Three complementary tools to help with everyday problems The Maintenance Guide

The Maintenance Guide - 3rd edition

Tips and reference information
The Maintenance Guide: this manual is the reference text for to keep your installed base up and running
your production, metrology and maintenance teams. Keep a
printed copy on your desk all year round and have a shortcut to
the PDF version on your computer desktop for quick reference.
The content is updated on a regular basis.

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. It 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.

Find these maintenance publications at

www.services.endress.com/maintenance_publications

Instruments International Other locations

Endress+Hauser Please visit:

Instruments International AG www.endress.com/worldwide
Kaegenstrasse 2
4153 Reinach
Switzerland
Tel. +41 61 715 81 00
Fax +41 61 715 25 00
http://www.endress.com
info@ii.endress.com
Endress+Hauser

EC00003H/29/EN/01.11

PF/INDD CS4
 Because your success
is important to us

This Maintenance Guide has been produced

to provide reference information for your
production, metrology and maintenance
teams. Developed by our experts, it contains
reminders on the measuring principles and
provides answers to frequently asked questions.
And we have included lots of tips to help
you make better use of your installed base!

Keep a copy on your desk all year round!

Tips & advice

p. 4

At your service
p. 110

The Endress+Hauser Maintenance Guide 3

4 The Endress+Hauser Maintenance Guide
 Tips & advice
Helping you to get the most
out of your installed base

Contents

Useful definitions 6
Level measurement 7
Flow metering 29
Liquid analysis 47
Pressure measurement 75
Temperature measurement 85
Recorders 91
Field communication 95

Installation Commissioning Operations Migration Re-engineering

Our contribution to your Please remember that

success goes far beyond our experts are always on
the sale of instrumentation. hand to help - so feel free
Every day our experts to call us at any time. We
help you to solve are at your service!
installation, commissioning,
operations, migration or
re-engineering problems.

In this Tips & advice section,

they have gathered a wide
selection of useful information
that will help you anticipate
the most common problems,
helping you to maintain your
instrument availability.

The Endress+Hauser Maintenance Guide 5

 Useful definitions

Metrology Maintenance (to EN 13306)

Accuracy of a measurement Check Down time Preventive maintenance

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

6 The Endress+Hauser Maintenance Guide

 Level measurement

Installation is the key

ToF (Time of Flight) and capacitive There is also plenty of useful information to Contents
instruments are the most popular help you get the best from your instruments
Endress+Hauser level devices. throughout their life cycle. Basics 8
The chapter Basics includes information
ToF instruments share common concepts Note: If you are intending to replace one of that is valid for all measurement
allowing simplified commissioning, your capacitive devices, please contact us. principles described hereafter.
We therefore strongly recommend
operation and maintenance. However, as Each migration project has to be examined that you read this chapter first!
the installation conditions are of utmost carefully.
importance, especially regarding the nozzle, Radar level measurement 11
we have included a reminder of these We also offer training sessions in a Guided radar level measurement 16
essential installation conditions in this guide. classroom or on site. See Training in the
At your service section. Ultrasonic level measurement 21
For capacitive level measurement Capacitive level measurement 26
instruments, the situation is different: due You will find several
to the physical principle, the key point is videos covering
the connection to the ground, especially in these topics at
case of a non-conductive tank. www.endress.com/videos

As in all other sections, we have also

recapped the most frequently asked
questions. With this information, you
will be able to prevent or resolve the vast
majority of potential problems yourself!

The Endress+Hauser Maintenance Guide 7

 Basics
Level

Information common to all types of level measurement devices

Radar level measurement Guided radar level measurement Ultrasonic level measurement Capacitance level measurement
Specific information p. 11 Specific information p. 16 Specific information p. 21 Specific information p. 26

The Time of Flight (ToF) product surface is calculated by representation of this sequence
principle d= (c . t)/2 is called an envelope curve.
A stylized envelope curve is
Radar, guided radar and Blocking distance displayed in fig. 3 and 4.
ultrasonic level measurement The span may not extend
instruments are downward- into the blocking distance The envelope curve can be
looking measuring systems (BD). Level echoes from the monitored on the built-in
that operate according to blocking distance cannot be display. For this purpose, the
the Time of Flight (ToF) evaluated due to the transient function envelope curve must
principle. What is measured characteristics of the sensor (see be selected in the operating
is the distance from the box for more details). menu. Sub-menus then allow
reference point to the product for adjustments of the envelope
surface. Pulses (microwave Envelope curve curve display. In addition, a
or ultrasound) are emitted by ToF instruments emit individual laptop or personal computer
the instrument, reflected by pulses in quick succession with the Endress+Hauser
the product surface, received and scan their reflection again software FieldCare, in
by the electronic evaluation with a fluctuating delay. The combination with a necessary
unit and converted into level amounts of energy received interface, can be used to display
information. The distance are arranged according to their and evaluate an envelope curve.
Fig. 1 : The Time of Flight principle. between the device and the Time of Flight. The graphic

ZOOM: Why is there a blocking distance?

The device is either emitting or receiving waves but cannot do both

at the same time. In case of an obstacle located within the area
between positions 1 and 2, the resulting echo would be surrounded
by the residual vibration and could not be differentiated. As it is
impossible to differentiate the echo within this area, the level to be
measured must not approach the membrane. This distance is the BD
blocking distance (BD).

Duration (ms)
Fig. 2 (example of an ultrasonic level measurement)
T0: Start of the emitted impulsion. An alternating current whose frequency corresponds
Distance (m)
to the systems resonance makes crystals oscillate.
T1: End of the emitted impulsion. Membrane continues to vibrate during 1ms and then
switches to the receiving position. T3: The echo comes back after 6 ms meaning the total distance represents 2m/6.56ft.
T2: The residual membrane vibration is weakened enough to reflect an echo and to Therefore the product surface is located 1m under the probe.
differentiate it. T4: Double reflection echo or numerous reflections can sometimes be observed.

8 The Endress+Hauser Maintenance Guide

 Level
Amplitude y
Customer map All
SendingEndress+Hauser
pulse with
reverberation time
ToF Fig. 3: Schematic envelope curve
Trigger pulse with a guided radar instrument.
For radar and ultrasonic level level measurement devices
measurement instruments, it is have the same display. The envelope curve contains the following
necessary to map out interference The display of the process value
Interference echo
caused by installations
signals in chronological order:
reflections created inside the and the configuration of the Reference pulse Trigger pulse. This starts recording the
envelope curve.
tank. This map is based on the device occur locally by means
Reference pulse. This is produced in the HF
factory map and preferably done of a large 4-line alphanumeric
Interference echo Gland pulse module and is used as a mark from which
with an empty tank. This way, all display with plain text
caused by agitator all distances are measured.
eventual interference reflections information. The menu-guided Negative gland pulse (fiducial). This stems
Interference echoes Signal level from the transmitter pulse gland to the probe
caused by installations in the system
caused by with integrated help
installations
Level echo and any interference echoes
tank are detected and stored in texts ensures quick and safe
Level echo End of probe End of probe signal (LN). This is
the memory. commissioning (see fig. 3).
x Time-of-flight Negative for unattached or insulated tie-
To access the display, the cover down probe ends
Time-of-flight Positive for grounded tie-down probe ends.
A customer map is recorded of the electronic compartment
over the actual factory map. may be removed even in
The customer map covers all hazardous area (IS and XP). Sending pulse with
Amplitude y

additional reflections from reverberation time T

inside the tank (see fig. 5). Only The VU331 liquid crystal
significant echoes will then display (LCD) can be removed Interference echo
exceed the customer map and to ease operation by simply caused by installations
R
be evaluated. The mapping can pressing the snap-fit
also be performed up to the level (see fig. 6). It is connected
or a defined distance, even if to the device by means of a Interference echo
caused by agitator
G

the tank is not empty. However, 500mm/19.7 cable. The

if the level drops below the display allows configuration Interference echoes
caused by installations
mapping distance, additional via three keys directly at the
Level echo E
reflections can interfere with the instrument. All device functions
x Time-of-flight
measurement. can be set via a menu system.
The menu consists of function Fig. 4: Example of a tank (equipped with a radar instrument)
Ti
Setup - configuration groups and functions. Within a with a schematic envelope curve.
of level instruments function, application parameters
can be read or adjusted. The user
General note: is guided through a complete [dB]
Respecting installation configuration procedure. 0

conditions is of key importance 20

for level measurement. You can also configure your Customer map
Operation in matrix levels "basic calibration"
Furthermore, it is necessary to ToF instruments from your 40
and "extended calibration
configure the measuring point to PC. Remote commissioning,
achieve correct measurement. including documentation of the 60 Interference echoes

measuring point and in-depth 80

The basic setup covers 95% analysis functions, is supported
of the situations. A generic via FieldCare software. More 100

screen is shown on fig. 7. information on FieldCare can Envelope curve with reflections / echoes in the tank
[m]
Specific setup procedures are be found at 120

End of
detailed on the pages dedicated www.products.endress.com/fieldcare Interference echo suppression
to radar, guided radar and
ultrasonic devices. Fig. 5: Customer map.

The Endress+Hauser Maintenance Guide 9

 Maintenance planning LCD
Level
Save time and resources Order
ENDRES
MICROP
Code:
Ser.-No.:

Messbereich
Measuring

4...20
range
U 16...36
S+HAUS
ILOT

max.
II ER

20
(liquid crystal display)

Maulburg
mA V DC m
IP
65
T

Our service team can set up any

A >70C

Made in Germany
: t
>85C

Endress+Hauser level measurement Do you know exactly which part of Symbols

device for you to ensure you your installed instrumentation base ENDRESS + HAUSER

immediately get the best from your is critical to the operation of the
instrument. plant and how you could maintain or
(See Device Commissioning in the calibrate it more efficiently? Are you
At your service section). sure that your present actions are + E
minimizing the risks of unplanned
breakdowns? Are you sure that
3 keys
your present actions are the most
Operation and maintenance cost-effective? snap-fit

With Endress+Hausers Installed Base

Routine maintenance Fig. 6: On-site operation with VU331.
Audit, our service consultant will L00-FMxxxxxx-07-00-00-en-001

ToF devices have no moving help you to quickly find an answer to

parts thus require very little these questions and move forward in
Headline Position indicator

ENDRESS + HAUSER
maintenance. However, because a controlled manner to a maintenance
plan which improves plant reliability
of their criticality to the quality,
while reducing costs
some instruments need to be (See Maintenance and calibration Symbol Main value Bargraph Unit

inspected or/and calibrated consulting in the At your service + E

periodically. section).
Selection list

Defining the right maintenance

frequency taking several Maintenance performing
parameters into account is an
experts job. Endress+Hauser In case your internal resources Help text

can also help you with this task! have neither the time, the
skill levels nor the right tools to Envelope
curve
efficiently perform your maintenance,
To test the 4-20mA loop: Endress+Hauser service contracts
The 2-wire, 4-20mA with provide you with the flexibility to Fig. 7: The Basic Setup covers 95% of the situations.
HART version includes test decide the right level of maintenance
support you require.
sockets for testing of the
signal current (see fig. 8). We provide regular checks on your DC AC / DC
On the 4-wire versions equipment and warranty extensions power display unit, power
(Levelflex and Prosonic), for your complete peace of mind and alternatively recorder, PCS

cost control. From regular support to

there are two terminals partnership agreements, we offer four
Commubox
FXA191/195 alternatively
communication
situated at the front of the distinct levels of service resistor
DXR375
communication
Commubox
(> 250 W) FXA191/195
electronic module (see fig. 9). (See Maintenance services in the resistor
(> 250 W)
DXR375

At your service section).

Checking the measurement 4...20 mA 4...20mA

(all devices)
Configuration of the level Corrective maintenance test sockets for testing
measurement instrument - spare parts of the signal current

is often undertaken during The more critical your 1 2 3 4

plant
ground 5 6 1 2
plant
ground

the commissioning phase. In instrument to your process, L- L+ I+ I- I+ I- L1/L+ N/L-

the majority of cases this is the shorter the acceptable

sufficient. repair time. Fig. 8: Terminal assignment - 2-wire, L00-FMxxxxxx-04-00-00-en-015
Fig. 9: Terminal assignment - 4-wire, L00-FMxxxxxx-04-00-00-en-011

In some cases it is useful to Thanks to the TOF concept, 4-20mA with HART. AC/DC power, 4-20mA with HART.
make additional checks of your most parts can be easily
level measurement in order to: replaced by the user (also
Validate the measured value for Ex) thus allowing quick
related to the real level in repair: display, electronic
the tank module, antenna.
Eliminate interference echoes Tags on each component
emitted by the installations in allow easy identification of
an empty tank (for ToF devices) spares.
An installation manual is
If level measurement instruments provided with every spare part.
are to be recalibrated following
an operational phase, this is often In case of a highly critical
done by gauging the capacity of a instrument, you might consider
container in liters, so there is no stocking a complete new
need to remove the device from instrument.
the process. We can provide you
with specific advice on this.

10 The Endress+Hauser Maintenance Guide

 Radar level measurement

Level
Micropilot series

It has been already several years since Micropilot M instruments constitute the main part
of the current range of radar level measurement. FMR230 (horn antenna) and FMR231
(rod antenna) instruments use 6 GHz waves, while FMR240 (horn antenna, FMR244
(horn antenna encapsulated in PTFE), FMR245 (flat antenna) and FMR250 (radar level
measurement on solids) use 26GHz waves.

In this section, you will find essential information and advice that will help you
to perform the optimum follow-up of your Micropilot M instruments throughout
their lifecycle. Please read Basics first (pages 8 to 10).

Micropilot series - overview

90% of the
Housing type T12 Housing type F12 Housing type F23
success of the Aluminum, coated IP65,
with separate terminal
Aluminum, coated IP65 Stainless steel (SS316L), IP65

compartment
setup depend
on proper
EN EN
DR DR
Ord ES ES
er
Co S+ Ord
S+
Se
r.-N de: HA er
Co HA
o.: US Se
r.-N de:
US
ER o.:
ER
Me
Messbere Me
asu ich Messbere
ring asu ich
ran ring
U 16. ge ma ran
x. 20 U 16. ge ma
4... ..36
Maulburg

20 V m 4... ..36 x. 20

Maulburg
mA DC

Maulburg
20
mAV DC m

installation
IP
65 IP
T
65
Made in Germany

A >70 T

Germany
C A >7

in Germany
: t 0C
>85 : t
C >85
C

Made in
Made

Videos available at
www.endress.com/videos

FMR240 FMR244 FMR245

with flange from DN50 with threaded boss with flange,
or threaded boss and and PTFE encapsulated PTFE cladded from DN50
FMR230 horn antenna DN40 ... DN100 40 mm horn antenna antenna DN50 and DN80
with flange from DN80 or Wave Guide antenna
and horn antenna DN80...DN250

FMR231
Fig. 10: Overview of
with flange from DN50 the Micropilot M series
or threaded boss and
rod antenna made of PPS or PTFE

Measuring principle

The Micropilot is a downward-looking measuring system, operating flange:

reference point of
based on the Time of Flight method. It measures the distance from 20 mA measurement
100%
the reference point (process connection) to the product surface. Radar
impulses are emitted by an antenna, reflected off the product surface
and received again by the radar system. D threaded
connection
E 1 BSPT (R 1)
or 1 NPT:
Input (see fig. 11) reference point of
F measurement
The reflected radar impulses are received by the antenna and
transmitted into the electronics. A microprocessor evaluates the signal inactive
length
and identifies the level echo caused by the reflection of the radar L
impulse at the product surface. The unambiguous signal identification
is accomplished by the PulseMaster eXact software, based on many 4 mA
years of experience with Time of Flight technology. 0%
The distance D to the product surface is proportional to the time of max.level

flight t of the impulse: D = c t/2, with c being the speed of light.

Solid Liquid Fig. 11: Measuring principle
Based on the known empty distance E, the level L is calculated: E = Zero (empty). This distance is
L=ED calculated from the reference point
F = Span (full).

The Endress+Hauser Maintenance Guide 11

 Operation and maintenance
Level

See Basics for general information on the maintenance of level devices (page 10).

Guidelines to fix application errors

Error Output Possible cause Solution

A warning or alarm Depending on the configuration 1. See table of error messages in the
has occurred F m/ft 100% instruction manual BA221F
D m/ft (008)

Measured value expected Measured distance (008) yes 1. Check empty calibr. (005) and
(00) is incorrect OK? full calibr. (006).
F m/ft 100%
2. Check linearization:
D m/ft (008)

actual Level/ullage (040)

E m/ft expected Max. scale (046)
0% t Diameter vessel (047)
Check table
actual
no
E m/ft
0% t Measurement in bypass yes 1. Is bypass or stilling well selected
or stilling well? in tank shape (002)?
2. Is the pipe diameter (007) correct?
no
An interference yes 1. Carry out tank mapping
echo may have been Basic setup
evaluated.

No change of Interference echo from 1. Carry out tank mapping

measured value on installations, nozzle Basic setup
filling/emptying 100% or extension on the 2. If necessary, clean the antenna
antenna 3. If necessary, select a better
mounting position
actual 4. If necessary due to wide interference
100% echoes, set function detection window
(047) to off
expected

0% actual t

expected
If the surface is not 100% Signal is weakened by 1. Carry out tank mapping
calm (e.g. filling, 0%
100% t the rough surface the Basic setup
100%
emptying, agitator actual interference echoes 2. Set the process cond. (004) to
running), the are sometimes stronger. turb. surface or agitator
actual
actual
measured value 3. Increase the output damping (058)
jumps sporadically 4. Optimize the orientation
to a higher level expected 5. If necessary, select a better mounting
expected
expected
position and/or a larger antenna
0% t

0
0%% tt

During 100%
Multiple echoes yes 1. Check the tank shape (002), e.g.
filling/emptying dome ceiling or horizontal cyl
the measured value 100%expected
100% 2. In the range of the blocking dist. (059)
jumps downwards expected there is no echo evaluation
expected
Adapt the value
actual 3. If possible, do not select central
installation position
actual
actual
4. Perhaps use a stilling well
0% t

0
0%% tt

E 641 (loss of echo) Level echo is too weak. yes 1. Check application parameters (002),
Possible causes: (003) and (004)
100% Rough surface due to 2. Optimize alignment
100% filling/emptying 3. If necessary, select a better installation
100% actual Agitator running position and/or larger antenna
actual Foam
actual
E 641
expected
E
E 641
641
0% expected
expected t

0
0%% tt

12 The Endress+Hauser Maintenance Guide

Installation conditions

Level
Because most problems reported by users are due to incorrect polarization of the electrical field in the signal beam. An
installation and/or initial calibration, here is a reminder of the optimization of the measurement can be achieved by turning the
essential points that must be considered. threaded boss or the flange (thus the electromagnetic field). Matrix field
056 displays a value [dB] that allows a judgment of the alignment.
Alignment of installed device according to electrical field
A signal beam is always composed of an electrical and a magnetic
field, oriented at 90 towards each other.
The marker point on the threaded boss or the flange marks a virtual Fig. 12
See Alignment of installed device according
horizontal extension of the antenna incoupling, thus the The marking is stamped on
to electrical field on pages 13 and 14.
the flange or threaded boss.

Installation in tank (free space)

ENDR

Marker aligned
Order ESS+
Ser.-NoCode: HAUS
.: ER
Messbe
Measur reich
ing
range

Weather protection cover Beam angles

U 16...36 max.
4...20

Maulburg
V
mA DC
IP
65

towards
T

Made in Germany
A >70C
: t
>85C

tank wall
Always recommended for outside The larger the antenna diameter the smaller the beam angle (see table 1 below).
installation to avoid strong temperature 90

changes of electronics FMR230 FMR231 FMR244

Size of DN150 DN200 DN250 Rod DN40 DN80
Installation antenna /6 /8 /10 antenna /1.5 /3
Not in the center
Not above the fillstream Beam angle 23 19 15 30 23 10
Distance to wall ~1/6 of the tank
diameter, at least, however, 30cm/12 FMR240 FMR245
(6GHz), or 15cm/6 (26GHz)
If these conditions cannot be met: Size of DN40 DN50 DN80 DN100 DN50 DN80
use stilling well antenna /1.5 /2 /3 /4 /2 /3
Marker at 90 90
towardsBeam
inlet angle 23 18 10 8 18 10
The marking is stamped on
(also applies to horn antenna)

Nozzle Table 1 the flange or threaded boss

Horn antenna should protrude from
the nozzle, otherwise use antenna tank
Alignment of installed bypass
device according to electrical field
extension.
The inactive part of the rod antenna
should be longer than the height of the
nozzle, otherwise contact us.

Marker pointing
towards END

Marker aligned
RES
Orde
r S+H
Ser.-NCode AUS
o.: : ER

slots
Mess
Measberei

Measuring range
uringch
range
U 16...3

tank
max.
4...20 6
Maulburg

mAV DC
IP
65

towards
T
Made in Germany

A >70C
: t
>85C

Measurement is possible up to the tip tank wall

of the antenna, on principle, however
the end of the measuring range should stilling
90
well
not be closer than 50mm/2 to the
tip of the antenna because of corrosion
and build-up formation.
The measuring range starts where the
radar beam meets the tank bottom.
With dish bottoms or conical outlets, Fig. 15
the level cannot be detected below
this point.
Optimum mounting position - special instructions

Tank installations
Avoid any installations such as limit FMR245 FMR250
spring washers

switches, temperature sensors, etc.

within the signal beam.
Symmetrical installations, e.g. vacuum
H
rings, heating coils, flow breakers, etc. D
Marker at 90 90
may impair measurement.
towards inlet
Fig.
(also16applies to horn antenna)

Formation of foam
Size of 50mm 80mm
Radar pulses may be absorbed by foam.
Fig. 13 antenna /2 /3 Fig. 17
tank
48mm 75mm
D bypass
/1.9 /3 The horn antenna should protrude from
Special instructions for FMR250
the nozzle. If this is not possible for
In extremely dusty applications, < 500mm < 500mm
H mechanical reasons, larger nozzle heights
the integrated air purge connection / <20 / <20
can be accepted.
can prevent clogging of the antenna
Air purge connection:
NPT (see fig.14). Pulsed operation is
or
G (max. torque 3.5 Nm)
recommended (max. pressure of purge
air: 6 bar abs / 87 psi). In case of
permanent operation, recommended Marker pointing
pressure range of the purge air is towards
200 to 500mbar (2.9 to 7.25 psi). slots
Make sure to use dry purge air. tank
Figure 14: FMR250 integrated
air purge connection.
L00-FMR250xx-17-00-00-en-010

stilling
well
The Endress+Hauser Maintenance Guide 13
 Installation in a bypass Installation in a stilling well
Level

Weather protection cover Weather protection cover

Always recommended for outside Always recommended for outside
installation to avoid strong temperature installation to avoid strong temperature
changes of electronics. changes of electronics.

Optimum horn size

Optimum horn size Select the largest possible horn
Select the largest possible horn antenna. In case of in-between sizes
antenna. In case of in-between sizes (e.g. 95mm/3.7) use the next larger
(e.g. 95mm/3.7) use the next larger antenna and adapt it mechanically.
antenna and adapt it mechanically.
Ball valve
Ball valve Measurements through an open ball
Measurements through an open ball valve with full passage are possible.
valve with full passage are possible.
Measuring range
Measurement is possible up to the tip
of the antenna, in principle, however,
Measuring range the end of the measuring range should
Measurement is possible up to the tip not be closer than 50mm/2 to the
of the antenna, in principle, however, tip of the antenna because of corrosion
the end of the measuring range should and build-up formation.
not be closer than 50mm/2 to the The marking is stamped on
tip of the antenna because of corrosion the flange or threaded boss. Slots / holes
and build-up formation. As few holes / slots as possible.
Slot width or hole diameter
max 1/10 of pipe diameter.
Recommendations for the bypass Deburred.
Metallic (without plastic Length and number do not
or enamel coating). affect the measurement.
The bypass pipe must be smooth inside END Slots / holes 180 offset (not 90).
(average roughness Ra 6.3m). Marker aligned
RES
Order
S+H
Ser.-NCode: AUS
o.: ER
Messb
Measuereich
ring
range
U 16...36 max.
4...20

Maulburg
V
mA DC
IP
65

towards
T

Made in Germany
A >70C
: t
>85C

Constant diameter. tank wall

In transition, caused for example Recommendations for stilling wells
by ball valves or joining of 90
Metallic (without enamel
individual pipe pieces, gaps of coating, plastic upon request).
max. 1mm/0.04 are permitted. Constant diameter.
Welding seam as even as possible
The marking is stamped on and placed in the axis of the slots.
the flange or threaded boss. The stilling well must be smooth inside
(averaged roughness Ra 6.3m).
Do not weld through the wall
of the pipe, the inside of the
pipe must remain smooth.
In transition, caused for example
by ball valves or joining of
individual pipe pieces, gaps of
END

Marker aligned
RES
Order
S+H
Ser.-NCode: AUS
o.: ER
Messb
Measuereich
ring
range
U 16...36 max.
4...20
Maulburg

V
mA DC
IP
65

towards
T
Made in Germany

A >70C
: t

Marker at 90 90
>85C

tank wall
max. 1mm/0.04 are permitted.
towards inlet
(also applies to horn antenna)
Fig. 18 90 Fig. 20

tank
bypass

Alignment of installed device according to electrical field (bypass) Alignment of installed device according to electrical field (stilling well)

Marker pointing marker at instrument flange

towards or threaded boss
slots
tank
Marker at 90 90

90

towards inlet
(also applies to horn antenna)
stilling
well

DN50 DN80150
tank
bypass Fig. 21 ANSI 2 ANSI 36

Fig. 19 Align marker toward slots.

