Endress + Hauser Operating Instructions Turbimax CUS51D Sensor for turbidity and solids content

BA00461C/07/EN/15.13 71219749 Products Solutions Operating Instructions Turbimax CUS51D Sensor for turbidity and solids content Services About this document Notes on safety icons The structure, signal words and safety colors of the signs comply with the specifications of ANSI Z535.6 ("Product safety information in product manuals, instructions and other collateral materials"). Safety message structure ! DANGER Cause (/consequences) Consequences if safety message is not heeded ‣ Corrective action ! WARNING Cause (/consequences) Consequences if safety message is not heeded ‣ Corrective action ! CAUTION Cause (/consequences) Consequences if safety message is not heeded ‣ Corrective action NOTICE Cause/situation Consequences if safety message is not heeded ‣ Action/note Meaning This symbol alerts you to a dangerous situation. Failure to avoid the situation will result in a fatal or serious injury. This symbol alerts you to a dangerous situation. Failure to avoid the situation can result in a fatal or serious injury. This symbol alerts you to a dangerous situation. Failure to avoid this situation can result in minor or medium injury. This symbol alerts you to situations that can result in damage to property and equipment. Symbols Additional information, tips Permitted or recommended Forbidden or not recommended Endress+Hauser Turbimax CUS51D Table of contents 1 Safety instructions . . . . . . . . . . . . . . . . . . 4 10 Technical Data . . . . . . . . . . . . . . . . . . . . 35 1.1 1.2 1.3 1.4 1.5 Requirements for the personnel . . . . . . . . . . . . . . . 4 Designated use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Workplace safety . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Operational safety . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Product safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 10.1 10.2 10.3 10.4 10.5 Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Performance characteristics . . . . . . . . . . . . . . . . . 36 Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Mechanical construction . . . . . . . . . . . . . . . . . . . . 38 2 Incoming acceptance and product identification . . . . . . . . . . . . . . . . . . . . . . 6 2.1 2.2 2.3 2.4 Incoming acceptance . . . . . . . . . . . . . . . . . . . . . . . . 6 Product identification . . . . . . . . . . . . . . . . . . . . . . . . 6 Scope of delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Certificates and approvals . . . . . . . . . . . . . . . . . . . . 6 3 Installation . . . . . . . . . . . . . . . . . . . . . . . . 7 3.1 3.2 3.3 3.4 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Installation instructions . . . . . . . . . . . . . . . . . . . . . . 8 Installation examples . . . . . . . . . . . . . . . . . . . . . . 10 Post-installation check . . . . . . . . . . . . . . . . . . . . . 14 4 Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 4.1 4.2 Connecting to the transmitter . . . . . . . . . . . . . . . 15 Post-connection check . . . . . . . . . . . . . . . . . . . . . 15 5 Device description . . . . . . . . . . . . . . . . . 16 5.1 5.2 5.3 5.4 5.5 5.6 5.7 Sensor design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Measuring principle . . . . . . . . . . . . . . . . . . . . . . . Measuring methods . . . . . . . . . . . . . . . . . . . . . . . Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Stability criterion . . . . . . . . . . . . . . . . . . . . . . . . . . Cyclic cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Diagnostics and troubleshooting. . . . . 30 7 Maintenance . . . . . . . . . . . . . . . . . . . . . . 31 7.1 Cleaning the sensor . . . . . . . . . . . . . . . . . . . . . . . 31 8 Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 8.1 8.2 Return . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 9 Accessories . . . . . . . . . . . . . . . . . . . . . . . 33 9.1 9.2 9.3 9.4 Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Compressed air cleaning . . . . . . . . . . . . . . . . . . . Transmitter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Endress+Hauser Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 16 16 19 21 23 29 29 33 33 34 34 3 Safety instructions Turbimax CUS51D 1 Safety instructions 1.1 Requirements for the personnel ‣ Installation, commissioning, operation and maintenance of the measuring system must ‣ ‣ ‣ ‣ only be carried out by trained technical personnel. The technical personnel must be authorized by the plant operator to carry out the specified activities. The electrical connection may only be performed by an electrical technician. The technical personnel must have read and understood these Operating Instructions and must follow the instructions they contain. Measuring point faults may only be rectified by authorized and specially trained personnel. Repairs not described in the enclosed Operating Instructions may only be carried out directly at the manufacturer's or by the service organization. 1.2 Designated use CUS51D is a sensor designed to measure the turbidity and solids content of water and wastewater. The sensor is particularly suited for use in the following applications: • Turbidity measurement in the outlet • Suspended solids in the activated sludge basin and in the recirculation • Suspended solids in the sludge treatment • Filterable solids in the outlet Any other use than the one described here compromises the safety of persons and the entire measuring system and is not permitted. The manufacturer is not liable for damage caused by improper or non-designated use. 1.3 Workplace safety As the user, you are responsible for complying with the following safety conditions: • Regulations for explosion protection • Installation instructions • Local standards and regulations Electromagnetic compatibility With regard to electromagnetic compatibility, this device has been tested in accordance with the applicable European standards for industrial applications. The electromagnetic compatibility indicated only applies to a device that has been connected in accordance with the instructions in these Operating Instructions. 