabilizes clean water A pH simulator consists of a
• By entering data for the slope • Rinse the glass bulb with simple voltage generator
and zero point adjustment clean water (do not rub Check of the slope after (-500 to +500 mV).
• By entering an offset value it: you might generate calibration of a pH electrode
• In the case of ORP electrostatic charges!) The theoretical slope is Regeneration of a pH
measurement, by entering 3) Immerse the electrode in the 59.16 mV/pH. The practical electrode whose response
the mV value or two different second buffer solution (pH 4, slope of a new electrode is 57 to time is too long:
% values 9, etc.) and start again at step 2 60 mV/pH. Use a mixture of nitric acid
4) Rinse the electrode with • If the slope ≤ 55 mV/pH, the (10%) and ammonium fluoride
pH electrode adjustment clean water electrode must be cleaned (5% max). Rinse with clean
1) Clean the electrode with • If the slope ≤ 50 mV/pH, the water then wipe with a soft
water (or specific product). ORP electrode adjustment electrode must be checked piece of cloth.
If harsh chemicals are used, 1) Clean the electrode with and replaced if needed
allow the sensor adequate water • If the slope ≤ 45 mV/pH, the Storage of an electrode
recovery time in water or a 2) Immerse the electrode in transmitter displays an error Store in a dry place between
KCl solution. a buffer solution (220 mV message: the electrode must be 50° and 86°F (10° and 30°C).
2) First immerse the electrode or 460 mV) replaced Always keep a glass electrode
in a pH 7 buffer solution • Measure the container’s hydrated (if possible in a diluted
• In the case of an temperature Checking a transmitter KCl solution (<5%)). Electrodes
automatic temperature • In the case of a - analog technology are always delivered with a
compensation, the symmetrical connection, (for digital technology, yellow cap which contains
temperature sensor must the potential matching pin see Memosens) a sponge saturated with a
be immersed in the must be connected and Bypass the pH input by special liquid in order to avoid
medium always immersed in the connecting the ‘Measure’ dessication of the bulb.
• In the case of a medium terminal to the ‘Reference’
symmetrical connection,
Easier maintenance with Memosens technology
Easy handling
Sensors with Memosens technology have integrated electronics that
allow saving calibration data and further information such as total
hours of operation and operating hours at very high temperatures.
When the sensor is mounted, the calibration data is automatically
transferred to the transmitter and used to calculate the current pH
or ORP potential. Storing the calibration data in the sensor allows for
calibration and adjustment away from the measuring point.
The result:
• The sensors can be calibrated under optimum external conditions
in the measuring lab. Wind and weather do not affect the Memocal T - dedicated Memocheck
calibration quality nor the operator. calibration tool This service tool enables a
• The measuring point availability is dramatically increased by the Memocal T is a calibration quick and easy check of the
quick and easy replacement of precalibrated sensors instrument for your laboratory: measuring loop by simulating
• The transmitter does not need to be installed close to the • pH measurement using digital fixed sensor status in order to:
measuring point but can be placed in the control room sensors • control the correct wiring
• Maintenance intervals can be defined based on all stored sensor • Wet or numeric calibration of the system during its
load and calibration data and predictive maintenance is possible (9.8 ft/3 m of cable) installation …
• The sensor history can be documented on external databases and • Readout of all software and
evaluation programs at any time. Thus, the current application of hardware version numbers
the sensors can be made to depend on their previous history. including sensor serial number

Corrective maintenance
Liquid analysis
Diagnosis of common
troubleshooting: See Table 1
Generic approach to
diagnose troubleshooting
We suggest five steps:
1) Check that the sensor
fully corresponds to
the application
2) Check the installation
(cabling), the configuration
and the hydraulic mounting
3) Take the environment
(electromagnetic, electrical,
moisture, sun) into account
4) Consider the
metrological level Problem / Possible cause Action
5) Find out which component Calibration is impossible
is out of order Bulb and/or diaphragm soiled Clean it
1) Installation Bulb broken Replace electrode
• Configuration of analog (non- Cabling error or defective cable Check and replace if needed
Memosens) systems to be
Buffer solution out-of-date Change buffer solution
symmetrical or asymmetrical
must be the same as the cabling Measurement is unstable
connection Incorrect connection Check cable and connections
• Review the programming
Interference Use double shielded cable;
matrix
check connection of the shield
• Consider the installation
to ground; change cable path
conditions of the electrode
(away from AC and high
voltage lines)
2) Environment
• Is the sensor installed inside Current or parasitic potential in In case of asymmetrical
or outside? Is it protected the product (for analog systems measurement, connect the
from sunlight? … only) product to the ground; switch
to symmetrical measurement
Sensor responds slowly
Electrode soiled Clean it
… • check the digital data transfer Sensor aging Test the measurement chain
during commissioning with a simulator; replace the
• solve troubleshooting in the electrode
running process
Display blocked on a fixed value
Insulation default and/or Test with a pH simulator
short-circuit on the cable or an insulation meter
Memocheck Plus Moisture on the connectors Check and dry
This tool enables qualification
of the measuring loop in Crack on the inside tube Replace electrode
pharmaceutical and (short-circuit between
biotechnology industries measurement and reference)
• with 5 plug-in heads each Reduction of the reference element (current circulation)
simulating a fixed, defined Insulation default and/or Test with a pH simulator
sensor status for a dedicated short-circuit on the cable or an insulation meter
type of sensor
• reading of all relevant Moisture on the connectors Check and dry
calibration and process data Inconsistency between Check
after simulation at predefined configuration and connection
pH and temperature value (Symmetrical/Asymmetrical)
• each plug-in head has passed a (for analog, non-Memosens
stringent test on computerized systems only)
inspection unit and a quality Table 1: Diagnosis of common troubleshooting
certificate is issued

• Take the electrode out of its Cable check: see page 47 Your Spare parts New
Liquid analysis
environment and check it in Transmitter check: see page 48 instrument availability generation
another environment
• Electromagnetic phenomena: Instrument and CPM220/240 NO - stopped 01/2004 CPM223/253
check the cables and the spare parts availability
connection to ground See table at the right. CPM221/252 NO - stopped 01/2005 CPM223/253
• Does temperature vary alot?
If yes, check that temperature If you want to get more information MyPro CPM431 YES - until 10/2010 Liquiline CM42
compensation is active call our hotline 800-642-8737.
• Moisture: visual check MyPro CLM431 YES - until 10/2010 Liquiline CM42
of the junction boxes’ Mycom CPM152 YES - until 06/2011 CPM153
watertightness, look for Spare parts stock
moisture or oxidation on the We recommend that you always
connectors, etc. keep a new electrode in stock.
3) Metrological level How to select and order List of consumables

Is there a drift, is the electrodes and tools: See the
Buffer solutions for pH electrodes
measurement unstable or selection guide and prices in Technical buffer solutions, accuracy 0.02pH, acc. to NIST/DIN
incorrect? ‘The Maintenance Store’. • pH 4.0 red, 250 ml, order no. CPY20-C02A1
• Is the electrode soiled? • pH 4.0 red, 1000 ml, order no. CPY20-C10A1
Then clean the electrode How to select and order • pH 7.0 green, 250 ml, order no. CPY20-E02A1
• pH 7.0 green, 1000 ml, order no. CPY20-E10A1
(see page 47) buffer solutions and cables: Technical buffer solutions for single use, accuracy 0.02pH, acc. to NIST/DIN
• Check the electrode in a Select the right order code from • pH 4.0 red, 20 x 18 ml, order no. CPY 20-C01A1
well known medium with the list hereafter; then refer to • pH 7.0 green, 20 x 18 ml, order no. CPY 20-E01A1
the actual configuration data the price list in The Maintenance
ORP solutions
of the transmitter. If there Store. • +220 mV, pH 7.0, 0.026 US gal. (100 ml); order no. CPY3-0
is a drift, come back to the • +468 mV, pH 0.1, 0.026 US gal. (100 ml); order no. CPY3-1
factory configuration. If Migration
this is not sufficient, apply KCl-electrolyte solutions for liquid filled electrodes
• 3.0 mol, T= 14 to 212°F (-10 to 100°C), 3 oz (100 ml), order no. CPY4-1
the procedure to adjust an Want to use a Memosens • 3.0 mol, T= 14 to 212°F (-10 to 100°C), 30 oz (1000 ml), order no. CPY4-2
electrode manually (see electrode with your current • 1.5 mol, T= -22 to 266°F (-30 to 100°C), 3 oz (100 ml), order no. CPY4-3
page 48). Read the slope and pH transmitter? • 1.5 mol, T= -22 to 266°F (-30 to 100°C), 30 oz (1000 ml), order no. CPY4-4
the Zero point. According to A special kit exists to upgrade
the value of the slope you any Liquisys M CPM223/253 List of accessories
may need to clean or replace from version 2.5 onwards Special cables
the electrode. and Mycom S CPM153. This • CPK1 special measuring cable for pH/ORP electrodes with GSA plug-in head
upgrade can be done either • CPK9 special measuring cable for sensors with TOP68 plug-in head, for high-
4) Which component by a service engineer on-site temperature and high-pressure applications, IP 68
• CYK10 Memosens data cable for digital pH sensors with Memosens technology
is out of order? or you can send it back to the (CPSxxD)
Electrode check: Endress+Hauser repair facility. • CPK12 special measuring cable for pH/ORP glass electrodes and ISFET sensors with
• Visual check of the outside TOP68 plug-in head
condition (damaged, cracked,
bulb broken, corrosion,
abrasion, oxidation or moisture
on the connector, etc.)
• Visual check of the inside
condition (Is KCl still
transparent? Is the reference
electrolyte level significantly
reduced? Is the inside glass
tube damaged?)

Conductivity measurement
Liquid analysis
Sensors and transmitters
A complete conductivity measuring system includes:

• a conductivity sensor
• a transmitter
• a special measuring cable
conductivity measuring systems throughout their life cycle.
Conductive measurement
of conductivity -
measuring principle
The conductivity of liquids is

measured with a measuring
system that has two coaxially
arranged electrodes like
“Always be aware a capacitor. The electric
resistance or its reciprocal
of the effect of value, the conductance G, is
temperature!” measured according to Ohm’s
law. The specific conductivity
is determined using the cell
constant k that is dependent on
the sensor geometry.
Inductive conductivity
measurement -
measuring principle
Figure 3: Example of a complete 5 Inductive sensor CLS50 C07-CLM2x3xx-14-06-00-xx-001.eps
A generator (1) generates an measuring system 6 Conductive sensor CLS21

alternating magnetic field in the 1 Conductive sensor CLS15 7 Immersion assembly CLA111
2 Liquisys M CLM253 transmitter Options: extension cable, junction box
primary coil (2) which induces a 3 Liquisys M CPM223 transmitter VBA or VBM
current in the medium (3). The 4 Inductive sensor CLS52
strength of the induced current
Figure 1: The principle of conductive a0003416
measurement of conductivity
depends on the conductivity and
AC Power supply thus the ion concentration Installation conditions corrected by multiplication
I Current meter of the medium. The current for inductive conductivity with the installation factor to
U Voltage meter flow in the medium generates measurement ensure correct measurement.
another magnetic field in the The value of the installation
secondary coil (4). For CLS50/52/54, the medium factor depends on the
The resulting current induced should flow through the conical diameter and the conductivity
in the coil is measured by the measuring channel in the of the pipe as well as the
receiver (5) and processed to indicated direction. Installation sensor distance from the wall.
determine the conductivity. of the sensor in pipes with If the distance from the wall
horizontal (middle) and vertical is sufficient (a > 0.59”/15
Benefits of inductive (right) flow directions. (see Fig. 4) mm, from 2.5”/DN 65), it is
conductivity measurement • In narrow installation not necessary to consider the
• No electrodes, therefore no conditions, the electrical field installation factor (f = 1.00).
polarization in the medium is affected by If the distance from the wall
Figure 2: Inductive conductivity
C07-CLXixxxx-15-0x-00-xx-001.eps
• Accurate measurement in the pipe walls. This effect is is smaller, the installation
measurement media or solutions with a high compensated by the so-called factor increases in case of
1 Generator soiling degree and a tendency installation factor. electrically insulating pipes
2 Primary coil
3 Current flow in the medium
to deposition • The installation factor can (f > 1) and decreases in case
4 Secondary coil • Complete galvanic separation be entered in the transmitter of electrically conductive
5 Receiver of measurement and medium or the cell constant can be pipes (f < 1). The installation

• Calibration by measurement
Liquid analysis
in a calibration solution with a
known conductivity
• Calibration by entering the
exact cell constant of the
conductivity sensor (included
with the sensor’s quality
certificate)
C07-CLS52xxx-11-05-00-xx-001.eps
• Calibration by comparison
Figure 4: Installation of a CLS52 inductive sensor in pipes with horizontal (middle) and to a reference device
vertical (right) flow directions
b Indicator arrow for the flow direction c Flow direction
(e.g. CONCAL)
1 Welding neck 2 Pipe
Calibration of inductive
measurement systems
Two different types
are possible:
factor can be measured using • Calibration by measurement display versus the table
calibration solutions or be in a calibration solution with a printed in the Operating
approximately determined known conductivity Instructions of your
from a diagram (see Fig. 5). • Calibration by comparison to transmitter.
• To compensate residual a reference device • For temperature simulation,
coupling in the cable and connect the decade resistor
between the two sensor coils, If removing your conductivity instead of the temperature
Figure 5: Dependence of installation perform a zero calibration in transmitter from process for 1 to sensor Pt100, using a
factor f on wall distance a 2 weeks is acceptable, the best
air («air set») before installing method is to send the instrument
three-wire arrangement,
1 Conductive pipe
2 Insulating pipe
the sensor. For further to one of our calibration facilities. i.e. connection to terminals
information, refer to the We provide calibration certificates 11 and 12, with a bridge
Operating Instructions of your (see ‘Calibration’ in the ‘At your from 12 to 13. Check the
transmitter. temperature display versus
• Choose immersion depth b the table printed in the
of the sensor in the medium Check of inductive sensors Operating Instructions of your
such that the coil body is Test sending and receiving transmitter.
completely immersed (see coils: Ohmic resistance should
Fig. 6). The pipe has to be be approx. 5 to 7 Ω. To check a transmitter with
completely filled with water. and inductivity approx. conductive sensors, please refer
Gas bubbles will have an 260 to 450 mH (at 2 kHz). to your Operating Instructions.
influence on the displayed Shorts between sensor coils is
value (avoid installation in not allowed. The measured Our service team can perform such
verifications (see ‘Service contracts’
down flowing pipes where resistance should be > 20 MΩ.
in the ‘At your service’ section).
Figure 6: Consider the immersion depth
flow can be affected by Test with ohmmeter between
gravity). red coaxial cable and white
coaxial cable. Instrument and
Operation and Maintenance spare parts availability
Check of transmitter See table below
Maintenance work includes: (inductive sensors)
• Cleaning of assembly • Conductivity can be checked If you want to get more information
and sensor with standard resistors, e.g. about spare parts availability, please
• Cable and connection check with decade resistors. For
(see ‘pH’ section) conductivity simulation, pull
• Calibration a cable through the cleaned Consumables stock
sensor opening and check the The calibration solutions must
Cleaning the be stored in a dry place and
conductivity sensors used within a year.
Please clean contamination on
the sensor as follows: carefully
clean with a synthetic brush Your Spare parts New
and, if needed, with diluted instrument availability generation
hydrochloric acid (5%).
Then rinse carefully with plenty CLD130 NO - stopped 01/2005 CLD132/134
of clear water. CLD431 YES - until 10/2010 Liquiline CM42
Calibration of conductive CLM221/252 NO - stopped 01/2005 CLM223/253

measurement systems
Three different types Mycom CLM152 YES - until 06/2011 CLM153
are possible:

Liquid analysis
List of consumables
Calibration solutions
Precision solutions, traceable to SRM (standard
reference material) by NIST, for qualified calibration of
conductivity measuring systems according to ISO, with
temperature table,
• CLY11-A, 74 μS/cm (reference temperature 77°F
/25°C), 16.9 fl.oz (500 ml), order no. 50081902
• CLY11-B, 149.6 μS/cm (reference temperature 77°F
/25°C), 16.9 fl.oz (500 ml), order no. 50081903
• CLY11-C, 1.406 mS/cm (reference temperature 77°F
/25°C), 0.13 US.gal. (500 ml), order no. 50081904
• CLY11-D, 12.64 mS/cm (reference temperature 77°F
• CLY11-E, 107.0 mS/cm (reference temperature 77°F
How to select and order code from the list hereafter; List of accessories
calibration solutions and then refer to the price lists in
Measuring cables (for conductive sensors)
cables: select the right order the ‘The Maintenance Store’. • CYK71 measuring cable: non-terminated cable for the
connection of sensors (e.g. conductivity sensors) or
the extension of sensor cables - sold by the meter,
order numbers:
non-Ex version, black: 50085333
Ex version, blue: 51506616
CONCAL calibration set
Measuring cables (for inductive sensors)
• CLK5 measuring cable: Extension cable for
Conductivimeter connecting CLS50/52/54 and transmitter via the
Concal reference tool VBM junction box - sold by the meter, order no.
50085473
MEAS CA L
DIAG PARA M
MEAS C AL
DIAG PARA M
Sampling outlet
3m max. Sampling valve
sterile
CONCAL is a conductivity calibration set for

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

Turbidity measurement
Liquid analysis
A complete turbidity measuring system includes:

• a turbidity sensor with a special measuring cable
• a transmitter
• an immersion, flow or retractable assembly
turbidity measuring systems throughout their life cycle.
Measuring principle
Nephelometric measuring
principle 90° NIR scattered
light according to EN 27027
The 90° scattered light method
with a wavelength in the
near-infrared range (880 nm)
“Be careful when according to ISO 7027 / EN
27027 records turbidity values
cleaning the optics” under standardized, comparable
conditions. A temperature signal
is also recorded and transmitted
in addition to the turbidity
signal. The excitation radiation
of an infrared transmitter (Fig. 2,
Item 1) strikes the medium at a0003125
a defined angle of beam. The Figure 1: Example of a complete 3 Assembly with gas bubble trap
different refractions of light measuring system 4 Liquisys CUM253
between the entrance window 1 Immersion assembly CYA611 5 Liquisys CUM223
2 Retractable assembly CUA451
and the medium (water) are
taken into account.
Particles in the medium (Item 5)
create a scattered radiation
which strikes the scattered • TE/F (Trübungseinheiten 300 g/l). Since the norm
light receivers (Items 3, 4) at Formazin) doesn’t apply any more, you
a defined angle of beam. The 1 FNU = 1 NTU = 1 FTU need to periodically perform
measurement in the medium is = 1 TE/F calibration and adjustment
constantly compared with the Formazine mother solution’s of the measuring system
values of a reference receiver turbidity is 4000 FNU which is with your process water. The
(Item 2). Digital filter functions equivalent to 10000ppm SiO2 3-point calibration is achieved
with excellent interference (1FNU = 2.5 ppm SiO2) after comparison to laboratory
signal suppression and sensor measurements.
self-monitoring ensure additional Note :
measurement reliability. • There is no direct There are two different sensors:
relationship between FNU CUS31: for drinking water
The standard reference particle and the suspended particles and process water
is formazine (C2H4N2) which is concentration. 0.000 to 9999 FNU
Figure 2: Turbidity measurement carcinogenic and unstable (short • The norm applies up to 0.00 to 3000 ppm
according to ISO 7027 / EN 27027 life time). 10000 FNU; beyond this to 200.0%
A Side view of the sensor
(cutaway scheme)
Various units are used: value, the particles disrupt 0.00 to 3 g/l
1 Infrared transmitter • FNU (Formazine each other and so absorb more
2 Reference diode Nephelometric Unit) than they diffuse. CUS41: for wastewater
3 Scattered light receiver 1 • NTU (Nephelometric Thanks to a second scattered and sludge
4 Scattered light receiver 2
5 Particles in the medium
Turbidity Unit) light receiver, Endress+Hauser 0.000 to 9999 FNU
B Top view of the sensor surface with • FTU (Formazine Turbidity Unit) sensors cover a much broader 0.00 to 100 to 300 g/l
optical windows • JTU (Jackson Turbidity Unit) measuring range (up to 0.0 to 200.0%

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

The measurement is altered by: installation (Fig. 4): Warning:
• Change of sludge type • parallel to the medium flow • Do not touch the optics with
• Flow variation • against the medium flow sharp-edged objects
• Do not scratch the optics
• Presence of air or foam • Orientation parallel to the
bubbles, suspended particles medium flow is required when
deposit using the CUR3 spray head Clean the sensor mechanically
• Back scatter (which results • Orientation against the using a soft brush. Then rinse
in a higher signal) due to the medium flow is used to thoroughly with water.
installation of the sensor in increase the self-cleaning
piping or very close to a wall effect in heavily-soiled Calibration and adjustment
• Deposits on the sensor optics media (> 15 FNU). The wall Note: The sensor contains all
Figure 3: Tube implantation
reflection is negligible here the calibration data.
Installation conditions due to the high absorption • In the FNU operating
tendency. mode, the sensor is factory
Pipe installation (see Fig. 3) We recommend the CUS31-xxE calibrated with formazine
• The pipeline diameter must or CUS31-xxS sensor version traceable to ISO7027
Figure 4: Installation in flow assemblies
be at least 4” (DN 100) if be used for turbidities < 5 FNU. • In the ppm operating mode, Parallel sensor orientation
reflective materials (e.g. the calibration data records for Sensor orientation against
stainless steel) are used Operation and Maintenance Kaolin and SiO2 are derived the medium flow
• Install the sensor in places from the FNU data records

with uniform flow conditions Maintenance work includes: • In the % operating mode, the
and not in places where air • Cleaning of assembly calibration data records are
may collect or foam bubbles and sensor set to the average of various
form or where suspended • Cable and connection check residual concrete waters.
particles may settle • Calibration They are preset in such a
• The best installation location way that correct values are
is in the ascending pipe. Cleaning the displayed for average clarity. • Recalibration is not
Installation is also possible in turbidity sensors However the settings do not required when the
a horizontal pipe, but should Deposits on the sensor optics follow a currently applicable transmitter is replaced
be avoided in a down flowing may result in inaccurate standard as none exist. • Customer-specific
pipe (where flow can be measurement. Therefore the • In the g/l operating mode recalibration is required,
affected by gravity). sensor must be cleaned at also, the sensor is not however, when the sensor
• Position the sensor surface regular intervals. The intervals calibrated to a fixed value is replaced
against the medium flow are specific to each installation as no standard is directly Three calibration data records are
(“self-cleaning effect”) and must be determined during applicable. You must carry saved in the sensor for each of
operation. Clean the optics with out a calibration because the four main operating modes.
Installation the following agents depending the media of the various
in flow assemblies on the type of soiling: applications differ too When do you need to calibrate?
• If possible, install the flow greatly here. Three-point sensor calibration
assembly vertically so that the • Limestone deposits: is the standard calibration. It is
medium flows to the sensor Short treatment with commercial The calibration data is saved absolutely essential:
deliming agent in an EEPROM directly in the • When commissioning the
from below. Alternatively, the • Oily and greasy soiling:
assembly can also be installed Cleaning agents based on
sensor. Therefore: sensor in sludge applications
horizontally. water-soluble surfactants • Recalibration is not required in • When changing to another
(e.g. household dish detergents) the event of a power failure sludge type

Three-point sensor calibration is You can send us the sensor and
• Sensor operating voltage is
Liquid analysis
not necessary: flow assembly for adjustment on OK but no measured turbidity
• When commissioning the a calibration bench according to value even with a new sensor.
sensor in the drinking ISO70027. You will be given a quality Replace the transmitter module
certificate.
water area (sensor has been MKT1.
calibrated for drinking water
applications in the factory) Installation adjustment Our service team can perform such
a0006961
Figure 5: Making the samples for a

verifications (see ‘Service contracts’ three-point calibration
• For residual concrete water. In installation adjustment, back in the ‘At your service’ section). A Original sample
Density measurement scatter from the immediate B 1 part sample A + 2 parts water
for determining the sensor environment is C 1 part sample A + 9 parts water
concentration of residual compensated. Installation Instrument and
concrete water is based on adjustment must be performed spare parts availability
%–data records. They are with a medium whose turbidity See table below.
preset in such a way that is lower than 2FNU or 5 ppm.
correct values are displayed If you want to get more information
for average clarity. One-point Our service team can perform such about spare parts availability, please
calibration is often sufficient adjustments by means of a reference call our hotline 800-642-8737.
tool named TURBICAL (see ‘Service
to adjust the system in the contracts’ in the ‘At your service’
event of deviating values. section). How to select and order
• When recalibrating with the accessories: Select the
same sludge type. One-point right order code from the list
calibration suffices here if Checking the hereafter; then refer to the price
the degrees of lightness and measuring point lists in ‘The Maintenance Store’.
clarity, for example, do not The sensors CUS31 and CUS41
differ too greatly. cannot be simulated as they
contain the complete data
Performing three-point processing and all the measured
calibration (on-site) values are transmitted to
You should perform the CUM223/253 using an RS485
calibration in the turbidity/ digital interface. Therefore a Your Spare parts New
solids concentration range in functional sensor is required for instrument availability generation
which you plan to measure. The the measuring point test.
overall calibration characteristic Method for testing a measuring CUM221/252 NO - stopped 01/2005 CUM223/253
of the measuring chain is point:
determined using three samples • Check that device is operable Mycom CUM151 NO - stopped 12/2005 CUM223/253
of known turbidity or known and that the display reacts
solids content. appropriately, e.g. by pressing
Calibration with a very dark, the PLUS key List of accessories
high-absorption medium returns • Check the current outputs
small slopes while light, clear by carrying out a current Measuring cables
simulation (Field O3(2)) • CYK81 measuring cable: non-terminated measuring cable for extension of sensor
media returns big slopes. cables of e.g. Memosens, CUS31/CUS41 - 2 wires, twisted pair with shield and
You can create the requisite • Measure the sensor operating PVC-sheath (minimum 20 AWG) - sold by the meter, order no. 51502543
samples by diluting a sample of voltage: approx. 10 to 16 V at
the process medium. In general, terminals 87 (+) and 88 (–) Other accessories
• The cause for an incorrect • CUY22 check unit for CUS31 and CUS41
very good calibration results are for checking the stability of the sensor,
achieved with a concentration voltage may be present either order no. 51504477
gradation of 10%, 33% and at the device or at the sensor • CUY31 service kit 3 spare wiper arms for CUS31-Wxx: The CUS31-W sensor is
100%. The following condition – Replace the sensor equipped with a rubber wiper for removing deposits from the sensor carrier plate.
– If the sensor operating The cleaning times and intervals are controlled by means of the transmitter (Liquisys
must be met for the calibration: M CUM223/253). Order no. 50089252
Sample A > 1.1 x sample B voltage is still too low replace • Flow assembly Flowfit CUA250 for CUS31/CUS41
> 1.1 x sample C (see Fig. 5) the power supply module Please contact us
LSGA/LSGD (make sure to use
the appropriate version)

Free Chlorine measurement
Liquid analysis
A complete chlorine measuring system includes:

• A chlorine sensor
• A transmitter
• A special measuring cable
• A flow assembly
• A reference measuring instrument for determination of free chlorine according to the DPD method
In this section, you will find essential information and advice to obtain the best from chlorine
measuring systems throughout their life cycle.
Measuring principle
The concentration of free

chlorine is determined
according to the amperometric
measuring principle. The
hypochlorous acid (HOCl)
contained in the medium
“The measurement diffuses through the sensor
membrane and is reduced to
is strongly influenced chloride ions (Cl-) at the gold
by pH, temperature cathode. At the silver anode,
silver is oxidized to silver
and flow” chloride. The electron release of
the gold cathode and electron
acceptance on the silver anode
result in a current flow which is
proportional to the free chlorine
concentration in the medium Figure 3: Measuring system in the flow 4 Mounting place for pH/ORP sensors
under constant conditions. The mode (example) 5 Chlorine sensor a0001691
1 CCA250 flow assembly 6 Medium outlet

concentration of hypochlorous 2 Medium inlet 7 Sampling tap
acid in the medium depends 3 Inductive proximity switch for flow 8 Fixed measuring cable
on the pH value. On pH monitoring 9 Transmitter
fluctuations higher than ± 0.1
pH, this dependence can be
compensated by the CCM2x3 contaminants. The CCS140 and • flow
transmitter by measuring the CCS141 sensors are used for • temperature
pH value in the sample via a measurement of free chlorine
pH sensor mounted in the flow (with a pH compensation as an Installation conditions
assembly. With the pH sensor, option).
the transmitter converts the To calibrate the measuring Installation in flow assembly
free chlorine sensor’s current system, determine the content CCA250
into the corrected free chlorine of free chlorine using the The flow assembly CCA250 is
concentration in mg/l or ppm DPD method. You need a designed for on-site installation of
units. photometer with the pertaining the measuring cell. In addition to the
reagents. The determined value chlorine measuring cell, a pH and
Function is the calibration value for the ORP electrode can be installed. A
The membrane covered transmitter. needle valve regulates the flow within
CCS140 / CCS141 sensors the range of 7.9 to 31.7 gal/h (30 to
consist of a cathode serving as The influences 120l/h).
the working electrode and an on chlorine measurement
anode acting as the counter The measurement is influenced If the measured water is fed back
electrode. These electrodes are by: into a surge tank, pipeline or the
immersed in an electrolyte. • pH value like, ensure that the generated back
Electrodes and electrolyte are CCS140 sensors cannot be used above pressure on the measuring cell does
separated from the medium by 8.0 pH not exceed 14.5 psi (1 bar) and
a membrane. The membrane CCS141 sensors cannot be used above remains constant.
prevents the loss of electrolyte 8.2 pH
and the penetration of
Negative pressure at the the pH value of the measured Routine check for CCS140/141
Liquid analysis
measuring cell, e.g. by feedback water. • Check the measurement at
of measured water to the Caution: The DPD method regular intervals, dependent
suction side of a pump, must be cannot be applied if organic on the respective conditions,
avoided. chlorination agents are used. at least once a month
In this case it causes a higher • Perform recalibration if
Operation and Maintenance measured value compared to required
the actual free active chlorine • If the membrane is
Maintenance work at the value (also note in DIN38408, visibly soiled, remove the
transmitter includes: part 4, section 5). measuring cell from the
• Calibration flow assembly. Only clean
• Cleaning of assembly and Calibration (CCS140/141) the membrane mechanically
sensor The calibration of a chlorine with a gentle water jet or
• Cable and connection check measuring unit is performed for several minutes in 1
by means of a colorimetric to 10% hydrochloric acid
Reference measurement comparative measurement (observe safety regulations!)
according to the according to the DPD method. without chemical additives. • If you are using a junction
DPD method DPD no. 1 pills fit for the Chemicals reducing the box, check the infeed and
The calibration of the measurement of free chlorine. surface tension must not be outfeed measuring cable
measuring system requires used. separately
a colorimetric reference Calibration according to the • Replace a heavily soiled or • Check the cable with
measurement according pH value damaged membrane (see 1000 VDC (at least with
to the DPD method. Free When pH is between 4 and 6, chapter 5.2). 500 VDC) testing voltage
chlorine reacts with diethyl- only active chlorine exists in • Refill the measuring cell • If the cable is intact, the
p-phenylenediamine(DPD) water, so the active chlorine with electrolyte once per insulation resistance > 100
by producing a red dye, the measured value = the free season or every 12 months. GΩ
intensity of the red color being chlorine measured value. Depending on the chlorine • If the cable is defective
proportional to the chlorine According to DPD no. 1 content on site, this period (moist), there is flashover.
concentration. method, the analyzed water can be reduced or extended The cable must be replaced.
Simple visual methods using is buffered at a pH value of (procedure see BA058C/07/
comparators are inaccurate and 6.3, thus the measurement is en chapter 5.3). Test and simulation
depend on the considerably independent from the pH and Chlorine sensors
varying subjective evaluation by no compensation is necessary. Maintenance of pH/ORP Chlorine sensors work according
the operator. sensors (version EP) to the amperometric principle
Today, the chlorine When pH is between 6 and 8, See pH/ORP section and supply very small direct
concentration can be the quantity of active chlorine current as measuring signals. A
determined objectively and (HClO) decreases, while the Maintenance pH connecting chlorine sensor can be simulated
accurately using low-cost quantity of hypochlorite (ClO-) lines and junction boxes (EP) by a DC source. Due to the
microprocessor photometers ions increases. Without any pH Check the cables and small currents, however, the
(order code CCM182). compensation, the displayed connections for moisture. simulation is highly sensitive.
value (active chlorine) would Moisture is indicated by a Lines should be screened and
An important fact must be kept be lower than the value sensor slope that is too small. the simulator grounded. You will
in mind: The DPD method obtained with the DPD no. 1 If no more display is possible find typical slope values in the
is not a selective measuring method (free chlorine). or if the display is fixed at pH7, table below.
method for free chlorine alone, To display the value of free please check the following
but other oxidants present chlorine, a pH compensation is components: Sensor Typical slope value
in the medium can also be necessary if the pH varies. • Sensor head CCS140 ≈ 25 nA per mg Cl/l
registered (see DIN38408, To display active chlorine, do • Sensor connector
CCS141 ≈ 80 nA per mg Cl/l
part 5, section 4). Moreover, not compensate the pH but • pH measuring cable
the measuring range of the measure it and use a conversion • Junction box, if fitted CCS240 ≈ 100 nA per mg ClO2/l
photometers has a lower table with DPD no. 1 method. • Extension cable CCS241 ≈ 350 nA per mg ClO2/l
limit and does not permit
measurements in the very low Maintenance of chlorine Caution! If there is moisture in
trace range. In addition to the sensors the measuring cable, the cable Temperature measurement
chlorinated probe, a sample Corrective maintenance for must be replaced! The transmitter uses the NTC
of the medium without added chlorine sensors and assemblies sensor of the chlorine sensor
chlorine should be checked by is described in the operating A short in the cable > 20 MΩ to measure the temperature.
a DPD measurement if possible. instructions. Use and refer cannot be measured with Due to the relatively high
The measured value must lie to the operating instructions normal multimeters but sensor resistance, a two-
near zero and differ significantly relating to your measuring is damaging for the pH wire connection is sufficient.
from the chlorinated sample. system: measurement. A reliable test Simulation can take place with
can be carried out with a usual a normal decade resistor. The
CCS140/141 BA058C/07/en
The measured water is always CCS240/241 BA114C/07/en
commercial insulation meter: table hereafter contains some
buffered to a pH value of 6.3 • Make sure to disconnect the simulation values.
with the DPD method, so the pH measuring cable from the
measurement is independent of sensor and device!