The marker is always exactly in the middle between two bolt-holes in the flange.
After mounting, the housing can be turned 350 in order to simplify access to
Align marker perpendicular (90) to tank connectors.
the display and the terminal compartment.
The marker is always exactly in the middle between two bolt-holes in the flange.
L00-FMR230xx-17-00-00-en-007

Measurements can be performed through an open full bore ball valve

Marker
Afterpointing
mounting, the housing can be turned 350 in order to simplify access to
towards without any problems.
the display and the terminal compartment.
slots
The horn must be alignedtankvertically.
Measurements can be performed through an open full bore ball valve
without any problems.

stilling
well

14 The Endress+Hauser Maintenance Guide

Blocking distance

Level
A
In principle it is possible
FMR 230/231/240 50mm (2)
to measure up to the
tip of the antenna with FMR 244 150mm (6)
FMR230/231/240/244/245 100% A FMR 245 200mm (8)
and 250. However, due to FMR 250 400mm (16)
considerations regarding
corrosion and build-up, the Fig. 22: Blocking distance
end of the measuring range
should not be installed any
closer thanA (see fig. 22) to
the tip of the antenna. 000 Contrast: + or +
measured 008
E dist./
value
B - +
H E
meas value
Setup - + E E

Group
selection 001 002 003 004 005 006 007 008 051 052 053
media tank medium process empty full pipe dist./ check range of start
The Basic Setup menu 00
basic
type shape cond. cond. calibr. calibr. diameter meas value distance mapping mapping
enables a quick and simple +
setup - liquid - dome - unknown - standard input E input F only for D and L are - ok confirm
ceiling - DC: <1.9 - calm bypass + displayed - too small suggestion
commissioning. The software 01
safety
- solid - horizontal - DC: 1.9 4 surface stilling well (see sketch) - too big or specify
helps the user to enter the main settings
cyl.
- bypass
- DC: 4 10 - add.
- DC: >10 agitator
- unknown
- manual
range

parameters which cover 95% of 04

linearisation

the cases. By entering the data 00A

vessel /
00B
medium
00C
proscess
005
empty
006
full
05 C
carefully you will avoid many silo cond. cond. calibr. calibr.
0%extended
problems. (See figure 23). calibr. - unknown - unknown
- metal silo - DC: 1.6...1.9
- standard
- fast change
input E input F
06 - concrete - DC: 1.9 2.5 - slow change
output (HART, FF) silo - DC: 2.5 4 - test: no filter
Spare parts profibus param. (PA) - bin / bunker ...
D
09 092
Special instructions display language

for all radar devices 0E

envelope
0E1
plot settings
0E2
recording
The replacement of either curve curve
- envel. curve - single curve
the electronic module or - - incl. FAC - cyclic
0A4
- incl. cust. map
the HF module requires a unlock parameter

0A 0A0 0A1
reprogramming. Some of the diagnostics present error previous error
= 100: unlocked
} HART
100: locked
default parameters have to 0C
be modified. The relevant system parameter
= 2457: unlocked
2457: locked }
PA, FF

procedure is delivered with the

Fig. 23: Basic Setup for Micropilot M devices
new module.

Instrument and
spare parts availability However, thanks to the recent demanding applications
All Micropilot devices are redevelopment, from software (with turbulent surface
currently in production. version 1.05.xx, the new or foam formation).
26GHz instruments can now
Re-engineering be used in process applications. See also our online Applicator tool:
https://wapps.endress.com/applicator
Please consult us.
Instruments that operate
at 26GHz used to be used Instruments that operate at For further information about the status of your instrument,
in storage applications. 6GHz are for use in more use our Device Viewer:
www.services.endress.com/device-viewer

The Endress+Hauser Maintenance Guide 15

 Guided radar level measurement
Level

Levelflex series

The current Levelflex guided radar range includes both Levelflex M FMP4x range
and new Levelflex FMP5x range. Due to the recent availability of the FMP5x family,
we decided to briefly introduce it to you and to keep maintenance information for
the next issue of this Maintenance Guide.

In this section we aim to provide efficient help to Levelflex M FMP4x users

throughout the life cycle. Please read Basics first (pages 8 to 10).

Measuring principle Levelflex M FMP4x series - overview

High-frequency pulses are Housing F12 Housing F23 Housing T12

(not for
injected into a probe and led 4-wire-devices)
along the probe. The pulses are
reflected by the product surface, Ord
EN
DR
LE ES
er Cod VELF S+HA Ord
EN
DR
LE ES
VE S+HA

received by the electronic

er LFLE
Ser LEX US Ser. Code:
X MUSER
.-N e:
o.: M ER -No
.:
Me Me
Messbereic Messbereic
asu
ring h asu
ring h
ran ran
ge ge
U 16. max U 16.
. 20 max
4... ..36 4... ..36 . 20
20 V DC m 20 V DC m
mA
Maulburg

mA

Maulburg
IP 65

evaluation unit and converted

IP 65
T T
A >70 A >70
Made in Germany

Made in Germany
: t C
>85 : t
C >85
C

into level information.

flange: reference point of measurement

20 mA
100%

D E+H-
G flange universal flange /dairy
E G1 DN40...200 adaptor
LN NPT
F 1 NPT

clamp
L 1 / 2 / 3
Process- Process-
connection connection
4 mA 400 C 280 C
0% G1 or G1 or
1 NPT or 1 NPT
flange or flange

Fig. 24: Measuring principle

facing PTFE
The distance D to the product
surface is proportional to the
Time of Flight t of the impulse:
D = c t/2, with c being the
speed of light. Based on the rope and rod
PFA coated
known empty distance E, level
L is calculated: L = E D
Reference point for E see fig. 24.
The Levelflex comes
with functions to suppress
interference echoes
(e.g. internals and struts).

Note: The dielectric constant Rope probes Rod probes Coax probes Rope probes Rod probes Coax probe Rod probe Rope probe

(DC) of the medium has FMP40 FMP41C FMP45

a direct impact on the
degree of reflection of the Fig. 25: Overview of the Levelflex M series
high-frequency pulses.

16 The Endress+Hauser Maintenance Guide

 Level
Consider blocking
distances and
pay attention
to the nozzle.

Videos available at
www.endress.com/videos

Operation and maintenance See Basics for general information on the maintenance of level devices (page 10).

Guidelines to fix application errors

Error Output Possible cause Solution

F m/ft 20mA / 100%
A warning or alarm Depending on the configuration. 1. See table of error messages in the
D m/ft (008)

has occurred. instructions manual BA245F.

expected

Measured value Measured distance (008) yes 1. Check empty calibr. (005) and
(00) is incorrect. OK? full calibr. (006).
F m/ft actual / 100%
20mA
2. Check linearization:
D m/ft (008)

E m/ft Level/ullage (040)

4mA / 0% t
expected Max. scale (046)
Diameter vessel (047)
Check table
actual
no
E m/ft
4mA / 0% t An interference echo may yes 1. Carry out tank mapping
have been evaluated. Basic setup

No change of Interference echo from 1. Carry out tank mapping

measured value on tank internals, nozzle or Basic setup
20mA / 100%
filling/emptying. build-up on the probe. 2. If necessary, clean the probe
3. If necessary, select a better
mounting position
actual

20mA / 100%
expected

4mA / 0% t
actual

Device displays a Incorrect probe length. 1. Carry out automatic probe length
level when the tank expected
20mA / 100% detection when the tank is empty.
20mA / 100%
is empty. 4mA / 0% t 2. Carry out mapping over entire probe
when the tank is empty (probe free!).

actual
actual
expected
expected
4mA / 0% t
4mA / 0% t

Measured value Tank properties yes LN < 4m and Aluminum tank

incorrect (slope incorrect. tank properties selected
error in the entire 20 mA/100% Calibration not possible
20 mA/100%
measuring range). expected Selection
expected Select standard
Thresholds too high

2.) actual Medium properties yes Select lower medium properties.

2.) actual
1.) actual
incorrect.
1.) actual
4mA / 0% t
4mA / 0% t

The Endress+Hauser Maintenance Guide 17

 Installation conditions
Level

Because most problems reported by users are due to incorrect installation and/or initial calibration, here is a reminder of the essential points
that must be considered.

Installation in a tank (measurement in liquids) Installation in a stilling Installation in concrete silos

Installation should be made flush with
well or a bypass
the lower edge. Alternatively, the probe
Weather protection cover can also be installed into a pipe that
Always recommended for outside must not protrude over the lower edge
installation to avoid strong temperature of the silo ceiling. The pipe should be
changes of electronics. kept at a minimum length.
The centering disk should be used for
Installation tube diameter >150mm/6 to prevent
Not in the center. build-up in the inner part of the tube.
Not above the fillstream. 4 (100 mm) 4 (100 mm)
Any wall distance, avoid wall contact.

Nozzle
Nozzles diameters of 50mm/2 to
150mm/6 and nozzle heights up to metal
150mm/6 are preferred.
For rope probes in nozzles with
> 150mm/6 in height, an HMP40
rod extension must be used.
BD

Measuring range metal

Smallest measuring range: 300mm tube
/12.
Largest measuring range: 35m/110ft
3...6 (80...150 mm)
(larger upon request). Extension rod
/ Centering

Fig. 28
Fig. 27
Tank installations Installation in plastic containers
Distance to obstacles min. 300mm The guided radar measuring principle
/12. Weather requires a metal surface at the process
During commissioning interference protection cover connection. When installing the rod and
echo can be suppressed. Always recommended for rope probes in plastic silos, where the
outside installation to avoid silo cover is made of plastic or wood,
strong temperature changes the probes must either be mounted in a
of electronics. DN50/2 metal flange, or a metal sheet
with diameter of 200mm/8 must be
Turbulent surface / foam mounted under the screw-in piece.
Bypass /
Turbulent surfaces do not
measuring tubes
affect measurement.
Metallic pipe. metal sheet or metal flange
Foam layers of up to approx. 100mm
No special requirements of
/4 do not affect measurement.
bypass pipe or stilling well.
Higher foam thickness may
Welding seams protruding
result in too small readings.
internally up to approx. silo roof of plastic or wood
5mm/0.2 do not impair
measurement. Fig. 29

Fig. 26

R = reference point of measurement

Upper blocking distance New FMP5x devices include factory E = empty calibration (= zero)
The upper blocking distance (UB) is the settings for the blocking distance: LN = probe length
minimum distance from the reference with coax probes: 0mm (0). F = full calibration (= span)
point of the measurement (mounting with rod and rope probes up UB = upper blocking distance
flange) to the maximum level. Within to 8m (26ft): 200mm (8).
the blocking distance, a reliable with rod and rope probes
measurement cannot be guaranteed. exceeding a length of 8m (26ft):
0.025 * (length of probe).
Depending on the application
these settings can be changed. () (mm)
rod probe and coax probe () (mm)
rope probe
3.2 80 3.2 80
sum of non- linearity, non- repeatability
sum of non- linearity, non- repeatability

2.4 60 2.4 60
DC = 2
Lower blocking distance If r (dielectric coefficient) value is 1.6 40 1.6 40
DC > 7

At the lowest part of the probe an less than 7 for rope probes, then 0.8 20
DC > 7
0.8 20
exact measurement is not possible. The measurement is not possible in the
and hysteresis
and hysteresis

0 0 0 0
following measuring error is present in area of the straining weight (0 to 10/ -0.8 -20 -0.8 -20
the vicinity of the probe end. 250mm from end of probe). (See table). -1.6 -40
-1.6 -40

-2.4 -60 -2.4 -60

-3.2 -80
-3.2 -80
0 2 4 6 8 10 12 0 2 4 6 8 10 12
0 50 100 150 200 250 300 mm 0 50 100 150 200 250 300 mm
distance from probe end distance from probe end

Fig. 30: Measuring error in the vicinity of the probe end L00-FMP4xxxx-05-00-00-en-001 L00-FMP4xxxx-05-00-00-en-002

18 The Endress+Hauser Maintenance Guide

 Level
000
measured value Contrast: + or +
008
- + E E dist./
meas value
Group E
- + E
selection
00 002 003 004 005 006 008 051 052 053
basic setup tank medium process empty full dist./ check range of start
properties property cond. calibr. calibr. meas value distance mapping mapping
+
Installation in a tank 01 - standard - unknown - standard input E input F D and L are confirm
(measurement in solids) safety settings - aluminium tank
- plastic tank
- 1.4 1.6
- 1.6 1.9
- fast
change
(see sketch) (see sketch) displayed suggestion
or specify FMP40
- bypass/pipe - 1.9 2.5 - slow FMP43 range FMP41C
- coax-probe - 2.5 4 change FMP45
- concrete -47 - test: no filter
wall ->7 reference point of
measurement
03 030 031 032 033 034 UB
length end of probe probe probe determine 100%
adjustment probe length length length
- free If shortened D
04
- tie down please enter probe length here.
linearisation E
isolated threaded LN
05 - tie down F
connection
extended calibr. gnd. or 1 BSP
(G or G 1) L
09 092
language or 1 NPT: 0%
display
reference point of
measurement
0E 09A 09B
envelope curve plot settings recording
- envel. curve curve
- substracted signal - single curve
- mapping - cyclic UB = upper blocking distance F = measuring span
- 0A 0A0 0A1 0A3 0A4 E = empty distance (= zero) LN = probe length
diagnostics present previous reset unlock D = distance L = level
error error parameter
0C (333 = reset customer parameters) = 100: unlocked
system 100: locked
parameters Fig. 32: Basic Setup
for Levelflex M devices

Fig. 31
Setup the product are then left in the explicitly need to be recorded,
Weather protection cover (1) subtracted signal. A mapping rather it constantly adapts itself
Always recommended for outside The Basic Setup menu curve (the factory map) is to the (changing) properties
installations (solar radiation and rain). enables quick and simple included in the Levelflex M on of the probe environment
100mm/4" 100mm/4"
commissioning. The software delivery. For rod probes it spans during ongoing operation. The
Installation
Do not install rod and rope
helps the user to enter the main the entire probe length, for rope dynamic map is valid beyond
probes in the filling curtain. [2] parameters that cover 95% probes only the first 1.5m/5ft. the range of the static map.
Install rod and rope probes at a distance of cases. By entering the data
to the wall [B], so that in case of build-up carefully, many problems are Once the device has been Spare parts
on the wall a distance
Metal to the probe
of at least 100mm/4 remains.
avoided. (See figure 32). installed, a customer map
Install rod and rope probes with the should be recorded in the Special instructions
largest possible distance to baffles. In Map and subtracted signal empty tank or over as much for all radar devices
case of distances <300mm/12, an free space as possible, so that The replacement of either
interference echo suppression must
be included in commissioning. In order to suppress interference each individual environment the electronic module or
When rod and rope probes are installed signals, the envelope curve (see of the probe is mapped as well the HF module requires a
in plastic vessels, the minimum distance Basics) is not directly evaluated as possible. The extended reprogramming. Some of the
of 300mm/12 is also applicable to in the Levelflex M. Instead, the calibration function group default parameters have to be
metallic parts outside of the vessel.
Rod and rope probes must mapping curve is first subtracted (05) is used to record the modified. The relevant procedure
not be in contact with metal from it. Level echoes are sought customer map. Depending on is delivered with the new module.
vessel walls or bottoms. in the resulting subtracted signal. the range of this customer map,
The minimum distance of the probe it overwrites part or all of the Instrument and
end to the bottom of the vessel is
applicable [C]: >10mm/0.4. Subtracted signal = factory map. spare parts availability
Avoid bending the rope probe sharply Envelope curve - Mapping curve All Levelflex devices are
during installation or operation (e. For rope probes, there is also currently in production.
g. by product movements against The mapping curve is intended a dynamic map. This does not
the wall of the silo) by the selection
of a suitable point of installation. to be as good a map as possible
of the probe and the empty tank For further information, use our Device Viewer:
or silo. Ideally, only signals from www.services.endress.com/device-viewer

The Endress+Hauser Maintenance Guide 19

 New Levelflex FMP5x family
Level

The new Leveflex FMP5x range was developed according

to the latest standards in security, accuracy and efficiency.

FMP50: Cost-effective FMP55: Premium device

basic device for supply with coated multiparameter
and storage applications probe for interface
and utility processes. measurement in the oil & gas,
chemical and power industry.
FMP51: Premium device
for level and interface FMP56: Cost-effective
measurement in liquids. basic device for common
bulk solids applications in
FMP52: Premium device small silos and tanks.
with coated probe for the use
in aggressive liquids. Wetted FMP57: Premium device
parts FDA listed materials. for level measurement
in bulk solids.
FMP53: Premium device
for the highest hygiene
requirements. ASME BPE
and USP Class VI compliant.

FMP54: Premium device

for high-temperature and
high-pressure applications,
mainly in liquids.

Fig. 33

Maintenance advantages at a glance

Installation Maintenance
No special tool required HistoROM: Data backup
Reverse polarity protection for instrument settings
Modern, detachable terminals and measured values
Main electronics protected Exact instrument and
by a separate connection process diagnosis to assist in
compartment fast decision-making with
clear details concerning Smart operation concept
Commissioning remedial solutions for flow and level Fig. 34
Fast, menu-guided Intuitive, menu-guided
commissioning in only 6 steps operating concept in Endress+Hauser has
Plain text display in national national languages standardized and harmonized
languages reduces the risk saves costs for training, its new 2-wire device concept
of error or confusion maintenance and operation for flow and level devices.
Direct local access Housing cover can be
of all parameters opened in hazardous areas Migration
Short instruction manual
Video about our 2-wire
integrated into the device Although the FMP4x familiy concept available at
is still available, the table www.endress.com/videos
Operation below provides information in
Multi-echo tracking: preparation for the migration
Increased echo rate from FMP4x to FMP5x devices.
and analysis as well as
automatic suppression Video about the new
of interfering echoes Levelflex family available at Liquids Solids
Diagnostics in accordance www.endress.com/videos
Levelflex M FMP40 FMP41C FMP43 FMP45 FMP40
with NAMUR NE107
New Levelflex FMP50/51 FMP52 FMP53 FMP54 FMP56/57

Table 2: Successors of Levelflex M FMP4x devices

20 The Endress+Hauser Maintenance Guide

 Ultrasonic level measurement

Level
Prosonic series

The current Prosonic ultrasonic transmitter range includes the Prosonic M

FMU40/41/42/43/44 and Prosonic S FMU90. With this section we aim to:
Provide help to Prosonic M users
Answer the most frequently asked question by Prosonic S FMU86x users and
give them key information to successfully migrate to FMU90.

Please read Basics first (pages 8 to 10).

Measuring principle Prosonic M series - overview

The installation of F12
T12
The Prosonic M sensor emits
the sensor and the ultrasonic pulses in the
presence of foam direction of the product surface. Ord
er
EN

Ser Cod
.-No e:
.:
DR
PR ES
OS S+
ON HA
IC US
M ER
Ord

Me
er
Ser Cod
.-N
EN

o.:

Messbere
DR
PR ES
OS S+
e: ON HA
IC US
FM ER
U

There, they are reflected back

asu ich
Mes ring
Measbe ran
surireich U 16. ge ma
ng 4... ..36 x. 20
ran

Maulburg
20 m
U 16.. ge max mAV DC
. 20
4...2 .36 IP

Maulburg
m
0 mA V DC 65

or bubbles have a
IP T
65 A >70

Made in Germany
C
T
A >70
: t

Made in Germany
>85

and received by the sensor.

C C
: t
>85
C

strong impact on The Prosonic M measures the

timet between pulse emission
the measurement. and reception. The instrument
uses time t (and the velocity of
sound c) to calculate distance D
between the sensor membrane
and the product surface:
D = c t/2
As the device knows the empty
distance E from a user entry,
it can calculate the level as
follows: L = E - D
Videos available at FMU42 FMU44
An integrated temperature FMU43
www.endress.com/videos FMU40 FMU41
sensor compensates changes in
the velocity of sound caused by Fig. 36
temperature changes.
Prosonic S FMU90 - overview
Interference echo
DIN rail housing DIN rail housing field housing
suppression (with options)
The interference echo
suppression feature of
ProsonicM ensures that
interference echoes (e.g. from
edges, welded joints and
installations) are not interpreted
as level echoes.

BD
20 mA
100%

E
E F

Fig. 35: Measuring principle

F = span (full distance)
E = empty distance
L
D = distance from sensor membrane FDU90 FDU91/91F FDU92 FDU93 FDU95 FDU96
to the product surface New range (compatible
FDU80/81+F)
(compatible
FDU82)
(compatible
FDU83)
(compatible
FDU84/85)
(compatible
FDU86)
BD = blocking distance 4 mA
0% Fig. 37
L = level
L00-FMU4x-15-00-00-de-001

The Endress+Hauser Maintenance Guide 21

Level

Operation and maintenance See Basics

F m/ft 100% for general information on the maintenance of level devices (page 10).
D m/ft (008)

Guidelines to fix application errors

expected

Error Output Possible cause Solution

actual
E m/ft
Measured value
0% t
Measured distance (008) yes 1. Check empty calibr. (005) and
(00) is incorrect. OK? full calibr. (006).
F m/ft 100%
2. Check linearization:
D m/ft (008)

Level/ullage (040)
expected Max. scale (046)
Diameter vessel (047)
Linearization table
actual
no
E m/ft
0% t An interference echo may yes 1. For measurements in bypass or stilling
have been evaluated. well: Select the relevant option in the
tank shape (002) function.
2. Carry out interference echo suppression.

No change of Interference echo 1. Carry out interference echo suppression.

measured value on from tank internals or 2. Clean sensor if necessary.
100%
filling/emptying. build-up on the probe. 3. If necessary, select better installation
position.
4. If necessary due to wide interference
actual
echoes, set function detection window
(0A7) to off.
expected

0% t
100%

With an uneven Signal is weakened by 1. Carry out interference echo suppression.

surface (e.g. filling, actual the rough surface the 2. Set the process cond. (004) to
100%
emptying, running interference echoes calm surface or add. agitator.
agitator) the are sometimes stronger. 3. Increase output damping (058).
actual
expected
measured value may 4. If necessary, select a different
jump sporadically to 0% t
installation position and/or a
higher levels. larger sensor.
expected

0% t

On filling/emptying Multiple echoes 1. Check tank shape (002), e.g.

the measured value dome ceiling or horizontal cyl..
drops. 100% 2. If possible, do not select a
expected
central installation position.
3. Perhaps use a stilling well.

actual

0% t

100%

22 actual The Endress+Hauser Maintenance Guide

E 641
Installation conditions

Level
Because most problems reported by users are due to incorrect installation and/or initial calibration, here is a reminder
of the essential points that must be considered.

Installation in a tank Installation in a stilling well

Weather protection cover

Always recommended for outside
installation to avoid strong temperature
changes of electronics.

Installation
Not in the center
Not above the fillstream
Distance to wall: ~1/6 of the tank Weather protection cover
diameter (min. 30cm/12) Always recommended for outside
If these conditions cannot be met: installation to avoid strong temperature
check stilling well changes of electronics.

Nozzle
The sensor membrane should be
Measuring range
below the nozzle, if this is not possible,
Measurement is possible up to the
please compare the dimensions of the
blocking distance (BD) of the sensor.
nozzle with the table below.
Please contact Endress+Hauser if
nozzle dimensions are different.

BD
BD

Measuring range Slots / holes

Measurement is possible up to the Slot width or diameter of holes
blocking distance (BD) of the sensor. max. 1/10 of pipe diameter
The measuring range begins where Deburred
the ultrasonic beam meets the tank Length and number do not
bottom. With dish bottoms or conical affect the measurement
outlets, the level cannot be detected At least one ventilation hole
below this point. (>10mm/ 0.4) is to be provided in
the blocking distance of the sensor
Tank installations
Avoid any installations like limit
switches, temperature sensors, etc.
within the signal beam (see table).
Recommendations for stilling wells
Symmetrical installations, i.e. heating
Any rigid pipe (metal, glass, plastics)
coils, flow breakers, etc can also
The stilling well must be smooth inside
interfere with the measurement.
Constant diameter
Do not weld through the wall of
Optimization options the pipe, the inside of the pipe must
Use a sensor with a smaller remain smooth
beam angle. The assembly of individual pipe
A stilling well or a sound guiding pieces may only cause a gap of max.
tube can always be used to avoid 1mm/0.04
interference. Please clarify buildup Recommended minimum inner
tendency of the medium. diameter > 80mm/3
Please observe sensor dimensions to
Formation of foam choose the right inner diameter
Ultrasonic signals may be
absorbed by foam.
Fig. 38 The surface of foam can reflect. Fig. 39
Solution: trial measurement with
ultrasonics or e.g. hydrostatic
measurement.