1.4 Operational safety ‣ Before commissioning the entire measuring point, make sure all the connections are ‣ ‣ 4 correct. Ensure that electrical cables and hose connections are not damaged. Do not operate damaged products, and safeguard them to ensure that they are not operated inadvertently. Mark the damaged product as defective. If faults cannot be rectified, the products must be taken out of service and secured against unintentional commissioning. Endress+Hauser Turbimax CUS51D Safety instructions 1.5 Product safety The product is designed to meet state-of-the-art safety requirements, has been tested and left the factory in a condition in which it is safe to operate. Relevant regulations and European standards have been observed. Endress+Hauser 5 Incoming acceptance and product identification 2 Turbimax CUS51D Incoming acceptance and product identification 2.1 Incoming acceptance ‣ Make sure the packaging is undamaged! ‣ Inform the supplier about any damage to the packaging. Keep the damaged packaging until the matter has been settled. Make sure the contents are undamaged! Inform the supplier about damage to the contents. Keep the damaged products until the matter has been settled. ‣ Check that the order is complete and agrees with your shipping documents. ‣ The packaging material used to store or to transport the product must provide shock protection and humidity protection. The original packaging offers the best protection. Also, keep to the approved ambient conditions (see "Technical data"). ‣ If you have any questions, please contact your supplier or your local sales center. ‣ ‣ 2.2 Product identification 2.2.1 Nameplate The nameplate contains the following information: • Manufacturer data • Order code • Extended order code • Serial number • Operating conditions • Safety icons Compare the order code on the nameplate with your order. 2.2.2 Identifying the product The order code and serial number of your device can be found in the following locations: • On the nameplate • On the front page of these Operating Instructions • In the delivery papers To find out the version of your device, enter the order code indicated on the nameplate in the search screen at the following address: www.products.endress.com/order-ident 2.3 Scope of delivery The scope of delivery comprises: • 1 sensor Turbimax CUS51D in the ordered version • 1 Operating Instructions BA00461C/07/EN If you have any questions, please contact your supplier or your local sales center. 2.4 Certificates and approvals Declaration of conformity The product meets the requirements of the harmonized European standards. It thus complies with the legal requirements of the EC directives. The manufacturer confirms successful testing of the product by affixing the 4 symbol. 6 Endress+Hauser Turbimax CUS51D Installation 3 Installation 3.1 Dimensions a0013179 Fig. 1: Dimensions See the "Accessories" section for the dimensions of the cleaning unit Endress+Hauser 7 Installation Turbimax CUS51D 3.2 Installation instructions 3.2.1 Measuring system A complete measuring system comprises: • Turbidity sensor Turbimax CUS51D • Transmitter Liquiline • Assembly: – Assembly Flexdip CYA112 and holder system Flexdip CYH112 or – Retractable assembly , e.g. Cleanfit CUA451 3 2 1 4 1 5 a0012965 Fig. 2: 1 2 3 8 Measuring system with immersion assembly (example) Holder system Flexdip CYH112 Transmitter Liquiline Weather protection roof 4 5 Assembly Flexdip CYA112 Turbidity sensor Turbimax CUS51D Endress+Hauser Turbimax CUS51D Installation 3 2 1 4 5 a0013334 Fig. 3: Measuring system with immersion assembly (example) 1 2 3 Transmitter Liquiline Weather protection roof Holder system Flexdip CYH112 1 4 4 5 Assembly Flexdip CYA112 Turbidity sensor Turbimax CUS51D 2 3 a0012964 Fig. 4: 1 2 3 4 Endress+Hauser Measuring system with retractable assembly (example) Turbidity sensor Turbimax CUS51D Transmitter Liquiline Retractable assembly Cleanfit CUA451 Flow direction 9 Installation Turbimax CUS51D 3.3 Installation examples 3.3.1 Immersion operation Fixed installation with wastewater assembly 3 3 2 1 4 4 2 1 1 5 a0013383 Fig. 5: 1 2 3 4 Installation secured on railing Turbidity sensor Turbimax CUS51D Flexdip CYA112 wastewater assembly Flexdip CYH112 holder Railing a0012965 Fig. 6: 1 2 3 4 5 Installation with upright post Flexdip CYH112 holder Multichannel transmitter Liquiline CM44x Weather protection cover Flexdip CYA112 wastewater assembly Turbidity sensor Turbimax CUS51D This type of installation is particularly suitable for strong or turbulent flow (>0.5 m/s (1.6 ft/ s)) in the basin or channels. 