Liquid analysis
T° NTC simulation
Instrument and
value spare parts availability
32°F (0°C) 29.490 kΩ
50°F (10°C) 18.787 kΩ
instrument availability generation
68°F (20°C) 12.268 kΩ
77°F (25°C) 10.000 kΩ CCM221/252 NO - stopped 01/2005 CCM223/253
86°F (30°C) 8.197 kΩ
104°F (40°C) 5.594 kΩ
pH/ORP measurement call our hotline 800-642-8737.
Simulation takes place with a

pH/mV simulator or an mV
voltage source (see pH/ORP How to select and order
section). accessories: Select the right
order code from the list below;
Flow monitoring then refer to the price lists in
The CCA250 flow assembly has ‘The Maintenance Store’.
an optional proximity switch to
alarm for low flow conditions.
Refer to the operating List of accessories
instructions relating to your Calibration accessories
measuring system for details. • Photometer CCM182; microprocessor-controlled photometer for chlorine, pH value,
cyanuric acid; Chlorine measuring range: 0.05 to 6 mg/l
pH measuring range: 6.5 to 8.4
Our service team can perform such
verifications (see ‘Service contracts’
Measuring cables
• CMK measuring cable: cable for the CCS140, 141, 240 and 241, order no. CMK
• CYK71 measuring cable: non-terminated cable for the connection of sensors
(e.g. conductivity sensors) or the extension of sensor cables -sold by the meter, order
numbers:
non-Ex version, black: 50085333


Oxygen measurement
Liquid analysis
Sensors and transmitters for dissolved oxygen
There are four variants of measuring systems:

• The transmitter Liquisys M COM223 or COM253 – DX or DS with oxygen sensor COS41
• The transmitter Liquisys M COM223 or COM253 – WX or WS with oxygen sensor COS31,
COS61 or COS71
• The transmitter Liquisys M COM223 or COM253 – HX or HS with oxygen sensor COS21
• The transmitter Liquiline CM42 with oxygen sensor COS21D
Each of them can include an immersion, flow or retractable assembly.
In this section, you will find essential information and advice to obtain the best from oxygen
measuring systems throughout their life cycle.
Measuring principle
Amperometric principle
The oxygen molecules diffuse
through the membrane and
are reduced to hydroxide ions
(OH-) at the cathode. Silver is
oxidized to silver ions (Ag+) at
“Periodically clean and the anode (this forms a silver
bromide layer, AgBr).
check the system.” A current flows due to the
electron release at the cathode
and electron acceptance at the
anode. In equilibrium, this flow
is proportional to the oxygen
content of the medium.
This current is converted in
the measuring instrument and
Figure 2: Sensor head - C07-COS41xxx-16-05-07-xx-001.eps indicated on the display as an
Amperometric principle oxygen concentration in ppm, Figure 1: Examples of complete 4 Weather protection cover CYY101
C07-COM2x3xx-14-06-00-xx-002.eps
1 Thread for protection guard mg/l, as a saturation index in measuring systems 5 Liquisys M COM253 transmitter
2 Sealing ring 1 Oxygen sensor 6 Liquisys M COM223 transmitter
% SAT or as an oxygen partial 2 Immersion assembly CYA611 7 Retractable assembly COA451
3 Thread for membrane cap
4 Electrolyte pressure in hPa. 3 Universal hanging assembly holder
5 Gold cathode CYH101
6 Membrane
7 Membrane cap
Fluorescence quenching
8 Anode
principle
• Sensor design: – If the sensor is immersed in – Oxygen molecules ‘quench’
– Oxygen-sensitive molecules the medium, the equilibrium the marker molecules. As a
(markers) are integrated is established very quickly result, the response signals
in an optically active layer • Measuring process: are shorter and less intense.
(fluorescence layer) of the – The sensor optics send • Measurement result:
sensor ‘cap’ green light pulses to the – The sensor returns a signal
– The surface of the fluorescence layer that is in proportion to the
fluorescence layer is in – The markers ‘answer’ oxygen concentration in the
contact with the medium (fluoresce) with red light medium
– The sensor optics are directed pulses – The fluid temperature and
at the underside of the – The duration and intensity air pressure are already
fluorescence layer of the response signals are calculated in the sensor
a0004151
Figure 3: Sensor design -

Optical principle • There is an equilibrium directly dependent on the
1 Sensor cable
2 Sensor shaft
between the oxygen partial oxygen contents and the
3 O-ring pressure in the medium and partial pressure
4 Protection guard that in the fluorescence layer: – If the medium is free from
5 Threaded connection oxygen, the response signals
6 Detector
7 Emitter diode
are long and very intense
8 Fluorescence cap

Liquid analysis
Operation and Maintenance Calibration and adjustment Calibration in air is the easiest The calibration intervals depend
To access the ‘Calibration’ method of calibration. heavily on:
Maintenance work includes: function group, press the CAL • The application and
• Cleaning of assembly key on your transmitter. This Calibration and adjustment • The installation position of the
and sensor function group is used to calibrate in air sensor
• Cable and connection check and adjust the measuring point. 1. Remove the sensor from the The following methods help
• Calibration and adjustment The sensor is calibrated in air or medium. you determine how long the
in the medium. 2. Clean the outside of the calibration intervals should be:
Cleaning the sensor Note! sensor with a damp cloth. Then 1. Check the sensor one month
To ensure reliable measurement, • At first start-up, sensor dry the sensor membrane e.g. by after being put into operation
the sensor must be cleaned at calibration of amperometric using a tissue. by taking it out of the fluid,
regular intervals. sensors is absolutely required 3. If the sensor is removed from drying it and then measuring the
Depending on the type of in order for the measuring a closed pressure system with a oxygen saturation index at air
soiling, proceed as follows: system to be able to generate process pressure greater than after 10 minutes.
accurate measuring values atmospheric pressure: Decide using the results:
• Salt deposits
Immerse the sensor in drinking water
• The optical oxygen sensor – Open the membrane cap to a. If the measured value is not
or in 1-5% hydrochloric acid for a few COS61 does not need a balance the pressure and clean between 98 and 102% SAT
minutes. Afterwards, rinse it with large calibration at first start-up. It is the cap if necessary for an amperometric system or
amounts of water. pre-calibrated. – Replace the electrolyte filling between 99.4 and 100.6% SAT
• Dirt particles on the sensor body
(not on the membrane!)
and close the membrane cap for an optical system, you have
Clean the sensor body mechanically Calibration and adjustment again to calibrate the sensor.
with water and a suitable brush. of amperometric systems – Wait for the polarization time b. Otherwise, double the length
• Dirt particles on the membrane cap Calibration is a means of to end of time to the next inspection.
or the membrane
Clean the membrane with water and a
adapting the transmitter to 4. Then wait while the sensor 2. Proceed as per Point 1 after
soft sponge. the characteristic values of the adjusts to the temperature of two, four and/or eight months.
After cleaning, rinse the sensor with sensor. As no zero calibration is the ambient air. This takes about In this way, you can determine
large amounts of clean water. required for the sensor, a single- 20 minutes. Check that the the optimum calibration interval
point calibration is carried out in sensor is not in direct sunlight for your sensor.
COS61, Cleaning the optics the presence of oxygen. during this time.
The optics only need to The sensor requires 5. If the measured value display Calibration and adjustment
be cleaned if medium has calibration after: on the transmitter is stable, carry of optical systems
penetrated through a defective • first commissioning out the calibration in accordance Calibration is a means of
fluorescence cap. • replacing a membrane or with the Operating Instructions adapting the transmitter to
To clean it, proceed as follows: electrolyte of the transmitter. the characteristic values of
1. Unscrew the protection guard • cleaning the cathode 6. Place the sensor in the the sensor. Normally, sensor
and fluorescence cap from the • long breaks in operation medium again. calibration is seldom necessary.
sensor head. without power supply It is necessary after changing the
2. Carefully clean the optical • typical time intervals dependent Note: Calibration and fluorescence cap.
surface with a soft cloth until on operating experience adjustment in air is only
the buildup is fully removed. possible if air temperature ≥ The slope calibration of
3. Clean the optics with Three different types of 23°F (–5°C). Make sure you the oxygen sensor COS61
drinking or distilled water. calibration are possible: comply with the instructions will be performed in air or
4. Clean the optics and screw on • Calibration in water for calibration in the Operating in air saturated water. The
a new fluorescence cap. • Calibration in air Instructions of the transmitter. calibration of the zero point
Caution! The optical surface • Calibration by comparison to a will be performed in nitrogen
may not be scratched or reference device or in oxygen-free water (water
damaged in any way! enriched with zero solution).

The sensor identifies the slope Simple check of the
Liquid analysis
calibration zero point
(75 to 140% SAT) and the Place the sensor in a recipient
calibration of the zero point which can be hermetically
(0 to 10% SAT). No further closed.
selection is necessary. These Add fresh water and sodium
limits are valid for the three bisulphite (Na2SO3) as powder
types of calibration ‘air’, ‘water’ (‘zero calibration solution’, order
and ‘ref’. number 50001041)
C07-COS41xxx-17-05-00-xx-001.EPS
Close hermetically and let the
Maintenance intervals powder dissolve for 1 to 2 hours.
Amperometric sensor: The measured value should be
suggested maintenance at 0.3% SAT or less (current is
intervals* < 1 nA)
Weekly: clean the sensor
Monthly: calibration in air Our service team can perform such
Annually: clean the gold verifications (see ‘Service contracts’ Figure 4: Changing the electrolyte and the membrane (Amperometric sensors)
cathode with specific polishing
paper (included in the accessory
kit) and change the electrolyte, Spare parts stock Your Spare parts New
the membrane, and the O-ring Amperometric system: instrument availability generation
We recommend to keep
COM220/240 NO - stopped 01/2005 COM223/253 WX/WS
Optical sensor: suggested membranes and electrolyte filling
maintenance intervals* in stock. COM221/252 NO - stopped 01/2005 COM223/253 DX/DS
Weekly: clean the sensor Optical system:
Annually: change the sensor We recommend stocking a COM121/151 NO - stopped 01/2005 COM223/253 WX/WS
cap and the O-ring and sensor cap.
calibrate in air
Instrument and
* intervals may differ according to spare parts availability List of accessories
the application
See table on the right.
Measuring cables for sensors COS31 and COS71 with TOP 68 connector
Changing the electrolyte • COK31; length: 4.92 ft (1.5 m) - order no. 51506820
• COK31; length: 22.97 ft (7 m) - order no. 51506821
and the membrane about spare parts availability, please
• COK31; length: 49.22 ft (15 m) - order no. 51506822
(Amperometric sensors) call our hotline 800-642-8737.
See Fig. 4 and the list of List of consumables
consumables. How to select and order For measurement of dissolved oxygen Oxymax-W COS31, COS41
accessories: Select the • COY31-WP Set of 2 cartridges with pretensioned membrane - std response, order no
Simple check of the right order code from the list 51506976
measuring function hereafter; then refer to ‘The • COY31S-WP Set of 2 cartridges with pretensioned membrane - fast response, order
1. Remove the sensor from the Maintenance Store’. no 51506977
medium. • COY31-OR Sealing ring (supplied in packs of 3), order no 51506985
• COY31-PF Polishing foil (supplied in packs of 6), order no 51506973
2. Clean and dry the membrane. • Zero calibration solution, order no 50001041
3. After about 10 minutes, • COY31-Z Accessory kit - standard response (containing 1 x COY3-F, 1 x COY31S-
measure the oxygen saturation WP, 1 x COY3-OR and 1 x COY31-PF), order no 51506784
index in air (without • COY3-S-Z Accessory kit - fast response (containing 1 x COY3-F, 1 x COY31-WP, 1 x
COY3-OR and 1 x COY31-PF), order no 51506785
recalibration).
4. The measured value should For oxygen measurement with optical sensor COS61
be at • Sensor cap, order no 51518598
• 98 to 102% SAT for an • Set of 2 sealing rings, order no 51518597
amperometric system
• 99.4 to 100.6% SAT for an
optical system

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

aqueous sample. The light
intensity is absorbed by the
coloration of the constituent
substances. Every substance
“Periodic maintenance has a characteristic coloration.
The more there is of this
is essential.” substance in the water, the
more these light beams are
absorbed. Detectors measure
the absorption of light at a
coloration typical for this
substance. A reference
measurement (sample without
chemicals) is performed
before every measurement
so that interferences caused
by inherent color, turbidity
or contamination can be
compensated for. The a0001352
Figure 1: Typical Stamolys analyzer 7 Dosage loop (with CA71SI only)

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

Operation and Maintenance Sample pump Reagents pump
Liquid analysis
Maintenance intervals Photometer
See table below. Valves

Inlet
All maintenance duties that
have to be carried out during
normal operation of the
Reagent 1
Reagent 2
Reagent 3
Cleaning
Standard
analyzer are explained below
(intervals may differ according
to the application). Outlet
Period of time Duty Who?

Weekly • Check and note User
calibration factor (for
service purposes) Instrument and How to select and order
• Move valve hoses into spare parts availability reagents and other
their position and spray See table below. consumables:
with silicone (extends Select the right order code
the service life) from the list hereafter; then
Monthly • Flush the sample tubing User about spare parts availability, please refer to the price lists in ‘The
system with 12.5% call our hotline 800-642-8737. Maintenance Store’.
bleaching lye (sodium
hypochlorite) and reflush
thoroughly with water
• Replace reagents and Your Spare parts New
standard solutions, if instrument availability generation
required
CA70 NO - stopped 01/2008 CA71
• Clean the sample
collector
Every 3 months (in addition to all the User
actions described above)
• Spray pump hoses with List of consumables and reagents (Stamolys range)
silicone spray (order no.
51504155) for CA70/71AM (ammonium)
• Replace pump hoses • for CA70/71AM (ammonium)
Active reagent set A1+A2, 100 ml each - order no. CAY140-V01AAE
• Manually check the Inactive reagent set A1+A2, 100 ml each - order no. CAY140-V01AAH
different parts (pump, Active reagent set A1+A2, 1 l each - order no. CAY140-V10AAE
etc.) Inactive reagent set A1+A2, 1 l each - order no. CAY140-V10AAH
Cleaning solution, 1 l - order no. CAY141-V10AAE
Every 6 months (in addition to all the User or Standard sol. 5 mg/l NH4-N, 1 l - order no. CAY142-V10C05AAE
actions described above) Endress+Hauser Standard sol. 10 mg/l NH4-N, 1 l - order no. CAY142-V10C10AAE
• Replace all hoses and ‘T’ service in the Standard sol. 15 mg/l NH4-N, 1 l - order no. CAY142-V10C15AAE
Standard sol. 20 mg/l NH4-N, 1 l - order no. CAY142-V10C20AAE
connectors scope of a service
Standard sol. 30 mg/l NH4-N, 1 l - order no. CAY142-V10C30AAE
contract Standard sol. 50 mg/l NH4-N, 1 l - order no. CAY142-V10C50AAE
Annually (in addition to all the Endress+Hauser Maintenance kit CAV740 - order no. CAV740-2A
Standards under 5 mg/l not available, because of the low stability
actions described above) service in the
• Replace the static mixer scope of a service for CA70/71PH (phosphate) - standard documents, ready to use
(order no. 51512101) contract Active reagent set P1 + P2, 100 ml each (A) - order no. CAY240-V01AAE
• Replace the photometer Inactive reagent set P1 + P2, 100 ml each (A) - order no. CAY240-V01AAH
Active reagent set P1 + P2, 1 l each (A) - order no. CAY240-V10AAE
optical cell (if necessary) Inactive reagent set P1 + P2, 1 l each (A) - order no. CAY240-V10AAH
(order no. 51505778) Active reagent set P1 + P2, 100 ml each (B) - order no. CAY243-V01AAE
Inactive reagent set P1 + P2, 100 ml each (B) - order no. CAY243-V01AAH
Active reagent set P1 + P2, 1 l each (B) - order no. CAY243-V10AAE
Inactive reagent set P1 + P2, 1 l each (B) - order no. CAY243-V10AAH
For the annual inspection, Calibration
Cleaning solution, 1 l (A) - order no. CAY241-V10AAE
please provide the maintenance Please refer to the Operating Standard sol. 1 mg/l PO4-P, 1 l (A) - order no. CAY242-V10C01AAE
kit relating to your analyzer Instructions relating to your Standard sol. 1,5mg/l PO4-P ,1 l (A) - order no. CAY242-V10C03AAE
(order no. CAV740-xxx, see Stamolys analyzer. Standard sol. 2 mg/l PO4-P, 1 l (A) - order no. CAY242-V10C02AAE
Standard sol. 5 mg/l PO4-P, 1 l (B) - order no. CAY242-V10C05AAE
list hereafter) and also a can of
demineralized water. Standard sol. 15 mg/l PO4-P, 1 l (B) - order no. CAY242-V10C15AAE
Maintenance kit CAV740 - order no. CAV740-1A
(A) = for CA70PH-A, (B) = for CA70PH-B

Liquid analysis
for CA70/71NO (nitrite) for CA70/71CU (copper)
Reagent, 1 l - order no. CAY343-V10AAE Reagent set CU1 + CU2, 1 l each - order no. CAY850-V10AAE
Cleaning solution, 1 l - order no. CAY344-V10AAE Standard sol. 1.00 mg/l Cu, 1 l - order no. CAY852-V10C10AAE
Standard sol. 250 mg/l NO2-N, 0,5 l (821.5 mg/l NO2) Standard sol. 2.00 mg/l Cu, 1 l - order no. CAY852-V10C20AAE
- order no. CAY345-V05C25AAE Maintenance kit CAV740 - order no. CAV740-1A
for CA70/71HA (hardness)
for CA70/71CR (chromate) Reagent set HA1 + HA2, 1 l each - order no. CAY743-V10AAE
Reagent set CR1 + CR2, 1 l each - order no. CAY846-V10AAE Standard sol. 10 mg/l CaCO3, 1 l - order no. CAY745-V10C10AAE
Standard sol. 1.00 mg/l CrVI, 1 l - order no. CAY848-V10C10AAE Standard sol. 20 mg/l CaCO3, 1 l - order no. CAY745-V10C20AAE
Standard sol. 2.00 mg/l CrVI, 1 l - order no. CAY848-V10C20AAE Standard sol. 50 mg/l CaCO3, 1 l - order no. CAY745-V10C50AAE
Maintenance kit CAV740 - order no. CAV740-1A Maintenance kit CAV740 - order no. CAV740-2A
for CA70/71SI (silicate) for CA70/71CL (chlorine)

Reagent set SI1 + SI2 + SI3, 1 l each - order no. CAY640-V10AAE Reagent set CL1 + CL2 (free), 1 l each - order no. CAY543-V10AAE
Cleaning solution, 1 l - order no. CAY641-V10AAE Reagent set CL1 + CL2 (total), 1 l each - order no. CAY546-V10AAE
Standard sol. 500 ppb, 1 l - order no. CAY642-V10C50AAE Cleaning solution, 1 l - order no. CAY544-V10AAE
Maintenance kit CAV740 - order no. CAV740-4A Maintenance kit CAV740 - order no. CAV740-1A
for CA70/71AL (aluminium) - standard documents, ready to use
Active reagent set AL1 + AL2 + AL3, 1 l each - order no. CAY940-V10AAE for the maintenance
Inactive reagent set AL1 + AL2 + AL3, 1 l each - order no. CAY940-V10AAH Silicon spray - order no. 51504155
Standard sol.100 µg/l Al, 1 l - order no. CAY942-V10C10AAE
Standard sol. 250 µg/l Al, 1 l - order no. CAY942-V10C25AAE for other analyzers
Standard sol. 500 µg/l Al, 1 l - order no. CAY942-V10C50AAE Filter element for CAT430/431 - order no. 51509236
Maintenance kit CAV740 - order no. CAV740-1A Hose set for CAT430 - order no. 51509225
Filter membrane (2 pcs.) for CAT411 - order no. 51511288
for CA70/71FE (iron)
Reagent set FE1, 1 l - order no. CAY840-V10AAE For STIP analyzers: see ‘The Maintenance Store’
Standard sol. 500 µg/l Fe, 1 l - order no. CAY842-V10C05AAE
Standard sol. 2 mg/l Fe, 1 l - order no. CAY842-V10C20AAE
for CA70/71MN (manganese)

Reagent set MN1 + MN2 + MN3, 1 l each - order no. CAY843-V10AAE
Cleaning solution, 1 l - order no. CAY844-V10AAE
Standard solution 100 µg/l Mn, 1 l - order no. CAY845-V10C10AAE
Standard solution 500 µg/l Mn, 1 l - order no. CAY845-V10C50AAE

Frequently asked questions related to liquid analysis devices
Liquid analysis
pH 1. Membrane rupture monitoring

• Sensors COS31 include conductivity measurement between
I have an error between the lab and inline measurements > stainless steel body and an inner electrode (see Fig. 1)
0.3 pH units. The lab and inline electrode are the same type
of sensor. If the tolerance for the measurement is ±0.2 pH, is
the 0.3 pH error OK? Conductive path no. 1
Check to see that both measurements were made at the same
temperature. Changes in temperature can change the ionic specie
Conductive path no. 2
in solutions and this can change the actual pH of the solution
(especially when pH > 8). This change in pH of the solution is not
compensated by standard automatic temperature compensation
(ATC). The change in pH for any specific solution must be
determined in the lab. It can then be automatically compensated • Step 1 detects loss of membrane integrity on conductive path no.
in high tech measuring instruments (e.g. Mycom S, Liquiline 1 (membrane rupture)
CM42) by entering a medium/solution temperature compensation
coefficient.
Practical significance of this: Auxiliary wire

• The temperature of the measuring solution must always be
specified for pH values to be processed by process control systems
• pH comparisons are only valid for identical medium temperatures Water with conductivity
>200 µS cm-1
• Step 2 detects loss of membrane integrity on conductive path no.