Blocking distance Sensor type

Max. nozzle
Span F may not extend length FMU40 FMU41 FMU42 FMU44 FDU91 FDU91F FDU92
into blocking distance BD.
Level echoes from the DN 50/2 76mm/3
blocking distance cannot be DN 80/3 240mm /9.5 240mm /9.5 254mm /10 330mm /13 330mm /13
evaluated due to the transient DN 100/4 305mm/12 305mm/12 305mm/12 381mm/15 381mm/15
characteristics of the sensor. DN 150/6 406mm /16 406mm /16 406mm /16 406mm /16 406mm /16 406mm /16 406mm /16
(See Basics for more details)
Beam angle 11 11 11 11 9 12 11
BD 10 14 16 20 12 12 16

Table 3: Recommended nozzle dimensions, nozzle length from sensor diaphragm, beam angle (3 dB)

The Endress+Hauser Maintenance Guide 23

 Installation in a tank - level measurement in bulk solids
Level

Weather protection cover Silo baffles

Always recommended for outside Make sure that baffles [1] like limit
installations (solar radiation and rain). switches, struts, etc. are not within the
beam cone (see the beam angle table).
Installation Symmetrically arranged baffles [2],
Not in the center e. g. discharge aids etc. may impair
Not above the filling curtain measurements.
Distance to wall: ~1/6 of the tank
diameter (min. 20cm/7.9) Optimization options
If two or more sensors are used Use a sensor with a smaller
in one vessel, please use separate beam angle. The smaller the beam
instrumentation (FMU90/95 + FDU9x) angle, the lower the occurrence of
interfering echoes.
Nozzle Interference echo suppression:
The sensor membrane should be electronic suppression of interfering
below the nozzle, if this is not possible, echoes optimizes the measurement.
please compare the dimensions of the Plates installed at an angle [3]
nozzle with the table below. disperse the signal and can
avoid interfering echoes.
Measuring range
Measurement is possible up to the Alignment
blocking distance (BD) of the sensor. Serves the avoidance of
Fig. 40 The measuring range begins where interfering reflections and
the ultrasonic beam meets the tank improved measurements since
bottom. With dish bottoms or conical the measurement can be aligned
outlets, the level cannot be detected to the angled surface (accessory
below this point. FAU40 or assembly bracket).
Fig. 41

Sensor type
FMU40 FMU41 FMU42 FMU43 FMU44 FDU90 FDU91 FDU91F FDU92 FDU93 FDU95 FDU96
Beam angle 11 11 9 6 11 12 9 12 11 4 5 6
Lmax(m/ft) 2/6 3.5/11 5/16 7/22 10/32 1.2/3.9 5/16 5/16 10/32 15/49 45/150 70/230
rmax(m/ft) 0.19/0.6 0.34/1.1 0.39/1.3 0.37/1.2 1.96/6.4 0.13/0.4 0.39/1.3 0.53/1.7 0.96/3.1 0.52/1.7 1.96/6.4 3.6/11.8
Blocking distance
0.25/0.8 0.35/1.15 0.4/1.3 0.6/2 0.5/1.6 0.07/0.23 0.3/1 0.3/1 0.4/1.3 0.6/2 0.7/2.3* 1.6/5.2
BD (m/ft)
* 0.9/2.9 in case of high temperatures (150C/302F)
Table 4: Beam angle and blocking distance according to the sensor type

Max. nozzle length in mm/inch (L)

Nozzle FMU40 FMU41 FMU42 FMU43 FMU44 FDU90 FDU91 FDU91F FDU92 FDU93 FDU95 FDU96
DN 50/2 80/3.15 50(2)/1.97(2)
390(1)/15.4(1)
DN 80/3 240/9.45 240/9.45 250/9.84 340/13.4 250/9.84*
250(2)/9.84(2)
390 /15.4
(1) (1)
DN 100/4 300/11.8 300/11.8 300/11.8 300/11.8 390/15.4 300/11.8*
300(2)/11.8(2)
400(1)/15.8(1)
DN 150/6 400/15.8 400/15.8 400/15.8 300/11.8 400/15.8 400/15.8 300/11.8* 400/15.8
300(2)/11.8(2)
400(1)/15.8(1)
DN 200/8 400/15.8 400/15.8 400/15.8 300/11.8 400/15.8 400/15.8 300/11.8* 400/15.8 520/20.5
300(2)/11.8(2)
400 /15.8
(1) (1)
DN 250/10 400/15.8 400/15.8 400/15.8 300/11.8 400/15.8 400/15.8 300/11.8* 400/15.8 520/20.5 630/24.8
300(2)/11.8(2)
400(1)/15.8(1)
DN 300/12 400/15.8 400/15.8 400/15.8 300/11.8 400/15.8 400/15.8 300/11.8* 400/15.8 520/20.5 630/24.8 800/31.5
300(2)/11.8(2)
Beam angle 11 11 9 6 11 12 9 12 11 4 5 6
BD (m/ft) 0.25/0.8 0.35/1.15 0.4/1.3 0.6/2 0.5/1.6 0.07/0.23 0.3/1 0.3/1 0.4/1.3 0.6/2 0.7/2.3* 1.6/5.2
* Applicable to flush flange installation, for assembly via
Table 5: Recommended nozzle dimensions, nozzle length from sensor beam angle G/NPT 1 starting DN100 see FDU91
(1)
Mounted at backside thread of the Sensor FDU90
(2)
Mounted at frontside thread of the Sensor FDU90

24 The Endress+Hauser Maintenance Guide

Setup

Level
000
measured value Contrast: + or +
008
- + E E dist./
The Basic Setup menu Group - + E
meas value
E
enables quick and simple selection
00 002 003 004 005 059 006 008 051 052 053
commissioning. The software basic setup tank shape medium process empty blocking full dist./ check range of start
property cond. calibr. distance calibr. meas value distance mapping mapping
helps the user to enter the +
01 - dome - unknown - standard input E BD is input F D and L are - ok confirm
main parameters that cover safety settings ceiling - liquid - calm (s. sketch) displayed (s. sketch) displayed - too small suggestion
- horizontal - > 4 mm surface (s. sketch) (s. sketch) - too big or specify
95% of cases. By entering 0E
temperature cyl. - < 4 mm - add. - unknown range
- bypass agitator - manual
the data carefully, many 04
linearisation
problems are avoided. 05
extended calibr.

Customer map 06
output (HART, FF)
BD
It is required to map out profibus param.(PA)
100%
interference reflections created 0E
Envelope curve
0E1 0E2
plot settings recording D
inside the tank. This map is curve

based on the factory map and 09

display
092
language
E
F
preferably done with an empty -
0A 0A0 0A1 0A3 0A4
tank. This way, all eventual diagnostics present
error
previous
error
reset unlock
parameter
L

interference reflections 0C 0C0 333 (HART) 100 (HART)

caused by installations in system
parameter
tag no. 33333 (PA,FF) 2457 (PA,FF) 0%

the tank are detected and BD: blocking distance

stored in the memory.
Fig. 42: Basic Setup for Prosonic M devices

Spare parts

Instrument and spare parts Warning: the sensors

Your Spare parts New
availability FDU83/84/85/86 with an
instrument availability generation
See table. ATEX, FM or CSA certificate
are not certified for connectiion FMU86x YES - until 03/2012 FMU90
to the FMU 90 transmitter.
Migration In addition, the new FDU9x FDU8x NO - since 08/2010 FDU9x
sensors cannot be used with
The new FMU90 transmitters FMU86x transmitters. FMU23xA NO - since 12/2010 FMU30
associated to FDU9x sensors
replace FMU86x transmitters Re-engineering FMU23xE NO - since 12/2010 FMU30
and FDU8x sensors.
The 2-channel version of
For further information, use our Device Viewer:
The FMU90 transmitter is fully FMU90 is flexible: each www.services.endress.com/device-viewer
compatible with the FDU8x channel can either be used
transmitters and can be used for flow measurement or level Table 6: Instrument and spare parts availability
in association with FDU8x measurement, thus allowing
sensors. three combinations:
level + level, level + flow and
flow + flow.

The Endress+Hauser Maintenance Guide 25

 Capacitive level measurement
Level

The current Endress+Hauser range of capacitive sensors includes:

Level measurement for liquids: Liquicap T FMI21 and Liquicap M FMI51/52
Level detection for liquids: Liquicap M FTI51/52
Level detection for solids: Solicap M FTI55/56, Solicap S FTI77, Nivector
FTC968 and Minicap FTC260/262

In this section we provide a concise reminder of the main guidelines for optimal
use of capacitive sensors. In addition, you will find useful tips and advice for
Liquicap M users.

Overview (example: Liquicap M FTI5x) Fig. 43

Polyester housing Aluminum housing Stainless steel housing Aluminum housing Aluminum housing
F16 F17 F15 T13 F13
with a separate connection with a gas-tight
compartment and gas-tight process seal
process seal

Electronics

separate housing

Thread Flanges Hygiene connections Tri-Clamp Thread Flanges Clad flanges Hygiene connections
(G, NPT; (EN, ANSI, JIS) Hose gland PFTE-clad (G, NPT; (EN, ANSI, JIS) (EN, ANSI, JIS) Hose gland
G, NPT; (DN50 PN40) G1, NPT1; (DN50 PN40)
G1, NPT1) G1, NPT1)

Tri-Clamp
(DN25 (1"); Tri-Clamp
DN38 (1")) (DN38 (1");
DN40-51 (2"))

Flush-mounted seal
Hygiene Hygiene
(G, G1) (universal adapter)

Rod probe with

Rod/rope probe Rod/rope probe active build-up Rod - / Rod/rope probe Fully insulated rod/rope probe
with inactive length compensation rope probe with inactive length with fully insulated inactive length

Measuring principle
1 2 3
The principle of capacitive level measurement is based on the change
in capacitance of the capacitor due to the change in the level formed
by the probe and the container wall (conductive material). When the
CE
probe is in the air (1), a low initial capacitance is measured.
C
When the container is filled, the capacitance of the capacitor CA C
increases the more the probe is covered (2), (3). As of a conductivity
CA
of 100s/cm, the measurement is independent of the value for the R

dielectric constant (DK) of the liquid. As a result, fluctuations in the

Fig. 44: Measuring principle L00-FMI5xxxx-15-05-xx-xx-001

DK value do not affect the measured value display. Furthermore, the R: Conductivity of liquid CE: Final capacitance (probe covered):
system also prevents the effect of medium build-up or condensate C: Capacitance of liquid change in capacitance
near the process connection for probes with an inactive length. CA: Initial capacitance (probe not covered) C: Change in capacitance

26 The Endress+Hauser Maintenance Guide

 Level
Ensure good
connection to
the ground in
any case.

Videos available at
www.endress.com/videos

A ground tube is used as see fig. 45) or remotely with

a counter electrode for FieldCare software.
containers made of
non-conductive materials. External cleaning
When externally cleaning
Phase-selective measurement Liquicap M, make sure that the
The electronic evaluation of cleaning agent used does not
the container capacitance attack or corrode the housing
works along the principle of surface or seals.
phase-selective measurement. L00-FMI5xxxx-07-05-xx-xx-000

In this process, the amount Seals Fig. 45: Local operation directly on the electronic insert
Green LED ( operational status)
of alternating current and the The process seals of the Red LED ( fault message)
phase shift between the voltage sensor should be replaced Key (-)
and current is measured. periodically, especially when Key (+)
using molded seals (aseptic Mode switch
1 : Operation 5 : Measuring range
With these two characteristic version)! The intervals between 2 : Empty calibration 6 : Self-test
quantities, the capacitive idle seal replacement depend on the 3 : Full calibration 7 : Reset (factory settings)
current can be calculated by frequency of the cleaning cycles 4 : Measuring modes 8 : Upload sensor EEPROM
the medium capacitor and the and on the fluid and cleaning 420mA current pick-off, e.g. for full/empty calibration with multimeter.
(No need to disconnect circuit!)
real current by the medium temperature. Display connection
resistance. Conductive build-up
stuck to the probe rod/rope Possible measuring errors
acts like additional medium Is the measured value incorrect
resistance and causes an error on an FMI5x device? F16 housing
in measurement. As the size
of the medium resistance can 1. Verify empty and 8 6 4
2
be determined with phase- full calibration.
1
selective measurement, 2. Clean probe if necessary, 7 5 3
an algorithm is used to verify probe.
compensate the build-up on 3. If necessary, alter for better
the probe. Thus, Liquicap M installation position of probe 1 = Guard
2 = SDA_TXD
has build-up compensation. (do not mount in a filling 3 = GND
4 = GND EEPROM
curtain). 5 = GND
4. Check ground from process 6 = DVCC (3V)
7 = Probe
Operation and maintenance connection to tank wall. 8 = SCL RXD
Resistance measurement < 1
Operation See fig. 46 for more details. Electronic insert FEI50H
The display can be used to 5. Check probe insulation
configure directly at the device (resistance measurement) 7 5 3
1
via three keys. All device > 800k (only possible for
functions can be set via menu conductive media). 8 6 4
2

operation. The menu consists of

function groups and functions. How to proceed when a fault
Application parameters can be occurs at the electronic insert Fig. 46: Connections
read or set in the functions. (FTI5x)? In the event of faults
You can also operate directly on during commissioning or
the electronic insert (FEI50H: operation of the device,

The Endress+Hauser Maintenance Guide 27

 you have the option to Calibration is necessary only at Weather protection cover
Level

Always recommended for outside

carryout fault diagnostics start-up. There will be no drift
installation to avoid strong temperature
on the electronic insert. This afterwards. changes of electronics.
function is supported by the
electronic inserts FEI51, Calibration - Installation
Not above the fillstream.
FEI52, FEI54, FEI55. Liquicap M FMIxx
Establish proper ground connection
For conductive liquids between sensor and tank wall.
The diagnostics provide (>100S/cm), the probe Use ground tube in non-conductive
information about the operating is calibrated at the factory tanks (e. g. of plastic material).
status of the device. The to the probe length
results of the diagnostics are ordered (0% to 100%). Nozzle
Use inactive length for
displayed by LEDs 1, 2, 4 and For non-conductive liquids installation in a nozzle.
5. If the diagnostics detect (<1S/cm), 0% calibration is
multiple faults, these are shown performed at the factory. Only
Measuring range
according to their priority. A the 100% calibration has to be Measuring range L 1 possible
serious fault (e.g. priority 3) is carried out on site. from the tip of the probe to
always displayed before a less the process connection.
Particularly suited to small tanks in
serious fault (e.g. priority 5). Calibration - Liquicap M
fast filling and discharging operations.
See error table in chapter 9 of FTIxx and Solicap M FTIxx

L1
BA299 Operating Instructions. Calibration at the detection point
has to be carried out on site.
Tank installations
Obstacles do not affect
Installation conditions the measurement.
Spare parts
Because most problems
reported by users are due to Instrument and Foam
incorrect installation and/ spare parts availability In slight foam formation, the Build-up
or initial calibration, here is a See table 9 compensation mode may be selected.
reminder of the essential points
that must be considered. Note: Once Liquicap M or the
FEI50H electronic insert has
Instructions for the been replaced, the calibration
installation in a tank values must be transferred to
See fig. 47 the replacement device.
=> When the probe is replaced,
Adjustment the calibration values in the
An adjustment is necessary for electronic insert are to be
non-conductive liquids or if the transferred to the probe DAT Fig. 47: Installation in a tank
er of a non-conductive medium module.
has changed. => When the electronic insert
is replaced, the calibration
Your Spare parts New
Full/empty calibration values of the probe DAT
instrument availability generation
You may use the 4 to 20mA module are to be transferred to
current pick-off, e.g. for the electronics. Multicap family NO - since 12/2010 Consult us
full/empty calibration with Measuring can continue
multimeter. (No need to without having to carry out a 11500Z NO - since 12/2010 FMP54, FTL70
disconnect circuit!) new calibration.

For further information, use our Device Viewer:

www.services.endress.com/device-viewer

Table 7: Instrument and spare parts availability

28 The Endress+Hauser Maintenance Guide

 Flow metering

Installation and setup require special care

Flowmeters are so reliable that users There is also plenty of useful information to Contents
consult us primarily during installation and help you get the best from your instruments
commissioning and very often it is not for throughout their life cycle and prepare Basics 30
several years that users come back to us. for renewing your equipment gradually. The Basics chapter includes
It is true that there are certain issues due information that is valid for all
to aging, but others can be resolved by For those who wish to go measurement principles described in
this section. We therefore strongly
recalibration. From time to time we also further in mastering this recommend that you read it first.
find that the flowmeter has been used for subject, Endress+Hauser
an application other than that for which has published the Flow Maintenance of
it had been selected, at the risk of it being Handbook, a genuine flow Proline flowmeters 32
unsuited to this application, and creating measurement bible. Electromagnetic flowmeters 34
a long term problem. Finally, we observe
that many apparently maintenance-related You will also find Mass flowmeters 37
problems prove to be installation and setup several videos Vortex flowmeters 40
problems. covering this topic at Ultrasonic flowmeters 42
www.endress.com/videos.
This guide serves as a reminder of the Thermal mass flowmeters 44
few operating constraints and installation We also offer training sessions, in classroom FAQ 46
conditions for flowmeters. We have and on site. See Training in the At your
also recapped the most frequently asked service section.
questions. With this information, you
will be able to prevent or resolve the vast
majority of potential problems yourself!

The Endress+Hauser Maintenance Guide 29

 Basics
Information common to any type of flowmeter

Electromagnetic Coriolis mass Vortex Ultrasonic Thermal mass

flowmeters flowmeters flowmeters flowmeters flowmeters
Specific information p. 34 Specific information p. 37 Specific information p. 40 Specific information p. 42 Specific information p. 44
Flow

Installation requirements Installation in a siphon Integration to

Compliance overview Sometimes it cannot be PROFIBUS networks
ensured that the pipe is always Cabling and termination are
with installation The specification of ANY full (i.e. wastewater pipes). the source of most reported
requirements flowmeter is based on an This could lead to measuring problems. Please refer to
ideal installation. Installation errors or situations where the the pages PROFIBUS DP/
would avoid guidelines for all technologies flowmeter will not work at all. PA networks in the Field
most reported exist. They should be viewed as The flowmeter should then be communication section.
MINIMUM requirements: installed in a siphon (fig.2).
errors! If solids are carried with the Setup - configuration
The flowmeter must remain fluid it is recommended to
completely full at all times. plan a cleaning access. A U- General note:
This is of utmost importance tube or a sloping pipe might If the installation and wiring
for filling or dosing provide simple solutions. conditions have been closely
applications, since many observed initially, you can
flowmeters (except mass Advice: the ideal mount be certain of getting correct
flowmeters) measure the for a flowmeter is in a fluid measurements from the
fluids velocity, assuming riser vertical pipe (fig.3) instruments first activation.
that the whole section is full The meter must be installed Configuration will only serve
flow direction
of liquid. If the flowmeter with sufficient straight pipe to optimize the operating
is not completely full, then upstream. parameters of the quantities
measurement errors are See technology-specific measured (current output
larger. Please note that this installation conditions for setup, etc.).
rule even applies to mass further details (mainly
Fig. 1 flowmeters. vortex, ultrasonic and Since 2007, all
thermal mass flowmeter). Endress+Hauser
F06-5xxxxxxx-11-00-00-xx-000

Installation at the highest flowmeters belong to the

point of pipework Wiring Proline family and thus
Installation at the top of a Take care with the instrument offer QUICK SETUP.
piping system poses a risk wiring, especially when the QUICK SETUP enables quick
that air will collect and transmitter is mounted remotely. and easy configuration of
negatively influence the the devices main functions
Fig. 2: Installation in a siphon performance (fig.1).
F06-5xxxxxxx-11-00-00-xx-002
Ensure correct tightening of (units, outputs, etc).
Avoid installing directly the wires and cable glands.
upstream of a free pipe outlet In case of humid atmosphere, You can also configure your
in a vertical pipe as air will check that water cannot flowmeters from your PC
flow direction

potentially rise up through get into the flowmeter. using our configuration and
the flowmeter causing asset management tool called
measuring errors. Further requirements may apply FieldCare.
The flowmeter should be for one particular technology.
Fig. 3: Ideal mount for a flowmeter installed in a lower part of Please check specific Our service organization can set up
the pipe work. This ensures
F06-5xxxxxxx-11-00-00-xx-004
installation conditions for any Endress+Hauser flowmeter for
you and thus ensure you immediately
enough head pressure to EMF*, mass flowmeters etc. get the most out of your instrument.
avoid cavitation and the in the next sections. (See Device commissioning in the
meter will always remain full. At your service section).

*EMF: Electromagnetic flowmeter

30 The Endress+Hauser Maintenance Guide

 Inspection of the
flowmeter pipe

Flowmeters connected to a PROFIBUS network Functional check using Flowmeters mounted in a fluid riser vertical pipe
the FieldCheck tool

Flow
Operation and maintenance Calibration input and output function Maintenance planning
Intrinsically our flowmeters of the transmitter.
offer long-term stability They may be checked using Do you know exactly which part of
In most applications, when
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 we so that problems can be plant and how you could maintain or
require very little maintenance recommend periodic calibration identified. For any flowmeter calibrate it more efficiently? Are you
for the measurement points that belonging to the Proline sure that your present actions are
as they are designed without
minimizing the risks of unplanned
any moving mechanical parts. are critical to the process and family (see next page) we breakdowns? Are you sure that
Nevertheless, due to their thus are important to control recommend the use of our your present actions are the most
criticality to quality, some the quality of your product. FieldCheck smart signal cost-effective?
flowmeters need to be inspected From on-site to accredited simulator which facilitates
With Endress+Hausers Installed Base
or/and calibrated periodically. services, you can be sure to find on-site verification. Audit, our service consultant will help
Defining the right maintenance the right method by finding The user may effect either you to quickly find an answer to these
frequency taking several the right balance between a manual simulation of the three questions and move forward in
a controlled manner to a maintenance
parameters into account is an the flowmeter downtime and flowmeter functions or a
plan that improves plant reliability
experts job. Endress+Hauser the calibration uncertainty. full check of the flowmeter, while reducing costs.
can also help you with this task! of its electronics only or (See Maintenance and calibration
Calibration can be performed by
Endress+Hauser either on-site or
of its sensor only. The tool consulting in the At your service
section).
Periodic inspection to assure in our accredited laboratories. incorporates procedures for
reliability of the application (See Calibration services in the automatically checking all
After a flowmeter has been At your service section). the electronic operations Maintenance performing
operating for a period of time, (linearity of the amplifier, the
users may falsely believe that Inspection of seals analog outs and frequency) If you do not have the time or the
right tools to efficiently perform your
just because the flowmeter and gaskets on the one hand, and all maintenance, an Endress+Hauser
signal is stable it is correct In some processes, operational the sensor operations on service contract can provide the
but this might not be the case. needs necessitate the use of the other (magnetic field appropriate level of maintenance
Even an indicated flow that frequent cleaning or sterilization and measuring electrode support you require.
appears to be within acceptable in place (CIP or SIP). The integrity). With FieldCare We provide regular checks of your
limits may be inaccurate and flowmeter seals and gaskets software, the user can equipment and warranty extensions
may then affect the quality of should then be carefully chosen upload the test results to providing you with complete peace of
the final product. and frequently replaced to avoid a PC, incorporate them in mind and cost control. From regular
support to partnership agreements, we
risks of leakage, contamination a certificate, print them offer four distinct levels of service
Pipe inspections and even process failure. or archive them, thus (See Maintenance services in the
Deposits in the pipe can cause meeting the requirements At your service section).
a slow drift of measured Routine maintenance of quality procedures.
values at meter output that is The need for routine
not detected and rectified. maintenance is defined Moreover, this solution combined Corrective maintenance
According to the type of according to the importance of with calibration could allow The more critical your
flowmeter, anything that the flowmeter in the process. users to reduce the calibration instrument is to your process,
alters the shape or diameter frequencies and thereby reduce the shorter the acceptable time
of the sensor could cause Flowmeters can be checked maintenance costs. for repair.
errors in the readings. in a variety of ways: Thanks to the Proline concept
The most common FieldCheck is presented on page 33. (see opposite), flowmeters offer
Due to the effects of sedimentation maintenance seems to be a modular design; one of the
or deposition, a periodical the use of electrical devices outcomes is that most parts can
cleaning of the flowmeter for simple checking of the be easily replaced thus allowing
pipe might be necessary. quick repair.

The Endress+Hauser Maintenance Guide 31

 Improved efficiency in the repair
process is another way to reduce
downtimes. Our training sessions help
you to quickly diagnose any failure and
to apply the most appropriate repair
method. (See Training in the
At your service section).

Spare parts stock

For any flowmeter belonging
to the Proline family (see next
page), we suggest you keep a full
set of electronic inserts in stock.
In case of a highly critical
instrument, you might also
consider stocking a complete
new instrument.
To easily select the right spare
part, we recommend the use of

Proline flowmeters
Flow

our Spare Part Finding Tool.

Our specialists can help you to define

the criticality of all your measuring
instruments (even for other makes).
A range of instruments designed
They will apply a structured
methodology adapted to your own to make your life easier!
application. (See Maintenance and
calibration consulting service in the
At your service section). Proline flowmeters provide you with several benefits
throughout their life cycle:
Instrument and
spare parts availability
You will find detailed Unified components and spare Better plant availability on The Proline family

information in the next sections parts minimize storage costs account of self-diagnosis
Electromagnetic
(EMF, mass flowmeters etc.) Time-saving by easily functions, data backup flowmeters
replaceable components (S-DAT, T-DAT), standardized Promag 10
without recalibration spare parts concept etc. Promag 23
Promag 50
Multi-option control with Quick Setups and
Promag 51
local display or configuration standardized configuration Promag 53
software (such as FieldCare), routines for user convenience Promag 55
locally through the service FieldCheck for testing
Mass flowmeters
interface or by digital flowmeters in-line
Promass 40
communication from a Promass 80
control center. Note that Promass 83
FieldCare is now the Promass 84
standard configuration
Vortex flowmeters
software and replaces Prowirl 72
FieldTool and TofTool. Prowirl 73

Ultrasonic flowmeters
Prosonic Flow 90
Prosonic Flow 91
Prosonic Flow 93
Prosonic Flow 92F
Permanent self-diagnosis
Thermal mass flowmeters
All Proline flowmeters have continuous
t-mass 65
self-diagnosis during operation. Faults, if
they occur, are clearly displayed.
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, 55
and 23, Promass83,
Prosonic Flow 91, 92F,
and 93 and T-mass65)
S-DAT for sensor data
(all devices)

32 The Endress+Hauser Maintenance Guide

 FieldCheck How does it work?
FieldCheck comprises a signal
generator, connector cables
Smart signal simulator and Simubox adapters for
connection to the various types
With FieldCheck, meter verification can be carried out of flowmeters (see picture).
without the removal of the Proline flowmeter from the pipe.
Where ISO 9000 requires frequent test cycles, FieldCheck is The user may effect:
an economical alternative to calibration. A manual simulation of
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
All Endress+Hauser flowmeters FieldCheck simulates sensor flowmeters can be tested the behavior of the outs
are based on unified electronics signals to test and evaluate directly on-site, without towards the device, or the
and operating concepts. The the behavior of an item of removal of the instrument. supervision system, without
modular Proline device concept equipment. It can also, thanks Simultaneous verification any actual flow in the pipe.
provides the user with obvious to its checking procedures, test of process outputs (current, A full check of the flowmeter,

Flow
advantages, e.g. in service proper flowmeter functioning frequency). of its electronics only or of its
situations: be it to meet in-house criteria Large, clear, multivariable sensor only (see photo). The
or regulatory requirements. The displays. tool incorporates procedures
Minimization of spare parts check and test results obtained Expanded functionality for automatically checking
costs through standardized with FieldCheck can then be with the FieldCare all the electronic operations
components. stored in a database and printed software program: reading (linearity of the amplifier, the
Time-saving with easily out for subsequent use, e.g. in and printing of test results analog outs and frequency)
replaceable meter electronics, connection with certification by (verification certificates). on the one hand, and all
without the need for resetting. audit organizations. the sensor operations on the
Individual retrofitting of other (magnetic field and
flowmeters for application- measuring electrode integrity).
specific modifications. Outputs
We can provide checks on your
Proline flowmeters as on-site
Service service for your installed devices.
interface Our specialist staff will carry out
all the test functions directly in the
installation.

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

Simubox
FieldCare is presented on
www.automation.endress.com/
Time-saving Quick Setups fieldcare

Fig. 4
The Quick Setup menus
make commissioning fast and
straightforward. It guides you
step by step through all the
operation-relevant parameters.
Quick Setups are available On-site functional check of a flowmeter using the FieldCheck.
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

The Endress+Hauser Maintenance Guide 33

 Electromagnetic flowmeters
Promag series

The current Endress+Hauser range of electromagnetic

flowmeters (EMF) includes Proline Promag 10, 23, 50, 51, 53
and 55.