10 Endress+Hauser Turbimax CUS51D Installation Installation with chain retainer 3 3 2 1 2 4 4 1 1 4 5 a0013384 Fig. 7: 1 2 3 4 Chain retainer on railing Flexdip CYA112 wastewater assembly with Turbimax CUS51D turbidity sensor Chain Flexdip CYH112 holder Railing a0013386 Fig. 8: 1 2 3 4 5 Chain retainer on upright post Flexdip CYH112 holder Multichannel transmitter Liquiline CM44x Weather protection cover Flexdip CYA112 wastewater assembly Turbidity sensor Turbimax CUS51D The chain retainer is particularly suitable for applications that require a sufficient distance between the mounting location and the edge of the aeration basin. As the assembly is freely suspended, any vibration of the upright post is practically ruled out. The swinging movement of the chain retainer enhances the self-cleaning effect of the optical window. Endress+Hauser 11 Installation Turbimax CUS51D Cleaning unit a0013259 Fig. 9: Turbimax CUS51D sensor with cleaning unit The cleaning unit is particularly suitable for clear water and media containing fats/oils that tend to cause heavy buildup. Mount the cleaning unit as follows: 1. Fit the cleaning unit onto the sensor as far as it will go. 2. Locate the two LEDs (they are installed at an angle and have a bright enclosure). 3. Position the cleaning unit in such a way that the nozzle is located at the side of the two LEDs (see  å 10). 4. Fix the cleaning unit in place with the securing screw (max. torque: 0.5 Nm (0.37 lbf ft)). 5. Insert the compressed air hose of the compressor into the hose connection. 1 1 1 2 2 a0013410 Fig. 10: 1 2 12 Aligning the cleaning unit LEDs Nozzle a0013411 Fig. 11: 1 2 Fixing the cleaning unit Hose connection Securing screw Endress+Hauser Turbimax CUS51D Installation 3.3.2 Pipe installation Arrow 1 shows the flow direction. The installation angle  must not exceed 90°. The recommended installation angle is 75°. The optical windows of the sensor have to be aligned parallel to the flow direction ( = 90°) or face the flow direction ( < 90°). For manual insertion/retraction of the assembly the medium pressure may not exceed 2 bar (29 psi). a0013009 Fig. 12: Installation with retractable assembly The installation angle is 90°. Turbidity measurement < 200 FNU will result in erroneous measuring results due to backscattering of pipe wall. a0015169 Fig. 13: Endress+Hauser Installation with flow assembly CYA251 13 Installation Turbimax CUS51D The following figure illustrates various installation positions in pipes and indicates whether they are permitted or not. 3 3 5 4 1 2 2 a0013011 Fig. 14: Orientation and installation positions (with retractable assembly CUA451) • The pipeline diameter must be at least 100 mm (4") if reflective materials (e.g. stainless steel) are used. An on-site calibration is recommended. • Install the sensor in places with uniform flow conditions. • The best installation location is in the ascending pipe (it. 1). Installation is also possible in the horizontal pipe (it. 5). • Do not install the sensor in places where air may collect or foam bubbles form (it. 3) or where suspended particles may settle (it. 2). • Avoid installation in the down pipe (it. 4). • Turbidity measurement < 200 FNU will result in erroneous measuring results due to backscattering of pipe wall. Therefore a multipoint calibration is recommended. • Avoid installations behind pressure reduction steps which can outgas. 3.4 Post-installation check ‣ Sensor and cable undamaged? ‣ Cap undamaged? ‣ Compliance with permissible sensor installation position? ‣ Is the sensor installed in an assembly and is not suspended from the cable? ‣ Avoid moisture by rain by putting the protective cap on the assembly? 14 Endress+Hauser Turbimax CUS51D Wiring 4 ! Wiring WARNING Device is energized Improper connection can cause injury or death. ‣ The electrical connection must only be carried out by a certified electrician. ‣ Technical personnel must have read and understood the instructions in this manual and must adhere to them. ‣ Prior to beginning any wiring work, make sure voltage is not applied to any of the cables. 4.1 Connecting to the transmitter The sensor will be connected to the transmitter as follows: • With the M12 plug (version: fixed cable, M12 plug) or • With the fixed cable connected to the terminal strips (version: fixed cable, end sleeves): a0012460 Fig. 15: Sensor connection The maximum cable length is 100 m (328 ft). 4.2 Post-connection check Instrument status and specifications Remarks Are the sensor, assembly, junction box or cable damaged? Visual inspection Electrical connection Remarks Does the supply voltage of the transmitter match the specifications on the nameplate? Are the installed cables strain-relieved and not twisted ? Is the cable type route completely isolated ? Power cable/weak current cable Are the power supply and signal cable correctly connected to the transmitter ? Use the connection diagram of the transmitter. Long enough length of cable core stripped and correct in terminal? Check seating (pull slightly) Are all the screws terminals properly tightened ? Tighten Are all the cable entries installed, tightened and sealed ? For cable entries lateral: cable loops downwards for water to be able to drip off. Are all the cable entries installed downwards or lateral ? Endress+Hauser 15 Device description Turbimax CUS51D 5 Device description 5.1 Sensor design The sensor is designed for the continuous in-situ measurement of turbidity and solids content. The sensor is designed as a 40 mm sensor that can be operated directly and completely in the process without the need for further sampling (in situ). All the necessary modules are contained in the sensor: • Power supply • Light sources • Detectors detect the measuring signals, digitize them and process them to form a measured value. • The sensor microcontroller is responsible for controlling the internal processes and transmitting the data. All the data - including the calibration data - are stored in the sensor. The sensor can thus be precalibrated and used at a measuring point, calibrated externally, or used for several measuring points with different calibrations. 5.2 Measuring principle For turbidity measurement a light beam is sent through the medium and is diverted from its original direction by optically denser particles, e.g. solid matter particles. This process is also called scattering. 