Conductivity 1+2
I have an error between the lab and inline measurements… If there was no alarm on conductive
1. Temperature coefficient (alpha) is not the same path no. 1 it is clear that an alarm
2. Temperature of the two solutions is not the same occurring now relates to conductive
3. The probe cell constants (k) are not the same path no. 2.
Solution: Always measure without temperature compensation
(alpha) at the same temperature for best results. Use the same cell
constant for the measurements.
2. DO sensor functionality check

Chlorine • Perform calibration in air (see page 61)
• Perform “simple check of the zero point” (see page 62)
I have an error between the DPD test and the inline
measurement… 3. Error possibilities on a hand-held meter
1. pH is not compensated (fluctuations higher than ±0.1 pH must • Sensors of hand-held meters include very thin membranes
be compensated) (e.g. 12.5 µm) for fast response. Therefore, hand-held sensors
2. The pH of the solution is not stable need high flow (e.g. 20-30 cm/s).
3. The pH is > 8.2 for CCS141 or > 8.0 for CCS140 • Insufficient flow on hand-held sensors results in too low a signal.
Solution: There is an additional chemical reaction with the DPD Make sure that there is sufficient flow. Move or stir the sensor if
test (e.g. other oxidizers like bromine, ozone or organic Cl2 or necessary.
interfering ions of substances like iron, copper and manganese) • Due to the fast response of hand-held sensors show signals that
are too high when immersed into aeration basins with small
bubble aeration
Dissolved Oxygen Measurement Remedy: immerse the sensor upside down (e.g. attached to an
Typical failures, methods of detection and failure removal extension pole, pipe or similar)
Typical errors in DO measurement

1. Membrane rupture monitoring
2. Measuring value deviates from a reference meter (e.g. hand-held
instrument)
3. Degradation of the reference electrode
4. Error possibilities on a hand-held meter

Pressure measurement
Duane Muir
Expert in Pressure measurement
Endress+Hauser USA
“Proper commissioning ensures peace of mind”
“Pressure measurement uses various You will also find plenty of useful Contents
principles and can, according to the information to help you get the best from
application, serve to calculate a flow rate or a your instruments throughout their life Basics 68
level. Thus these devices are used frequently cycle… and prepare for renewing your The chapter ‘Basics’ includes
in a broad scope of applications. equipment gradually.” information which is valid for all
pressure measurement devices principles
described hereafter. Thus you should
No wonder most of the reported questions read it before any other chapter.
occur during commissioning. Therefore,
we have decided to focus on this in the Absolute/relative pressure
following pages. However with proper transmitters 70
installation and cabling, immediate operation Differential pressure
will be achieved. measurement 73
Hydrostatic pressure
measurement 75
FAQ 76

Basics
Pressure
Information common to any

type of pressure sensors
The current Endress+Hauser range of pressure measurement
devices includes:
• The Cerabar S and M absolute/relative pressure
transmitters
• The Deltabar S differential pressure transmitters
• The Deltapilot S hydrostatic pressure transmitters
Installation instructions - Setup - Configuration parts. Furthermore they are

general notes insensitive to the medium.
• General note: Thus they require very little
Seal for flange mounting If the installation and wiring maintenance.
Warning! The seal is not allowed conditions have been
to press on the diaphragm as this observed initially, you can be We recommend to periodically
could affect the measurement certain of receiving correct perform a visual check of the
“It’s even easier with result (see Fig.1). measurements from the devices:
instrument’s first activation. • check the cap and housing’s
the new ‘Evolution’ The device specific instructions Configuration will only serve condition
generation!” are described in the next pages. to optimize the operating • check the diaphragm’s
parameters of the quantities condition
measured (current output • check the cable gland’s
setup, etc.) watertightness
• ensure there is no
• Cerabar S, Deltabar S and condensation inside the
1 2
Deltapilot S offer a QUICK housing
SETUP • check the connections to the
Instead of the matrix electronic module
programming present on the
first generation of Cerabar S, Taking 4 to 20 mA test
Deltabar S and on the signal - Cerabar S, Deltabar
Deltapilot S DB5x, the new S, Deltapilot S
Figure 1: Mounting the versions with flange or diaphragm seal P01-FMD7xxxx-11-xx-xx-xx-002
‘Evolution’ generation offers a A 4 to 20 mA signal may be
Fig. 11: Mounting the versions with flange or diaphragm seal
1

Diaphragm
1 Diaphragm 2 Seal QUICK SETUP. measured via the positive
2 Seal QUICK SETUP enables quick and test terminal without
and easy configuration of interrupting the measurement.
the device’s main functions The minimum supply voltage
(units, outputs…). of the device can be reduced
by simply changing the position
• You can also configure of the jumper. As a result,
your flowmeters from your operation is also possible with
PC lower voltage sources. Observe
See presentation of FieldCare the position of the jumper in
on page 107. accordance with the following
table. (see Fig. 3)
Our service organization can set up
P01-xxxxxxxx-19-xx-xx-xx-104
any Endress+Hauser device for you Calibration
Configuration with operating keys Figure 2:insert HART
Electronic
and thus ensure you immediately get
situated either on the exterior of the Cerabar
1 S, Deltabar
Operating keys S and Deltapilot S:
device (see photo) or below the 4-line Operating
2 keys
Slot for anddisplay
optional elements located measurement sensors need
3 Slot for optional HistoROM ®/M-DAT (see ‘Commissioning’ in the
display. Data is stored in a HistoROM / internally on the electronic insert (HART)
M-DAT allowing easy duplication from a
4 DIP-switch for locking/unlocking
1 Operating keys
‘At your service’ section). calibration at start-up.
measured-value-relevant parameters
device to another. 25Slot DIP-switch
for optional display
for damping on/off All pressure sensors require
6 Green LED to indicate value being accepted
3 Slot for optional HistoROM®/M-DAT periodic calibration; the
4 DIP-switch for locking/unlocking Operation and Maintenance calibration’s frequency
measured- value-relevant parameters
5 DIP-switch for damping on/off
depends on the expected
6 Green LED to indicate value being Pressure measurement precision. Calibration can be
accepted instruments contain no wear performed either on-site or

Pressure
in the laboratory (for greater Corrective maintenance Our specialists can help you to define
precision and/or for accredited The more critical your instru- the criticality of all your measuring
calibration). ment is to your process, the instruments (even for other makes).
shorter the acceptable time They will apply a structured
methodology adapted to your own
Endress+Hauser can help you for repair is. Thanks to the application (see ‘Installed Base Audit’
calculate the right calibration Endress+Hauser’s spare part service in the ‘At your service’ section).
frequency and perform calibration concept (see hereafter), most
either on-site or in accredited
laboratories (see ‘Calibration’ in
parts can be easily replaced by
the ‘At your service’ section). the user thus allowing quick Instrument and
repair. spare parts availability
You will find detailed
Maintenance planning Being more efficient in the repair
information in the pages to
process is another way to reduce follow.
Do you know exactly which part of downtimes. Our training sessions help
your installed instrumentation base you to quickly diagnose any failure and
is critical to the operation of the to apply the most appropriate repair Migration
plant and how you could maintain method (see ‘Training’ in the ‘At your
or calibrate it more efficiently? Are service’ section). You will find detailed
you sure that your present actions are information in the pages to
minimizing the risks of unplanned
breakdowns? Are you sure that your
follow.
Spare parts stock
present actions are the most cost
effective?
As members of the Evolution
range, Cerabar S, Deltabar S Re-engineering
With Endress+Hauser’s Installed Base and Deltapilot S use the same
Audit, our service consultant will help electronic modules (for HART You wish to use an instrument
you to quickly find an answer to these for a new application? We can
three questions and move forward in
output, for Profibus output, etc.),
the same housings, caps, display, help you check the relevant
a controlled manner to a maintenance
plan which improves plant reliability terminal compartment, mounting parameters. See our online
while reducing costs… (see ‘Installed set, and Histo-ROM. Only the Applicator tool.
Base Audit’ in the ‘At your service’
section).
sensor and its electronic board
vary from one device to another.
This allows a consistent spare
Maintenance performing parts stock reduction.
If you do not have the time or the For each device type, we P01-xMx7xxxx-04-xx-xx-xx-001
right tools to efficiently perform
suggest stocking a full setElectrical
of connectionJumper
4 to 20 position
mA HART, forhere
testshown
signalwith aluminum housing (T14)
Description
service contract can provide you the electronic inserts. 1 Housing
– Taking 4 to 20 mA test signal via plus and test
2
Jumper for 4 to 20 mA test signal
appropriate level of maintenance support
See also Page 19, "Taking 4 to 20 mA test signal". terminal: possible. (Thus, the output current
you require. On each part you will find
3 a Internal ground terminal can be measured without interruption via the
4 External diode.)
We provide regular checks on your
sticker with the part number, for ground terminal
5 – Delivery status
4 to 20 mA test signal between positive and test terminal
equipment and warranty extensions easy spare parts ordering.6 Minimum supply voltage 10.5 V DC, if the jumper is–inserted
minimumin accordance with the11.5
supply voltage: illustration.
V DC
providing you with complete peace of 7 Minimum supply voltage 11.5 V DC, if the jumper is inserted in "Test" position.
mind and cost control. 8 Devices with integrated overvoltage protection are labelled OVP (overvoltage protection) here ( see also Page 25).
In case of a highly critical – Taking 4 to 20 mA test signal via plus and test
From regular support to partnership
instrument, you might also terminal: not possible.
agreements, we offer four distinct consider stocking a complete – minimum supply voltage: 10.5 V DC
levels of service… (see ‘Service new instrument.
Contracts’ in the ‘At your service’
section).
Figure 3: Taking test signal

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

Cerabar M and S transmitters throughout their life cycle.
Measuring principle
Cerabar S specific information
Ceramic measuring For PMP75
diaphragm (PMCxx devices) The operating pressure acts on Installation instructions for Pressure measurement
The ceramic sensor is a dry the diaphragm of the diaphragm devices without diaphragm in liquids
sensor, i.e. the process pressure seal and is transferred to the seals – PMP71, PMC71 Mount Cerabar S with shut-off
acts directly on the robust separating diaphragm of the device below or at the same level
ceramic diaphragm and deflects sensor by a diaphragm seal fill Pressure measurement as the tapping point. (see Fig. 6)
it. A pressure-dependent fluid. The separating diaphragm in gases
change in capacitance is is deflected and a fill fluid Mount Cerabar S with shut-off Level measurement
measured at the electrodes of transfers the pressure to a device above the tapping point • Mount Cerabar S below the
the ceramic carrier and the resistance measuring bridge. so that the condensate can flow lowest measuring point
diaphragm. The measuring The pressure-dependent change into the process. (see Fig. 4) (see Fig. 7)
range is determined by the of the bridge output voltage • Do not mount the device at
thickness of the ceramic is measured and processed Pressure measurement the following positions: In
diaphragm. (See Figure 1) further. in steams the fill flow, in the tank outlet
• Mount Cerabar S with or at a point in the container
Metallic measuring Level measurement (level, siphon below the tapping which could be affected by
diaphragm (See Figure 2) volume and mass) point. The siphon reduces pressure pulses from the
For PMP71 Design and operation mode is the temperature to almost agitator
The operating pressure deflects shown on Figure 3. ambient temperature. • The calibration and functional
the separating diaphragm and a (see Fig. 5) test can be carried out more
fill fluid transfers the pressure • Fill the siphon with fill fluid easily if you mount the device
to a resistance measuring bridge before commissioning after a shut-off device
(semi-conductor technology).
The pressure-dependent change
of the bridge output voltage
is measured and processed further.
p
h= g
p p p p
P01-PMC71xxx-03-xx-xx-xx-000
P01-PMC71xxx-03-xx-xx-xx-000 P01-PMP7xxxx-03-xx-xx-xx-000
P01-PMP7xxxx-03-xx-xx-xx-000
P01-PMx7xxxx-11-xx-xx-xx-00
Ceramic
Ceramic
sensor
sensor Metal
Metalsensor
sensor
Fig. 5: Measuring arrangement for pressure measurement in gases
1
2
1
2
Figure 1: Ceramic sensor
Atmospheric
Atmospheric
Ceramic
Ceramic
vent
vent
substrate
(gauge
substrate
(gauge
pressure
pressure
only)
only) 1
2
1
2
Figure 2: Metal sensor
Measuring
Measuring
Measuring
Measuring
element
element
diaphragm
diaphragm with
with
Wheatstone
Wheatstonebridge
bridge
Figure 3: Level measurement Figure 4: Measuring arrangement for
3
4
3
4
1 Atmospheric vent
Electrodes
Electrodes
Ceramic
Ceramic
diaphragm
diaphragm
3
4
3
4
1 Measuring element
Channel
Channel
Process
Process
with
with
fill fill
diaphragm,
diaphragm,
fluid
fluid
Metal
Metal
separating
separating
diaphragm
diaphragm
with Cerabar S pressure measurement in gases
(gauge pressure only) 2 Measuring

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

Pressure
Operations and Maintenance (see ‘Basics’) and the explosion
protection. (see Fig. 8)
Taking 4 to 20 mA test
signal Calibration
A 4 to 20 mA signal may be See ‘Basics’. Figure 6: Measuring arrangement
for pressure measurement in liquids
measured via the positive
1 Cerabar S
and test terminal without Instrument and 2 Shut-off device
interrupting the measurement. spare parts availability
(see page 68) (see table below)
Fig. 7: Measuring arrangement for pressure measurement in liquids
Load – 4 to 20 mA and 4 to If you want to get more information 1 Cerabar S

2 Shut-off device
20 mA HART about spare parts availability, please
Load diagram, observe the
position of the jumper

Figure 7: Measuring arrangement for level
instrument availability generation
P01-PMP75xxx-11-xx-xx-xx-000
Fig. 8: Measuring arrangement for level
PMC731 YES - until 12/2010 PMC71 RLmax RLmax ≤

U – 10.5 V RLmax RLmax ≤
U – 11.5 V
23 mA 23 mA
[ ] [ ]
Test Test
PMP731 YES - until 12/2010 PMP71 1500 1456
1282 1239
PMP635 YES - until 12/2010 PMP75 847 804
PMC631 YES - until 12/2010 PMP75 413 369
10.5 20 30 40 45 U 11.5 20 30 40 45 U
[V] [V]
RLmax U – 11 V RLmax U – 12 V
RLmax ≤ RLmax ≤
[ ] 23 mA [ ] 23 mA
1478 1434
1260 1217
826 782
391 347
11 20 30 40 45 U 12 20 30 40 45 U
[V] [V]
Figure 8: Load diagram

1 Jumper for the 4 to 20 mA test signal inserted in «Non-test» position
2 Jumper for the 4 to 20 mA test signal inserted in «Test» position
3 Supply voltage 10.5 (11.5) to 30 V DC for 1/2 G, 1 GD, 1/2 GD, FM IS, CSA
IS, IECEx ia, NEPSI Ex ia and TIIS Ex ia
4 Supply voltage 10.5 (11.5) to 45 V DC for devices for non-hazardous areas, 1/2
D, 1/3 D, 2 G EEx d, 3 G EEx nA, FM XP, FM DIP, FM NI, CSA XP, CSA Dust-
Ex, NEPSI Ex d, TIIS Ex d
Fig. 6: Measuring arrangement for pressure measurement in steams

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

Cerabar M specific information
Pressure
Operations and Maintenance
Taking 4 to 20 mA test signal

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

Load diagram, observe explosion protection. (see Fig. 3)
Figure 1: Analog electronic insert
P01-PMx4xxxx-04-xx-xx-xx-000 Figure 2: 4 to 20 mA HART P01-PMx4xxxx-04-xx-xx-xx-001
Analog
Analog electronic
electronic
• Remove insert
insert
the sensor from the 4 tomA
20HART
mAinsert
4 to electronic
20 HART electronic
electronic insertinsert
process and take the display off • Remove the sensor from the
• Connect a multimeter to the process and take the display off
terminal lugs • Connect a multimeter to the
• Generate the pressure that terminal lugs
corresponds to the lower range • Generate the pressure that
value corresponds to the lower range
• Check that I = 4 mA value
• Use ‘Zero’ potentiometer to • Check that I = 4 mA
correct the value • To correct the value, please press
• Generate the pressure that twice the ‘Zero’ button or confirm
corresponds to the upper range the value in the matrix
value • Generate the pressure that
• Check that I = 20 mA corresponds to the upper range
• Use ‘Span’ potentiometer to value
correct the value • Check that I = 20 mA
• To correct the value, please press
twice the ‘Span’ button or confirm
the value in the matrix
RLmax
[Ω] Figure 3: Load diagram
1522 1 Power supply 11.5 to 45 V DC for
devices for non-hazardous areas,
1295
1/3 D, EEx d, EEx nA, FM XP,
FM DIP, CSA XP and CSA Dust-Ex
840 2 RLmax
PowerU – 11.5 V
≤ supply 11.5 to 30 V DC for
22 mA
EEx ia, 1 D, 1/2 D1/2G, FM IS
386 and CSA IS
RLmax Maximum load resistance
0 U Supply voltage
11.5 20 30 40 45 U
[V]