In this section, you will find essential information and advice

that will help you to perform the optimum follow-up of your
Promag electromagnetic flowmeters throughout their lifecycle.
Videos available at
www.endress.com/videos
Flow

Measuring principle
The meter
To measure flow based on
must remain Faradays law of induction an
completely full alternating magnetic field is
produced with coils of copper
at all times. wire. A controlled coil current
ensures that the magnetic field
strength remains constant during
the measurement. The length
of the conductor (the distance
between the two measuring
electrodes at the internal
diameter of the measuring tube)
is also a constant value. The only
variable in Faradays equation is
the flow velocity of the passing
fluid. The generated voltage is
exactly proportional and linear When installed a short distance electrode is at the highest point
to the velocity of the fluid. An from a profile disturbance an of the pipe and will function
EMF does not measure volume EMF will suffer measuring correctly. In applications where
but velocity. The induced voltage errors due to the disturbed flow a partially filled pipe is unlikely
of a general purpose EMF at profile entering the meter. The the orientation of the electrodes
Endress+Hauser equals approx. flowmeter should therefore does not matter.
300V per m/s velocity. be installed according to the
installation recommendation The grounding of the EMF
Installation conditions with sufficient straight pipe must be in accordance with
F06-5xxxxxxx-11-00-00-xx-005
up- and downstream. The the guidelines (see FAQs). For
In addition to installation recommended straight lengths further information please refer
Fig. 5: Recommended straight lengths
guidelines for all technologies are measured from the center to the corresponding chapter
(see Basics), the particular of the flowmeter. This means in the Operating Manual.
installation requirements of an in small diameter there is often
EMF are: enough straight length within Setup - configuration
the device itself.
Inlet and outlet runs All Proline flowmeters feature a
The meter must be installed If the Empty Pipe Detection Quick Setup program to make
with sufficient straight pipe is used the correct sensor standard commissioning easy.
up- and downstream. orientation must be considered
F06-5xxxxxxx-11-00-xx-xx-000 If possible, install the sensor well (see figure 5). Our service organization can set up
clear of fittings such as valves, T- The empty pipe detection any Endress+Hauser flowmeter for
you and thus ensure you immediately
pieces, elbows, etc. Compliance electrode must be at the get the most out of your instrument.
with the following requirements highest point of a horizontally (See Device commissioning in the
for the inlet and outlet runs is installed EMF. If the EMF must At your service section).
necessary in order to ensure be installed in a horizontal
measuring accuracy: F06-5xxxxxxx-11-00-xx-xx-000
pipe, the transmitter/terminal
Fig. 6: Orientation in case of Empty Pipe Inlet run 5 x DN housing must be located on
Detection (1) Outlet run 2 x DN top of the pipe. Then the EPD

34 The Endress+Hauser Maintenance Guide

 EMF mounted
vertically

EMF mounted
in a siphon

EMF mounted horizontally EMF with remote electronics

Flow
Operation and Maintenance Note: a measurement In the knowledge that Spare parts stock
consistency check may calibration frequencies should For any flowmeter belonging to
Preventive maintenance be obtained by means be optimized over time in line the Proline family, we suggest
How can you minimize the of comparison with a with the operating histories, you keep a full set of electronic
risks of failure or drift of your non-intrusive ultrasonic you need to set an initial inserts in stock.
measurement point? flowmeter. This is, however, frequency. Hereafter you will
Having no moving parts, EMFs not a calibration. find a table of recommendations
require very little preventive to help you define this
maintenance. Abrasive fluids frequency, taking into account
Process conditions may affect Is your flowmeter used to the process conditions and
your flowmeters lifetime or measure abrasive fluids (e.g. ambient conditions:
accuracy (abrasive products, phosphates in the mining
soiling of the electrodes, effects industry)? We suggest to: Note:
from high temperatures or high Use a sensor with a a natural For abrasive or corrosive
temperature cycles (e.g. SIP), rubber liner to minimize the fluids, the calibration
vibration, aggressive chemical impact of abrasion. frequency must be lowered
products etc). Turn the meter by 45 according to the wear.
If you face one of these every 6 months in case of These calibration
situations, you can drastically an horizontal installation. recommendations are
decrease the risk of process This reduces wear due to no substitute for the
downtime by planning solids settling to a higher maintenance operations
periodical checks and concentration because required to keep the device in
calibrations. Another topic of the low velocity. perfect working condition.
requires particular attention:
Calibration can be performed by
the seals on H sensors (hygienic Calibration Endress+Hauser either on-site or
or small diameter) which are Calibration frequency should in our accredited laboratories.
exposed to repeated cleaning be in line with the operating (See Calibration services in the
or sterilization (CIP/SIP) may conditions. Device calibration At your service section).
quickly deteriorate. Ensure that procedures and intervals
they are regularly replaced. depend on: Instrument and
The precision required spare parts availability
To control the functional for the application
integrity of the Promag we Its criticality to the
Your Spare parts New
use special tools that provide process, the legislative
instrument availability generation
thorough checks of the internal constraints imposed.
parameters of the electronics So it is important to define the Promag30/33 NO - since 12/2007 Promag10/50/53
including elements of the calibration intervals and the
sensor (See full description of maximum permissible error Promag39F/H NO - since 09/2007 Promag50/53
FieldCheck on page 33). of a measurement point.
The main factors influencing Dosimag A NO - since 12/2010 Dosimag5BH
Our service contracts can include flowmeter drift are:
such verifications once a year is The process conditions (fluid Promag35S NO - since 12/2010 Promag55S
recommended.
(See Maintenance services in the
type, product temperature etc.)
At your service section). The ambient conditions
For further information, use our Device Viewer:
in which the sensors are www.services.endress.com/device-viewer
fitted (ambient temperature,
moisture). Table 1: Instrument and spare parts availability

The Endress+Hauser Maintenance Guide 35

 Migration For a more in-depth analysis of your 0.05 S/cm
Oil, Hydrocarbons
Ultra pure water
current installed base, we can help you Water
Endress+Hausers new with our Installed Base Audit service.
1 S/cm Pure water
(See Maintenance and calibration Minimal Conductivity 5 S/cm
generations of electromagnetic consulting in the At your service for EMFs
flowmeters are Promag 10 section). 10 S/cm
Industrial water
and Promag 5X series. These
new instruments offer new Re-engineering 100 S/cm
Potable water
ways to carry out preventive
1 mS/cm
verification (see FieldCheck on You wish to apply an EMF to Food Beer
page 33). They can substitute a different application than 10 mS/cm
Milk
Orange juice
all Endress+Hausers previous the one for which it had been Apple juice
instruments. selected? Please take the 100 mS/cm Tomato juice

following advice into account. Process Phosphoric acid

Sulphuric acid
The old generation primarily 1000 mS/cm
Hydrochloric acid
includes the Promag 30, No or low conductivity Fig. 7 Caustic soda

Promag33 and Promag 35. If a fluid has a rather low

conductivity, an EMF can
With which device should not be used. The following
you replace your Promag 30? liquids can NOT be measured
Flow

For identical applications, because their conductivity is

the answer would be the too low: vegetable or mineral
Promag 10, which is much oil, de-mineralized water,
more user-friendly and easy hydrocarbons/solvents, etc.
to use. In addition, you will (see graphics)
only need to stock a single However, if these liquids are Fig. 8: The effect of build-up
electronics board. mixed with even a low quantity on the electrodes
With which device should of a conductive liquid, an EMF
you replace your Promag33? might be used. For abrasive slurries suitable If the build-up is conductive
For standard applications To apply an EMF successfully liners and electrode designs/ (e.g. magnetite in heating
it would be its designated the fluid must have a minimum materials must be chosen. water systems), it is possible to
successor, the Promag 50. conductivity of: >5 S/cm for Install the sensor as far as use an electronic solution: ECC
For special applications, the Promag 50/53/55 (55 also for possible from any potential (electrode clean circuit) keeps
Promag53 offers a broader water) >20 S/cm for water source of disturbance. the measuring electrodes clean
range of options and better applications in general and free from build-up.
measurement uncertainty. >50 S/cm for Promag 23/10. Temperature range
Promag 53 also includes All available liner materials Measuring range
passive or active pulse output, Solid content in a fluid are isolating plastics or You also need to check that the
similar to Promag 33. Since the influence of rubbers with a limited flowmeters measuring range
With which device should solids depends heavily on operating temperature. This fits the application. In case of
you replace your Promag35? concentration, mixture, particle is the limiting factor for the a different pipe diameter, a
Replace with the Promag55, characteristics and other applicability of EMFs. certain flow rate is required
typically for applications parameters, expert knowledge at minimum flow so that
involving high-load is required to select and size the Build-up / ECC the flowmeter operates with
fluids (paper mill, mining best fitting model and options. While an EMF is very tolerant the expected accuracy. The
extraction, etc.) Two typical influences must be regarding build-up on the Applicator software allows you
considered: measuring tube, there are to check the devices accuracy
Please call our sales force for Excessive signal noise limitations. A layer on the over the measuring range.
more information. due to solids requires a electrodes will eventually lead Applicator is available online at
high performing transmitter to a reduced flow signal and the https://wapps.endress.com/
(Promag 55). device might stop functioning. applicator

Again consider proper

installation and setup.

36 The Endress+Hauser Maintenance Guide

 Coriolis mass flowmeters
Promass series

The current Endress+Hauser range of mass flowmeters

includes Proline Promass 40, 80, 83, 84 and the new
two-wire device Promass E 200.

In this section, you will find essential information and

advice that will help you to get the most out of your Promass
flowmeters throughout their lifecycle.
Videos available at
www.endress.com/videos

Flow
Measuring principle

Ensure that The measuring principle

is based on the controlled
cavitation does generation of Coriolis forces.
not occur! These forces are always present
when both translational and
rotational movements are
superimposed.

FC = 2 m (v w)
FC = Coriolis force
m = moving mass
w = rotational velocity
v = radial velocity

The amplitude of the Coriolis

force depends on the moving flow. Electrodynamic sensors in the mass and thus the
mass m, its velocity v in the register the tube oscillations at density of the oscillating system
system, and thus the mass flow. the inlet and outlet. (consisting of the measuring
Instead of a constant rotational tube and fluid) results in a
velocity w, the Promass sensor System balance is ensured by corresponding, automatic
uses oscillation. the antiphase oscillation of adjustment in the oscillation
the two measuring tubes. The frequency. Resonance frequency
In the Promass E, F and M measuring principle is thus a function of fluid
sensors, two parallel measuring operates independently of density. The microprocessor
tubes containing flowing temperature, pressure, viscosity, utilizes this relationship to
fluid oscillate in antiphase, conductivity and flow profile. obtain a density signal.
acting like a tuning fork. The
Coriolis forces produced at the Note: For Promass H, The temperature of the
measuring tubes cause a phase I, P and S, the system measuring tube is determined
shift in the tube oscillations (see balance required for proper in order to calculate the
illustration): measurement is created by compensation factor due to
exciting an eccentrically temperature effects. This
At zero flow, in other arranged swinging mass to signal corresponds to the
words when the fluid is at antiphase oscillation. This process temperature and is also
a standstill, the two tubes patented TMB (Torsion Mode available as an output.
oscillate in phase (1). Balanced) system guarantees
Mass flow causes deceleration perfect measurements, even
of the oscillation at the inlet of in changing process and
the tubes (2) and acceleration environmental conditions.
at the outlet (3).
The measuring tube is
The phase difference (A-B) continuously excited at its
increases with increasing mass resonance frequency. A change
Fig. 9

The Endress+Hauser Maintenance Guide 37

 Commissioning and
configuration with
FieldCare

Mobile flow rig for

on-site calibration
Coriolis mass flowmeter with remote electronics

Installation conditions Measuring ranges for gases

The full scale values depend on the density of the gas. Use the
In addition to installation guidelines for all technologies (see Basics), formula below to calculate the full scale values:
please note specific installation requirements for a mass flowmeter: mmax(G) = mmax(F) r(G) / X [kg/m3]
Flow

When using a bent measuring tube and horizontal installation, the

Promass F, M, X X Promass E X X
position of the sensor has to be matched to the fluid properties! I, S and P new* old* new* old*
DN8 60 160 DN8 85 225
DN15 80 160 DN15 110 225
DN25, 40, 50 90 160 DN25, 40, 50 125 225
DN80 110 160
Tables 2 and 3
DN100 130 160
DN150, 250 200 250

* X new is valid starting with amplifier hardware 2.00.00/software 3.00.00 or later.

F06-xxxxxxxx-11-00-00-xx-003
For any older hardware/software use value X old
Fig. 10
Horizontal installation for sensors with a bent measuring tube mmax(G) = Maximum full scale value for gas [kg/h]
1 Not suitable for fluids with entrained solids. Risk of solids accumulating. mmax(F) = Maximum full scale value for liquid [kg/h]
2 Not suitable for outgassing fluids. Risk of air accumulating. r(G) = Gas density in [kg/m3] at operating conditions
Here, mmax(G) can never be greater than mmax(F).
System pressure
It is important to ensure that cavitation does not occur because it Mounting location
would influence the oscillation of the measuring tube. No special No special precautions need to be taken for fittings which create
measures need to be taken for fluids that have properties similar to turbulence (valves, elbows, T-pieces etc.), as long as no cavitation
water under normal conditions. occurs. Entrained air or gas bubbles in the measuring tube can result
In the case of liquids with a low boiling point (hydrocarbons, solvents, in an increase in measuring errors. Therefore, avoid the following
liquefied gases) or in suction lines, it is important to ensure that mounting locations in the pipe installation:
pressure does not drop below the vapor pressure and that the liquid Highest point of a pipeline - risk of air accumulating.
does not start to boil. It is also important to ensure that the gases that Directly upstream of a free pipe outlet in a vertical pipeline.
occur naturally in many liquids do not outgas. Such effects can be
prevented when system pressure is sufficiently high.
Therefore, the following locations should be preferred for installation:
Downstream from pumps (no danger of vacuum)
At the lowest point in a vertical pipe

Recommended measuring ranges: limiting flow

Please refer to the Measuring range section of the Technical
Information documentation. Select nominal diameter by optimizing
between required flow range and permissible pressure loss. See the
Fig. 11 F06-xxxxxxxx-11-00-00-xx-004

Measuring range section for a list of maximum possible full scale values.
The minimum recommended full scale value is approx. 1/20 of F06-xxxxxxxx-11-00-00-xx-00
the maximum full scale value. Note : We recommend vertical orientation with upward direction of
In most applications, 20 to 50% of the maximum full scale value flow. When fluid is not flowing, entrained solids will sink down and
can be considered ideal. gases will rise away from the measuring tube. The measuring tubes can
Select a lower full scale value for abrasive substances such as fluids be completely drained and protected against build-up of solids.
with entrained solids (flow velocity <1 m/s).
For gas measurement the following rules apply: Setup - configuration
Flow velocity in the measuring tubes should not be more than half
the sonic velocity (0.5 Mach). All Proline flowmeters feature a Quick Setup program for
The maximum mass flow depends on the density of the gas: straightforward commissioning. Promass 83 provides an application-
formula shown below. specific Quick Setup program.

38 The Endress+Hauser Maintenance Guide

Operation and maintenance Calibration
See Basics (page 29) and also page 33 for information regarding
Preventive maintenance calibration of flowmeters.
Having no moving parts, mass flowmeters require very little
preventive maintenance. Nevertheless, many process conditions Calibration can be performed by Endress+Hauser either on site or in our accredited
laboratories (see Calibration services in the At your service section).
may 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 the deposit of medium in the
measure pipe, inhomogeneous mediums, gas bubbles and solids. Your Spare parts New
Are you facing one of these situations? By planning periodical instrument availability generation
checks you will drastically decrease the risk of process downtime.
Promass 60F/I/M NO - since 12/2008 Promass 80
There are two simple ways to check a mass flowmeter:
Promass 63F/I/M NO - since 12/2010 Promass 83
1 - Zero point adjustment
Promass 80/83/84M YES - until 12/2016 *
All measuring devices are calibrated to state-of-the-art technology.
The zero point determined in this way is imprinted on the nameplate. * According to application: Promass 80/83/84 F/I/S or CNG mass
Calibration takes place under reference conditions. Therefore, a zero

Flow
point adjustment is generally not required! Experience shows that the
For further information, use our Device Viewer:
zero point adjustment is advisable only in special cases: www.services.endress.com/device-viewer
When the highest measuring accuracy is required and the flow
rates are very low. Table 4: Instrument and spare parts availability
Under extreme process or operating conditions (e.g. very high
process temperatures or highly viscous fluids). Spare parts stock
For any flowmeter belonging to the Proline family, we suggest you
How to check the zero point? keep a full set of electronic inserts in stock.
First you have to set the low flow cutoff to 0 and close the pipe.
Then check the zero-point in the display, while the flow in the Migration
pipe is definitely 0. In this state, the display has to show a value Promass 60 and 63 flowmeters must be replaced by the Promass
close to the zero stability of the sensor and has to be stable. 80 and 83 respectively. The electronic board must be changed at
the same time. 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 that is in the pipe
(e.g. d water = 0.998kg/dm3 at 20C). You must not stop the flow. The new Promass E 200 for mass flow
Compare the displayed density to the density of the medium. The and density measurement is a true
displayed value has to be stable and accurate in the possible tolerance 4-20mA loop powered device and
threshold. is an excellent alternative to old
If one of these two methods gives a wrong result, please contact us. generations e.g m-point + ZL6072
Note: To get a good result with these two methods, it is necessary to and Promass F/I/M + DZL363.
have no air or gas bubbles in the liquid.
Video about our 2-wire
Re-engineering concept available at
During operation, the meter is permanently in self-diagnosis mode; Check that the flowmeters measuring www.endress.com/videos
therefore either severe process conditions or meter faults will be range fits the application. In case of a
indicated. Over and above that, we use special tools that provide different pipe diameter, a certain flow rate is required at minimum
complete checks of the internal parameters of the electronics flow so that the flowmeter operates with the expected accuracy. The
including elements of the sensor. (See full description of FieldCheck Applicator software allows you to check the devices accuracy over
on page 33). the measuring range. Applicator is available online at
https://wapps.endress.com/applicator
Our service contracts can include such verifications once a year is recommended.
(See Maintenance services in the At your service section). Again consider proper installation and setup.

New Promass E 200 for mass flow

and density measurement

The Endress+Hauser Maintenance Guide 39

 Vortex flowmeters
Prowirl series

The current Endress+Hauser range of vortex flowmeters

includes Proline Prowirl 72 and 73.

In this section, you will find essential information and advice

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

Videos available at
www.endress.com/videos
Flow

Measuring principle

Vortex shedding flowmeters

Take care of inlet work on the principle of the
and outlet runs. Karman vortex street. When
a fluid flows past a bluff body,
vortices are alternately formed
and shed on both sides with
opposite senses of rotation.
These vortices each generate a
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. viscosity and density. In this way, The nominal diameter and
the K-factor is also independent pipe inside diameter have to
The K-factor is used as the of the type of fluid to be be as close as possible.
proportional constant: K-Factor measured, regardless of whether Note: The Reynolds number
= pulses / unit volume (dm3). this is steam, gas or liquid. The must be >20.000 to ensure
primary measuring signal is linear performance. You can
Within the application limits of already digital (frequency signal) check it at https://wapps.
the device, the K-factor only and a linear function of the flow. endress.com/applicator
depends on the geometry of the After manufacturing the meter,
device. It is independent of the the K-factor is determined in the Orientation (see fig. 12)
Fig. 12: Recommended orientations fluid velocity and its properties factory by means of calibration The device can generally be
and is not subjected to any long installed in any position in the
term drift or zero point shift. piping. For liquids, upward
flow is preferred in vertical
Installation conditions pipes to avoid partial pipe
filling (see orientation A).
Vortex meters require a fully Temperature may affect
developed flow profile as a the long term reliability of
prerequisite for correct volume electronic modules. Thus:
flow measurement. For this In the case of hot fluids (e.g.
reason, please note the following steam or fluid temperature
points when installing the device: 200C/ 392F), select
Welds, burrs and gaskets orientation C or D so that
should not protrude into the permitted ambient
the pipe inside the inlet and temperature of the electronics
A = Inlet run 3 = 90 elbow or T-piece
B = Outlet run 4 = 2 x 90 elbow, 3-dimensional
outlet runs. This is very is not exceeded.
1 = Reduction 5 = 2 x 90 elbow important in order to ensure Orientations B and D are
2 = Extension 6 = Control valve that the flow profile is free of recommended for very cold
Fig. 13: Inlet and outlet runs secondary disruptions. fluid (e.g. liquid nitrogen).

40 The Endress+Hauser Maintenance Guide

 The use of the remote
version is recommended
for cryogenic applications

Orientation for applications

with hot water

Flow
The arrow indicated on the Setup - configuration of the instrument by means of Spare parts stock
device must always point in the FieldCheck simulator. For any flowmeter belonging to
the direction of flow in all All Proline flowmeters are (See full description of the Proline family, we suggest
mounting orientations. equipped with a Quick Setup FieldCheck on page 33). you keep a full set of electronic
program to make standard inserts in stock.
Caution! commissioning easy. In case of Our service contracts can include
If fluid temperature is vortex flowmeters, the Quick such verifications once a year is Migration
recommended.
3200C/ 392F, orientation Setup can configure the device (See Maintenance services in
B is not permitted for the according to the application the At your service section). Prowirl 72 is fully compatible
wafer version (Prowirl 72W) (liquid, gas, steam). with Prowirl 77. Please consult
with a nominal diameter of us regarding migration from
DN100 /4 and DN150/6. Our service team can set up any Calibration Prowirl 70H.
In case of vertical orientation Endress+Hauser flowmeter for you See Basics (page 29) and
and thus ensure you immediately get
and downward flowing liquid, the most out of your instrument.
also page 33 for calibration Re-engineering
the piping always has to be (See Device commissioning in the information.
completely filled. At your service section). Please take into account the
Calibration of flowmeters can be following limitations when
Inlet and outlet runs (fig. 13) performed by Endress+Hauser either considering using a vortex
on site or in our accredited laboratories.
As a minimum, the inlet and Operation and maintenance (See Calibration services in the
flowmeter for a new application:
outlet runs shown below must At your service section). Pulsating flow and swirl
be observed to achieve the The measuring range depends have a detrimental effect on
specified accuracy of the device. on the fluid and the nominal measuring accuracy.
The longest inlet run shown diameter. Do not work outside Note: On-site calibration is only Long inlet and outlet runs are
must be observed if two or more the measuring range. possible for liquid applications. necessary, depending on the
flow disturbances are present. Factory calibration also uses type of fitting upstream.
Note: A specially designed For steam and gas applications, only water as fluid. The water Vortex is not adapted for
perforated plate flow conditioner if temperature and pressure calibration is also valid for gas highly viscous liquids.
can be installed if it is not possible vary during the process and and steam measurement, based Measurement with low flow
to observe the inlet runs required. mass flow measurement on the measuring principle. velocities is not possible.
is required, you need to
Piping insulation compensate volume flow by Instrument and The Applicator software allows
When insulating, please ensure pressure and temperature spare parts availability you to check the devices
that a sufficiently large area of using a flow computer. accuracy over the measuring
the housing support is exposed. For further information, use range. Applicator is available at
The uncovered part serves In steam pipes, it is essential our Device Viewer www.services. https://wapps.endress.com/
endress.com/device-viewer
as a radiator and protects the to avoid any steam, water or applicator
electronics from overheating pressure shock on the meter.
(or undercooling). Your Spare parts New
The maximum insulation height Measurement with low instrument availability generation
permitted is illustrated in the flow velocities (Re < 4000)
diagrams. These apply equally is not possible. Prowirl 70F/W/D NO - since 12/2008 Prowirl 72/73 F/W
to both the compact version and
the sensor in the remote version. Preventive maintenance Prowirl 70H NO - since 12/2009 Prowirl 72F
Perfect centering The device does not contain Prowirl 77F/W NO - since 12/2008 Prowirl 72/73 F/W
The centering rings supplied with any moving parts and requires
the wafer style meters are used to no particular maintenance.We
mount and center the instrument. recommend periodic checking Table 5: Instrument and spare parts availability

The Endress+Hauser Maintenance Guide 41

 Ultrasonic flowmeters
Prosonic Flow series

The current Endress+Hauser range of ultrasonic flowmeters includes:

Proline Prosonic Flow 91 and 93 clamp on flowmeters
Prosonic Flow 92 F Inline flowmeter
Prosonic Flow 93T portable clamp on flowmeter

In this section, you will find essential information and advice to obtain
the best from ultrasonic devices throughout their lifecycle.
Videos available at
www.endress.com/videos
Flow

Common features
Measuring principle The values of some fluids are
available as factory presets. For
Prosonic Flow operates on other fluids, the sound velocity
the principle of transit time in the fluid is required. The
difference. An acoustic Quick Setup will then help
(ultrasonic) signal is transmitted you configure the transmitter
in both directions from one and will give you the exact
measuring sensor to the other. As positioning of the sensors.
the signal propagation velocity
of the waves is less when the Operation and maintenance
waves travel against the direction
of flow than along the direction Take care of the sensor
of flow, a transit time difference cable: if it gets twisted,
occurs. This difference is directly the measurement will be
proportional to the flow velocity. affected and replacements
Prosonic Flow calculates the flow are relatively expensive. Calibration Instrument and
from the pipe cross-sectional area See Basics (page 29) and spare parts availability
and the measured transit time Preventive maintenance also page 33 for calibration See table below.
difference. Periodically check that the information. According to
connectors are tight enough. quality constraints, you may Spare parts stock
v ~ t Q=vA Ensure that the sensors wish to periodically calibrate For any flowmeter belonging to
position is kept constant. your instrument. Ultrasonic the Proline family, we suggest
v = flow velocity
t = transit time difference
Coupling medium should be flowmeters can be calibrated you keep a full set of electronic
v = volume flow periodically changed in case on a flow rig. Please note that inserts and sensors in stock.
A = pipe cross-sectional area of important variations of the the conditions are different Note: changing the sensor does
temperature. from the process conditions. not affect the electronics; no
In addition to the volume flow, recalibration is necessary.
the system measures the sound On-site verification is possible Calibration of flowmeters can be
performed by Endress+Hauser either
velocity in the liquid. The with the FieldCheck simulator on site or in our accredited laboratories.
sound velocity can be used to (see page 33). The service test (See Calibration Services in the
distinguish different liquids or block offers a simple way to test At your service section).
as a measure of product quality. the function of both sensors as
well as the electronics and sensor
Setup - configuration cables functionality. Your Spare parts New
instrument availability generation
All Proline flowmeters are Our service contracts can include
such verifications once a year is DMU93 NO - since 12/2007 Prosonic Flow 91/93
equipped with a Quick Setup
recommended.
program to make standard (See Maintenance services in Prosonic Flow 90 YES - until 12/2013 Prosonic Flow 91/93
commissioning easy. In case the At your service section)
of ultrasonic flowmeters, you
need to know precisely the For further information, use our Device Viewer:
pipe material, the pipe external www.services.endress.com/device-viewer
diameter, the pipe thickness
and the type of fluid. Table 6: Instrument and spare parts availability

42 The Endress+Hauser Maintenance Guide

 Prosonic Flow93T
used for the
measurement
consistency check of
an electromagnetic
flowmeter

Standard horizontal installation of a clamp-on device Installation on Inline versions (2 pictures)

coated pipes

Flow
Tips for clamp on devices Tips for inline devices
Installation conditions Inlet and outlet runs Measuring principle
If possible, install the sensor well
Pipe material clear of fittings such as valves, A Prosonic Flow inline flowmeter
The pipe material should be T-pieces, elbows, etc. measures the flow rate of the
as homogeneous as possible, Compliance with the following passing fluid by using sensor pairs
either metallic or synthetic, and requirements for the inlet and located on opposite sides of the
must conduct sound waves. outlet runs is recommended meter body and at an angle so
Recommended materials: cast in order to ensure measuring that one of the sensors in the pair
iron (with or without cement accuracy (see figure 14). is slightly downstream.
liner) stainless steel, carbon
steel, PVC, PE, GRP (composite Orientation Installation conditions flow disturbances are present.
material), fibrocement. See figure 15. (see figure 16).
Note: If the pipe material does Inlet and outlet runs
not conduct sound waves Coupling medium If possible, install the sensor well Orientation
(e.g. granular concrete), use A coupling medium is required clear of fittings such as valves, Make sure that the direction of
insertion sensors instead of to ensure the acoustic coupling T-pieces, elbows, etc. the arrow on the nameplate of
clamp on sensors. between the sensor and the As a minimum, the inlet and the sensor matches the direction
piping. This is applied to outlet runs shown below must of flow (direction of fluid flow
Mounting location the sensor surface during be observed to achieve the through the pipe). See figure 17.
Correct measuring is possible commissioning. Periodic specified accuracy of the device.
only if the pipe is full. Avoid the replacement of the coupling The longest inlet run shown
following locations: medium is usually not required. must be observed if two or more
Highest point of a pipeline Prosonic Flow 93 offers a
- risk of air accumulating. coupling medium monitoring
Directly upstream of a free function as part of its Extended
pipe outlet in a vertical pipe. Diagnostics software package.
This function outputs the signal
strength as a limit value.