1 2 3 4 3 Light source Light beam particle Scattered light 2 4 1 4 4 a0013159 Fig. 16: Deflection of the light The impinging light will be scattered in different angles. Two angles are of interest in this matter: • The scattered light in the 90° direction is less influenced by the size of the particles. • The scattered light in the 135° direction gives enough information also at a high number of particles. 16 Endress+Hauser Turbimax CUS51D Device description 135° 1 2 90° 3 a0012986 Fig. 17: 1 2 3 Principle operating mode of the turbidity sensor Light source 135° light receiver 90° light receiver If only a small number of particles is in the medium, most of the light will be scattered to the 90° channel and less light will be scattered to the 135° channel. When the number of particles increases the relationship will change (more light scattered to the 135° channel, less light scattered to the 90°channel). Ir 1 135° 90° FNU a0013158 Fig. 18: Ir Endress+Hauser Signal distribution depending on the number of particles Relative intensity 17 Device description Turbimax CUS51D The turbidity sensor CUS51D is equipped with two independent sensor units that are arranged in parallel. The application-specific analysis of both signals results in stable measured values. 4 6 5 3 1 2 a0012966 Fig. 19: 1,2 3,5 4,6 Arrangement of the light souces and the light receivers Light sources 1 and 2 135° light receivers 90° light receivers This allows the optimal turbidity and suspended solids measurement: • For low turbidity values preferably the 90° channel is used. • For average and high turbidity values and for suspended solids measurement the 135° channel is used. • The dual sensor technology allows operation with a large range of soiling compensation, e.g. suspended solids measurement in the activated sludge basin (basis: four-beam pulsed light). Based on the chosen application the appropriate model is used automatically inside the sensor. The available sensor types differ in their measuring ranges and therefore in the selection of the available applications. 18 Endress+Hauser Turbimax CUS51D Device description 5.3 Measuring methods Four-beam pulsed light method The method is based on two light sources and four light receivers. Long-life LEDs are used as monochromatic light sources. To eliminate interference from extraneous light sources, these LEDs are pulsed. Two measuring signals are detected at the four light receivers. The eight measuring signals are processed in the sensor and are converted into turbidity units and solids concentrations. The four-beam pulsed light method compensates the sensor soiling as well as the wearing of the optical components. The number of the used signals depends on the application. S1 E1-135 E1-90 S2 E2-135 E2-90 a0012987 Fig. 20: Four-beam pulsed light method S1 S2Light sources E9090° channel light-receiver E135135° channel light-receiver 90° scattered light method The measurement uses a wavelength of 860 nm like described in ISO 7027 / EN 27027. The transmitted light beam is scattered by the solid matter particles in the medium. The scattered beams are detected by scattered light receivers which are arranged at an angle of 90 ° to the light sources. The turbidity of the medium is determined by the amount of the scattered light. S = Light source E = Light receiver P = Particle E P a S a0013168 Fig. 21: Endress+Hauser Principle of the 90° scattered light method 19 Device description Turbimax CUS51D 135° backscattered light method The transmitted light beam is scattered by the solid matter particles in the medium. The backscattered beams are detected by scattered light receivers, which are arranged next to the light sources. The turbidity of the medium is determined by the amount of backscattered light. This method is used to measure high turbidity values. I0 = Intensity of transmitted light IS = Intensity of backscattered light A = Geometric factor C = Concentration P = Particle f() = Angle dependence Is = I0 · C · A · f(a) IS E1 a P I0 S1 a0013304 Fig. 22: 20 Principle of backscattered light method Endress+Hauser Turbimax CUS51D Device description 5.4 Application The sensor enables measurement in a variety of ways that are adapted to suit the specific measurement problems. The method is set by the choice of application and the reference model. Application type "Clear water" Application Method Measuring range Formazine 135° turbidity, single channel 0 to 4000 FNU Display range up to 9999 FNU Kaolin 135° turbidity, single channel 0 to 5 g/l TiO2 (titanium oxide) 4-beam pulsed light, 135° 0 to 150 g/l SiO2 (silicon dioxide) 4-beam pulsed light, 135° 5 to 100 g/l a0020168-en Application type "Solids" Application Method Measuring range Thin sludge 135° turbidity, single channel 0 to 5 g/l Sludge activation 4-beam pulsed light, 90° 2 to 15 g/l Return sludge 4-beam pulsed light, 135° 3 to 50 g/l Digested sludge / ooze 135° turbidity, single channel 5 to 100 g/l / 300 g/l a0020169-en Endress+Hauser 21 Device description Turbimax CUS51D Application areas Model name Application Unit Compensation * Formazine Process water, sewage treatment plant outlet FTU / FNU Kaolin Filterable solids, process water, sewage treatment plant outlet, activated sludge in low concentration mg/l ; g/l; ppm; % SiO2 SiO2, mineralic solids (sands) g/l; ppm; % X TiO2 TiO2, (white medium) g/l; ppm; % X Thin sludge From activated sludge down to clear water g/l; ppm; % Activated sludge Activated sludge basin and comparable medium g/l; ppm; % X Excess sludge Excess sludge, primary sludge, thickened sludge g/l; ppm; % X Digested sludge Digested sludge, black - homogeneous g/l; ppm; % * compensation of contamination with four-beam pulsed light Detailed information about application areas are described in the following section "Calibration". 