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

Deltabar S devices throughout their life cycle.
Measuring principle Specific installation

conditions
Ceramic measuring
diaphragms used for PMD70 We remind you hereafter the
and FMD76 main installation requirements
The ceramic measuring cell is regarding the most frequently
based on the principle of a plate used applications.
capacitor with an electrode on
(1) and a movable electrode on Flow measurement in steam
the interior of the diaphragm with PMD70/PMD75
(3). Standard silicone oil or • Mount the Deltabar S below P01-FMD78xxx-11-xx
Fig. 12: Figureent

Measuring layout for level measurem 3:inMeasuring layoutwith
a closed container for level
FMD78
mineral oil filling oils for this the measuring point measurement in a closed container
1 Deltabar S, here FMD78
Figure 1: Measuring layout for flow measuring cell. P01-PMD75xxx-11-xx-xx-xx-001
(see Fig. 1) with FMD78
layout for flow measurement
measurementin steam withwith
in steam PMD75
PMD75 A differential pressure (p1 ≠ • Mount the condensate 1 Deltabar S, FMD78 shown here
1 Condensate traps p2) causes a corresponding traps at the same level as
ps
2 Orifice plate or pitot tube
pitot tube
3 Shut-off valves
deflection of both diaphragms. the tapping points and at
4 Deltabar S, PMD75 shown here Both capacitance values are the same distance to the
e PMD75 5 Separator converted and are fed to Deltabar S
6 Drain valves the microprocessor of the • Prior to commissioning, fill the
7 Three-valve manifold
anifold transmitter as a digital signal. impulse piping to the height of
the condensate traps
Metallic measuring
diaphragms used for Level measurement in
PMD75, FMD77 and FMD78 a closed container with
The separating diaphragms (3/9) superimposed steam with
are deflected on both sides by PMD70/ PMD75
the acting pressures. A filling oil
(4/8) transfers the pressure to a • Mount the Deltabar S P01-FMD76xxx-11-x
Fig. 9: Measuring layout for level measurement in open containers with FMD76
resistance circuit bridge (semi- below the lower measuring Figure 4: Measuring layout for level
1 Deltabar S, here FMD76 measurement in open containers
conductor technology). The connection
2 so negative
The that the side is op en to atmospheric pressure
with FMD76
differential-pressure-dependent impulse piping is always filled 1 Deltabar S, FMD76 shown here
change of the bridge output with liquid (see Fig. 2) 2 The negative side is open to
voltage is measured and further • Always connect the negative side atmospheric pressure
processed. above the maximum level
• A condensate trap ensures
constant pressure on the
Figure 2: Measuring layout for level P01-PMD75xxx-11-xx-xx-xx-005 negative side
measurement
easuring layout for level measurement in aincontainer
a container with
with superimposed steam with PMD75
• When measuring in media
superimposed steam with PMD75
nsate trap
1 Condensate trap
with solid parts, such as dirty
f valves
ar S, here PMD75 2 Shut-off valves liquids, installing separators
or 3 Deltabar S, PMD75 shown here and drain valves is useful
valves 4 Separator
valve manifold for capturing and removing
5 Drain valves
6 Three-valve manifold
sediment

Level measurement in Operations and Maintenance Figure 1: Operating keys and elements
Pressure
located internally on the electronic insert
a closed container with
(HART)
FMD78 Taking 4 to 20 mA test 1 Operating keys
• Mount the Deltabar S below signal 2 Slot for optional display
the lower diaphragm seal (see A 4 to 20 mA signal may be 3 Slot for optional HistoROM®/M-DAT
4 DIP-switch for locking/unlocking
Fig. 3) measured via the positive
• The ambient temperature and test terminal without 5 DIP-switch for damping on/off
should be the same for both interrupting the measurement. 6 Green LED to indicate value being
capillaries (see page 68) accepted
Note! Level measurement
is only ensured between Load – 4 to 20 mA and 4 to P01-xxxxxxxx-19-xx-xx-xx-104
Electronic insert HART

the upper edge of the lower 20 mA HART
1 Operating keys
diaphragm seal and the Load diagram, observe the posi- 2 Slot for optional display
R RLmax
3 Slot forLmax
optional HistoROM ®/M-DAT
lower edge of the upper tion of the jumper (described [ ]
4 Test DIP-switch for locking/unlocking Test
[ ]
1500
diaphragm seal. on page 69) and the explosion 5
1282 for damping on/off
DIP-switch
1456
1239
protection. (see Fig. 2) 6 Green LED to indicate value being accepted
Level measurement in 847 804
an open container with Instrument and 413 369

FMD76/FMD77 spare parts availability
• Mount the Deltabar S directly See table below. 10.5 20 30 40 45 U 11.5 20 30 40 45 U
[V] [V]
on the container (see Fig. 4) If you want to get more information
• The negative side is open to about spare parts availability, please RLmax ≤
U – 10.5 V
23 mA
RLmax ≤
U – 11.5 V
23 mA
atmospheric pressure call our hotline 800-642-8737.
P01-xMD7xxxx-05-xx-xx-xx-005
Fig. 31: Load diagram, observe the position of the jumper and the explosion protection ( ? See also page 25, "Taking
Figure 2:4...20
Load mAdiagram
test signal" part.)
1
1 Jumper
Jumper for the
for 4...20 4 to
mA test 20inserted
signal mA test signal inserted
in "Non-Test" position in «Non-test» position
2 Jumper
2 Jumper for the
for 4...20 4 to
mA test 20inserted
signal mA test signal
in "Test" inserted in «Test» position
position
3
3 Supply voltage
Supply 10.5 (11.5)...30
voltage V DC forto
10.5 (11.5) 1/2
30G,V1GD,
DC1/2 forGD,
1/2FM IS,
D,CSA IS, IECEx
1 GD, 1/2ia,GD,
NEPSIFM
Ex iaIS,
andCSA
TIIS Ex ia
Your Spare parts New 4 Supply voltage 10.5 (11.5)...45 V DC for device for non-h azardous areas, 1/2 D, 1/3 D, 2 G EEx d,
3 IS, IECEx
G EEx nA, FMia, XP,NEPSI
FM DIP,Ex FM ia
NI,and TIIS
CSA XP, CSAExDust
ia Ex, NEPSI Ex d und TIIS Ex d
instrument availability generation 4 Maximum
RLmax Supply load
voltage 10.5 (11.5) to 45 V DC for device for non-hazardous areas, 1/2
resistance
U Supply voltage
D, 1/3 D, 2 G EEx d, 3 G EEx nA, FM XP, FM DIP, FM NI, CSA XP, CSA Dust-
PMD230 YES - until 12/2010 PMD70 Ex, NEPSI Ex d and TIIS Ex d
PMD235 YES - until 12/2010 PMD75 U Supply voltage
FMD230 YES - until 12/2010 FMD76

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

Deltapilot S devices throughout their life cycle.
Measuring principle Specific installation

conditions
(See Figure 1)
Due to its weight, a liquid Note!
column creates hydrostatic • Do not clean or touch
pressure. If the density is diaphragm seals with hard or
constant, the hydrostatic pointed objects
pressure depends solely on the
height h of the liquid column. • Always install the device
The CONTITE™ measuring under the lowest measuring
cell which works on the point
principle of the gauge pressure • Do not install the device at
sensor constitutes the core the following positions:
of Deltapilot S. In contrast to – in the filling curtain
conventional gauge pressure – in the tank outlet
sensors, the precision – or at a point in the tank
measuring element (2) in the that can be reached by
CONTITE™ measuring cell is pressure pulses from
absolutely protected between agitator Deltapilot S hydrostatic level meas urement and measuring principle
P01-FMB70xxx-15-xx-xx-xx-000
Figure 1: Deltapilot S hydrostatic level p tot Total pressure = hydrostatic pressure

the process diaphragm (3) and 1 Measuring diaphragm
measurement and measuring principle + atmospheric pressure
the measuring diaphragm (1). The calibration and functional 2
3
Measuring element
1 Process
Measuring diaphragm
diaphragm (separating diaphragm) p atm Atmospheric pressure
Thanks to this hermetic sealing test can be carried out more g 2 Gravitational
Measuring element
acceleration p hydr. Hydrostatic pressure
h 3 Level Process
height diaphragm (separating p meas Measured pressure in the measuring
of the measuring element, easily if you mount the device p tot Total pressure = hydrostatic pr essure + atmospheric pressure
diaphragm) cell = hydrostatic pressure
the CONTITE™ measuring after a shut-off device. p atm Atmospheric
p hydr.g Hydrostatic
pressure
Gravitational
pressure acceleration ρ Density of fluid
cell is absolutely insensitive to p meas Measured pressure in the meas uring cell = hydrostatic pressure
h Density
Level height
of fluid
condensate, condensation and Deltapilot S must be included
aggressive gases. The pressure in the insulation for media that
applied is transferred from can harden when cold.
the process diaphragm to the
measuring element by means
of an oil without any loss in Operations and Maintenance
pressure.
Taking 4 to 20 mA test
Two temperature sensors are signal
arranged between the process A 4 to 20 mA signal may be
diaphragm and measuring measured via the positive
P01-FMB70xxx-11-xx-xx-xx-00
element which measure the and test terminal without P01-FMB70xxx-11-xx-xx-xx-000
distribution of temperature in interrupting the measurement.

the cell. The electronics can (see Fig. 2)
compensate any measuring 6 Endress+Hauser
errors resulting from Load – 4 to 20 mA and 4 to
fluctuations in temperature 20 mA HART
with these measured Load diagram, observe the posi-
temperature values. tion of the jumper (described
on page 69) and the explosion
protection. (see Fig. 3)

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

1 Operating keys
2 Slot for optional display
3 Slot for optional HistoROM ®/M-DAT
Your Spare parts New 4 DIP-switch for locking/unlocking
instrument availability generation 5 DIP-switch for damping on/off
6 Green LED to indicate value being accepted
DB50L YES - until 10/2011 FMB70
DB50S YES - until 10/2011 FMB70
DB50A YES - until 10/2011 FMB70

P01-xMD7xxxx-05-xx-xx-xx-005
Figure
Load 3: Load
diagram, observediagram
the position of the jumper and the explosion protection. ( ? See also page 19, section "Taking
1 mAJumper
4...20 test signal"for
.) the 4 to 20 mA test signal inserted in «Non-test» position
12 Jumper
Jumper for thefor themA4 test
4...20 to signal
20 mA testinsignal
inserted inserted
"Non-test" position in «Test» position
about spare parts availability, please 23 Jumper for the 4...20 mA test signal inserted in "Test" position
Supply voltage 10.5 (11.5) to 30 V DC for 1/2 G, 1 GD, 1/2 GD, FM IS, CSA IS
call our hotline 800-642-8737. 3 Supply voltage 10.5 (11.5) to 30 V DC for 1/2 G, 1 GD, 1/2 GD, FM IS, CSA IS, TIIS Ex ia and IEC Ex ia
4 andvoltage10.5
Supply TIIS Ex (11.5)
ia to 45 V DC for devices for no n-hazardous areas, 1/2 D, 1/3 D, 3 G EEx nA, FM DIP,
4 FMSupply
NI, CSA voltage
Dust-Ex 10.5 (11.5) to 45 V DC for devices for non-hazardous areas, 1/2
D, 1/3 D, 3 G EEx nA, FM DIP, FM NI, CSA Dust-Ex
U Supply voltage
U Supply voltage
What to do in case of warning or alarm in the display? The pressure is about 14.5 psi (1 bar) too high!
See error codes listed in documentation/operating instructions. An absolute cell is built in instead of a relative cell.
The local display is dark – why? Current permanently at 20.5 mA and possibly display
• With analog output: Only the display is defective. flashing!
• With current = 0 mA: Check terminal voltage or plug to the E-board Measuring cell selected too small, possibly confused relative with
• If there is no voltage on the plug, but on the terminals: absolute!
defective terminal module (filter/interlock diode)
• If there is a voltage on the plug: defective electronics Tanks with a conical outlet
- entry of the linearization
Display/current does not show 0% value upon start-up… table
Perform additional position alignment (position, temperature) as Please refer to the Operating
described in the manual. Instructions of your device.
The current is too low…

The sensor is not connected in 2-wire technique, but probably in P01-PMP75xxx-19-xx-xx-xx-002
4-wire technique by testing terminals, which is forbidden!

Temperature measurement
Duane Muir
Expert in Temperature measurement
Endress+Hauser USA
“Finding the right balance in calibration”
Temperature is the most frequently You will also find plenty of useful Contents
measured parameter in the process industry. information to help you get the best from
your instruments throughout their life Basics 78
Maintenance of temperature measurement cycle… and prepare for renewing your FAQ 82
consists mostly of periodic calibration. This equipment gradually.
is why we have focused on calibration in
the next pages. As experts, we also offer training sessions,
in classroom and on-site. We would be glad
Please note that new transmitters like to meet with you and help you to go one
TMT162 include advanced diagnostics step further. See ‘Training’ in the section ‘At
functions (like drift or corrosion detection) your service’.”
which can increase the system’s
performance and availability.

Basics
Temperature
Information common to all types

of temperature sensors
The current Endress+Hauser range of temperature measurement
devices includes:
• The family of RTD (Resistance Temperature Detector) sensors
• The family of TC (Thermocouple) sensors
Measuring principle thermocouples reference tables normally consists of a mineral

(see IEC 584) the temperature insulated cable, Ø0.12” or
RTD-sensors at the connection (measuring 0.24” (3 or 6 mm), including
(See Figure 1) junction) can be concluded. 4 or 6 copper wires embedded
In RTD-sensors the electrical Thermocouples are suitable for in stone hard pressed MgO
resistance changes with a temperature measurement in powder, surrounded by a very
change in temperature. They are the range of 32°F to +3272°F thin sheath in stainless steel.
Figure 1: Measuring principle of
RTD-sensors suitable for the measurement of (0°C to +1800°C). They stand On one end of the stem the
temperatures between -328°F out due to the fast response sensing element is welded to
(-200°C) and approx. 1472°F time and high vibration the wires and encapsulated;
(800°C) and stand out due to resistance. the sensitive zone of an insert
high measurement accuracy and has a length of about 0.98” (25
long-term stability. The mechanical construction mm) from the closed end (tip).
The resistance sensor element of a thermometer used in On the other end a ceramic
most frequently used is a Pt100 process plants is the same for terminal board or a free wires
which has a nominal value of resistance thermometers and connection system is mounted
100 Ω at 32°F (0°C). Pt100 thermocouples and consists of on a metal flange; the spring
Figure 2: Measuring principle of
sensors are manufactured in the following components: loaded set screws, integral with
thermocouples different formats: • Measurement insert with the metal flange, guarantee the
• Wire wound ceramic sensors: ceramic terminal block or insert coupling to the terminal
A spiral of platinum wire is head transmitter (A) housing and a tight contact
wound and embedded in • Thermowell: The between the insert end tip and
ceramic powder within a thermowell is the process the thermowell.
capillary and is fed to the wetted component of the Inserts are generally equipped
outside by platinum wires thermometer (B) with single or double resistance
• Thin film sensors: A platinum • Process connection: The sensing elements.
layer is vaporized on a ceramic process connection is the Twin resistors are normally
C plate (sputtered). A glass connection between the used to split the destination of
layer is melted on in order to process and the thermometer the output signals.
protect the connection wires • Neck: The neck is the The use of a double sensing
and the platinum layer. connection between element to increase the
As a standard, Endress+Hauser connection head and process measuring point reliability is
RTD sensors fulfill the connection / thermowell not recommended because the
A B IEC 60751 accuracy class F 0.15. • Connection head with cable two elements are embedded
glands: The connection head in the same point: therefore,
TC - Thermocouples is fitted to the thermowell or when a mechanical or electrical
(See Figure 2) the neck of the sensor cause damages the insert
A thermocouple is a component construction, the complete
made of two different metals Insert resistor set goes out of order.
connected with each other at (See Figure 3) This problem can be solved
one end. An electrical potential First step of Pt100 protection with two independent sensors.
(thermoelectric force) is caused consists of making an
due to the Seebeck effect at the insert, which will be used Thermowell
Figure 3: Construction of temperature
sensors
open end if the connection for installation in the final A second protection of the
A Insert and the free ends are exposed assembly and which has sensor assembly consists
B Thermowell to different temperatures. the big advantage to be of installing the insert in
C Terminal head With the help of the so-called interchangeable. The insert appropriate metal thermowells