Note: with proper mounting,

uncertainty will be less than 2%.
Fig. 16: Inlet and outlet runs
Minimum inlet and outlet runs with various flow obstructions.
A = Inlet run, B = Outlet run, 1 = 90 elbow or T-piece, 2 = Pump,
3 = 2 90 elbow, out of plane, 4 = Control valve
The upstream values given in the graph are for the 3 and 4-path meters, the 2-path
meters require twice the upstream values indicated.
F06-9xxxxxxx-11-05-00-xx-004
F06-9xxxxxxx-11-05-00-xx-010

Fig. 15: Orientation

View A shows the recommended
orientation with upward direction of flow.
Fig. 14: Inlet and outlet runs View B shows the recommended Fig. 17: Orientation
1 = Valve, 2 = Pump, 3 = Two pipe installation range (C 120) in a Orientations A, B and C recommended, orientation D only recommended under certain
bends in different directions horizontal installation position circumstances

The Endress+Hauser Maintenance Guide 43

 Thermal mass flowmeters
t-mass series

The current Endress+Hauser range of thermal mass

flowmeters includes Proline t-mass 65.

In this section, you will find essential information and advice

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

Videos available at t-mass insertion version mounted on

www.endress.com/videos a low pressure air pipe
Flow

Measuring principle
Ensure the
sensor is The thermal principle operates
by monitoring the cooling effect
mounted at of a gas stream as it passes over
90 to the a heated transducer (Pt100).
Gas flowing through the
flow direction sensing section passes over two
and avoid Pt100 RTD transducers one of
which is used conventionally
condensation. as a temperature sensing
device, while the other is used
as a heater. The temperature
sensor monitors the actual
process values while the heater
is maintained at a constant
differential temperature above Pipework requirements
this by varying the power Good installation practice
consumed by the sensor. The should be followed at all times:
greater the mass flow, the Cleaned pipe and flange
greater the cooling effect and welded joints.
power required to maintain Correctly sized gaskets.
the differential temperature. Correctly aligned flanges and
The measured heater power is gaskets.
therefore a measure of the gas The use of seamless pipe
mass flow rate. immediately upstream of the
flowmeter.
These devices need to be The use of pipework with a
programmed for a certain gas matching internal diameter
or gas mixture. In the factory, to that of the flowmeter
calibration is performed on to ensure that no step
air, using a highly accurate disturbance greater than
and state-of-the-art flow rig. 1mm/0.04 can occur at
The integrated gas engine the meter inlet or outlet,
determines mass flow for the 3mm/0.12 for diameters
gas application. > DN200/8.

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 the goal should be a smooth,
fully developed flow profile as uninterrupted internal surface.
Fig. 18: Minimum inlet and outlet runs
a prerequisite for correct flow For further information please
a0005113

A = Inlet run 3 = 90 elbow or T-piece

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

44 The Endress+Hauser Maintenance Guide

 Endress+Hausers new
gas calibration flow rig

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

calibration flowrig nitrogen consumption in the pond of aeration
(wastewater)

Flow
Inlet and outlet runs air. The necessary information is The t-mass flowmeters are Migration
If possible, install the sensor well requested before delivery. Thus designed to support in-situ
clear of fittings such as valves, commissioning is quite simple. calibration using a reference Thermal mass flowmeter
T-pieces, elbows, etc. meter signal (mobile rig), t-mass AT70 is being phased
Compliance with the following Requested information: thus saving time and cost by out. With the brand new 65F/I
requirements for the inlet and Gas type if not air reducing the need for factory re- series, Endress+Hauser offers
outlet runs is recommended (composition if more than calibration. An adjustment may full interchangeability. What
in order to ensure measuring one gas in % Mole). complete the calibration work. about the interchangeability
accuracy (see figure 18). It Gas pressure. Please discuss your specific with existing sensors?
is recommended to install a Line size - internal diameter. requirements with your
perforated plate flow conditioner 20mA range required. Endress+Hauser service From the mechanical side:
if the recommended inlet runs Flow engineering units representative. The t-mass 65I available
are not available. (kg/h, Nm3/h etc). process connections are G1
For higher precision, t-mass 65 and NPT 1
Orientation DELIVERY SETTINGS are the flowmeters can be calibrated The t-mass 65F face-to-face
The device can generally be programmed parameters (factory with an ISO/IEC 17025 length is identical to the AT70
installed in any position in the settings plus customer specific accredited specific gas flow rig.
piping. In the case of wet/dirty settings) originally delivered From the electrical side: the
gases, upward flow is preferred Calibration of flowmeters can be 65F/I series can be supplied
with the device.
performed by Endress+Hauser either
in vertical pipes to minimize on site or in our accredited laboratories. with 24V DC, allowing total
condensation/contamination The Quick Setup menu contains (see Calibration in the At your interchangeability with AT70.
on or around the sensing the default settings that are service section)
element. In particular, where adequate for commissioning. Re-engineering
free condensation can occur You may use the Quick Setup in Corrective maintenance
(e.g. biogas), the sensor should order to change parameters or See Basics (page 31). Besides the utilities,
be mounted to prevent water to use the device on a different You can change the sensor and t-mass65F/I series is ideally
collecting on or around the application. the transmitter on site. Thanks suited for air injection regulation
sensing elements (e.g. do not to S-DAT and T-DAT, no further in the pond of aeration of a
install the sensor at a low point Operation and maintenance programming is necessary. wastewater treatment plant.
in the installation without See Installation conditions
adequate drainage). Preventive maintenance Instrument and before you decide to change
Make sure that the direction Full compatibility with spare parts availability the devices application. Use
arrow on the sensor matches FieldCheck (see page 33) See table below. the gas engine software to
the direction of flow (direction allows on-site verification. change the gas mixture.
of fluid flow through the pipe). Spare parts stock
Note: The best accuracy is Calibration For any flowmeter belonging to
obtained only if the gas is dry See Basics. the Proline family, we suggest
and clean. you keep a full set of electronic
The sensors aging directly inserts in stock.
Setup - Configuration impacts the measurement. Aging
may be sped up in case of build-
The sensor is provided fully up due to solids deposit, of shock Your Spare parts New
calibrated with an S-DAT. on any of the transducers or of instrument availability generation
Each meter is programmed to abrasion due to the presence t-mass AT70 YES t-mass 65
individual requirements, i.e. in of impurities in the gas. In all
particular the gas type or gas cases, we recommend having the
composition and calibrated with device calibrated once a year. Table 7: Instrument and spare parts availability

The Endress+Hauser Maintenance Guide 45

 Frequently asked questions

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

Note: See Process parameters menu in the Operating Instructions.

Grounding should be ensured at first installation; nevertheless in
some cases it may be corrected later. The measurement exhibits peaks or fluctuating values.
The measurement is unstable. What should I do?
How to connect a flowmeter to a programmable logic Check the installation conditions
controller (PLC) and then make them communicate? Make sure that the pipe is completely filled (no air in the unit)
Correct electrical wiring. Use a specific cable to connect the High or low fluid load?
sensor to the transmitter (Please read carefully 4.1 Wiring Make sure there are no air bubbles
connecting the remote version in the Promag 50 Operation Electrical connection: if electronics separate: earth connection?
Manual). Synthetic pipe?
Ensure full compatibility between the emitter and the receiver
by a proper parameterization of the pulse/frequency output With the PROFIBUS version, are different values displayed
according to your PLCs settings. on the display and the PLC?
Go to the programming matrix at level (4207) Output signal and Go to the communication menu
select: Validate the set unit to bus box.
0 = PASSIVE - POSITIVE Note: this is also valid after any programming alteration.
1 = PASSIVE - NEGATIVE
2 = ACTIVE - POSITIVE How do I test the pulse output?
3 = ACTIVE - NEGATIVE For the test, set a pulse period of 1 second
Factory setting: PASSIVE-POSITIVE Connect a diode mode multimeter to the unwired (+) and (-)
See also the Proline Promag 53 operating manual, p.68 for more terminals
explanation. The value changes can be seen on the multimeter
(one step = 1s): Equipment OK
What is the unlocking code for my instrument?
Name of device: e.g. 0050 or 50 for Promag 50 How do I test the current output?
Connect a milliammeter to the unwired terminals 26 (+)
How do I set the end of the 4 to 20 mA output scale? and 27 (-)
Go to the current output menu Go to the current output menu
Go to the 20mA end of scale box Activate the current simulation box
Define the current to be simulated in the sim. curr. value box
How do I set the pulse output?
Go to the pulse output/frequency menu There is a high measurement error. What should I do?
Go to the pulse value box Check the installation conditions
Make sure that the pipe is completely filled (no air in the unit)
How do I wire the pulse output on a Promag 50? Is the set-up correct?
Connect the 24V DC to the + terminal of the pulse output
Retrieve the signal on terminal 25 (Input/Output terminal The Promass shows Error#587, 701 or 702 and the
numbers). measurement is unstable or wrong. What is the reason for that?
Perhaps the pipe is only partly filled or the pressure is low
and gas bubbles are in the medium. Please check:
Is the pipe completely filled?
Are there gas bubbles in the medium?
The solution: increase the pressure.

46 The Endress+Hauser Maintenance Guide

 Liquid analysis

We are always there for you!

Analysis devices typically require more specialized partner such as Endress+Hauser Contents
maintenance than the other measurement with this service.
principles. As a consequence, the Basics 48
maintenance staff that takes care of a plant As most reported questions concern either The Basics chapter includes
generally knows exactly what has to be done. the use of an Endress+Hauser device information that is valid for all
The major improvements are due itself or troubleshooting (generally due measurement principles described in
this section. We therefore strongly
to the growing importance of digital to the application), this guide serves as recommend that you read it first.
communication, resulting in numerous a reminder of the different principles
benefits for maintenance personnel. used in liquid analysis. You will also pH and ORP measurement 50
find some recommendations related to Conductivity measurement 55
Concerning the calibration of analysis maintenance intervals to help you keep
devices, it is important to remember that your instruments fit! Turbidity measurement 58
for some measuring parameters calibration Chlorine measurement 61
and adjustment in comparison to a buffer In addition to this, we have included expert Oxygen measurement 64
solution is impossible, either because no approaches to diagnosis and frequently
buffer solution exists (e.g. chlorine) or asked procedures to help you make the right Analyzers 67
because a buffer solution would not be diagnosis and take the correct actions in case Samplers 70
representative of the chemical matrix of trouble.
of the process (e.g. COD with spectral FAQ 74
absorption principle). In these situations As experts, we also offer training sessions,
calibration and adjustment have to be in classroom and on site. We would be
performed in conjunction with laboratory glad to meet with you and help you go one
analysis. Therefore you will require these step further. See Training in the At your
specialist skills in-house or you can entrust a service section.

The Endress+Hauser Maintenance Guide 47

 Basics
Information common to all types of liquid analysis devices

Dissolved oxygen
Conductivity

Disinfection
Turbidity
pH/ORP

pH/ORP measurement Conductivity measurement Turbidity measurement Chlorine measurement Oxygen measurement
Specific information p. 50 Specific information p. 55 Specific information p. 58 Specific information p. 61 Specific information p. 64

Digital communication speak the same language based

makes life easier on the Memosens protocol.
Controller -
Measuring station
With digital communication Main benefits
between sensors and Time saving due to easy sensor
transmitters, many problems exchange with pre-calibrated
Cable
concerning information Memosens sensors and
exchange between analog pre-commissioned controller.
devices are now things of the Easy to use, simple
Sensor
past. The Memosens systems to maintain - standardized
provide safety and operating operation and
comfort in analytical measuring maintenance strategy
Holder
technology - something users Reduction of maintenance
and producers have been and stock costs
striving for for generations.
The same benefits apply to the
One transmitter new samplers (Liquistation
for all parameters CSF48 and Liquiport CSP44)
The heart of the new since they include the same
Liquid analysis

Endress+Hauser liquid hardware and software. Fig. 1: Memosens systems enable simplified selection and uniform operation and
analysis platform is Liquiline maintenance strategy
CM442. Liquiline CM442 is a Our aim is to facilitate your
multiparameter and multichannel daily work (commissioning,
controller. It is suitable for operation and calibration)
all parameters: pH, ORP, by maximizing uniformity Advantages of Memosens Data transfer monitoring
conductivity, dissolved oxygen, for highest process digital communication Emission of an alarm
turbidity, nitrate, SAC, chlorine safety at low costs. if signal is broken.
and ammonium. All sensors Memosens connector
No more metallic contact Sensors equipped
between cable and sensor. with memory
The current range of transmitters (analog and digital) Completely tight: no more Calibration data is stored
problems with humidity, directly in the sensors head.
Liquiline CM442 The multiparameter and multichannel corrosion, dirtiness. Sensor interrogation for
controller is suitable for all Memosens sensors and digital sensors Quick connection system. predictive maintenance as
with Memosens protocol. Autoclavable and sterilisable. the working time, maximum
Liquiline CM42 The high-performance two-wire transmitter can and minimum values of main
be used in hazardous and non-hazardous locations. Version for pH/ Cable characteristics parameter and temperature
ORP, conductivity, dissolved oxygen easy switch of parameters via No special cable necessary. found, etc.
sensor modules. Cable length is no
Liquisys The four-wire transmitter is available with a field or longer an issue. Simplified calibration
panel-mounted housing. Version for pH/ORP, conductivity, No high impedance All sensors are
dissolved oxygen, turbidity and chlorine. junction box required pre-calibrated in factory.
to extend the cable. Cleaning and calibration
of the sensor can be done
Total galvanic separation easily in laboratory in
No more electromagnetic optimal conditions.
interferences. Laboratory pre-calibrated
No interference between sensors can be quickly
the process potential and the and simply replaced to
transmitter. minimize downtime.
Liquiline CM42 Liquiline CM442

48 The Endress+Hauser Maintenance Guide

Centralized management Memosens data pH 0 (T -10C); pH 4
of sensors and data management (T 25C); pH 7 (T 60C);
OK
SIMU

1
Manage the complete pH 10 (T 90C) and pH 14
Designed for Memosens life cycle of a sensor from (T 135C).
systems, Memobase is a delivery to scrapping Each cap has its own 2
database and software that Trace the calibration history serial number
allows you to manage your Log the sensor load data, Non-Ex and Ex versions
data and sensors centrally thus e.g. over all operating hours
offering numerous benefits: and operating hours under Memocheck CYP02D 3
More precise calibration extreme process conditions This service tool enables a
Fig. 2: Measuring system with
in the laboratory under Export the data to Excel, html quick and easy check of the Memocheck Plus CYP01D
ideal conditions by measuring loop by simulating 1 Transmitter with Memosens
trained personnel Memosens sensor fixed sensor status in order to: technology, e.g. Liquiline M CM42
2 Memosens coupling
Reduction of process costs management Check the digital
3 Memocheck Plus CYP01D
and downtime through Assignment of sensors data transfer during

Liquid analysis
sensor replacement by to dedicated measuring commissioning
non-trained personnel points by TAG number or Solve troubleshooting
Standby times of trained group of TAG numbers in the running process
personnel are minimized Deactivation of scrapped
(weekends, night shifts) sensors in the database Some combinations available:
Traceable documentation of all Outside marking of pH 7 (glass) + pH 4 (glass)
sensor and process-related data sensors with Memoclip pH (glass) + pH (Isfet) 1
pH (glass) + ORP
Documentation of pH (glass) + dissolved oxygen
complete sensor life cycle Check of Memosens chains pH (glass) + conductive
From commissioning conductivity
to scrapping Memocheck Plus CYP01D
Automatic data transfer This tool enables simple Memocheck Sim CYP03D
upon calibration qualification of the measuring This tool enables the simulation
With lab calibration system loop: of measured values of all
Liquiline M CM42 With five plug-in heads digital sensors (Memosens
For pH glass and each simulating a fixed, sensors with inductive plug-
ISFET electrodes defined sensor status for a head and fixed-cable sensors Fig. 3: Measuring system with
dedicated type of sensor with Memosens protocol) Memocheck Sim CYP03D
1 Transmitter with Memosens
Filter functions Reading of all relevant Operates with technology, e.g. Liquiline CM442
for Memosens data calibration and process data Liquiline CM442 and 2 Memosens data cable CYK10
Memobase allows a after simulation at predefined Liquiline M CM42 3 Memocheck Sim CYP03D
complete documentation pH and temperature values Full loop check capability
of sensor history: Each plug-in head has Programmable continuous
Information about passed a stringent test on simulation sequences
measuring system a computerized inspection Simulation of fixed-cable
Calibrations unit and a quality sensors with CYK10
Trends of calibration data certificate is issued Non-Ex version and ATEX
(slope, zero point) for Liquiline M CM42
Process conditions Concept of CYP01D
Video about Memosens and
Kit of five Memosens Liquiline available at
simulation caps. Example: pH www.endress.com/videos

The Endress+Hauser Maintenance Guide 49

 pH/ORP
pH and ORP measurement
Electrodes and transmitters

A complete pH or ORP measuring system includes:

Analog (CPSxx and CPFxx series) or a digital (CPSxxD and CPFxxD series) sensor
Transmitter (Liquisys M CPM223/253, Mycom S CPM153, Liquiline CM42
and CM442)
Special measuring cable
Assembly

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

pH measurement -
You can carry potentiometric measuring
principle
out many tasks
by yourself. This principle is based on a
pH-sensitive glass membrane
on which hydrogen ions
accumulate, thereby causing
electrical potential to build-up.

The method of pH measurement using

glass electrodes is a potentiometric
measurement method. Since glass is
an electric insulator, transmitters for
analog pH measurement must have an
extremely high input impedance. In the
case of Memosens electrodes, signals
Liquid analysis

are transmitted without interference.

The measuring effect is based on a pH-
sensitive glass membrane whose surface
reacts to the acid content of the solution Fig. 6: Example of a complete measuring 6 Retractable assembly Cleanfit W
with a specific voltage. This voltage is system CPA450
then measured relative to a reference 1 Flow assembly CPA250 7 Electrode, e.g. Orbisint CPS11
element made of silver/silver chloride 2 Junction box VBA 8 Immersion assembly CPA111
Fig. 4: Potentiometric measuring principle: (Ag/AgCI) which remains constant.
potential build-up during pH 3 Liquisys M CPM253 transmitter 9 Extension cable
measurement with glass electrodes 4 Measuring cable e.g. CPK9 Options: extension cable, junction box
Glass pH electrodes using 5 Liquisys M CPM223 transmitter VBA or VBM
the potentiometric method
Sensors with a Teflon
diaphragm and gel reference The pH value can also be measured with Glass-free pH electrodes
an ion-selective field effect transistor
(CPS11D/11) using the ISFET method
(ISFET). It is, in effect, a simple transistor
Sensors with a ceramic with a source and drain that are Glass-free sensors with
diaphragm and liquid separated from the base by a diverse reference systems
reference (CPS41D/41) semiconductor. Hydrogen ions from (CPS441D/441/471D/
the medium may accumulate here.
Sensors with a ceramic 471/491D/491)
The resulting positive charge on the
diaphragm and gel reference outside is mirrored on the inside
(CPS71D/71) of the base where a negative charge The influences
Sensors with an open occurs. This makes the semiconductor on pH measurement
channel conductive. The lower the pH
diaphragm and gel reference Temperature influences at two
value of the liquid, the more H+ ions
(CPS91D/91) accumulate on the base and the more levels. First on the electrode
current can measurably flow between slope sensitivity. Temperature
Fig. 5: Ion-selective measuring principle: the source and drain. The accumulation compensation serves to bring
the current between source and of protons is a purely electrostatic
pH measurement - back this sensitivity from
drain of the semiconductor element effect. As a result, the sensor material
depends on the charge at the base
ion-selective measuring does not change and the need for its value at the operating
and thus directly on the pH value principle recalibration is by no means as frequent temperature to its value at the
as with glass electrodes. Since there is reference temperature 25C
no gel-like layer, ISFET electrodes are
The ISFET is a simple transistor /77F. Secondly temperature
also suitable for pH measurement in
which is isolated from the gate media with a low proportion of water. influences on pH: the pH
by an isolator. Hydrogen ions of a fluid will not be the
can accumulate on this gate. same at 90C/194F as at

50 The Endress+Hauser Maintenance Guide

 15C/59F. With Liquiline ORP electrodes Follow the installation
and Mycom S, you can Standard sensor Orbisint instructions detailed in
compensate the mediums CPS12D/12 for long- the operating instructions
temperature. term monitoring in water of the assembly.
Contamination of the treatment, detoxification or
reference element the chemical industry Cabling
Electrical phenomena High-performance sensor Cable should not be
Heterogeneous media Ceraliquid CPS42D/42 longer than 50m/164ft.
Soiling for chemical industry, (CPK7, CPK9, CYK71);
Aggressive chemical products detoxification, water for longer distances use
treatment, power stations; Memosens technology as Fig. 7: Electrode installation; inclination
for media that tend to form this has no limit on cable angle min. 15 from the horizontal
ORP measurement - build-up, and fast-changing length (up to 100m).
measuring principle medium compositions The cabling should not
Hygienic sensor Ceragel be interrupted (avoid any

Liquid analysis
ORP measurement also uses CPS72D/72 for food industry, temporary connection). If
the potentiometric measuring fermenter, biotechnology with an extension is necessary,
principle. rapidly changing oxidation use a high impedence
reduction potential junction box (VBM).
The ORP value is an indicator of the Sensor for suspensions
oxidizing or reducing properties of a
process medium and is measured in
Orbipore CPS92D/92 for Connecting analog
mV. In aqueous media, the measuring paper and pulp industry pH and ORP sensors
range is between -1,500mV and The pH and ORP analog Fig. 8: Asymmetrical connection
+1,500mV. A precious metal electrode sensors can be connected
(gold or platinum) acts as the measuring
electrode. As is the case with pH
Installation conditions either symmetrically
measurement, the electrochemical for pH/ORP sensors or asymmetrically.
potential is measured against a silver/
silver chloride reference (Ag/AgCl) and Do not install the electrode Advantages of symmetrical
indicated in mV.
All ORP pairs in a process make up
upside down (see fig. 7). measurement (fig. 8):
the oxidation reduction potential. As The inclination angle must be No leak current since the
such, in contrast to pH measurement, at least 15 from the horizontal. reference and the pH/ORP
the ORP value is a sum parameter A smaller inclination angle electrode is connected with
that cannot be assigned quantitatively
to the individual ORP pairs.
is not permitted as such an high resistance
Fig. 8bis: Symmetrical connection
Even though only one sum parameter inclination results in the Safe measurement under
is measured, ORP measurement is formation of air cushions. This difficult process conditions
an effective and low-cost method might impair the contact of (strong flowing and high-
that can be used for chromate
detoxification, cyanide detoxification
reference and metal lead. resistance media, partially
or to measure the metering of Caution! soiled diaphragm)
oxidants for disinfection purposes. Make sure that the assemblys
threaded connection for Advantage of asymmetrical
The ORP value can also be indicated as
a percentage. Here, two characteristic
the electrode is clean and measurement (fig. 8bis):
mV values are assigned to a 20% and an working properly before Use of assemblies without
80% value, making it possible to detect installing the electrode. potential matching possible
activities pertaining to chemical reactions Hand tighten the electrode
and also of reaction end points. Caution! In the case of a symmetrical
(3Nm)! (This value only
connection, the potential matching pin
applies to installation in must be connected and always immersed
Endress+Hauser assemblies.) in the medium.