22 Endress+Hauser Turbimax CUS51D Device description 5.5 Calibration The sensor is precalibrated on leaving the factory. As such, it can be used in a wide range of applications (e.g. clear water measurement) without the need for additional calibration. The factory calibrations are based on "three-point calibration". The kaolin and formazine applications are already fully calibrated and can be used without further calibration. All other applications are pre-calibrated with reference samples and need to be calibrated to the appropriate application. In addition to the factory calibration data, which cannot be modified, the sensor has five other data records to be used for storing process calibrations. 5.5.1 Selecting the application On the CM44x, select the appropriate application for your field of application during initial commissioning. This application can be adopted during calibration or can be reselected by you. Wastewater treatment plant inlet (X) (X) Digested sludge (g/l, % of TS) Waste activated sludge (WAS) (g/l, % of TS) Sludge activation (mg/l, g/l) Diluted sludge (mg/l, g/l) Kaolin (mg/l, g/l) Turbidity (formazine, FTU) Wastewater application X Primary sludge extraction, primary clarification X Aeration basin, range 0 - 5 g/l, e.g. SBR (X) X Aeration basin, range 2 - 15 g/l X (X) Recirculation line X Waste activated sludge extraction X X Sludge thickener (primary sludge) X (X) Digester inlet X (X) Digester outlet (sludge) (X) X Wastewater treatment plant outlet X Sand filter control X X (X) X Depending on the arrangement of the facility, individual measuring points can be declared as Ex zones. Endress+Hauser 23 Device description Turbimax CUS51D X X X X X (X) Sedimentation tank X Process water X X X X Process sludges X X X X 5.5.2 Digested sludge (g/l, % of TS) Filter rinsing X Waste activated sludge (WAS) (g/l, % of TS) Process control Dilute sludge (mg/l, g/l) X TiO2 (ppm, g/l) X SiO2 (ppm, g/l) Kaolin (mg/l, g/l) Inlet Turbidity (formazine, FTU) Process water application Choosing the type of calibration 1 to 5 points can be calibrated for all applications. The following recommendation describes the common types of calibration. Model Single-point calibration (in the medium) Formazine X Kaolin X Two-point or multipoint (outside the medium) SiO2 X TiO2 X Dilute sludge X Activated sludge X Waste activated sludge (WAS) X Digested sludge X With the "dilute sludge" model, measurements can be carried out in the aeration basin up to approx. 5 g/l. This model has the advantage of being able to be calibrated at a single point in the process during operation. 24 Endress+Hauser Turbimax CUS51D Device description Effects of the various types of calibration Signal Factory calibration New calibration curve Calibration point Signal Factory calibration New calibration curve Calibration point 0 0 0 2 4 6 8 0 Suspended solids (g/l) 4 2 6 Suspended solids (g/l) a0020210-en Fig. 23: 8 Single-point calibration a0020211-en Fig. 24: Single-point calibration causes a change in the slope. Two-point calibration Two-point calibration causes a change in the slope and the zero point. This type of calibration is used if the measured value changes across a wide range. Factory calibration New calibration curve Calibration point Factory calibration New calibration curve Calibration point Δ4 Signal Signal Δ5 Δ2 Δ3 Δ1 0 0 0 2 4 6 8 0 Suspended solids (g/l) 2 6 8 Suspended solids (g/l) a0020213-en Fig. 25: 4 Three-point calibration With three-point calibration, a new calibration curve is drawn through all three calibration points. This leads to higher accuracy in the calibrated range. a0020214-en Fig. 26: Five-point calibration With four- or five-point calibration, the calibration curve between the calibration points is determined. This leads to better alignment with the selected calibration points; however, it does not improve accuracy. Single-point and two-point calibration are based on the data record stored internally in the device. Calibration at three or more points always causes the measuring curve to be recalculated. With multipoint calibration, the calibration points must always cover the complete measuring range of the application. Furthermore, no points outside the specified measuring range of the application may be selected. In this way, a calibration with zero water (0 g/l) usually results in unusable calibrations for the following applications: •Activated sludge •Waste activated sludge (WAS) •Digested sludge •SiO2 Endress+Hauser 25 Device description Turbimax CUS51D 5.5.3 Single-point calibration With single-point calibration, the sensor can remain immersed in the process medium. Proceed as follows: 1. Remove a sample of the medium in close proximity to the sensor for the laboratory measurement. 2. Send the sample to the laboratory to measure the turbidity or solids content. 3. Select a data record in the CM44x transmitter. 4. Start the calibration as simultaneously as possible to the sampling and enter the laboratory value of the sample as the set point. If there is no laboratory value available during calibration, enter an approximate value as the set point. As soon as the laboratory value is available, you can edit the set point on the transmitter retrospectively. 5.5.4 ! Multipoint calibration CAUTION Risk of injury due to acid or medium ‣ Switch off the cleaning unit before removing the sensor from the medium. Sample preparation: 1. Remove a sample from the process (e.g. 10 liters - bucket). a0020482 a0020483 a0020484 a0020485 2. Wait until the sludge parts have settled. 