Temperature
(i.e. thermowells or pockets). wiring. This component can through the connection mass,
This component is normally provide a protective housing that can affect the correct
required for medium and heavy for built-in transmitters or can measurement: this problem
duty applications but it can be act as a junction box if remote can be solved with a longer
employed also for light duty mounted transmitters/receivers immersion length
services whenever the insert are used. The head also permits • Process requirements
replacement must be allowed the complete sensor assembling should also be considered to
without any plant shut-down. and facilitates the insert guarantee a representative
In order to reduce the sensor replacement. measuring point for sensing
response time lag due to A wide choice of terminal and for control efficiency
thermowells, tapered end heads covers general purposes, • For a correct temperature
Figure 4: Pipe installations:
constructions are available. heavy duty, explosion proof and measurement the a) at elbows, against the flow
The sensor thermowell can be sanitary applications. A widely thermowell/sensor b) in smaller pipes, against the flow
mounted in tanks or pipes by used version of connection immersion length must be c) perpendicular to the flow
means of threaded, flanged or heads is constructed in light at least 20 times its diameter
welded connections. metal alloy, usually aluminum, (30 times for non M.I. cable
Since the thermowell is the and conforms to DIN type). Shorter immersion
component that comes into standard 43729 type B. The lengths can be specified but
contact with the process, exact Endress+Hauser metallic heads the sensor requires an external
specification is most important are delivered with gaskets (process connection, neck
as it determines the lifetime to withstand a temperature and connection head) thermal
of assembly. The appropriate of 266°F (130°C). Some insulation.
selection depends upon the connection heads can include • Furthermore, if a calibration
chosen method of mounting, a built-in transmitter and/or certificate is requested,
the space available, the an indicator: in this case the the probe design (length
pressure, the temperature, the temperature has to be checked and diameter) has to be
flow speed and the nature of considering the electronic defined also according to
Figure 5: Thermal insulation examples:
the product. device limits. the certification lab size a) insulating material
Among different international requirements b) pipe
and corporate standards, the Installation instructions c) thermowell with insert
DIN 43763 defines a series of Pipe installations d) external plate
standard thermowell designs Immersion length (See Figure 4 and 5)
including: The sensors should insert in the In small diameter pipes the
• threaded thermowells type B medium where the temperature most suitable immersion length
or C has to be measured at such a can often be achieved only
• flanged thermowells type F depth that a good compromise by installing the assembly at
• weld-in thermowells type D among different measuring an angle to the pipe axis or in
problems is obtained. bends. In this case the inserted
Terminal head • The heat conducted into assembly must be mounted
A terminal head is sensors from ambient may against the flow. …
recommended to protect the alter the temperature of the
connections between the insert sensing tip: for this reason a
and the external circuit wires. short sensor is preferable
The heads are normally • The sensor/thermowell
provided with two connections, process connection may
one for the thermowell and introduce a thermal drift,
one for the electrical output due to heat dissipation

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

An accredited calibration curve drifts slightly. This
Temperature
is carried out under a strict drifting is usually particularly
compliance with national marked with new devices,
or international norms and while later on a certain
guidelines. The normals stabilization is observed. Old generation New Description Spare parts
and gauges used as well as Therefore, calibration should availability
the calibration process and be performed somewhat more TST10/TST111/TST221 TR10 RTD-sensor until 10/2010
algorithms of the evaluation often in the beginning (about
TST42 TR24 RTD-sensor until 10/2011
and measuring accuracy every 3–6 months). Later on,
calculation were checked and having gained experience TST425 TR25 RTD-sensor NO
approved and confirmed in with the drifting behavior of TST11/TST211 TR11 RTD-sensor until 10/2010
the accreditation authority one special thermometer, the TST12/TST221 TR12 RTD-sensor until 10/2010
approval. The compliance is recalibration intervals may TST13/TST131 TR13 RTD-sensor until 10/2010
regularly supervised by an certainly be prolonged (about
TST140/TST141 TR15 RTD-sensor until 10/2010
accreditation authority by every 9-12 months).
audits and tests. In Europe TST288 TR88 RTD-sensor until 01/2013
the national accreditation Thermocouples: The user TST44N TR44 RTD-sensor until 10/2009
authorities have united might be recommended (if a TST14 TR45 RTD-sensor until 10/2009
themselves within the EU (e.g. particularly high precision of
TST74 TR47 RTD-sensor NO
DKD: Germany, SIT: Italy; measurement is required), to
SCS: Switzerland) to the EA buy only a TC calibrated by us TST76 TR48 RTD-sensor NO
(European Cooperation of and to recalibrate it himself, TST262 until 10/2009
TR62 RTD-sensor
Accreditation). in the beginning maybe every TST264 until 01/2013
2-3 months. TST266 TR66 RTD-sensor until 10/2013
The factory calibration is carried
TET100 NO
out depending on production If the TC turns out to be stable,
RTD-sensor,
norms and sets of rules or after some time the calibration TET102 TPR100
measurement insert
NO
according to requirements of cycles may certainly be TET105 NO
the customer. The results are prolonged to 9-12 months. TSC110S TC10 Thermocouple until 10/2010
documented in a calibration It absolutely depends on
TSC130S TC13 Thermocouple until 10/2010
certificate. Of course all test the individual case. After
equipment used are traceable all, drifting is different with TSC140T TC15 Thermocouple until 10/2010
to national/international every TC, therefore general TSC288 TC88 Thermocouple until 10/2011
standards. The measurement recommendations regarding TSC262/TSC264 TC62 Thermocouple until 10/2012
accuracy of a device is not calibration cycles can hardly TSC266 TC66 Thermocouple until 10/2012
influenced by a calibration. be made. If precision is of
TEC100/TEC105 TPC100 Thermocouple, NO
Just the opposite, during an major importance to him, the measurement insert
adjustment (defined on page 8) customer will have to monitor
TMT136/TMT137 TMT180 Head transmitter NO
a measurement device is the drift himself and decide
adjusted and calibrated in such then, how often he will have TMD831 TMT181 Head transmitter NO
a way that the measurement the TC recalibrated - or not. TMD832 TMT182 Head transmitter NO
deviation does not exceed TMD834 TMT184 Head transmitter NO
predetermined error limits Note: With nearly all
TMD842 TMT112 Transmitter NO
(defined by the user). The transmitters you can compensate TMT122 DIN-rail transmitter
following are part of any the drift via ReadWin® 2000
TMD833 TMT162 Field transmitter NO
adjustment: Trim, offset and (‘sensor matching’).
sensor-transmitter matching. TMT165 TMT162 Field transmitter until 10/2010
Spare parts TMT165 TMT85 Head transmitter until 10/2010
How often must a sensor TMD833T TMT162R Compact NO
be calibrated? At which The insert, the thermowell, the thermometer,
intervals is recalibration terminal head and the transmitter RTD-sensor and
Field transmitter
required? can be exchanged if necessary.
How often a sensor should be TMD833C TMT162C Compact sensor, NO
Thermocouple and
recalibrated depends on: Migration Field transmitter
• the user’s requirements
TA10 TW10 Thermowell NO
regarding precision You will find detailed
• which thermic (maximum information regarding the new TA11 TW11 Thermowell NO
temperature, possible thermo generations of temperature TA12 TW12 Thermowell NO
shocks, frequent changes sensors in the following table. TA13 TW13 Thermowell NO
of temperature, etc.) or
TA573/TA574 TW15 Thermowell NO
mechanical strains (vibrations, Re-engineering
jolts, etc.) the thermometer TA250 TW251 Thermowell NO
will be exposed to You wish to use an instrument Note: these dates are periodically updated on www.endress.com (to be confirmed)
• legal requirements for a new application? We can
help you check the relevant
As we know, RTD are affected parameters. See our online
by aging, i.e. their characteristic Applicator tool.
Temperature
The PLC doesn’t display the right temperature value… • For TMT122/142/182 (HART products) and TMT162 (HART
• Check the Pt100 signal by means of an ohmmeter version only), ensure that the load resistance at the Commubox’s
• Thermocouple: terminals equals 250 Ω. If the loop is overloaded (due to
• Is the right thermocouple selected? the PLC’s impedance or the presence of a recorder) the load
• Is the right temperature for the reference junction used? resistance can be much higher thus reducing the signal’s intensity.
• Ensure that both 4-20 mA ranges of the transmitter and the PLC • You are using TXU10:
correspond • Is the USB driver installed on the PC? The driver is stored on
• Check or calibrate the sensor the Readwin® 2000 CD-ROM. You can download the latest
• Check the installation (see Fig. 4 and 5 on the previous pages) version from www.readwin2000.com
• To install the driver you need ‘admin’ rights on your PC
• Also take care of the selected communication port: From
I have no communication to the transmitter from Windows®, ‘START’/’CONTROL PANEL’/’SYSTEM’/
Readwin® 2000… ‘HARDWARE/’DEVICE MANAGER’/’PORTS’
• Ensure that your transmitter can communicate From this window, use the port number that corresponds to the
• Is the latest version of Readwin® 2000 installed on the PC? connected communication interface (FXA195 if you are using a
You can download it from www.readwin2000.com HART modem).
• Ensure that the power supply is min. 9 V for TMT181 and
TMT121
• For TMT182 (HART) and TMT122 (HART), switch off the ‘FIFO
active’ setting. In order to do this proceed as follows:
• Windows NT® Version 4.0:
Using the menu ‘START’/‘SETTINGS’/‘SYSTEM CONTROL’/
‘CONNECTIONS’ select the menu point ‘COM-Port’. Switch
off the ’FIFO active’ command off using the menu path
‘SETTINGS’/’EXPANDED’.
• Windows® 2000:
Select ‘Advanced settings for COM1’ from the ‘START’/
‘SETTINGS’/‘SYSTEM CONTROL’/‘SYSTEM’/‘HARDWARE’/
‘DEVICE MANAGER’/‘CONNECTIONS (COM and
LPT)’/‘COMMUNICATION CONNECTION (COM1)’/
‘CONNECTION SETTINGS’/‘ADVANCED’ menu. Deactivate
‘Use FIFO buffer’.
• Windows® XP:
Select ‘Port settings’ from connections Port (Com 1)/’START’/
’SETTING’/’SYSTEM’/‘HARDWARE’/‘DEVICE MANAGER’/
’PORTS (COM and LPT)’/‘COMMUNICATION PORT
(COM1)’/‘PORT SETTING’/‘ADVANCED’ menu. Deactivate
‘Use FIFO buffer’.

Recorders
Duane Muir
Expert in Recorders
Endress+Hauser USA
“The advantages of switching to paperless recorders”
“Today, maintenance of strip chart These devices are maintenance free. So in Contents
recorders is considered (too) high. The need the next pages we focus on advice for better
for many consumables (paper and pens) and operation. Basics 84
the fact that data isn’t stored electronically FAQ 86
are big inconveniences in the process Nevertheless paper recorders still
world. constitute a pretty big part of the market.
Endress+Hauser will keep providing
This is why electronic (paperless) recorders consumables for its recorders.
have rapidly become very ‘popular’.
Whereas the first generation stored the data As experts, we also offer training sessions,
on diskettes, the new range uses Compact in classroom and on-site. We would be glad
Flash or Secure Digital cards for even more to meet with you and help you go one step
reliability and storage capacity. further. See ‘Training’ in the section ‘At
your service’.”

Basics
Recorders
Information common to any type

of modern recorders
The current Endress+Hauser range of recorders includes:
• Ecograph RSG20/22/24 and Ecograph T RSG30 multi-channel
electronic (paperless) recorders
• Memograph S RSG10/12 and Memograph M RSG40, system
compatible data managers with a unique safety concept for critical
applications. Compliant to the high FDA requirements laid down in
the 21 CFR Part 11
Measuring principle • Display of historical data 21 CFR 11 the device to put the device into
and main features on-site • Memograph M and S together service/configure it via PC.
• Display of statistics with ReadWin® 2000 You can also download the
The electronic recorders carry • Various display modes fulfill the requirements latest software version directly
out the electronic acquisition, of 21 CFR 11 concerning from the internet under the
display, recording, analysis, Memory (Fig. 1) electronic documents and following address:
remote transmission and • Redundant memory electronic signature www.readwin2000.com
archiving of analog and digital ensures safe data recording: For further information on
input signals. internal Flash memory + CF Installation instructions ReadWin®2000, refer to
(CompactFlash) or SD (Secure the operating manual of the
Communication Digital) cards and USB stick + Outside installation software (BA137R/09).
• Communication interfaces data transfer to a PC The front side seal should be
available: USB, RS232, RS485, Note: Please use the correctly positioned to ensure Advantages of configuration
Ethernet, Profibus DP and original memory cards from watertightness and avoid any via PC:
MODBUS (RSG40) Endress+Hauser, because these problem due to condensation. • The device data is saved in a
are industry proven. And the backside should also be database and can be accessed
Inputs/Outputs protected against humidity. again at any time
• Galvanically isolated universal Analysis/archiving • Text entries can be carried out
inputs (U, I, TC, RTD, and • Long-term archiving is carried Cabling more quickly and efficiently by
frequency) out at the PC, whereby the • Please cable the unit keyboard
• Digital input (high/low) data is transferred to the with care. Many reported • Measured values can also
• Digital output database, via Ethernet or problems come from wrong be read out, archived and
(relay/open collector) serially to the PC connections. We remind you displayed on the PC with this
• Mathematic channels for • Using the supplied PC that the cabling synopsis is program
calculations software package, the devices printed on the rear side of the
can be operated, read-out and recorder. Operations and Maintenance
Display of measured values the measurement data can be • Please use shielded cables
• Electronic recorders are easy archived and visualized Electronic recorders are
to program via the ‘Set up’ Surge arrester maintenance free.
window or from a PC We recommend the use of If your unit includes a floppy
surge arrester(s) (HAW56x disk drive, we recommend that
family) to protect the you clean the disk drive once a
instrumentation against year with a cleaning disk (several
overvoltage. times a year in dusty areas).
Setup Using the ‘screensaver’ mode

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

Recorders
Recorders
• Use the ‘Safely remove USB. Start the provided PC Interface connection
CF/SD/USB’ function (on software. Select ‘Read out
Ecograph T and Memograph -> Read out memory card
M) to ensure safe removal of by interface/modem’. Select
the memory card: all internal the appropriate unit from
access is ended and you the PC data base. Select
receive a message when the ‘Unit -> open unit(s)’. The
card can be safely removed. connection is developed.
Only remove the card using Select the appropriate file on
this function otherwise data the memory card and confirm CompactFlash or SD Secure Digital
can be lost! with ‘OK’. The measured memory card
values are read out. The Figure 2: Data transfer to the PC

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

Recorders
Recorder
MODBUS
MODBUS
Ethernet
Profibus
RS232
RS485
RTU
TCP
USB
DP
Ecograph RSG20 • • •
Ecograph T RSG30 • • • •
Memograph RSG10 • • • •
Memograph S RSG12 • • • •
Memograph M RSG40 • • • • • • •
Table 1: Communication interfaces available
How to start with Readwin® 2000? (see also BA137R) The display of the % of external memory is not correct after
• Create a unit ‘Group/plant’ read out to a PC…
• ‘Unit\Display/Change unit setup/Add new unit\Unit group plant’ The displayed percentage will be refreshed after the first new
memory block is sent to the external memory.
How to insert and configure the unit? (see also BA137R)
• ‘Unit\Display/Change unit setup/Add new unit\Unit\ I have no communication via USB to the recorder…
Add new unit’ • Is the USB driver installed on the PC? You can download the lat-
est version from www.readwin2000.com
How to store and display measured values on the PC? • To install the driver you need ‘admin’ rights on your PC
There are two ways to read out data: • Also take care of the selected communication port: From Windows®,
• Via the Compact Flash card ‘START’/’CONTROL PANEL’/’SYSTEM’/‘HARDWARE/’DEVICE
Click ‘Read out/Read out measured values using PC card drive’ MANAGER’/’PORTS’
then ‘New unit’ and give it a name. Data will then be transferred. From this window, use the port number that corresponds to the
• Via the interface connected communication interface (FXA195 if you are using a
Click ‘Read out/Read out measured values using interface/modem’ HART modem).
then ‘New unit’ and give it a name. Data will then be transferred.
Will the database of measured values be deleted after an
To display the data, click ‘Display/Display measured values from update of Readwin® 2000?
database’ No.
Choose the unit to be displayed, then the data timescale, etc.
Will the configuration and the measured values be deleted
How to export data from Readwin® 2000 to Excel®? after a software update?
• To display the data, click ‘Display/Display measured values from Yes. Please read out and save data before.
database’
Choose the unit to be displayed, then the data timescale, etc. Can the language be changed on the recorder?
• Click ‘Tabular’ at the bottom left of the screen then click on the Yes. Please ask the helpdesk for the right software.
‘Display’ tag at the top left then choose ‘Save table’ (choose .txt
or .xls file format) Can I define different levels of user rights in Readwin® 2000?
Yes: ‘Extras\Program options\Set-up\Security\Password protection’
How long can we store measured values on the external and must be activated
internal memories?
Please refer to the Operating Instructions of your device. The terminals on the back side of the unit are missing…
Only the terminals that correspond to the options you have ordered
are delivered.