The Endress+Hauser Maintenance Guide 51

 Operation and maintenance Lime and metal hydroxide layers:
Dissolve layers with diluted
hydrochloric or citric acid (max 10%).
To ensure the safe transmission Layers containing sulphide:
of measured values from analog Use mixture of hydrochloric acid
systems, double-shielded (max 10%) saturated with urea.
Layers containing proteins:
measuring cables are required
Immerse the electrode in a
to prevent electromagnetic mixture of hydrochloric acid
interference. With Memosens (max 10%) saturated with pepsin
technology, the sensor data is (8500 units) at 37C/98.6F.
stored directly in the sensor
Note! Always rinse carefully with
head and transmitted with plenty of clear water and wipe with
a standard bus cable of low a soft cloth.
impedance.

The advantages of Memosens Cable and connection check

technology are particularly Check cables and connections
evident in pH measuring for moisture, cuts or kinks.
technology. Problems with Check electrical continuity:
moisture are a thing of the establish a short-circuit
past. In addition to excellent between two wires at one
transmission reliability, for end of the cable (e.g. between Enter the actual buffer value If the slope is 50mV/pH,
the first time ever a system is Measure and Ref). in the transmitter (at current the electrode must be checked
available that can detect a cable Measure the resistance temperature). and replaced if needed.
break or other interruptions at the other end (should Keep the electrode immersed If the slope is 45mV/pH,
in the measuring signal. This, be 0.1/m). for a few seconds before you the transmitter displays an
in turn, significantly reduces Detection of insulation validate the measurement. error message: the electrode
process downtime. default: disconnect both ends Rinse the glass bulb with must be replaced.
of the cable and measure clean water (do not rub
Preventive maintenance the impedance between the it: you might generate Checking a transmitter
Maintenance work at the wires with an insulation electrostatic charges!). - analog technology
transmitter includes: meter that measures with 3) Immerse the electrode (for digital technology,
Cleaning of assembly 1000V (should be R=). in the second buffer see Memosens)
and sensor solution (pH 4, 9, etc) Bypass the pH input by
Cable and connection check Calibration of andstart again at step 2. connecting the Measure
Calibration and adjustment analog systems 4) Rinse the electrode terminal to the Reference
Liquid analysis

Use the CAL key to access the with clean water. terminal (+ the PA terminal
Cleaning glass pH calibration function group. in case of a symmetrical
and redox electrodes Use this function group to ORP electrode adjustment connection). As the pH meter
There are five levels of cleaning: calibrate the sensor. The 1) Clean the electrode input has a potential of 0mV,
Level 1: use water + sponge calibration can take place in a with water. the display should indicate
Level 2: use water + soap number of ways: 2) Immerse the electrode the zero value of the last
(presence of grease) By measuring in two in a buffer solution calibration (i.e. around pH7).
Level 3 (ORP only): carefully buffer solutions with known (220mV or 460mV). You need a pH simulator if you
clean the metal pins or pH value. Measure the containers wish to test the whole scale.
surfaces mechanically (polish By entering data for the slope temperature. A pH simulator consists of a
under water using ultra fine and zero point adjustment. In the case of a symmetrical simple voltage generator
abrasive paper). By entering an offset value. connection, the potential (-500 to +500mV).
Level 4: use diluted In the case of ORP matching pin must be
hydrochloric acid HCl measurement, by entering connected and always Regeneration of a pH
(3 to 5%) and rinse with the mV value or two different immersed in the medium. electrode whose response
clean water. % values. Keep the electrode immersed time is too long:
Note! After chemical cleaning, for 1 minute before you Use a mixture of nitric acid
the ORP sensor can require pH electrode adjustment validate the measurement. (10%) and ammonium fluoride
several hours conditioning 1) Clean the electrode with 3) Enter the actual buffer (50 g/l). Rinse with clean water
time. Therefore check the water (or specific product). value in the transmitter then wipe with a soft cloth.
calibration after a day. 2) First immerse the electrode (at current temperature).
Level 5: use specific products in a pH 7 buffer solution. 4) Rinse the electrode Storage of an electrode
to clean contamination (see In the case of an automatic with clean water. Store in a dry place between
the following list). temperature compensation, 10 to 30C/50 to 86F. Always
the temperature sensor must Check of the slope after keep a glass electrode hydrated
Oily and greasy films: be immersed in the medium. calibration of a pH electrode (if possible in KCl 3 mol/l).
Clean with detergent and water or
any solvent such as alcohol, acetone.
In the case of a symmetrical The theoretical slope is Electrodes are always delivered
Inorganic layers: connection, the potential 59.16mV/pH. The practical with a cap that contains
Immerse the electrode for 15 matching pin must be slope of a new electrode is 57 to a sponge saturated with a
mins in diluted hydrochloric connected and always 60mV/pH. special liquid in order to avoid
acid or soda (max 5%).
immersed in the medium. If the slope is 55mV/pH, dessication of the bulb.
the electrode must be cleaned.

52 The Endress+Hauser Maintenance Guide

Easier maintenance with The sensor history can be Problem / Possible cause Action
Memosens technology documented on external
databases and evaluation Calibration is impossible
Easy handling programs at any time. Thus, Bulb and/or diaphragm soiled Clean it
Sensors with Memosens the current application of the
Bulb broken Replace electrode
technology have integrated sensors can be made to depend
electronics that allow calibration on their previous history. Cabling error or defective cable Check and replace if needed
data to be saved along with Buffer solution out-of-date Change buffer solution
additional information such as Memocal T - dedicated or contaminated
total hours of operation and calibration tool
Measurement is unstable
operating hours at very high Memocal T is a calibration
temperatures. When the sensor instrument for your laboratory: Incorrect connection Check cable and connections
is connected, the calibration pH measurement using digital Interference Use double-armored cable;
data is automatically transferred sensors check connection of the armor
to the transmitter and used to Wet or numeric calibration plating to the ground; change

Liquid analysis
calculate the current pH or ORP (3m/9.8ft of cable) cable path
potential. Storing the calibration Readout of all software and
data in the sensor allows for hardware version numbers Current or parasitic potential in In case of asymmetrical
calibration and adjustment away including sensor serial number the product (for analog systems measurement, connect the
from the measuring point. only) product to the ground; switch
to symmetrical measurement
The result: Corrective maintenance Slow sensor response
The sensors can be calibrated Electrode soiled Clean it
under optimum external Diagnosis of common
conditions in the measuring troubleshooting: see table 1 Sensor aging Test the measurement chain
lab. Wind and weather do not with a simulator; replace the
affect either the calibration Generic approach to electrode
quality or the operator. diagnose troubleshooting Display blocked on a fixed value
The measuring point We suggest five steps: Insulation default and/or Test with a pH simulator
availability is dramatically 1) Check that the sensor short-circuit on the cable or an insulation meter
increased by the quick and is correct for the application
easy replacement of 2) Check the installation Moisture on the connectors Check and dry
pre-calibrated sensors. (cabling), the configuration Crack on the inside tube Replace electrode
The transmitter does not need and the hydraulic mounting (short-circuit between
to be installed close to the 3) Take the environment measurement and reference)
measuring point but can be (electromagnetic, electrical,
Reduction of the reference element (current circulation)
placed in the control room. moisture, sun) into account
Maintenance intervals 4) Consider the Insulation default and/or Test with a pH simulator
can be defined based on metrological level short-circuit on the cable or an insulation meter
all stored sensor load and 5) Find out which component Moisture on the connectors Check and dry
calibration data and predictive is out of order
Incoherence between Check
maintenance is possible.
configuration and connection
1) Installation
(symmetrical/asymmetrical)
Configuration of analog
(for analog systems only)
systems (symmetrical or
asymmetrical) has to be Table 1: Diagnosis of common troubleshooting
coherent with connection.

The Endress+Hauser Maintenance Guide 53

 Review the programming 4) Which component
Your Spare parts New
matrix. is out of order?
instrument availability generation
Consider the installation Electrode check:
conditions of the electrode. Visual check of the outside
condition (damaged, cracked, Mypro CPM431 NO - since 10/2010 Liquiline CM42
2) Environment bulb broken, corrosion,
Is the sensor installed abrasion, oxidation or moisture Mypro CLM431 NO - since 10/2010 Liquiline CM42
inside or outside? Is it on the connector, etc.)
protected from sunlight? Visual check of the inside Mycom CPM152 NO - since 12/2007 CPM153
Take the electrode out of its condition (Is KCl still
environment and check it transparent? Has the
in another environment. reference thread reduced? For further information, use our Device Viewer:
www.services.endress.com/device-viewer
Electromagnetic phenomena: Is the internal glass tube
check the cables and the damaged?)
Table 2: Instrument and spare parts availability
connection to the ground.
Does temperature vary a lot? Cable check: see page 52
If yes, check that temperature Transmitter check: see page 52
compensation is active. List of consumables
Moisture: visual check Instrument and Buffer solutions for pH electrodes
of the junction boxes spare parts availability Technical buffer solutions, accuracy 0.02pH, acc. to NIST/DIN
watertightness, look for See table on the right. pH 4.0 red, 250mL, order no. CPY20-C02A1
moisture or oxidation on pH 4.0 red, 1000mL, order no. CPY20-C10A1
pH 7.0 green, 250mL, order no. CPY20-E02A1
the connectors, etc. Spare parts stock pH 7.0 green, 1000mL, order no. CPY20-E10A1
We recommend that you always pH 9.2 blue, 250mL, order no. CPY20-I02A1
3) Metrological level keep a new electrode in stock. pH 9.2 blue, 1000mL, order no. CPY20-I10A1
Is there a drift, is the Technical buffer solutions for single use, accuracy 0.02pH, acc. to NIST/DIN
pH 4.0 red, 20 x 18mL, order no. CPY 20-C01A1
measurement unstable For how to select buffer pH 7.0 green, 20 x 18mL, order no. CPY 20-E01A1
or incorrect? solutions and cables:
Is the electrode soiled? see list on the right. Redox solutions
Then clean the electrode +220mV, pH 7.0, 100mL (0.026 US gal); order no. CPY3-0
+468mV, pH 0.1, 100mL (0.026 US gal); order no. CPY3-1
(see previous page). Migration
Check the electrode in a KCl-electrolyte solutions for liquid filled electrodes
well known medium with How to use a Memosens 3.0 mol, T=-10...100C (14 ... 212F), 100mL (3oz), order no. CPY4-1
the actual configuration data electrode with your current 3.0 mol, T=-10...100C (14 ... 212F), 1000mL (30oz), order no. CPY4-2
1.5 mol, T=-30...100C (-22 ... 266F), 100mL (3oz), order no. CPY4-3
of the transmitter. If there is pH transmitter? 1.5 mol, T=-30...100C (-22 ... 266F), 1000mL (30oz), order no. CPY4-4
Liquid analysis

a drift, return to the factory Upgrade kits are available for

configuration. If this is not any Liquisys M CPM 223/253 List of accessories
sufficient, apply the procedure (from version 2.5 upwards),
to adjust an electrode MycomS CPM153 and Special cables
CPK1 special measuring cable for pH/ORP electrodes with GSA plug-in head.
manually (see previous page). Liquiline CM42. This CPK9 special measuring cable for sensors with TOP68 plug-in head, for high-
Read the slope and the zero upgrade can be done either temperature and high-pressure applications, IP 68.
point. Depending on the value by a service engineer on CYK10 Memosens data cable for digital pH sensors with Memosens technology
of the slope you may need to site or you can send it back (CPSxxD).
CPK12 special measuring cable for pH/ORP glass electrodes and ISFET sensors with
clean or replace the electrode. to the Endress+Hauser TOP68 plug-in head.
service department.

List of tools
Memocheck Sim CYP03D is a service tool that simulates and controls the
contactless, digital signal transmission. Freely configurable measured values, errors
and calibration values.
Memocheck CYP02D is a service tool for quick checkof two predefined sensor status.
Memocheck Plus CYP01D is a tool for qualification of the measuring system during
plant qualification.

54 The Endress+Hauser Maintenance Guide

 Conductivity measurement

Conductivity
Sensors and transmitters

A complete conductivity measuring system includes:

Analog (Condumax W CLS12/13/15/16/19/21, Indumax CLS50/52/54) or
digital (Condumax W CLS15D/16D/21D, Indumax CLS50D) conductivity sensor
Transmitter (Liquisys M CLM223/253, Liquiline CM42 and CM442,
MycomCLM153)
Special measuring cable
Assembly

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

Conductive
Always take measuring principle

care of the An alternating voltage is applied

temperature! to two electrodes located in
the medium. The conductivity
value is calculated according to
Ohms law.

The electrical conductivity of liquids

is determined using a measuring
arrangement incorporating two
electrodes located opposite from one
another - as is the case in a capacitor.
The electrical resistance R, or its
reciprocal value - the conductance value
G - are measured following Ohms law.

Liquid analysis
From this, the specific conductivity
(Greek; kappa) is calculated using the
cell constant k, which describes the
geometry of the individual electrode
arrangement:
=k.G=k/R
Fig. 11: Example of a complete 5 Inductive sensor CLS50D
Fig. 9: Conductive measuring principle: The cell constant k usually has the unit measuring system 6 Conductive sensor CLS21
two electrodes are located opposite cm-1 and is specified by the manufacturer 1 Conductive sensor CLS15 7 Immersion assembly CLA111
from one another as in a capacitor. for each sensor. With an ideal plate 2 Liquisys M CLM253 transmitter Options: extension cable,
capacitor, the cell constant is: 3 Liquiline CM442 transmitter junction box VBA or VBM
k = electrode spacing / electrode surface 4 Inductive sensor CLS52 or CLS54

Conductivity sensors using

the conductive method Inductive Conductivity sensors using
High-temperature sensor measuring principle the inductive method
Condumax CLS12/13 for Robust sensor Indumax
industrial and power plant Based on an alternating CLS50D/50 for
applications (boiler feedwater) magnetic field that induces an concentration measurements
Pure and ultrapure water electrical current in the medium for acids, bases and salts,
sensor Condumax CLS15D/ which generates a magnetic field product monitoring,
CLS15 in the secondary coil. wastewater treatment
Hygienic sensor Condumax Hygienic sensors Indumax
In the case of inductive conductivity
CLS16D/16 measurement, a transmitter coil
CLS52/54 for food and life
Fig. 10: Inductive measuring principle: Low-cost sensor Condumax generates a magnetic alternating field sciences industry
a magnetic alternating field induces CLS19 for pure and ultrapure that induces an electrical voltage in
an electrical voltage in the medium. water the medium. This sets the positively or Installation conditions
negatively charged ions in the liquid
Drinking water and in motion and an electrical alternating
for inductive conductivity
wastewater sensor current flows through the liquid. measurement
Condumax CLS21D/21 This current produces a magnetic
alternating field in the receiver coil. For CLS52 and CLS54, the
The induction current produced in
the coil in this way is evaluated by the
medium should flow through
electronics system and used to calculate the conical measuring channel
the conductivity. in the indicated direction.

The Endress+Hauser Maintenance Guide 55

 Installation of the sensor To compensate residual Calibration of conductive
in pipes with horizontal coupling in the cable and measurement systems
(middle) and vertical (right) between the two sensor coils, Three different types
flow directions. (see fig. 12) perform a zero calibration in air are possible:
In narrow installation (air set) before installing the Calibration by measurement
conditions, the ion flow in sensor. For further information, in a calibration solution with a
the medium is affected by refer to the transmitter known conductivity.
the pipe walls. This effect is Operating Instructions. Calibration by entering the
compensated by the so-called Choose immersion depth b exact cell constant of the
installation factor. of the sensor in the medium conductivity sensor (given by
The installation factor can such that the coil body is a quality certificate).
be entered in the transmitter completely immersed (see Calibration by comparison
or the cell constant can be fig. 14). The pipe has to be to a reference device
corrected by multiplication completely filled with water. (e.g. CONCAL).
with the installation factor to Gas bubbles will have an
ensure correct measurement. influence on the displayed Calibration of inductive
The value of the installation value (avoid installation in an measurement systems sensor opening and check the
factor depends on the open falling tube). Two different types display versus the table
diameter and the conductivity are possible: printed in the transmitter
of the pipe as well as the Operation and maintenance Calibration by measurement Operating Instructions.
sensor distance from the wall. in a calibration solution with a For temperature simulation,
If the distance from the wall is Maintenance work includes: known conductivity. connect the decade resistor
sufficient (a > 15mm/0.12in, Cleaning of assembly Calibration by comparison to instead of the temperature
from DN 65/2), it is not and sensor a reference device. sensor Pt100, using a
necessary to consider the Cable and connection check three-wire arrangement, i.e.
installation factor (f = 1.00). (see pH section) If removing your conductivity connection to terminals 11
transmitter from process for 1 to 2
If the distance from the wall Calibration weeks is acceptable, the best method and 12, with a bridge from 12
is smaller, the installation is to send the instrument to one of to 13. Check the temperature
factor increases in case of Cleaning the our calibration facilities. We provide display versus the table printed
electrically insulating pipes conductivity sensors calibration certificates. in the transmitter Operating
(See Calibration services in the
(f > 1) and decreases in case Please clean contamination on At your service section). Instructions.
of electrically conductive the sensor as follows: carefully
pipes (f < 1). The installation clean with a synthetic brush To check a transmitter with
factor can be measured using and, if needed, with diluted Check of inductive sensors conductive sensors, please refer
calibration solutions or be hydrochloric acid (5%). Testing sending and receiving to your Operating Instructions.
Liquid analysis

approximately determined Then rinse carefully with coils: Ohmic resistance should
from a diagram (see fig. 13). plenty of clear water. be approx. 5 to 7 and Our service team can perform such
verifications.
inductivity approx. 260 to (See Maintenance services in
450mH (at 2kHz). Shunt the At your service section)
between sensor coils is not
allowed. The measured
resistance should be>20M. Instrument and
Test with ohmmeter between spare parts availability
red coaxial cable and white See table below.
coaxial cable.
Consumables stock
Check of transmitter The calibration solutions must
(inductive sensors) be stored in a dry place and
Conductivity can be checked used within a year.
C07-CLS52xxx-11-05-00-xx-001.eps

Fig. 12: Installation of a CLS52 inductive sensor in pipes with horizontal (middle) and
with standard resistors, e.g.
vertical (right) flow directions with decade resistors. For For how to select calibration
b Indicator arrow for the flow direction c Flow direction conductivity simulation, pull solutions and cables: see the
1 Welding neck 2 Pipe a cable through the cleaned list on next page.

Your Spare parts New

instrument availability generation

CLD431/CLM431 NO - since 10/2010 Liquiline CM42

Mycom CLM152 NO - since 12/2007 CLM153

Fig. 13: Dependence of installation factor
f on wall distance a
1 Conductive pipe For further information, use our Device Viewer:
2 Insulating pipe www.services.endress.com/device-viewer

Fig.14: Consider the immersion depth Table 3: Instrument and spare parts availability

56 The Endress+Hauser Maintenance Guide

List of consumables List of tools
Calibration solutions Memocheck Sim CYP03D is a service tool that
Precision solutions, traceable to SRM (standard simulates and controls the non-contact, digital signal
reference material) by NIST, for qualified calibration of transmission. Freely configurable measured values,
conductivity measuring systems according to ISO with errors and calibration values.
temperature table: Memocheck CYP02D is a service tool for quick
CLY11-A, 74 S/cm (reference temperature 25C/ checkof two predefined sensor status.
77F), 500mL (16.9 fl oz), order no. 50081902 Memocheck Plus CYP01D is a tool for qualification of
CLY11-B, 149.6 S/cm (reference temperature the measuring system during plant qualification.
25C/77F), 500mL (16.9 fl oz), order no.
50081903
CLY11-C, 1.406 mS/cm (reference temperature
25C/77F), 500mL/0.13 US gal, order no. CONCAL and CONDUCAL calibration sets
50081904
CLY11-D, 12.64 mS/cm (reference temperature Conductivimeter
25C/77F), 500mL/0.13 US gal, order no. Concal reference tool
50081905
CLY11-E, 107.0 mS/cm (reference temperature
25C/77F), 500mL/0.13 US gal, order no. MEAS

DIAG
CA L

PARA M

50081906

List of accessories

Liquid analysis
Measuring cables (for conductive sensors)
CYK71 measuring cable: non-terminated cable for the
Sampling outlet
connection of sensors (e.g. conductivity sensors) or 3m max. Sampling valve
the extension of sensor cables - sold by the meter,
order numbers:
non-Ex version, black: 50085333 sterile
Ex version, blue: 51506616
CYK10 Memosens data cable: cable for digital Fig.15
conductivity sensors, ordering according to product
structure
CONCAL is a conductivity calibration set CONDUCAL is a conductivity calibration
Measuring cables (for inductive sensors) for ultrapure water applications, factory- set using a Memosens reference chain.
CLK5 measuring cable: Extension cable for calibrated with certificate, traceable to
connecting CLS52 and transmitter via the VBM SRM of NIST and DKD. CONCAL is
junction box - sold by the meter, order no. 50085473 Our service team can perform the periodic
suitable for comparative measurement in
recalibration of ultrapure conductivity
ultrapure water applications measurement systems. Please contact us.
up to 20 S/cm (50.8 S/inch) and
temperature < 100C/212F.

The Endress+Hauser Maintenance Guide 57

 Turbidity
Turbidity measurement
Sensors and transmitters

A complete turbidity measuring system includes:

Analog turbidity sensor (Turbimax W CUS31/41/65) with a special
measuring cable or a digital sensor (Turbimax CUS51D)
Transmitter (Liquisys M CUM223/253, CUM740 and Liquiline CM442)
Assembly

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

Measuring principle
Take care
Optoelectronic measuring
when cleaning principle
the optics. A beam of light is directed
through the medium and
scattered by elements with a
greater optical density.

Scattered light methods

The 90-degree scattered light method in
accordance with ISO 7027 / EN27027
measures turbidity values under
standardized, comparable conditions
mainly in the low turbidity range. The
135-degree scattered light method is
Liquid analysis

optimized for the measurement of high

turbidities. With both methods, the
solid particles in the medium cause the
incident light to scatter. The scattered Fig. 18: Example of a complete 3 Assembly with gas bubble trap
light thus generated is measured using measuring system 4 Liquisys CUM253
scattered light detectors. The turbidity 1 Immersion assembly CYA611 5 Liquiline CM442
Fig. 16: Scattered light methods: of the medium is calculated from the 2 Retractable assembly CUA451
the scattered light generated by solid amount of scattered light. A temperature
particles is measured at 90 and 135. signal is recorded and transmitted in
addition to the turbidity signal. Digital
filter functions with interference signal
suppression and automatic sensor
Analog sensor TurbimaxW Availalble systems for
monitoring make measurements even CUS31 for drinking and sludge measurement
more reliable. industrial water Optoelectronic system
Analog sensor Turbimax W CUC101
Four-beam alternating light method
The method is based on two lights and
CUS41 for all wastewater Ultrasonic system
four detectors. Long-life light emitting applications CUS71D/CM442
diodes are employed as monochromatic Digital sensor Turbimax
light sources. These light emitting CUS51D for all wastewater
diodes are pulsed at a frequency of The influences
severalkHz so as to eliminate any effects
applications on turbidity measurement
of extraneous light. With each light signal, The measurement is altered by:
two measuring signals are detected at the Sludge level measurement Change of sludge type
four detectors. Eight measuring signals uses either the optoelectronic
in total are processed in the sensor and Flow variation
converted to solid concentrations. The
(four-beam) or the ultrasonic Presence of air or foam
four-beam alternating light method allows method. bubbles, suspended particles
users to compensate for any fouling and
deposit
Fig. 17: Ultrasonic measurement: aging of optical components. Ultrasonic measurement
a piezoelectric crystal generates an In the ultrasonic method, a piezoelectric Backscatter (which results
ultrasonic signal that reaches solid crystal is encased in a flat cylindrical in a higher signal) due to the
Turbidity sensors using the
particles and comes back to the receiver. plastic body. When the crystal is excited installation of the sensor in
optoelectronic measuring with voltage it generates a sonar signal.
piping or very close to a wall
principle In the process, ultrasonic waves are
emitted to scan the separation zones. Deposits on the sensor optics
Online turbidimeters
The measured variable is the time the
Turbimax CUE21 and CUE22 emitted ultrasonic signal needs to reach
for drinking water and treated the solid particles in the separation zone
process water and return again to the receiver.

58 The Endress+Hauser Maintenance Guide

 New picture

Installation conditions CUS 31-xxE, CUS 31-xxS In the FNU operating

and CUS51D sensors can be mode, the sensor is factory
Pipe installation (see fig. 19) used for turbidities < 5 FNU. calibrated with formazine
The pipeline diameter must However, CUS51D is not traceable to ISO7027.
be at least DN 100/4 if designed for potable water. In the ppm operating mode,
reflective materials (e.g. the calibration data records for
stainless steel) are used. Operation and maintenance Kaolin and SiO2 are derived
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 Fig. 19: Tube implantation
The best installation location way that correct values are
is in the ascending pipe. Cleaning the displayed for average clarity.