3. Remove the residual water (if possible). You now have a sample with an increased concentration. Stir the sample to increase the homogeneity. 4. Remove part of the sample for analysis in the laboratory. 5. Add a defined part of the sample (e.g. 2 liters) to the calibration vessel (black bucket) Stir the sample again to maintain the homogeneity. a0020486 26 Endress+Hauser Turbimax CUS51D Device description Preparing the CUS51D sensor for calibration: 1. Clean the optical components (windows) of the sensor with water and a brush. 2. Put the sensor into the calibration vessel. When doing this, observe the following instructions. • Do not immerse the sensor vertically into the sample. Immerse the sensor at an angle. By doing this, you will prevent air bubbles building up around the windows. a0020487 Fig. 27: Immersing the sensor • The LEDs on the sensor should be directed towards the middle of the calibration vessel. • The minimum clearance between the sensor and the wall of the vessel is 10 mm (0.4 inches). • The distance to the floor of the vessel should be as large as possible, but at the same time, the sensor must be immersed at least 10 mm (0.4 inches). a0020448 Fig. 28: 1 2 Positioning the sensor Beam direction of the LEDs LEDs • Fix the sensor in this position (ideally with a laboratory stand). During calibration, make sure the medium is as homogeneous as possible. A magnetic stirrer would be the best solution. Endress+Hauser 27 Device description Turbimax CUS51D During calibration, note the following points: • The calibration points should cover the complete measuring range. • Be extremely careful when determining the laboratory measured value (the quality of the laboratory measurement has a direct impact on the accuracy of the sensor). • Use a graduated cylinder to measure the volumes for the sample and the dilution water with the highest possible accuracy. • Air bubbles on the optical components distort the calibration result significantly and must therefore be removed before each calibration. • Ensure that the medium is always well mixed (homogeneity). • Avoid changes in temperature during calibration, and make sure the dilution water and the medium are the same temperature, as far as possible. • The position of the sensor should not be changed during calibration. • The calibration set points can also be edited retrospectively in the CM44x (e.g. if the reference value of the laboratory measurement is not known at the time of calibration). Carrying out a calibration (example of a three-point calibration): 1. Select a data record in the CM44x transmitter. 2. Wait for at least one minute (for stabilization). 3. Start the calibration for measuring point 1 (example: 2 l sample with a concentration of 6 g/l). Enter the value of the sample determined in the laboratory as the set point (example: 6 g/l) or adopt the suggested value and adapt it later to the laboratory value. 4. Dilute the sample to a ratio of 1:2 (add 2 l water to produce 3 g/l in the example) H 2O 5. Avoid the build-up of air bubbles under the sensor. 6. Calibrate measuring point 2. Enter half of the laboratory value as the set point or edit the value later. 7. Dilute the sample to a ratio of 1:3 (add 2 l water to produce 2 g/l in the example) H 2O 8. Avoid the build-up of air bubbles under the sensor. 9. Calibrate measuring point 3. Enter a third of the laboratory value as the set point or edit the value later. You can also carry out the calibration in increasing concentrations (less advisable). 28 Endress+Hauser Turbimax CUS51D Device description 5.6 Stability criterion During the calibration process, the measured values returned by the sensor are checked to ensure they remain constant. The stability criterion defines the maximum amount the measured values may deviate during calibration and still be accepted. The data comprise: • The maximum permissible deviation in temperature measurement • The maximum permissible deviation in the measured value in % • The minimum timeframe in which these values must be maintained As soon as the stability criteria for the signal values and the temperature are reached, the calibration is continued. If these criteria are not fulfilled within the maximum time frame of 5 minutes, no calibration takes place, and a warning is displayed. The stability criteria monitor the quality of the individual calibration points in the course of the calibration. The aim is to achieve the best possible calibration quality in a short timeframe while taking external conditions into account. For calibrations in the field under tough weather and environmental conditions, the measured value windows selected can be large and the timeframe short. 5.7 Cyclic cleaning Compressed air is most suitable for cyclic cleaning. The optional cleaning unit is either ready-supplied or can be retrofitted, and is fitted on the sensor head. It operates at a rate of 50 l/min (13.2 US gal/min) The following settings are recommended for the cleaning unit: Type of fouling Endress+Hauser Cleaning interval Cleaning duration Severe fouling with rapid buildup 5 min 10 s Low degree of fouling 10 min 10 s 29 Diagnostics and troubleshooting Turbimax CUS51D 6 Diagnostics and troubleshooting Troubleshooting must take account of the whole measuring system: • Transmitter • Electrical leads and connectors • Assembly • Sensor The possible causes of failure listed in the following table primarily refer to the sensor. Problem Check Remedy No display, no sensor reaction Mains voltage at transmitter? Sensor connected correctly? Film formation on optical windows? Connect mains voltage. Set up correct connection. Clean the sensor. Reading too high or too low Film formation on optical windows? Sensor calibrated? Clean the sensor. Calibrate. Reading greatly fluctuating Check mounting location. Select other mounting location. Please pay special attention to the instructions on handling errors in the Operating Instructions of the transmitter. Check the transmitter, if necessary. 