Field communication
Brian Howsare
Expert in Digital Communication
Endress+Hauser USA
“An introduction to the maintenance of fieldbus networks”
“The use of digital communication We have issued ‘Guidelines for planning Contents
and fieldbus networks provides lots of and commissioning’ for both Profibus and
advantages in terms of maintenance. Foundation Fieldbus networks. For further Basics 88
details, please refer to BA034S (Profibus) FAQ 90
Digital instrumentation can simultaneously and to BA013S (Foundation Fieldbus). You
exchange data with PLC’s and computers. can download these documents from our Tip: hardware tools
web site. for the maintenance of
Once the instruments have been installed, fieldbus networks 92
their parametrization can be performed As experts, we also offer training sessions,
remotely, from technical premises, a control in classroom and on-site. We would be glad
room, or at any point of the network with a to meet with you and help you go one step
laptop - which is nice in case of hazardous further. See ‘Training’ in the section ‘At
environments or difficult access. your service’.
In case of troubleshooting, the diagnosis

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

Basics
Field communication
Helping you to maintain fieldbus networks
Endress+Hauser’s instrumentation is involved in networks that may combine:

• the HART® protocol
• Profibus® DP/PA architectures
• Foundation™ Fieldbus architectures
HART is a point to point protocol protocol differs -, the ‘low output control commands. The PROFIBUS PA is used at field
(see Fig. 1): a PC talks to a level’ maintenance is identical asset management program, level. The segment coupler
single instrument (or to several in both networks. e.g. FieldCare, serves as a serves both as interface to the
instruments via a multiplexer). Class 2 master. It uses the PROFIBUS-DP system and as
Profibus DP/PA typical acyclic services and serves power supply for the PROFIBUS
Conversely, Foundation Fieldbus architecture (Fig. 2) to parameterize the bus PA field devices. Depending
and Profibus fit for the data participants during installation upon the type of segment
exchange to a programmable The process is controlled by and normal operation. coupler, the PROFIBUS PA
logic controller (PLC) or a a process control system or a segment can be installed in safe
process control system (PCS). programmable logic controller The PROFIBUS DP system or hazardous areas.
(PLC). The control system or is used to handle the
Since Foundation Fieldbus and PLC serves as a Class 1 master. communication at the control Foundation Fieldbus typical
Profibus use the same electric It uses the cyclic services to level. Drives, remote I/Os, etc. architecture (Fig. 3)
signal and encoding - only the acquire measurements and may all be found upon the bus.
It is also possible to connect The Foundation Fieldbus system
externally powered field devices architecture has been designed
to this level, e.g. the flowmeters to promote interoperability
PLC PLC
e.g. e.g.
Promass and Promag. between and among devices of
PROFIBUS DP PROFIBUS DP Ethernet
PROFIBUS DP ensures that data different manufacturers. Since
4-20 mA
HART
4-20 mA
HART
Remote
I/O
PLC + HART
interface is quickly exchanged, whereby Foundation Fieldbus supports
4-20 mA
HART
4-20 mA
HART in mixed PROFIBUS DP/PA both a high speed and low speed
systems the baud rate supported (H1) network, two architectures
HART Multidrop (up to 15 devices)
by the segment coupler is often exist. These provide the same

the limiting factor. basic functionality but differ in
Figure 1: Typical HART architecture
Process operation and PROFIBUS

visualization with P View Visualization Network
master for cyclic
Plant Asset Management process data and Monitoring engineering
with FieldCare communication e.g. P View e.g. ControlCare
Ethernet (I/O) Configurator
PROFIBUS master for
acyclic communication
PROFIBUS DP
e.g.
AS-Interface High Speed Ethernet
Devices from third-party vendors
(Remote I/O, drives, pumps, etc.)
Field Controller/ Field Controller
PROFIBUS PA Gateway
4x 4x
Safe Area FOUNDATION Fieldbus H1 FOUNDATION Fieldbus H1
Hazardous Area
PROFIBUS PA
Figure 2: Typical architecture of a Profibus DP/PA network Figure 3: Standard Foundation Fieldbus architecture

Field communication
the communication stack. The separate terminator must be PLC
H1 layer is IEC 61158-2 based
and the high speed layer uses
used
• T-boxes with switchable
FieldCare A Connection Commubox FXA195
High Speed Ethernet (HSE). terminators may not be used

in explosion hazardous areas.
Installation instructions The terminator requires Commubox 270
Off
On
FXA191/195
the corresponding FISCO Switch Commubox FXA195

EX
Cabling and termination are approval and is a separate A
at the origin of most reported unit.
EX
problems. • For a segment with a tree Transmitter power-
supply unit,
Measured Value
64.50 %
architecture, the bus ends at e.g. RMA422

or RN221N
(with communication
Cabling the device that is the furthest Display and
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HELP SAVE
(optional)
When installing a PROFIBUS from the segment coupler
Page
Up
Bksp Delete
Page
On
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Copy Paste Hot Key
network, particular attention • If the bus is extended by

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FIELD COMMUNICATOR
DXR375
must be paid to the cabling. This the use of a repeater, then DXR375
covers both choice of cabling, the extension must also be

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

Diagnosis of Profibus networks • Did I use the correct GSD* file?
Field communication
• Enable ‘Set unit to bus’ at the device to ensure correct scaling
• Is the decoding correct at the PLC?
If you are facing a problem (be it during commissioning or be it a
troubleshooting) with a device installed in a Profibus network: * The PROFIBUS system requires a description of the device parameters, e.g. output
• First search for addressing errors data, input data, data format and supported transmission rate, so that it can inte-
• Then search for connection problems grate the field devices into the bus system. This data is contained in a PROFIBUS
device description file (GSD file) which is placed at the disposal of the PROFIBUS-DP
• Then check the correct integration of the device in the system master when the communication system is being commissioned. Device bitmaps,
(how data is transferred to the PLC): which appear as symbols in the network tree, can also be integrated. See Chapter
7-2 of BA034S
HART protocol • The bus is terminated by using a separate terminator or a T-

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

No connection between the PLC and the PROFIBUS PA network FieldCare
Field communication
• The bus parameters and baud rate were not set when the PLC
was configured. The baud rate to be set depends upon the seg- FieldCare cannot open connection to the PROFIBUS PA
ment coupler used (Chapter 7-5 of BA034S). devices…
- Pepperl+Fuchs SK1: 93,75 kBit/s FieldCare is a Class 2 master that allows the transmission of acyclic
- Siemens: 45.45 kBit/s values. The PROFIBUS-DP baud rate to be set depends upon the
- PA-link (Siemens IM 153/157): freely selectable segment coupler used.
- Pepperl+Fuchs SK1: 93.75 kBit/s
- Pepperl+Fuchs SK2 and SK3: freely selectable The connection to the devices cannot be opened
• For Pepperl+Fuchs SK2 and SK3, the PROFIBUS PA GSD has not • If the PLC and FieldCare are used in parallel, the bus parameters
been converted must be mutually compatible. The bus parameters must be
• The bus parameters require adjustment identical for all connected masters.
• The polarity of the PROFIBUS-DP line is reversed (A and B)? If FieldCare is used, the Token Rotation Time (TTR) calculated by
• PROFIBUS-DP bus not terminated? the PLC configuration tool must be increased by 20,000 bit times
• Both the beginning and the end of the bus must be terminated and the corresponding value entered in the FieldCare Profibus
configuration and in the PLC.
Data transmission on Profibus networks • The HSA parameter (Highest Station Address) must permit
the FieldCare address. The HSA specifies the highest address
How is data transferred to the PLC? permitted for active participants (masters) on the bus. Slaves can
• The measured values are transmitted in 5 byte long data blocks. have a higher address.
4 bytes are used to transmit the measured value. The fifth • Is the FieldCare address free or is it being used by another device?
byte contains standardized status information. Error codes for • Is the correct baud rate set?
Endress+Hauser device faults, e.g. E 641, are not transmitted • Have the drivers and cards been correctly installed? Is the green
with the status. LED on the TAP of the Proficard or Profiboard lit?
• For limit switches, the information is transmitted in two bytes: • Is the GAP update too high (the result is longer waiting times)?
Signal condition and status information.
A device does not appear in the live list
How can the PLC switch on the positive zero return of the • Device is not connected to segment
Promag 53? Via the output word of the cyclic services. • Address used twice
How can the totalizer of the Promag 53 / Promass 83 be reset? Device cannot be fully operated
Via the output word of the cyclic services for the totalizer in • The device version is not supported by FieldCare. An appropriate
question, see corresponding operating manual. DTM is necessary. The default parameters of the PROFIBUS-PA
profile are offered.
How can I suppress a measured value in cyclic communication?
By using the placeholder «EMPTY_MODULE» or «FREE_PLACE» A change of unit at the device has no effect on the value on
during configuration. the bus
If the measured value at the device display is to be the same as that
How can I write a value to the local display? transmitted to the PLC, the parameters PV_SCALE and OUT_
By using the Display_Value model from the GSD (if supported). SCALE must be matched.
- OUT_SCALE_MIN = PV_SCALE_MIN
General note: You can refer to Chapters 7.2 and 7.3 of BA034S - OUT_SCALE_MAX = PV_SCALE_MAX
(Profibus) for more details. See the device operating instructions.

Tip: hardware tools for the
Field communication
maintenance of fieldbus networks

Commubox FXA191/FXA193 and USB HART interface
Commubox FXA191 is an intrinsically safe interface for Smart

transmitters. It converts INTENSOR and HART protocols to
RS232 signals.
The Commubox FXA191 The USB HART interface makes

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

Power supply Either from RS232 port or external power
pack (accessory)
Electrical connection 9 pin DIN female connector for computer;
0.16” (4 mm) plug terminals for transmitter,
polarity protected, supply (optional): clutch
socket, 9VAC / VDC, polarity protected Typical application of Commubox FXA191: HART connection to a Micropilot
Intrinsic safety [EEX ia] IIC BVS 95.D.2060X for
connection to intrinsically safe circuits
EEx IIC with voltages up to 30V
Operating range -4°F to +122°F (-20°C to +50°C)
Storage -40°F to +185°F (-40°C to +85°C)
Humidity 0% to 95% (no condensation)
Dimensions Housing 5.63” x 2.36” x 1.18” (143 x 60
x 30 mm) with plastic housing for industrial
use
How to order this tool:

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

Field communication
Fieldgate FXA520 - Modem for remote maintenance
Fieldgate FXA520 enables remote monitoring, diagnosis and

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

using remote monitoring, diagnosis
• Worldwide access to • Efficient employment of
and configuration:
measuring points with HART standby and maintenance staff
protocol via the Internet • The Fieldgate FXA520 has
• Simple configuration with standard two channels for
web browsers without HART devices and two chan-
additional software nels for analog inputs 4 to
• Visualization of all sensor data 20 mA (use of multiplexers is
• Remote monitoring, diagnosis possible up to 30 channels)
and configuration • DAT module for configuration
• Uses standard Internet data backup
protocols (http, html)
• Event message via e-mail and
SMS
How to order this tool:

Refer to the price lists in ‘The Maintenance Store’.

At your service
An extended set of tools and services
to efficiently manage your assets
Contents
W@M - Life Cycle

Management for
process automation 96
Commissioning 100
FieldCare ®
101
Field Xpert 102
Calibration services 104
CompuCal™ 107
Maintenance services 108
Installed Base Audit 111
Training 114

At your service
W@M www.us.endress.com/W@M
Life Cycle Management for process automation
Knowledge is a critical factor in driving productivity and Management from Endress+Hauser provides up-to-date and
competitiveness - and full knowledge of your plant status complete information on all your assets, including products
allows for good maintenance planning. W@M – Life Cycle from other suppliers.
Engineering
Reorder Selection
Replacing Configuration
spare parts
Buying
Documentation
management
Procurement
Calibration
Order tracking
Maintenance
Installation
Spare part planning

Configuration
Condition monitoring
Commissioning
Operation
What is W@M – technical and operational management of replacement of individual components,

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

How does W@M support
At your service
your internal processes?
During the procurement phase, W@M helps you check availability

and prices quickly and efficiently – simply place the configured
instrument in the shopping cart and place your order. Immediately,
the status of the order or shipment can be monitored online.
What’s more, the preparation of catalogs and spare parts files makes
ordering as easy as possible. Your orders can be prepared and fully
completed in the Endress+Hauser e-shop.
Operations
• Up-to-date information:
365 days a year / 24 hours a day Engineering
• Effectively service, maintain and • Fast and safe selection and sizing of
optimize your installed base the correct measuring instrument for
• Constant planning reliability your application
• Documentation and administration
of projects
Commissioning
• Simplified remote commissioning
• Increased safety of your personnel
• Eliminate the need for time Procurement
consuming testing • Reduce procurement costs
• Optimize the quality and speed
of your procurement processes
• Your price and delivery data is
always available on-line
Installation
• Product documentation is available in
different languages
• Software versions are always up-to-date
In the commissioning phase, W@M – Life Cycle Management During the operations phase, W@M provides updated and quickly
provides all the information you need for safe installation and available information: be it on spare parts, the verification of
commissioning. You can quickly download documentation, software versions, tracing instrument history records or viewing the
software, or certificates in a variety of different languages. plant database with its installed instruments. Using tools such as
FieldCare, CompuCal, and the Installed Base Assistant, data can be
freely exchanged with the equipment record within W@M. So, you
can safely comply with continually increasing quality requirements
through traceable and certified calibration and documentation.

With the help of tree
At your service
view navigation, any
combination of location
or sub-locations,
applications, loops and
bus systems can be
mapped, allowing W@M
to reproduce the exact
structure of your plant.
Spare parts lists for

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

information recorded and stored by Endress+Hauser
about your instruments, e.g. product availability,
original calibration certificates, operating manual, etc.
In addition to this, you can archive your own

information and documentation related to your assets.
Therefore, W@M is centrally organized information
management for you and your colleagues.
Easy integration into your existing tools

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

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

W@M Portal or W@M Enterprise?
At your service
W@M is available in two versions: W@M Portal and W@M Enterprise. Depending on factors
like IT requirements, security level and internet availability at the plant, you may choose which
IT architecture will provide the optimum solution for the end user.
Endress+Hauser W@M Portal Endress+Hauser W@M Portal
www 128 bit

www 128 bit
Local server W@M
Enterprise
Plant users access W@M via Internet Plant users access W@M via your intranet
W@M Portal features W@M Enterprise features

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

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

At your service
Start-up and commissioning www.us.endress.com/start-up
Optimize your instruments’ performance right from the start
The demands on your engineering and maintenance staff Your main benefits
are higher than ever before. They are expected to be able to • Short start-up times performed by experienced
maintain existing equipment yet still be able to accommodate Service staff
the start-up of new plants often faced with the latest technology • Cost-efficient packages focused on your start-up
and equipment that they are not familiar with. requirements
• Device performance guaranteed from the beginning of
This is where Endress+Hauser can help - our experienced start-up
Service staff can reduce the time to commission to the essential • Briefing and documentation by Endress+Hauser
minimum. That saves time and money. • All test equipment and special tools provided
Not only a start-up - we offer more …

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

to define exact instrument commissioning services required. Standard
settings and confirm Beside the standard components Short Functional Verification of
instrument choice each start-up contains, we offer introduction checks measurement
• All electrical connections are optional services to you for Installation

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

At your service
Commissioning in the Other example Other example
regulated industries demands a high level demands a high level
demands a high level of experience and of experience and
of experience and documentation to documentation to
documentation to ensure that your IQ/OQ ensure that your IQ/OQ
ensure that your IQ/OQ requirements are fulfilled. requirements are fulfilled.
requirements are fulfilled. Our service Engineers are
Our Service Engineers trained in accordance to
are trained in accordance GMP and we can offer
with GMP and we can full validation services as
offer full validation required.
services as required.
FieldCare® www.us.endress.com/fieldcare
From device configuration to plant asset management

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

Field Xpert
High performance device configurator that meets the
needs and requirements of the process industry
Field Xpert Field Xpert offers functions to reduce your By supporting special device functions,
Field Xpert is a compact, flexible, instrument setup and diagnosis time. It e.g. envelope curves from Endress+Hauser
ergonomic and robust industrial PDA operates with HART/BluetoothTM modem time-of-flight level transmitters and
adapted to your needs for high and WLAN supported networks. automatic distribution of Device
productivity. Descriptions (DD) via Internet or WLAN,
Device Xpert Device Xpert ensures quick and flexible
The Field Xpert package includes: Device Xpert configuration software operation.
• Field Xpert device makes Field Xpert the complete HART
• Device Xpert configuration software communicator for industrial applications. Device Xpert supports Endress+Hauser‘s
for all registered HART devices Device Xpert is designed for project Fieldgate FXA520, allowing Ethernet
• HART/BluetoothTM modem for device commissioning and maintenance. It is communication to your remote
connection designed to support the daily requirements HART field devices. Support for
of field technicians. other communication protocols is in
development.
Connection Flexible architecture

The Windows MobileTM operating system
makes it possible to install other software
Ethernet TCP/IP applications for Plant Asset Management
activities such as maintenance and
documentation.
The Endress+Hauser software packages of

Existing
controller the Xpert series run well on Field Xpert.
This makes Field Xpert a real all-rounder
for tough industrial applications.
Fieldgate
FXA520 HART
Multiplexer
4 to 20 mA 4 to 20 mA
Field Xpert with Bluetooth™ connection Field Xpert with WLAN (WiFi™) connection

Field Xpert Device Xpert
Display • Connections
• 3.5” transreflective TFT color Device Xpert supports the use
• 64k, QVGA, 240 x 320 pixel of multiple connections. The
• Portrait and landscape mode user can configure a specific
• Protected by a Makrolon panel serial port and address scan
range appropriate to one
Power Supply scenario and then configure
Rechargeable lithium ion battery another connection to address
• Non-Ex version: 2880 mAh a different requirement. Each
• Ex version: 3600 mAh device is shown in a group
view, so that the correct
Housing parameter is easily found.
• Protection class IP 65 (immersion for brief periods)
• Antistatic
• Non-corroding
Dimensions L x W x D • Device configuration

• 7” x 3.3” x 1.5” (178 x 85 x 39 mm) Every parameter is easy to
find and to configure. If the
Weight location of a specific function
• Non-Ex version: 1.2 lbs. (550 gram) is unknown, the integrated
• Ex version: 1.5 lbs. (700 gram) Function Finder locates it
in all HART devices. This
Temperature ranges is especially useful with
• Storage: 14°F up to 140°F complex devices with many
(-10°C up to +60°C) parameters.
• Charging: 32°F up to 113°F
(0°C up to +45°C)
• Working, non-Ex version: 14°F up to 140°F
(-10°C up to +60°C)
• Working, Ex version: 14°F up to 122°F
(-10°C up to +50°C)
• Device diagnosis
Relative humidity Device Xpert offers the range
• Storage and operation: up to 90% r.h. of diagnosis supported by the
Device Description (DD).
Accessories Basic information such as
• Leather carrying case: 71066838 device status can be seen at a
• USB data transmission set: 71066841 glance, making diagnosis easy.
• Viator Bluetooth interface
for HART: 71066844
• Charger LG10: 71066847
• Spare stylus (2 pcs/pk) 71066850
• Device extensions
Device Xpert interprets DD
extensions, allowing access
to custom functionality that
is normally not available in
a handheld terminal. Such
functions include envelope
curves for Endress+Hauser
level transmitters, valve
signatures for positioner
actuators and custom
calibration routines.