Liquid analysis
Installation is also possible turbidity sensors However, the settings do not
in the horizontal pipe, but Deposits on the sensor optics follow a standard currently
should be avoided in the may result in inaccurate applicable. Fig. 20: Installation in flow assemblies
down pipe. measurement. Therefore the In the g/L operating mode Parallel sensor orientation
Mount the sensor surface sensor must be cleaned at also, the sensor is not Sensor orientation against
the medium flow
against the medium flow regular intervals. The intervals calibrated to a fixed value
(self-cleaning effect). are specific to each installation as no standard is directly
and must be determined during applicable. You must carry
Installation operation. Clean the optics with out a calibration because
in flow assemblies the following agents depending the media of the various
If possible, install the flow on the type of soiling: applications differ too
assembly vertically so that the greatlyhere.
medium flows to the sensor Limestone deposits:
Short treatment with
from below. Alternatively, the commercial deliming agent
The calibration data are saved When commissioning the
assembly can also be installed Oily and greasy soiling: directly in the sensor. Therefore: sensor in sludge applications.
horizontally. Cleaning agents based on Recalibration is not required in When changing to another
Two sensor orientations water-soluble surfactants the event of a power failure. sludge type.
(e.g. household dish detergents)
are possible for horizontal Other types of soiling:
Recalibration is not
installation (fig. 20): With water and brush required when the Three-point sensor calibration is
parallel to the medium flow transmitter is replaced. not necessary:
against the medium flow Warning: Customer-specific When commissioning the
Do not touch the optics with
Orientation parallel to the sharp-edged objects.
recalibration is required, sensor in the drinking
medium flow is required when Do not scratch the optics. however, when the sensor water area (sensor has been
using the CUR 3 spray head. is replaced. calibrated for drinking water
Orientation against the Clean the sensor mechanically Three calibration data records are applications in the factory).
medium flow is used to using a soft brush. Then rinse saved in the sensor for each of For residual concrete water.
increase the self-cleaning thoroughly with water. the four main operating modes. Density measurement
effect in heavily-soiled for determining the
media (> 15 FNU). The Calibration and adjustment When do you need to calibrate? concentration of residual
wall reflection is negligible Note: The sensor contains all Three-point sensor calibration concrete water is based on
here due to the high the calibration data. is the standard calibration. It is %data records. They are
absorption tendency. absolutely essential: preset in such a way that

The Endress+Hauser Maintenance Guide 59

 correct values are displayed Installation adjustment Sensor operating voltage
for average clarity. One-point In installation adjustment, is o.k. but no measured
calibration is often sufficient backscatter from the immediate turbidity value even with
to adjust the system in the sensor environment is a new sensor. Replace the
event of deviating values. compensated. Installation transmitter module MKT1.
When recalibrating with the adjustment must be performed
same sludge type. One-point with a medium whose turbidity Our service team can perform
a0006961

Fig. 21: Making the samples for a

such verifications. three-point calibration
calibration suffices here if is lower than 2 FNU or 5 ppm. (See Maintenance services in A Original sample
the degrees of lightness and the At your service section) B 1 part sample A + 2 parts water
clarity, for example, do not Checking the C 1 part sample A + 9 parts water
differ too greatly. measuring point
The system CUS51D + CM442 Instrument and
Performing three-point can be simulated using the spare parts availability
calibration (on site) Memocheck Sim CYP03D.
For further information,
You should perform the use our Device Viewer:
calibration in the turbidity/ The sensors CUS31 and CUS41 www.services.endress.com/
solids concentration range in cannot be simulated as they device-viewer
which you plan to measure. The contain the complete data
overall calibration characteristic processing and all the measured
of the measuring chain is values are transmitted to For how to select and
determined using three samples CUM223/253 using the digital order accessories:
of known turbidity or known interface RS 485. Therefore a seethe following list.
solids content. functional sensor is required for
the measuring point test.
Calibration with a very dark, Method for testing a measuring
high-absorption medium returns point:
small slopes while light, clear Check that device is operable List of accessories
media return big slopes. and that the display reacts
Measuring cables
You can create the requisite appropriately, e.g. by pressing CYK81 measuring cable: non-terminated measuring cable for extension of sensor
probes by diluting a medium the PLUS key. cables of e.g. Memosens, CUS31/CUS41 - two wires, twisted pair with shield and
sample. In general, very good Check the current outputs PVC sheath (2 x 2 x 0.5mm2 + shield) - sold by the meter, order no. 51502543
calibration results are achieved by carrying out a current
Other accessories
with a concentration gradation simulation (Field O3(2)). CUY 22 check unit for CUS 31 and CUS41 for checking the stability of the sensor,
of 10%, 33% and 100%. The Measure the sensor operating order no. 51504477
following condition must be met voltage: approx. 10 to 16V at CUY 31 service kit 3 spare wiper arms for CUS 31-Wxx: The CUS 31-W sensor is
Liquid analysis

terminals 87 (+) and 88 (). equipped with a rubber wiper for removing deposits from the sensor carrier plate.
for the calibration: Order no. 50089252
Sample A > 1.1 x sample B The cause for an incorrect Calibration kit for CUE 21 Values: 0.02 NTU; 10.0 NTU and 1000 NTU
> 1.1 x sample C (see fig. 21) voltage may be present either order no. 51518580
at the device or at the sensor. Replacement basin including transducer for ultrasonic cleaning,
Replace the sensor. order no. 51518576
You can send us the sensor and
Flow assembly Flowfit CUA250 for CUS31/CUS41: Please contact us
flow assembly for adjustment on If the sensor operating
a calibration bench according to voltage is still too low replace
ISO70027. You will be issued List of tools
a quality certificate.
the power supply module
LSGA/LSGD (make sure to use Memocheck Sim service tool that simulates and controls the non-contact,
the appropriate version). digital signal transmission ref. CYP03D

60 The Endress+Hauser Maintenance Guide

 Chlorine measurement

Disinfection
Sensors and transmitters

A complete chlorine measuring system includes:

Analog (CCS120/140/141/240/241) or a digital (CCS142D) chlorine sensor
Transmitter (Liquisys M CCM223/253, Liquiline CM442)
Special measuring cable
Assembly
Reference measuring instrument for determination of free chlorine
according to the DPD method

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

Measuring principle
The
Chlorine is reduced at the
measurement gold electrode. The electron
is strongly acceptance is proportional to
the concentration of chlorine.
influenced by
pH, temperature The sensors work in accordance
with the amperometric principle in a
and flow. membrane-covered cell. How they work
can be described using the example
of chlorine dioxide measurement:
The sensor features a metallic cathode,
which is separated from the medium
by a thin membrane. Chlorine
dioxide coming from the medium
diffuses through this membrane and

Liquid analysis
is reduced at the gold cathode. The
circuit is completed by means of the
silver anode and the electrolyte.
The electron reduction at the cathode
is proportional to the concentration of
chlorine dioxide in the medium. The Fig. 23: Measuring system in the flow 4 Mounting place for pH/ORP sensors
transmitter converts this current to the mode (example) 5 Chlorine sensor
appropriate display value. With 1 CCA250 flow assembly 6 Medium outlet
chlorine dioxide, this process works in 2 Medium inlet 7 Sampling tap
a wide pH and temperature range. 3 Inductive proximity switch for flow 8 Fixed measuring cable
The situation with free available monitoring 9 Transmitter
Fig. 22: Amperometric principle: chlorine is somewhat different. Here,
chlorine dioxide diffuses through hypochlorous acid diffuses through the
the membrane and is reduced membrane and produces a reaction.
at the gold cathode. The presence of hypochlorous acid in
the medium depends on the pH value. Sensors for chlorine dioxide: Installation conditions
This dependency is compensated
by means of pH measurement
CCS240 for recreational
in the flow assembly and water and industrial water Installation in flow assembly
balancing in the transmitter. CCS241for drinking water CCA250
Total chlorine measurement is more The flow assembly CCA250
complicated. In addition to hypochlorous
acid, chloramines also play a part in
Sensor for total chlorine: is designed for on-site
a complex system of reactions. CCS120 for drinking water, installation of the measuring
recreational water, industrial cell. In addition to the chlorine
Sensors for disinfection using water and wastewater measuring cell, a pH and ORP
the amperometric principle electrode can be installed.
Sensors for free available The influences A needle valve regulates the
chlorine: on chlorine measurement flow within the range of 30 to
CCS140 for recreational The measurement is influenced 120L/hr (7.9 to 31.7gal/hr).
water and industrial water by:
CCS141 for drinking water pH value If the measured water is fed
Digital Memosens sensor Flow back into a surge tank, pipeline
CCS142D for drinking water, Temperature or the like, ensure that the
process water, industrial generated back pressure on the
water and wastewater measuring cell does not exceed
1 bar/14.5 psi and remains

The Endress+Hauser Maintenance Guide 61

 constant. Negative pressure to the actual free active Perform recalibration
at the measuring cell, e.g. by chlorine value (cf. also note in if required.
feedback of measured water DIN38408, part 4, section 5). If the membrane is
to the suction side of a pump, visibly soiled, remove the
must be avoided. Calibration (CCS142D) measuring cell from the
The sensor reading must be flow assembly. Only clean
Operation and maintenance stable (no drifts or unsteady the membrane mechanically
values for at least 5 minutes). with a gentle water jet or for
Maintenance work at the This is normally fulfilled when: some minutes in 1 to 10%
transmitter includes: The polarization hydrochloric acid (observe
Calibration period is finished. safety regulations!) without
Cleaning of assembly and The flow is constant and chemical additives. Chemicals
sensor within the correct range. reducing the surface
Cable and connection check The sample medium tension must not be used.
and the sensor are at the Replace a heavily soiled
Reference measurement same temperature. or damaged membrane.
according to the The pH value is within Refill the measuring cell of chlorine bleaching lye NaOCl
DPD method the admissible range. with electrolyte once per approx. 13%, pharmaceutical
The calibration of the A zero-point adjustment is not season or every 12 months. quality (available at chemical
measuring system requires required thanks to the zero Depending on the chlorine stores or pharmacies).
a colorimetric reference stability of the membrane- content on site, this period
measurement according covered sensor. can be reduced or extended. Maintenance of pH/ORP
to the DPD method. Free If you, however, wish sensors (version EP)
chlorine reacts with diethyl- to perform a zero-point Regenerating the sensor See pH/ORP section.
p-phenylenediamine(DPD) adjustment, operate the sensor During measurement, the
by producing a red dye, the in chlorine-free water for electrolyte in the sensor Maintenance pH connecting
intensity of the red color being at least 15 min. is gradually exhausted by lines and junction boxes (EP)
proportional to the chlorine chemical reactions. The Check the cables and
concentration. For slope calibration, perform silver chloride layer, applied connections for moisture.
The intensity of the red dye the following steps: to the anode at the factory, Moisture is indicated by a
is measured by a photometer 1. Ensure a constant pH continues to grow during sensor slope that is too small.
(e.g. CCM182, see accessories) value and temperature sensor operation. This has If no more display is possible
and displayed as chlorine of the medium. no effect on the reaction or if the display is fixed at pH7,
concentration. 2. Take a sample for DPD taking place at the cathode. please check the following
measurement. The sampling A change in color of the components:
Liquid analysis

An important fact must be kept location has to be close silver chloride layer, however, Sensor head
in mind: The DPD method to the installed sensor. indicates effects on the reaction Sensor connector
is not a selective measuring Use the sampling at the cathode. Therefore, pH measuring cable
method for free chlorine alone, tap if available. ensure by visual inspection that Junction box, if fitted
but other oxidants present 3. Enter the measured the grey-brown color of the Extension cable
in the medium can also be value into the transmitter anode has not changed. If the
registered (see DIN38408, (see Operating Instructions anode color has changed, e.g. Caution! If there is moisture in
part 5, section 4). Moreover, of the transmitter). if it is spotted, white or silvery, the measuring cable, the cable
the measuring range of the 4. After initial installation the sensor must be regenerated. must be replaced!
photometers has a lower of the sensor, check Send it to the manufacturer for
limit and does not permit the calibration by DPD this purpose. A shunt in the cable of > 20M
measurements in the very low measurement 24 hours later. can no longer be measured
trace range. In addition to the Carry out a slope calibration Reconditioning the sensor with normal multimeters
chlorinated probe, a sample every time the membrane or Long-term operation but is damaging for the pH
of the medium without added electrolyte is changed. (>threemonths) in chlorine- measurement. A reliable test
chlorine should be checked by free media, i.e. with very low can be carried out with a usual
a DPD measurement if possible. Maintenance of sensor currents, may lead to a commercial insulation meter:
The measured value must lie chlorine sensors deactivation of the sensor. Make sure to disconnect the
near zero and differ significantly Corrective maintenance for This deactivation is a pH measuring cable from the
from the chlorinated sample. chlorine sensors and assemblies continuous process that results sensor and device!
is described in the operating in a lower slope and longer If you are using a junction box,
The measured water is always instructions. Use and refer response times. check the infeed and outfeed
buffered to a pH value of 6.3 to the operating instructions After long-term operation in measuring cable separately.
with the DPD method, so the relating to your measuring a chlorine-free medium, the Check the cable with
measurement is independent of system. sensor must be reconditioned. 1000VDC (at least with
the pH value of the measured You need the following 500VDC) testing voltage.
water. Routine check for CCS140/ materials for reconditioning: If the cable is intact, the
Caution: The DPD method 141/142D Demineralized water insulation resistance > 100G.
cannot be applied if organic Check the measurement at Polishing sheet If the cable is defective
chlorination agents are used. regular intervals, dependent (see Accessories) (moist), there is flashover. The
In this case it causes a higher on the respective conditions, Beaker cable must be replaced.
measured value compared at least once a month. Approx. 100ml (3.381fl oz)

62 The Endress+Hauser Maintenance Guide

Test and simulation Temperature NTC simulation List of consumables
Chlorine sensors value
For measurement of chlorine CCS140, CCS141 and CCS142D
Chlorine sensors work according 0C/32F 29.490k Set of 2 replacement cartridges CCY14-WP, order no 50005255
to the amperometric principle Electrolyte (50 mL) CCY14-F, order no 50005256
10C/50F 18.787k
and supply very small direct Polishing sheets COY31-PF, 10 pieces for cleaning of the gold cathode,
current as measuring signals. A 20C/68F 12.268k order no. 51506973
Service kit CCS14x: 2 replacement cartridges, filling electrolyte 50ml,
chlorine sensor can be simulated 25C/77F 10.000k
polishing sheets, order no. 71076921
by a DC source. Due to the small 30C/86F 8.197k
currents, however, the simulation 40C/104F 5.594k
For measurement of chlorine dioxide CCS240 and CCS241
is highly sensitive. Lines should Set of 2 replacement cartridges CCY14-WP, order no 50005255
be screened and the simulator Table 5
For measurement of total chlorine CCS120
grounded. You will find typical Electrolyte (50mL), order no 51516343
slope values in the table hereafter. pH/ORP measurement Kit containing 2 membranes and electrolyte (50mL), order no 51517284
Simulation takes place with a
Sensor Typical slope value*
pH/mV simulator or an mV List of accessories
CCS120 115nA per mg Cl/l voltage source.
CCS140 25nA per mg Cl/l (see pH/ORP section) Calibration accessories
Photometer CCM182; microprocessor-controlled photometer for chlorine, pH value,
CCS141 80nA per mg Cl/l cyanuric acid; Chlorine measuring range: 0.05 to 6 mg/L
Flow monitoring pH measuring range: 6.5 to 8.4, order no CCM182-0
CCS240 100nA per mg ClO2/l

Liquid analysis
Use and refer to the operating
CCS241 350nA per mg ClO2/l instructions relating to your Measuring cables
CMK measuring cable: cable for the CCS 140, 141, 240 and 241,
CCS142D-A -25nA per mg/l measuring system. order no. 50005374
CCS142D-G -80nA per mg/l CYK71 measuring cable: non-terminated cable for the connection of sensors
Our service team can perform such
verifications. or the extension of sensor cables, sold by the meter,
* At 25C/77F
(See Maintenance services in order numbers:
Table 4 non-Ex version, black: 50085333
the At your service section).
Ex version, blue: 51506616
Temperature measurement CYK10 Memosens data cable: cable for CCS142D,
The transmitter uses the NTC Instrument and ordering according to product structure
sensor of the chlorine sensor spare parts availability CYK81 measuring cable: non-terminated measuring cable for extension of sensor
cables of e.g. Memosens sensors, two wires, twisted pair with shield and PVC sheath
to measure the temperature. (2 x 2 x 0.5mm2 + shield), sold by the meter, order no.: 51502543
For further information,
Due to the relatively high use our Device Viewer:
sensor resistance, a two- www.services.endress.com/ List of tools
wire connection is sufficient. device-viewer
Simulation can take place with Memocheck Sim CYP03D is a service tool that simulates and controls the non-
contact, digital signal transmission. Freely configurable measured values, errors and
a normal decade resistor. The For how to select and calibration values.
following table contains some order accessories: Memocheck CYP02D is a service tool for quick check of two predefined sensor status.
simulation values. see the following list. Memocheck Plus CYP01D is a tool for qualification of the measuring system during
plant qualification.

The Endress+Hauser Maintenance Guide 63

 Dissolved oxygen
Oxygen measurement
Sensors and transmitters
for dissolved oxygen
A complete dissolved oxygen measuring system includes:
Analog (Oxymax COS31/41/61/71) or a digital (Oxymax COS22D/51D/61D)
oxygen sensor
Transmitter (Liquisys M COM223/253, Liquiline CM42 and CM442)
Special measuring cable
Immersion, flow or retractable assembly

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

Measuring principle
Periodically
Amperometric principle
clean and check Oxygen reaches the
the system. working electrode via a
membrane and is reduced to
hydroxide at the cathode.

When performing measurements

according to the amperometric principle,
the sensor comprises a working
electrode and a counterelectrode in the
simplest version of the two-electrode
system. Both are surrounded by an
electrolytic liquid in a common chamber.
A membrane provides the link to the
medium or process: oxygen permeates
Liquid analysis

from the medium into the electrolyte

through the membrane and is reduced
at the working electrode. The resulting
current response is in direct proportion
to the oxygen partial pressure.
The current is converted in the Fig. 26: Examples of complete measuring 4 Weather protection cover CYY101
Fig. 24: Amperometric principle:
downstream transmitter and displayed to systems 5 Liquisys M COM253 transmitter
oxygen permeates into the
the user in the familiar units of oxygen 1 Oxygen sensor 6 Liquiline CM442 transmitter
electrolyte through the membrane
saturation, concentration (in mg/l or 2 Immersion assembly CYA611 7 Retractable assembly COA451
and is converted to a current.
ppm) and oxygen partial pressure. In 3 Universal hanging assembly holder
more complex three-electrode systems, CYH101
an extra electrode is used (the reference
electrode) to accurately control and
regulate the internal condition of the
sensor. This sensor demonstrates a high
level of long-term stability. Fluorescence quenching (quench) the fluorescence light emitted.
The reduction in fluorescence light is
principle (optical)
connected to the oxygen partial pressure,
Oxygen sensors using the Marker molecules are excited both in terms of the amplitude and the
amperometric principle by a green light and respond duration. The light signal is converted in
Hygienic sensor Oxymax with a red fluorescent light. the downstream transmitter and made
available to the user in the familiar units
COS22D - Digital sensor Oxygen molecules quench
of oxygen saturation, concentration (in
for food, pharmaceuticals, the fluorescent light. mg/l or ppm) and oxygen partial pressure,
energy, chemicals, just as with the amperometric sensor.
With the fluorescence quenching
Fig. 25: Optical principle: inertization method, a layer that is permeable to
oxygen molecules adapt to the Water sensor Oxymax oxygen also forms the junction with
Oxygen sensors using
marker molecules and decrease the optical principle
the fluorescence light emitted
COS41 - Analog sensor for the process. This layer contains just as
water treatment many oxygen molecules as the medium Optical sensor Oxymax
(the partial pressure of the oxygen is COS61 - Water, wastewater,
All-round sensor Oxymax just as high in the medium as in the
COS51D - Digital sensor for layer). It is separated from the optics
fish farming; digital signal
water and wastewater at the sensor by means of a substrate processing in the sensor
that is permeable to light. The layer Memosens sensor Oxymax
contains marker molecules that are COS61D - Water, wastewater,
optically excited with a green light
and respond with a red fluorescence
fish farming; digital signal
light. Oxygen molecules adapt to processing in the sensor
these marker molecules and decrease

64 The Endress+Hauser Maintenance Guide

Operation and maintenance Calibration and adjustment Calibration and adjustment The following methods help you
To access the Calibration in air determine the time intervals
Maintenance work includes: function group, press the CAL 1. Remove the sensor from the between calibrations:
Cleaning of assembly key on your transmitter. This medium. 1. Check the sensor one
and sensor function group is used to calibrate 2. Clean the outside of the month after it has been put
Cable and connection check and adjust the measuring point. sensor with a damp cloth, then into operation by taking it out
Calibration and adjustment The sensor is calibrated in air or dry the sensor membrane e.g. of the fluid, drying it and then
in the medium. with a tissue. measuring the oxygen saturation
Cleaning the sensor Note! 3. If the sensor is removed from index in air after 10 minutes.
To ensure reliable measurement, At first start-up, sensor a closed pressure system with a Decide based on the results:
the sensor must be cleaned at calibration of amperometric process pressure greater than a. If the measured value is not at
regular intervals. sensors is absolutely essential atmospheric pressure: 102% SAT (for an amperometric
Depending on the type of in order for the measuring Open the membrane cap to system) or not at 100.6% SAT
soiling, proceed as follows: system to be able to generate equilibrate the pressure and (for an optical system), you have
accurate measuring values. clean the cap if necessary. to calibrate the sensor.
Salt deposits

Liquid analysis
Immerse the sensor in drinking water
The optical oxygen sensor Replace the electrolyte filling b. Otherwise, double the length
or in 1-5% hydrochloric acid for a few COS61 does not need a and close the membrane cap of time to the next inspection.
minutes. Afterwards, rinse it well with calibration at first start-up. again. 2. Proceed as per Point 1 after
plenty of water. Wait for the polarization time two, four and/or eight months.
Dirt particles on the sensor body
(not on the membrane!)
Calibration and adjustment to end. This way you can determine the
Clean the sensor body mechanically of amperometric systems 4. Then wait while the sensor optimum calibration interval for
with water and a suitable brush. Calibration is a means of adjusts to the temperature of your sensor.
Dirt particles on the membrane cap adapting the transmitter to the ambient air. This takes about
or the membrane
Clean the membrane with water and a
the characteristic values of the 20minutes. Check that the Calibration and adjustment
soft sponge. sensor. As no zero calibration is sensor is not in direct sunlight of optical systems
After cleaning, rinse the sensor well required for the sensor, a single- during this time. Calibration is a means of
with plenty of clean water. point calibration is carried out in 5. If the measured value adapting the transmitter to
the presence of oxygen. displayed on the transmitter is the characteristic values of
Cleaning the optics The sensor requires stable, carry out the calibration in the sensor. Normally, sensor
The optics only need to be calibration after: accordance with the Operating calibration is seldom necessary.
cleaned if the medium has first commissioning Instructions of the transmitter. It is necessary after changing the
penetrated through a defective replacing a membrane or 6. Place the sensor in the fluorescence cap.
fluorescence cap. electrolyte medium again.
To clean it, proceed as follows: cleaning the cathode The slope calibration of
1. Unscrew the protection guard long breaks in operation Note: Calibration and the oxygen sensor COS61
and fluorescence cap from the without power supply adjustment in air is only will be performed in air or
sensor head. typical time intervals dependent possible if air temperature in air saturated water. The
2. Carefully clean the optical on operating experience 5C/23F. Make sure you calibration of the zero point
surface with a soft cloth until comply with the instructions will be performed in nitrogen
the buildup is fully removed. Three different types of for calibration in the Operating or in oxygen-free water (water
3. Clean the optics with calibration are possible: Instructions of the transmitter. enriched with zero solution).
drinking or distilled water. Calibration in water.
4. Clean the optics and screw on Calibration in air The calibration intervals depend The sensor identifies unassisted
a new fluorescence cap. Calibration by comparison to a heavily on: the slope calibration
Caution! The optical surface reference device The application and (75 to 140% SAT) and the
may not be scratched or Calibration in air is the easiest The installation position of the calibration of the zero point
damaged in any way! method of calibration. sensor. (0 to 10% SAT). No further

The Endress+Hauser Maintenance Guide 65

 C07-COS41xxx-17-05-00-xx-001.EPS
selection is necessary. These Simple check 1 2 3
limits are valid for the three of the zero point
types of calibration air, water Place the sensor in a
and ref. recipient which can be
hermetically closed.
Maintenance intervals Add fresh water and sodium

C07-COS41xxx-17-05-00-xx-001.EPS
Fig. 27: Changing the electrolyte and the membrane (Amperometric sensors)
Amperometric sensor: bisulphite (Na2SO3) as powder
suggested maintenance (zero calibration solution,
intervals* order number 50001041)

C07-COS41xxx-17-05-00-xx-001.EPS
Weekly: clean the sensor. Close hermetically and let the List of accessories
Monthly: calibration in air. powder dissolve for 1 to 2 hours.
Annually: clean the gold cathode The measured value should be Measuring cables for sensors COS21D
with specific abrasive paper at 0.3% SAT (current is < 1nA). Cable for COS21D; length: 5m - order no. CYK10-A051;
length: 10m - order no. CYK10-A101
and change the electrolyte, the Measuring cables for sensors COS21
membrane, and the O-ring. Our service team can perform COK21; length: 3m - order no. 51505870; length: 10m - order no. 51505868
such verifications (see Measuring cables for sensors COS31 and COS71 with TOP68 connector
Optical sensor: suggested Mantenance services in the COK31; length: 1.5m (4.92ft) - order no. 51506820; length: 7m (22.97ft) - order
At your service section) no. 51506821; length: 15m (49.22ft) - order no. 51506822
maintenance intervals*
Weekly: clean the sensor.
Annually: change the sensor Spare parts stock List of consumables
cap and the O-ring and Amperometric system:
calibrate in air. We recommend you For measurement of dissolved oxygen COS3, COS4
COY3-WP Set of 2 cartridges with pretensioned membrane, order no. 50053348
keep membranes and COY3-F Electrolyte filling (10 doses of 5ml), order no. 50053349
* intervals may differ according to electrolyte filling in stock. COY3-TR Trapezoidal seal (supplied in packs of 3), order no. 50080252
the application
Optical system: For measurement of dissolved oxygen Oxymax H COS21, COS21D
We recommend you keep Electrolyte for COS21D,version COS21D-A, order no. 51505873
Changing the electrolyte a sensor cap in stock.
version COS21D-B, order no 51518701, version COS21D-C, order no. 51518703
and the membrane Electrolyte for COS21, order no. 51505873
For measurement of dissolved oxygen Oxymax W COS31, COS41
(Amperometric sensors) Instrument and COY31-WP Set of 2 cartridges - std response, order no. 51506976
See fig. 27 and the list spare parts availability COY31S-WP Set of 2 cartridges - fast response, order no. 51506977
of consumables. COY31-OR Sealing ring (supplied in packs of 3), order no. 51506985
COY31-PF Polishing foil (supplied in packs of 6), order no. 51506973
For further information, Zero calibration solution, order no. 50001041
Simple check of the COY31-Z Accessory kit - standard response (containing 1 x COY3-F, 1 x COY31S-WP,
you can use our Device Viewer:
measuring function www.services.endress.com/ 1 x COY3-OR and 1 x COY31-PF), order no. 51506784
1. Remove the sensor device-viewer COY3-S-Z Accessory kit - fast response (containing 1 x COY3-F, 1 x COY31-WP,
from the medium. 1 x COY3-OR and 1 x COY31-PF), order no. 51506785
Liquid analysis

For oxygen measurement with optical sensor COS61

2. Clean and dry the membrane. For how to select and Sensor cap, order no. 51518598
3. After about 10 minutes, order accessories: Set of 2 sealing rings, order no. 51518597
measure the oxygen seethe following list.
saturation index in air List of tools
(without recalibration).
Memocheck Sim CYP03D is a service tool that simulates and controls the non-
4. The measured value contact, digital signal transmission. Freely configurable measured values, errors and
should be at calibration values.
102% SAT for an Memocheck CYP02D is a service tool for quick check of two predefined sensor status.
amperometric system Memocheck Plus CYP01D is a tool for qualification of the measuring system during
plant qualification.
100.6% SAT for an
optical system

66 The Endress+Hauser Maintenance Guide

 Online analyzers
and photometric measurement
The current Endress+Hauser range of analyzers includes:
The Stamolys range of colorimetric analyzers for
ammonium, iron, manganese, chlorine, silica, etc.
The STIP analyzers for BOD (biological oxygen demand),
TOC (total organic carbon), COD (chemical oxygen demand),
toxicity and multiparameter UV analyzers.
The multiparameter controller Liquiline CM442 with new Memosens sensor
Viomax CAS51D (nitrates and SAC - spectral absorption coefficient).
In this section, you will find essential information and advice that will help you to
perform the optimum follow-up of your analysis devices throughout their lifecycle.