30 Endress+Hauser Turbimax CUS51D Maintenance 7 Maintenance You have to perform maintenance tasks at regular intervals. We recommend setting the maintenance times in advance in an operations journal or log. The maintenance cycle primarily depends on the system, the installation conditions and the medium in which measurement takes place. ! CAUTION Risk of injury caused by acid or medium ‣ Switch off the cleaning unit before removing the sensor from the medium. 7.1 Cleaning the sensor Sensor fouling can affect the measurement results and even cause a malfunction. The sensor must be cleaned at regular intervals to ensure reliable measurement results. The frequency and intensity of the cleaning process depends on the medium. Clean the sensor: • As specified in the maintenance schedule • Before every calibration • Before returning the sensor for repair Type of fouling Cleaning measure Lime deposits Immerse the sensor in 1-5 % hydrochloric acid (for a few minutes). Dirt particles on the optical windows Use a cloth to clean the optical windows. You must rinse the sensor thoroughly with water after cleaning. Endress+Hauser 31 Repair Turbimax CUS51D 8 Repair 8.1 Return The device must be returned if repairs or a factory calibration are required, or if the wrong device has been ordered or delivered. According to legal regulations, Endress+Hauser, as an ISO-certified company, is required to follow certain procedures when handling returned products that are in contact with medium. To ensure swift, safe and professional device returns, please read the return procedures and conditions on the internet site: www.services.endress.com/return-material 8.2 Disposal The device contains electronic components and must therefore be disposed of in accordance with regulations on the disposal of electronic waste. Please observe local regulations. 32 Endress+Hauser Turbimax CUS51D Accessories 9 Accessories 9.1 Assemblies Wastewater assembly Flexdip CYA112 • Modular assembly system for sensors in open basins, channels and tanks • Versions in stainless steel or PVC • Ordering per product structure (--> Online configurator: www.products.endress.com/ cya112) • Technical Information TI00432C/07/EN Retractable assembly Cleanfit CUA451 • Retractable assembly with ball valve; for turbidity sensors; material: stainless steel • Ordering per product structure (--> Online configurator, www.products.endress.com/ cua451) • Technical Information TI00369C/07/EN Flow assembly Flowfit CYA251 • Connection: see product structure • Material: PVC-U • Order as per product structure 9.2 Holder Holder system Flexdip CYH112 for water and wastewater assembly CYA112 • Modular holder system for sensors and assemblies in open basins, channels and tanks • The holder system CYH112 works for nearly any type of fixing - fixing on the floor, wall or directly on a rail. • Material: stainless steel • Ordering acc. to product structure (--> Online configurator: www.products.endress.com/ cyh112) • Technical Information TI00430C/07/EN Endress+Hauser 33 Accessories Turbimax CUS51D 9.3 Compressed air cleaning Cleaning system with pressurized air • Connection: 6 or 8 mm (metric) or 6.35 mm (¼") • Materials: POM/V4A • 6/8 mm order number: 71110782 • 6.35 mm (¼") order number: 71110783 B 17.8 (0.70) 72 (2.83) Ø 40.1 (1.58) Ø 50 (1.97) mm (inch) 48 (1.89) 11.5 (0.45) 77.3 (3.04) 17.8 (0.70) 65.8 (2.59) A a0013261 Fig. 29: A B Cleaning system Version 6 mm Version 6.35 mm (¼") Compressor • For cleaning system • 230 V AC order number: 71072583 • 115 V AC order number: 71194623 9.4 Transmitter Liquiline CM442/CM444/CM448 • Multiple-channel transmitter for the connection of digital sensors with Memosens technology • Power supply: 100 to 230 V AC, 24 V AC/DC • Universally upgradeable • SD card slot • Alarm relay • IP 66, IP67, NEMA 4X • Ordering per product structure (--> Online configurator on product page) 34 Endress+Hauser Turbimax CUS51D Technical Data 10 Technical Data 10.1 Input Measured variable Turbidity Solids content Temperature Measuring range CUS51D-**C1 Turbidity Solids content Temperature CUS51D-**D1 Turbidity Solids content Temperature 0 to 4000 FNU display range up to 9999 FNU 0 to 4 g/l -20 to +80 °C (-4 to +176 °F) 0 to 4000 FNU display range up to 9999 FNU 0 to 300 g/l 0 to 30 % -20 to +80 °C (-4 to +176 °F) Application Formazine Kaolin, filterable solids Formazine Solids content according to chosen application (see list) Measuring range of solids content: For solids the achievable measuring ranges are depending of the actual medium and can deviate from the recommended operating ranges. Nonhomogeneous media produce fluctuations in measured values and restrict the measuring range. Endress+Hauser 35 Technical Data Turbimax CUS51D 10.2 Maximum measured error Performance characteristics Turbidity Solids < 2% of the measured value or 0.1 FNU (the respectively larger value is valid) < 5 % of the measured value or 1 % of full scale ( the respectively larger value is valid); valid for sensors in the calibrated measuring range Wavelength 860 ± 30 nm Applications The sensor is factory calibrated in the application "formazine" and hereof derived for "kaolin filterable solids)". Further precalibrated applications are optimized for the corresponding medium. The calibration can be performed up to 5 