At your service
Calibration services www.us.endress.com/calibration
A complete range of calibration services to suit your requirements
Does the instrumentation that controls your quality critical Endress+Hauser covers all these critical aspects, and can
processes need regular checking, validation and calibration? perform and advise on all aspects of calibration from in-situ
Do you need a cost-effective service that is fast, of high quality, testing to fully accredited factory calibration. We calibrate
traceable and accredited? Do you need clear and concise your equipment at just the right time. This ensures optimal
calibration certificates? process performance at minimum cost.
Calibration Endress+Hauser performs instrument calibrations across a variety

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

1
Calibration
SOPs
2
At your service
Test
Calibration Equipment
specification
2
7 Circle of quality
Calibration
software
calibration Trained
Employees
Calibration
4
1
6 SOPs
5
Calibration Calibration
Documentation Work
Test
Calibration Equipment
specification
3
Endress+Hauser has carried out more than one million calibrations.
Above all we see our calibration service as part of your repair and
maintenance planning. Our aim is to provide you with complete Trained
calibration management solutions. At the forefront of this is
the tuning of calibration cycles, planning dates for carrying out Employees
calibration work, the coordination of personnel and certified
4
calibration equipment.
Calibration specification
Endress+Hauser will help you to establish
1 your metrology plan by fixing your

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

SOPs ensure that our work is repeatable all
over the world. We also provide site specific Trained employees
SOP’s noting which measuring parameters On-site calibration is performed by special,
have to be calibrated on-site and in case of
high accuracy requirements, which need
calibrating in the laboratory.
4 highly trained staff. This relieves your in-
house maintenance staff from routine time
consuming tasks and allows them to focus
on improving plant availability. For you this
means reliable advice, optimum performance
of your instruments and true cost-
effectiveness. Our Service technicians
are trained in accordance with GMP.
Discussion around the metrology plan SOPs, calibration certificates, labels and
electronic recordings

Calibration work
At your service
All of our primary calibration facilities
5
7
operate and are accredited to ISO 17025
and are located around the world. We own
and operate more calibration laboratories
than any other instrumentation supplier.
As a leading supplier of field instrumentation
we not only can calibrate, but also quickly
Calibration and efficiently adjust, repair or replace
equipment that is failing to meet the specified
software criteria. Our specialists have the necessary
skills and equipment to calibrate all makes of
instruments.
6
5
Calibration Calibration
Documentation Work
Calibration management software

CompuCal™ is a high performance
7 scheduling and electronic software tool

that helps to control the scheduling activity Calibration documentation
We support our service with certified and
6
around your installed base, providing
traceable and auditable records. traceable documentation.
A calibration certificate compliant with the
ISO 17025 standard is issued. It details
all required data in a way that is easy to
understand. Importantly, it also satisfies all
relevant authorities.
On-site calibration of temperature On-site calibration of pressure devices Laboratory calibration of level instruments On-site calibration of analysis devices
instruments
We fulfill the needs of all industries:
Oil & gas industries Life sciences industry Food & beverage industries
• On-site flow calibration rigs up to 6” As a compliant partner, we: • Calibration within HACCP requirements
(DN150) • Perform calibration of any kind of process • Calibration management strategies to
• Calibration of all kinds of custody transfer measuring point according to cGMP support production costs concepts
devices regulations and universal guidelines
• Calibration of flowmeters up to 80” • Document any service provided Chemical industries
(DN2000) • Prove traceability by ensuring the • On-site flow calibration rigs up to 6”
conformity to Standard Operating (DN150)
Environmental industry Procedures • Calibration of all kinds of safety relevant
• Calibration of all kinds of measurement • Keep Service staff trained to GxPs. measuring points
equipment • Calibration of flowmeters up to 80”
• Verification of flowmeters (DN2000)
• Calibration of custody transfer instruments
• Calibration of flowmeters up to 80” Renewable fuels industry
(DN2000) • On-site flow calibration rigs up to 6”
(DN150)

CompuCal™
At your service
www.us.endress.com/compucal
Calibration & maintenance management software

CompuCal can be used in
direct connection to W@M
If we consider on-site calibration, the

needs are to schedule the activities,
arrange with the production personnel CompuCal™ and life cycle management
to make the plant available and then CompuCal will dramatically improve
plan the tools and the technician. Once calibration planning, improve the efficiency
the job is done, the user has to edit of your metrology department, reduce the
and archive a calibration certificate. cost of maintenance and at the same time
satisfy the requirements of your auditors.
CompuCal, Endress+Hauser’s calibration CompuCal also provides links to W@M,
management software, is fully able to Endress+Hauser’s life cycle management
handle all these demands. Developed with solution. This connection allows the user
key users and proven in the pharmaceutical access to enhancement possibilities for your
and regulated industries, CompuCal allows installed base.
Compucal™ is high
you to efficiently maintain and calibrate
performance scheduling and
electronic software tools that your on-site instrumentation. According to the serial number of your
helps to control the scheduling equipment in the plant, the link allows the
activity around your installed CompuCal is a fully validated (to 21 CFR user to download the calibration certificate
base providing traceable and
Part 11) solution, used for many years by issued in Endress+Hauser’s laboratories, to
auditable records.
well-known pharmaceutical companies such find out technical information on status of
as Roche, GlaxoSmithkline and Pfizer for the the product, to search for the spare parts list
management of their quality critical devices. with exploded view of the equipment and
even to access the price and delivery time of
spares or a new device, etc.
Special tools
for unique calibration services
Precision calibration
of conductivity
measurement on
ultra-pure water
using ‘Concal®’.
CONCAL calibration set Mobile flow rigs
CONCAL is a conductivity calibration set Traceable to international standards, they
for ultrapure water applications, factory- provide calibration of flowmeters up
‘In-situ’ precision
calibration of flowmeters
calibrated with certificate, traceable to SRM to 4” (DN 100). Available for hygienic
by using mobile flow rigs of NIST and DKD (See full description in applications, they are also suitable for
which are traceable the ‘Analysis/Conductivity’ section). calibration of safe and hazardous areas.
to international Mobile flow rigs allow totalization for tank
standards.
volume calibration.

At your service
Maintenance services www.us.endress.com/contracts
The right maintenance support for all your measuring points
With Endress+Hauser service contracts, you decide the From regular support to partnership agreements, we offer
right level of maintenance support you require. We provide four distinct levels of service:
regular checks on your equipment and warranty extensions
providing you with complete peace of mind and cost control.
Preventive service Extended service Total service Tailor-made service

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

A gradual level of features
At your service
Standard Options
Functional Commissioning* Travel & Spare Wear Consumables Phone Calibration On-site
checks labor parts parts support services response
costs** *** obligation time
Total service • • • • • • • • •
Extended service • • • • • • •
Preventive service • • • • •
* for new instruments entering within the scope of the contract
** for on-site repairs
*** annual change of wear parts for instruments like samplers, automatic pH measurement system…
Within the scope of these contracts, we can take the responsibility to maintain devices from other manufacturers. Please contact your local Endress+Hauser company to evaluate the
technical possibilities.
Special tools
for unique maintenance services
These pocket meters are dust proof and waterproof and Automatic switch-off combined with an energy saving system
can also be submerged. The large clear multifunctional permits continuous operation for up to 3000 hours.
display allows the values to be read safely and comfortably.
CPM280 - pH/ORP measurement CLM280 - conductivity measurement CPM280 - dissolved O2 measurement
Main advantages Main advantages Main advantages

• Easy to use, waterproof • Waterproof • Waterproof
• Simple calibration procedure with • Simplified operation via 5 push-buttons • Simplified operation via 5 push-buttons
automatic buffer recognition • Joint measurement of both conductivity • Ideal for wastewater treatment and the
• ‘Autoread’ function with and temperature fish farming industry
reproducibility better than 0.05 pH • 4-electrode technique • Manual calibration is possible using the
• Simplified 1, 2 or 3-point calibration with Winkler method
automatic buffer recognition Measuring range/accuracy
• Operating period: 3000 h supplied by • Conductivity: 0.0 µS/cm to 500 mS/cm; Measuring range/accuracy
4 x 1.5 V batteries with 5 ranges in AutoRange • O2 Conc.: 0.00 to 9.9 mg/l
(± 0.5% of value) (± 0.5 % of value)
Measuring range/accuracy • 0.00 to 19.99 µS/cm (for K = 0.1cm-1) • 0.0 to 90 mg/l
• pH: -2.00 to +16.00 pH • Temperature: 23°F to 59°F/-5.0 to • 02 Sat.: 0.0 to 199 % (± 0.5 % of value)
(± 0.03 at 59°F to 95°F/15°C to +35°C) +15°C (± 0.1 K) • 0.0 to 600%
• mV: -1999 to +1999 mV • Salinity: 0.00 to 70.0 • Temp.: 23°F to 122°F/-5.0 to +50°C
• Temperature : 23°F to 221°F/-5.0 to • Resistivity: 0.00 to 19.99 MΩ x cm (±0.1 K)
+105°C (± 0.1K) • Reference Temp. 77°F (25°C) • Temperature compensation: 2% at 32°F
• Cell constant: Fixed 0.475 cm-1, 0.1 cm-1 to 104°F (0 to +40°C)

Special tools for unique maintenance services (cont’d)
At your service
Prosonic Flow 92
portable ultrasonic flowmeter
The Prosonic Flow 92 gives you the

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

• Ideally suited for bidirectional measurements • 4” to 160” (DN100 to DN4000)
of pure and slightly soiled liquids (gas • -4°F to +176°F (-20°C to +80°C)
content <1% or solids content < 5%) • Stainless steel sensor holders
• Portable transmitter battery operated • Protection:
• Built-in datalogger with a capacity of Sensor NEMA 4X/IP67
40,000 measuring values BNC adaptor IP52
• Simultaneous logging of volume flow,
flow velocity, totalizer and one external
value (4 to 20mA)
• Site setup operating menus for
straightforward of up to 20 measurement
sites
• Clamp on sensors, non-contact
measurement technique
• Very wide range of nominal diameters ½”
to 160” (DN15 to DN4000), temperature U sensor
range -4°F to +176°F (-20°C to +80°C) • ½” to 4” (DN15 to DN100)
• Data readout software for use with • -4°F to +176°F (-20°C to +80°C)
personal computer • Plastic/aluminum sensor assembly
• Current inputs and outputs (4 to 20mA) • Protection: IP52
Available for short-term rental.

See www.us.endress.com/rental
FieldCheck® smart signal simulator checking procedures, test proper flowmeter

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

At your service
Installed Base Audit www.us.endress.com/IBA
Auditing and analyzing your installed base of process instrumentation
Ask yourself three simple questions: Finding the right balance

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

Target zone:
• Are you sure that your present preventive actions are the most Optimized relationship,
cost effective? minimum cost
With Endress+Hauser’s Installed Base Audit, you will

quickly find an answer to these three questions and move
forward in a controlled manner to a maintenance plan No Too much
which improves plant reliability while reducing costs. maintenance maintenance
Degree of preventative maintenance
ARC studies point out new ways to optimize maintenance costs

Asset Management can reduce unplanned equipment related incidents.
The targets People and process related incidents could be reduced by better
decision support tools found in Asset Management
Installed Base Audit allows you: • To point out your out-of-date

% Total equipment costs
• To make the right decisions plant documentation not

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

How we work with you
At your service
Step 1 - Collecting data Step 2 - Revealing process critical

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

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

Equipped with a dedicated Personal Digital Assistant, the • During a meeting, the Endress+Hauser Advisor
Endress+Hauser Audit Technician collects and records: has the moderator role asking the relevant questions
• Instrument data (serial number, tag, order code, manufacturer, to define the critical point
type and model, location, age, measuring principle, process • Each measuring point is assigned with the criticality level (High,
conditions) Medium, Low)
• Application data (pressure, temperature, medium)
Step 4 - Analysis and

recommendations definition
Consists of: a detailed analysis of your installed base focused on
the maintenance activities you choose in step 3

Involves: the Endress+Hauser consultant

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

At your service
• He defines and presents the global improvement you could bring
to the different areas of your maintenance activities (preventive
and corrective maintenance, standardization, migration)
• He opens your W@M portal (see picture below) - there you
will find the status report and the collected data presented in a
structured manner
Step 3 - Highlighting
potential improvements
Consists of: assessment of the status report giving you an overview
of the status of your installed base with global improvement
recommendations

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

during steps 1 and 2
Step 5 - Presentation of the

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

• Presentation of the detailed analysis and the different possibilities
for each topic to optimize
• Decision points and action plan definition
• Delivery of the final Installed Base Audit report covering all the
detailed analysis and recommendations
At the conclusion of step 5, you are delivered

the final Installed Base Report allowing you to
implement an action plan.
Concerned about constantly improving the quality of our

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

At your service
Training www.us.endress.com/training
Investing in people
Have you recently purchased new instrumentation that is

operated using unfamiliar principles? Do you want to improve
your response times in case of possible measurement failure?
If the answer is ‘yes’, why not improve your technical
knowledge and apply to your maintenance schedule.
Our specialists can provide your maintenance staff with the techni- We provide training for: Training topics include:
cal product knowledge they require to run the plant efficiently and • Engineers and technicians • Theoretical and hands-on
cost-effectively. • Plant operators knowledge
• Maintenance engineers • Installation advice
Training can be performed in-house or on-site. Your maintenance • New recruits, apprentices, • Start-up and maintenance
personnel will benefit from professional, up-to-date and hands-on refresher courses diagnostics
training, using a range of working instruments. • Troubleshooting tips
• Practical exercises using a
The training program will be pre-defined according to your require- range of working instruments
ments and participants will receive supplementary
literature and a certificate of attendance.
Your main benefits
• Learn how to operate and maintain your equipment
efficiently and effectively
• Discover methods for preventive and corrective
planned maintenance
• Increased plant efficiency

Services: reaping the benefits of balance.
In the world of measurement and automation, striking the right services balance is critical. Too little service can lead to costly breakdowns;
too much service results in unnecessary overhead. That’s why Endress+Hauser provides carefully balanced services to suit your individual
needs. Let us help you to find the right balance. www.us.endress.com/services
Endress+Hauser, Inc
2350 Endress Place
inquiry@us.endress.com
The Service: 800-642-8737
Endress+Hauser Maintenance Guide 115
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The information you need at your fingertips.
Information at your fingertips in seconds! Whether you’re planning, procuring, installing and commissioning or operating
a plant, W@M – Life Cycle Management from Endress+Hauser keeps you up to date on the complete installed base of process automation
equipment, even for non-Endress+Hauser products. W@M is designed as an open and flexible information platform with software applications
and services that reduce equipment failure and plant downtime, and minimize repair and maintenance costs, cutting total life cycle costs. Talk
to us today. We’ll be glad to tell you more about how W@M can help improve your business. www.us.endress.com/W@M
Endress+Hauser, Inc
2350 Endress Place
inquiry@us.endress.com Service: 800-642-8737
Three complementary tools to help with everyday problems
• The Maintenance Guide: this fully revised manual is the

reference text for your production, metrology and maintenance
teams. Keep a copy on your desk all year round.
• “Maintenance Today” is a magazine for all instrument users

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

sheets dealing with a specific subject of direct relevance to your
day-to-day operations. Each sheet identifies your option(s) for
immediate action. We publish several sheets each year.
Coming soon: dedicated web pages!
To receive the next issues …
You have this copy already but would like to receive the electronic version (PDF)?
A colleague told you about “Maintenance Today” or “Maintenance Actions”? You’d like a subscription for a colleague?
Fax the coupon below to 317-535-2171.
Company:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tel:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Name:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-mail:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Title:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Please send me:
Department: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . the electronic version (PDF) of Maintenance Today
Mailing Address: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . the paper version Maintenance Actions
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . both The Maintenance Guide
City, State, Zip: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ISO 9001:2000 Certified

11.07/SCUSA
USA Canada Mexico International
Endress+Hauser, Inc. Endress+Hauser Canada Endress+Hauser México S.A. de C.V. For international locations
2350 Endress Place 1075 Sutton Drive Fernando Montes de Oca 21 Edificio A Piso 3 visit: www.endress.com/worldwide
Greenwood, IN 46143 Burlington, ON L7L 5Z8 Fracc. Industrial San Nicolás
Tel: 317-535-7138 Tel: 905-681-9292 54030 Tlalnepantla de Baz
Sales: 888-ENDRESS 800-668-3199 Estado de México
Service: 800-642-8737 Fax: 905-681-9444 México
Fax: 317-535-8498 info@ca.endress.com Tel: +52 55 5321 2080
inquiry@us.endress.com www.ca.endress.com Fax: +52 55 5321 2099
www.us.endress.com eh.mexico@mx.endress.com
www.mx.endress.com
EC 003H/24/ae/07.08
US/INDD CS2

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The Maintenance Guide

Tips and reference information

How to deal with Endress+Hauser 3

Tips & Advice 7 At your service 95

Level measurement 9 - 26 W@M - Life Cycle Management

 The Endress+Hauser Maintenance Guide

Contacts list and links at a glance

• Helpdesk Tel.: 800-642-8737 Option #3 • The W@M portal www.us.endress.com/W@M

• Factory repairs Tel.: 800-642-8737 Option #1 • Plant Asset Management www.us.endress.com/fieldcare

‘The Maintenance Store’: Documentation management

The Endress+Hauser Maintenance Guide 

Total support throughout your plant life cycle

Behind each local organization is also a logistical infrastructure

Our Hotline - Real technical support

You can contact us:*

 The Endress+Hauser Maintenance Guide

To arrange an on-site visit

Factory Repair & Calibration -

Once the ‘Declaration of Decontamination’ is complete, please place it in a

The Maintenance Store - consumables, spare parts and tools

Quick delivery - an essential asset of our worldwide support.

As a complement to this Maintenance

You can also use our online tool:

The Endress+Hauser Maintenance Guide 

A handy collection of information sheets dealing with a specific subject of direct

A magazine for all instrument users and anyone

e-Talkline subscription Online shop

Together with our logistics provider, we supply you with tracking

 The Endress+Hauser Maintenance Guide

Installation Commissioning Operations Migration Re-engineering

Our contribution to your Time spent reading the chapters

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

The Endress+Hauser Maintenance Guide 

 The Endress+Hauser Maintenance Guide

“Installation is the key”

Information common to all types of level measurement devices

read or adjusted. The user is and repeatability of your

calibration for the measurement

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

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

10 The Endress+Hauser Maintenance Guide

test sockets for testing

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

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

The Endress+Hauser Maintenance Guide 11

Measuring principle flange:

depends on proper and received again by the radar

transmitted into the electronics.

mounting position (see Fig. 4) exactly in the middle between

two bolt-holes in the flange) • For optimum measurement,

access to the display and the Select version with 4”

extend below the nozzle,

lbf-ft. (60 to 100 Nm). beam launched

• After mounting, the housing can to simplify access to the

terminal compartment Figure 5: Optimum mounting position FMR231

space) FMR240, FMR244, due to mechanical reasons.

mounting position (see Fig. Note! 1½” BSPT (R 1½”),

6) Please contact Endress+Hauser for 90

• The antenna must be aligned vertically

Figure 6: Installation in a tank - optimum mounting position

FMR245 (see Fig. 8) inside of the stilling well must remain

• After mounting, the housing can

• In the area of the tank connections (~ ±20

The Endress+Hauser Maintenance Guide

The Endress+Hauser Maintenance Guide

The Endress+Hauser Maintenance Guide

The Endress+Hauser Maintenance Guide

The Endress+Hauser Maintenance Guide

The Endress+Hauser Maintenance Guide

The Endress+Hauser Maintenance Guide