points. Application water Recommended working ranges CUS51DC1 D1 Factory calibration formazine 0 to 4000 FNU X X Factory calibration kaolin 0 to 4 g/l X X Application SiO2 5 to 100 g/l X Application titanium dioxide 0.2 to 150 g/l X a0020168-en Application wastewater 36 Recommended working ranges CUS51DC1 D1 Application thin sludge 0 to 5 g/l X Application activated sludge 0.5 to 15 g/l X Application excess sludge 3 to 50 g/l X Application digested sludge / ooze 5 to 100 g/l / 300 g/l X Endress+Hauser Turbimax CUS51D Technical Data a0020169-en For solids the achievable measuring ranges are depending of the actual medium and can deviate from the recommended operating ranges. Factory calibration FNU, FTU and solids concentration according to the application table Standard: 3 points Drift Thanks to electronic control the sensor works drift compensated in a wide range. Limit of detection Application Formazine Kaolin 10.3 Measuring range Limit of detection 0 to 50 FNU 0.006 FNU 0 to 9999 FNU 0.4 FNU 0 to 4000 mg/l 0.85 mg/l Environment Ambient temperature range -20 to 60 °C (-4 to 140 °F) Storage temperature -20 to 70 °C (-4 to 158 °F) Ingress protection IP 68 (test conditions: 1 m (3.3 ft) water column during 60 days, 1 mol/l KCl) 10.4 Process Process temperature -5 to 50 °C (23 to 120 °F) max. 80 °C (175 °F) short term(1 h) Process pressure 0.5 to 10 bar (7 to 145 psi) absolute Minimum flow No minimum flow required. Make sure that there is a sufficient turbulence for solids with a tendency to sedimentation. Endress+Hauser 37 Technical Data Turbimax CUS51D 10.5 Mechanical construction Dimensions See "Installation conditions" Weight approx. 0.7 kg (1.5 lbs) without cable Materials Sensor Optical windows O-rings Process connections 38 Stainless steel 1.4404 (AISI 316 L) or Stainless steel 1.4571 (AISI 316 L) Sapphire EPDM G1 and NPT ¾'' Endress+Hauser Turbimax CUS51D Index A Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ambient temperature range . . . . . . . . . . . . . . . . . . . . . . Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 37 21 36 33 C Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Multipoint. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Single point. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Checking Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Compressed air cleaning. . . . . . . . . . . . . . . . . . . . . . . 29, 34 Connection Transmitter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 D Declaration of conformity. . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Designated use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Disposal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Drift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 E Electromagnetic compatibility . . . . . . . . . . . . . . . . . . . . . . . 4 F Factory calibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 H Holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 I Identifying the product . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Immersion operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Incoming acceptance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Ingress protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Input Measured variable . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Measuring range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–8 Installation examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 N Nameplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 O Operational safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 P Pipe installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Post-connection check . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Process calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Process connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Process pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Process temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Product identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Product safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 R Requirements for the personnel . . . . . . . . . . . . . . . . . . . . . 4 Return . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 S Scope of delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Sensor design. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Single-point calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Stability criterion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Storage temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 T Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Transmitter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Transmitter connection . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 U Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 W Wavelength . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Workplace safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 M Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Materials. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Maximum measured error . . . . . . . . . . . . . . . . . . . . . . . . 36 Measured variable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Measuring methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Measuring principle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Measuring range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Measuring system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Minimum flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Multipoint calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Endress+Hauser 39 71219749 www.addresses.endress.com