Photometry
Periodic measuring principle

maintenance Light is shone through the

is essential. aqueous sample. The light
intensity is attenuated by the
coloration of the constituent
substances. Every substance
has a characteristic coloration.
The more there is of this
substance in the water, the
more these light beams
are attenuated. Detectors
measure the attenuation of
light at a coloration typical for

Liquid analysis
this substance. A reference
measurement (sample without
Fig. 28: Photometry measuring principle
chemicals) is performed Fig. 30: Typical Stamolys analyzer Fig. 31: Viomax CAS51D photometric
before every measurement (housing version, without hoses) sensor for SAC or nitrate measurement
1 Reagents pump, inlet from canister Measuring system with flow assembly
so that interferences caused 2 Display (example)
by inherent color, turbidity 3 Serial interface RS 232 1 Sensor Viomax CAS51D
or contamination can be 4 Photometer optical cell 2 Inlet
compensated for. The 5 Static mixer (acc. to version) 3 Flow assembly Flowfit CYA251
6 Valve V4 (version with sample outlet 4 Sealing cap
concentration of the right side only) 5 Outlet
substance is ascertained 7 Dosage loop (with CA71SI only) 6 Transmitter Liquiline CM442
using this information. 8 Valve V2
9 Sample resp. reagents mix outlet
(left or right acc. to version)
When using colorimetric 10 Valve V1
Fig. 29: Stamolys analyzers design
1 Reference LED analyzers, a reagent is added 11 Channel switch
2 Emitter LED to the water sample to 12 Sample pump
3 Sample chemically dye the substance
4 Reference detector that is to be analyzed.
5 Measuring detector
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 5 to 40C (41 to 104F)
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 clean rooms
determines the samples aging of the LEDs. The device is IP43 and must be
absorption of an emitted light at The temperature in the protected from rain and frost.
a specific wavelength. photometer is controlled Outdoor installation is only
The wavelength is parameter automatically so that the possible with protective
specific. The absorbance reaction is reproducible and devices (customer supplied)

The Endress+Hauser Maintenance Guide 67

 Operation and maintenance Sample pump Reagents pump

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 Fig. 32

Time interval Duty Who?

Weekly Check and note User
calibration factor (for
service purposes). Instrument and For how to select reagents
Move valve hoses into spare parts availability and other consumables:
their position and spray See the list below.
with silicone (extends
the service life).
Your Spare parts New
Monthly Flush the sample tubing User instrument availability generation
system with 12.5%
bleaching lye (sodium Stamosens CNM750 until 09.2015 Liquiline CM442
hypochlorite) and reflush
thoroughly with water. Stamosens CSM750 until 09.2015 Liquiline CM442
Replace reagents and
standard solutions, if Stamosens CNS70 until 09.2015 Viomax CAS51D
required.
Stamosens CSS70 until 09.2015 Viomax CAS51D
Clean the sample
collector.
Every 3 months (in addition to all the User For further information, use our Device Viewer:
actions described above) www.services.endress.com/device-viewer
Spray pump hoses with
silicone spray (order no. Table 7: Instrument and spare parts availability
Liquid analysis

51504155).
Replace pump hoses.
Check manually the List of consumables and reagents (Stamolys range)
different parts (pump, for CA71AM (ammonium)
etc.). Active reagent set A1+A2, 1L each - order no. CAY140-V10AAE
Inactive reagent set A1+A2, 1L each - order no. CAY140-V10AAH
Every 6 months (in addition to all the User or Cleaning solution, 1L - order no. CAY141-V10AAE
actions described above) Endress+Hauser Standard sol. 5 mg/l NH4-N, 1L - order no. CAY142-V10C05AAE
Replace all hoses and T service in the Standard sol. 10 mg/l NH4-N, 1L - order no. CAY142-V10C10AAE
Standard sol. 15 mg/l NH4-N, 1L - order no. CAY142-V10C15AAE
connectors. scope of a service
Standard sol. 20 mg/l NH4-N, 1L - order no. CAY142-V10C20AAE
contract Standard sol. 30 mg/l NH4-N, 1L - order no. CAY142-V10C30AAE
Annually (in addition to all the Endress+Hauser Standard sol. 50 mg/l NH4-N, 1L - order no. CAY142-V10C50AAE
Maintenance kit CAV740 - order no. CAV740-2A
actions described above) service in the Standards under 5 mg/l not available, because of the low stability
Replace the static mixer scope of a service
(order no. 51512101). contract for CA71PH (phosphate) - standard documents, ready to use
Replace the photometer Active reagent set P1 + P2, 1L each (A) - order no. CAY240-V10AAE
Inactive reagent set P1 + P2, 1L each (A) - order no. CAY240-V10AAH
optical cell (if necessary). Active reagent set P1 + P2, 1L each (B) - order no. CAY243-V10AAE
Cleaning solution, 1L (A) - order no. CAY241-V10AAE
Table 6
Standard sol. 1 mg/L PO4-P, 1L (A) - order no. CAY242-V10C01AAE
Standard sol. 1.5 mg/L PO4-P , 1L (A) - order no. CAY242-V10C03AAE
Standard sol. 2 mg/L PO4-P, 1L (A) - order no. CAY242-V10C02AAE
For Stamolys analysers, it is kit relating to your analyzer Standard sol. 5 mg/L PO4-P, 1L(B) - order no. CAY242-V10C05AAE
advisable to use support from (order no. CAV740-xxx, see Standard sol. 10 mg/L PO4-P, 1L (B) - order no. CAY242-V10C10AAE
Endress+Hauser in the scope the following list) and also a Standard sol. 15 mg/L PO4-P, 1L (B) - order no. CAY242-V10C15AAE
of a service contract. This can of demineralized water. Standard sol. 20 mg/L PO4-P, 1L (B) - order no. CAY242-V10C20AAE
Standard sol. 25 mg/L PO4-P, 1L (B) - order no. CAY242-V10C25AAE
support is even compulsory
Standard sol. 30 mg/L PO4-P, 1L (B) - order no. CAY242-V10C30AAE
for STIP analyzers. Calibration Standard sol. 40 mg/L PO4-P, 1L (B) - order no. CAY242-V10C40AAE
Please refer to the Operating Standard sol. 50 mg/L PO4-P, 1L (B) - order no. CAY242-V10C50AAE
For the annual inspection of Instructions relating to your Maintenance kit CAV740 - order no. CAV740-1A
(A) = for CA70PH-A, (B) = for CA70PH-B
Stamolys analyzers, please Stamolys analyzer.
provide the maintenance

68 The Endress+Hauser Maintenance Guide

for CA71NO (nitrite)
Reagent, 1L - order no. CAY343-V10AAE for CA71CU (copper)
Cleaning solution, 1L - order no. CAY344-V10AAE Reagent set CU1+CU2, 1L each - order no. CAY850-V10AAE
Standard sol. 250 mg/L NO2-N, 0.5L (821.5 mg/L NO2) Standard sol. 1.00 mg/L Cu, 1L - order no. CAY852-V10C10AAE
- order no. CAY345-V05C25AAE Standard sol. 2.00 mg/L Cu, 1L - order no. CAY852-V10C20AAE
Maintenance kit CAV740 - order no. CAV740-1A Maintenance kit CAV740 - order no. CAV740-1A

for CA71CR (chromate) for CA71HA (hardness)

Reagent set CR1+CR2, 1L each - order no. CAY846-V10AAE Reagent set HA1+HA2, 1L each - order no. CAY743-V10AAE
Standard sol. 1.00 mg/L CrVI, 1L - order no. CAY848-V10C10AAE Standard sol. 10 mg/L CaCO3, 1L - order no. CAY745-V10C10AAE
Standard sol. 2.00 mg/L CrVI, 1L - order no. CAY848-V10C20AAE Standard sol. 20 mg/L CaCO3, 1L - order no. CAY745-V10C20AAE
Maintenance kit CAV740 - order no. CAV740-1A Standard sol. 50 mg/L CaCO3, 1L - order no. CAY745-V10C50AAE
Maintenance kit CAV740 - order no. CAV740-2A
for CA71SI (silicate)
Reagent set SI1+SI2+SI3, 1L each - order no. CAY640-V10AAE for CA71CL (chlorine)
Cleaning solution, 1L - order no. CAY641-V10AAE Reagent set CL1+CL2 (free), 1L each - order no. CAY543-V10AAE
Standard sol. 0ppb, 1L - order no. CAY642-V10C00AAE Reagent set CL1+CL2 (total), 1L each - order no. CAY546-V10AAE
Standard sol. 50ppb, 1L - order no. CAY642-V10C50AAE Cleaning solution, 1L - order no. CAY544-V10AAE
Standard sol. 100ppb, 1L - order no. CAY642-V10C01AAE Maintenance kit CAV740 - order no. CAV740-1A
Standard sol. 500ppb, 1L - order no. CAY642-V10C05AAE Maintenance kit CAV740 - order no. CAV740-4A
Standard sol. 1000ppb, 1L - order no. CAY642-V10C10AAE
Maintenance kit CAV740 - order no. CAV740-4A for the maintenance
Silicon spray - order no. 51504155
for CA71AL (aluminum) - standard documents, ready to use

Liquid analysis
Active reagent set AL1+AL2+AL3, 1L each - order no. CAY940-V10AAE for other analyzers
Standard sol.100 g/L Al, 1L - order no. CAY942-V10C10AAE Filter element for CAT430/431 - order no. 51509236
Standard sol. 250 g/L Al, 1L - order no. CAY942-V10C25AAE Hose set for CAT430 - order no. 51509225
Standard sol. 500 g/L Al, 1L - order no. CAY942-V10C50AAE Filter membrane (2 pcs.) for CAT411 - order no. 51511288
Maintenance kit CAV740 - order no. CAV740-1A

for CA71FE (iron)

Reagent set FE1, 1L - order no. CAY840-V10AAE
Standard sol. 500 g/L Fe, 1L - order no. CAY842-V10C05AAE
Standard sol. 2 mg/L Fe, 1L - order no. CAY842-V10C20AAE
Maintenance kit CAV740 - order no. CAV740-1A

for CA71MN (manganese)

Reagent set MN1+MN2+MN3, 1L each - order no. CAY843-V10AAE
Cleaning solution, 1L - order no. CAY844-V10AAE
Standard solution 100 g/l Mn, 1L - order no. CAY845-V10C10AAE
Standard solution 500 g/l Mn, 1L - order no. CAY845-V10C50AAE
Maintenance kit CAV740 - order no. CAV740-1A

The Endress+Hauser Maintenance Guide 69

 Water samplers

The current Endress+Hauser range includes:

The stationary water samplers ASP Station 2000 and Liquistation CSF48
The portable water samplers Liquiport 2000 and Liquiport CSP44

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

Measuring principle Hydraulic connection Liquiport 2000 ASP Station 2000

Keep wear Maximum suction height 6m/19.7ft 6m/19.7ft
The ASP station 2000 and (optional: 8m/26.2ft) (optional: 8m/26.2ft)
parts in stock. the Liquistation CSF48 are
Maximum hose length 30m/98.4ft 30m/98.4ft.
stationary samplers for fully
automated sampling, defined Hose connection 10mm/0.39 13mm, 16mm or 19mm
diameter (0.51, 0.63 or 0.75)
distribution and thermostatic internal diameter
storage of liquid media. The
Suction velocity > 0.5 m/s (1.64 ft/s), > 0.5 m/s (1.64 ft/s),
Liquiport 2000 and CSP44 to EN 25667 to EN 25667
are portable devices.
Hydraulic connection Liquiport CSP44 Liquistation CSF48
Sampling control (fig.33)
Sampling is triggered by an Maximum suction height 8m/26ft Vacuum pump: standard
6m/20ft, optional 8m
event (e.g. pH limit value). /26ft - Peristaltic pump:
Sampling can be time-paced, standard 8m /26ft
Liquid analysis

flow-paced, or time/flow-paced, Maximum hose length 30m/98.4ft 30m/98.4 ft

or single samples can be taken.
Hose connection 10mm/3/8 Vacuum pump: internal
Single and multiple samples can diameter internal diameter diameter of 10mm (3/8),
also be grouped in a program in 13mm (1/2), 16mm
addition to the sampling (5/8) or 19mm (3/4)
methods listed. Furthermore, Peristaltic pump:
internal diameter of
the software allows interval 10mm (3/8)
sampling, switchover and event
Intake speed > 0.5 m/s (1.6 ft/s) > 0.5 m/s (1.6 ft/s)
functions. The latter permit up
in accordance with for 13mm (1/2)
to 24 subprograms to be active EN25667, ISO 5667 ID, in accordance with
simultaneously for a variety of > 0.6 m/s (1.9 ft/s) in EN25667, ISO 5667
applications. A sampling table accordance with 5893 > 0.6 m/s (1.9 ft/s)
(Austrian standard), US EPA for 10mm (3/8) ID, in
makes it possible for users to
Fig. 33: Sampling control accordance with 5893
(CSF48 and CSP44 samplers)
program the bottle assignment, (Austrian standard), US EPA

a. Flow curve time interval and sample

b. Time proportional sampling: volume. Signals for external Table 8: Hydraulic connection
Constant time constant volume (CTCV) control can be connected via
A constant sampling volume is taken at
steady intervals.
two analog inputs and two Ensure that air can circulate Hydraulic connection
c. Flow proportional sampling: binary inputs in the standard unhindered at the back of See table 8.
Variable time constant volume (VTCV) version of the device. the cabinet. Do not position
A constant sampling volume is taken the device directly against a Sampling point
at variable intervals (depending on the
inflow volume).
Installation conditions wall (the distance between Do not connect the sampling
d. Flow proportional sampling/time the wall and the rear side hose to pressurized systems
override: Constant time variable Position the device of the cabinet should be at Fit a filter if the medium
volume (CTVV) on a level surface. least 100mm/3.94in). contains large and
A variable sampling volume (the
sampling volume depends onthe
Protect the device Do not position the abrasive solids
inflow) is taken at steady time intervals. against additional heat cabinet directly above Always install the hose
e. Event-controlled sampling (e.g. radiators or sun). the inflow channel to the in the flow direction
Sampling is triggered by an event Protect the device against wastewater treatment plant Always choose a representative
(e.g. pH limit value). Sampling can be
time-paced, flow-paced, or time/flow-
mechanical vibration and (sulphurous vapors!). sampling point (turbulent flow;
paced, or single samples can be taken. strong magnetic fields. not at the channel base)

70 The Endress+Hauser Maintenance Guide

 5
3

4
Commissioning Operation and maintenance Table 9: Maintenance intervals (ASP Station 2000)

Quick commissioning Cleaning

5 1
of the Liquistation CSF48 Use only a safe cleaning 3
After having switched agent that will not damage 2
on the power supply: the mechanical and electrical
Chose the language equipment. For the cabinet
(Menu > Language). body, we recommend a 6
Then enter in > Setup stainless steel cleaner. For
then General settings. any parts conveying media,
Change the TAG if needed. use water or soap. Thorough,
Then enter in > Date/hour regular cleaning of the parts 4

and set those parameters. which convey media is essential Period of time Part to be changed
Then enter in > Sample to for reliable operation. You
Every 6 months The dosing chamber Acryl (6)
set the characteristics of the can mount and disassemble 1
(order no. 50072149)

Liquid analysis
bottles and of the sampling. all the parts which convey 2
Then enter in > Inputs media easily and without tools. Every year The seal set for dosing system (5)
and set them if necessary (Please refer to the Operating (order no. 50079747)
(example: flowmeter Instructions related to your The membrane hose clamp (4)
input to sample according device). (order no. 51002657)
to a volume). Thorough, regular cleaning of The air filter (3) (order no. 50086064)
Then enter in > Outputs the dosing unit is essential for Every 2 years The air manager (2) (order no. 51003139)*
and set them if necessary. reliable operation. The seals of the vacuum pump (1)
Then enter in > Sampling The sample compartment has (order no. 51003140)
programs then Setup a permeable inner plastic shell.
* It is recommended to have this done by our field service engineers.
program. In the Setup Once you have removed the
program menu, it is possible bottle trays, the distribution
either to modify the pre- pan and the tap (open the
existing program, or to connector of the distribution
duplicate it to modify it after, drive), you can clean the Hint (CSF48): The modular Simple checks
or to create a new one. Each whole sample compartment cooling unit is easy to exchange for your sampler
program can be renamed. easily using a water hose. if needed. As a sampler has a lot of
Depending on the ambient moving mechanical parts, it
Beware! The input affectations conditions (e.g. high level of Maintenance intervals is recommended to check it
are shown only if they were dust formation), you should See table 9. In addition to this, periodically (twice a year is a
set into Menu > Setup > purge the ventilator and the The lid should be checked minimum). In order to comply
General settings > Inputs. liquefier with compressed air for leakage and cleaned every with ISO 5667-10, you have to
at regular intervals. 6months. prove three criteria:
To reset to default values: The conductivity probes have The cooling temperature
Menu > Diagnostics Hint (ASP 2000): Since software to be checked for corrosion inside the sampler is kept at a
> System test/Reset > version V4.16 it is possible to once a year. max of 4C/39.2F.
Factory default values. use the HOLD function for the The suction air flow rate
time of the maintenance. The Note: these are average figures should be higher than
In case of alarm, the program will run at this time in and should be adapted to your 0.5m/s (1.64ft/s). This can
screen turns red. Check the background (for more application. See the FAQs on be controlled by means of
the Diagnostic menu to information, see chapter 5.1 in the next page. a manometer (<-0.6bar
get the error message. the Operating Instructions) /8.7psi).

The Endress+Hauser Maintenance Guide 71

 The sampling volume Checking the new samplers List of the main spare parts (Liquistation CSF48, vacuum pump)
repeatability is 5 %. The new generation (Liquistation
Fastening clips for suction hose, 10 pcs, order no. 71113508
CSF48 and Liquiport CSP44) Internal intake hose, complete, including 110 angular piece, 90 hose connection
To carry out this check in enables the complete chain nipple, thread adapter nut 1 PP, 2 x fastening clips, 3 x O-rings, order no.
optimal conditions, you need to be simulated using 71111048
several tools like a thermometer, Memocheck Sim CYP03D. Feedthrough, sample infeed ID 13 with cylinder pin, order no. 71110853
Dosing pipe 350ml with O-ring, order no. 71110628
a chronometer, a manometer Glass dosing chamber, 350ml, with fixing ring and O-ring, order no. 71103168
and measuring glasses. Spare parts stock Plastic dosing chamber, 350ml, with O-ring, order no. 71103173
Several parts of the sampler have Conductive dosing chamber flange, with conductivity sensors, insulation sleeves and
to be considered as wear parts O-ring, order no. 71102985
All these operations can be part of
Capacitance dosing chamber flange, complete, order no. 71103166
a maintenance contract where our and thus should be kept in stock Dosing chamber inlet with sealing ring, intermediate ring and pipe clamp, order no.
skilled technical engineers deliver (see Maintenance intervals). 71111006
specific certificates which prove your
Air filter for vacuum pump, 2 pcs Hose, silicone, 320mm (12.6), order no.
samplers compliance to the local
Instrument and 71103283
authorities.
Seal set for dosing chamber, order no. 71103176
(See Maintenance Services in the spare parts availability Dosing hose to distributor, 2 pc set, order no. 71111188
At your service section). See table below. Dosing hose to distributor, 25 pc set, order no. 71111189

How to select the

main spare parts:
see the following list.
Frequently asked questions

When do I have to calibrate the distribution tap?

Your Spare parts New
When the tap motor was replaced.
instrument availability generation
When the error message tap calibration appears on the display.
Liquibox D until 01.2014 Liquibox D2 (RPB10)
How to calibrate the distribution tap?
Liquibox A until 01.2014 Liquibox A2 (RPB10)
1 Switch the device on.
Liqui-Compact A/A2 until 01.2013 Liquiport 2000 (RPT20) 2 Under SET/SERVICE/
CALIBRATION, select
ASP Port A/A2 until 01.2014 Liquiport 2000 (RPT20) the item DIST.TAB.
3 When you select START, the
ASP Port D/D2 until 01.2014 Liquiport 2000 (RPT20)
Liquid analysis

tap turns and stops just before

ASP Station A/A2 until 01.2014 ASP Stat. 2000 (RPS20) the calibration position.
4 At the controller, keep selecting
ASP Station D/D2 until 01.2014 ASP Stat. 2000 (RPS20) 1step until the arrow on the
front side of the tap is located
exactly in the notch in the middle
For further information, use our Device Viewer: of the distribution pan (point A).
www.services.endress.com/device-viewer In the pick list, select the menu
Table 10: Instrument and spare parts availability
option SAVE.
5 The tap is calibrated.

List of the main spare parts (ASP Station 2000)

Vacuum pump
single head / KNF023, order no. RPS20X-PC
double head / KNF023.1, order no. RPS20X-PE
Seals set
for KNF023, order no. 51003140
(You need two sets for KNF023.1)
Dosing chamber, Acryl 200mL, order no. 50072149
Flange with dosing tube 200mL, order no. 50090342
Silicon hose, for distribution 15 x 2, l = 1m, order no. 50031916
Dosing bracket cpl., including hose clamp, order no. RPS20X-DA
Membrane, order no. 51002657
Then quit all sub menus (press ESC)
Air filter, order no. 50086064
Air manager, order no. 51003139 and come back to the main menu.
Seal set for dosing system, order no. 50079747 Press AUTO and check that the
Tap drive, order no. 51003682 tap goes to the right position.
Dosing system, 200mL, order no. RPS20X-DC
Otherwise, try the procedure again.
LF probe, order no. RPS20X-DD
Pneumatic hoses, order no. RPS20X-PA If the second attempt also fails,
Controller/CPU ASP 2000, 1 program, order no. RPS20X-1CA replace the tap motor.
Fig. 34

72 The Endress+Hauser Maintenance Guide

ERROR : AIR MANAGER
Replace the air manager. If the error remains, test by exchanging Tips for the ASP Station 2000
the mainboard RPS20X-GA (version without RS485), or RPS20X-GB
(version with RS485) and/or the connection cable distribution tap How to connect the passive pulse output of a
drive (order no. RPS20X-VC). Endress+Hauser Proline electromagnetic flowmeter to
enslave an ASP Station 2000?
ERROR : Conductivity 2 Connect terminal 24 at the flowmeter to terminal2
There are three conductivity probes in the dosing funnel lid. During of connector X2 at the ASP 2000.
the suction process, the sample liquid first reaches the longer Connect terminal 25 at the flowmeter to terminal4
conductivity probes (item A and B). In this way, the filling of the of connector X2 at the ASP 2000.
dosing funnel is detected and the suction process is stopped. If the
conductivity probes 1 (item A and B) fail, safety switch off takes place
by means of the shorter conductivity probe 2 (item C). My sampler is enslaved
to an electromagnetic
Contact on probe 2 may be due to:
Earth
U+
flowmeter and the
Condensation or dirt on the probes contacts.
Digital inputs U+
Digital input 1 sampling does not
Digital input 2

A faulty connection.
Digital input 3 operate any more
Simulate the pulses by
In any case, the first step consists of
Relay 1
shunting terminals 2 and
cleaning the dosing system 4 of connector X2 by
Clean the flange on both Relay 2 means of a cable.
sides. If the probes are too Check if there is a
oxidized, exchange the flange Relay 3
direct voltage between
(order no. 50090342). terminals 1 and 2 of
Clean, if necessary exchange connector X2.
the dosing tube (order no.
Fig. 36
50042898) and exchange the
seals (order no. 50079747).
Clean the pins situated at the
dosing bracket, exchange dosing Tips for the Liquistation CSF48
bracket if there is too much
oxidation (order no. RPS20X-DA). How to connect the passive pulse output of a
Clean the contacts behind Endress+Hauser Proline electromagnetic flowmeter to
the dosing bracket (cable enslave an Liquistation CSF48?
and tightening screws), The connections for the sampler controller are in the controller
housing.

Liquid analysis
exchange dosing bracket, if
there is too much oxidation
(order no. RPS20X-DA).
Fig. 35: Level detection synopsis
Item A : Conductivity probe (long)
Clean the distribution motor
Item B : Conductivity probe (long) connector situated against the
Item C : Conductivity probe (short) sampler background wall above Fig. 37: Position of the terminals
Item D : Dosing pipe the distribution. Exchange the 1 Analog inputs 1 and 2
connection cable distribution 2 Binary inputs/outputs
tap drive (order no. RPS20X-
VC) if it is too oxidized.
If the suction height is small
(<1.5m/4.9ft) and the diameter
of the suction hose is <
this error can occur. Then use
a suction hose or bigger.

Assign analog inputs 1 or 2 according to your device

Fig. 38: Assignment of analog inputs 1 and 2
* Analog input for passive devices (2-wire
transmitter)
Out + In terminals (125/123 or 225/223)
** Analog input for active devices (4-wire
transmitter)
In + Gnd terminals (123/124 or 223/224)

Two binary inputs and two binary outputs easy to configure

Fig. 39: Assignment of the two binary inputs
(191/192 and 291/292) and the two binary
outputs (145/146 and 245/246)

The Endress+Hauser Maintenance Guide 73

 Frequently asked questions related to liquid analysis devices

pH 1. Membrane rupture monitoring

Sensors COS3/31 include conductivity measurement between
I have a tolerance between the laboratory and the the stainless steel body and an inner electrode (see picture).
inline measurements which is > 0.3 pH. The labor
electrode and the inline electrode are in the same
probe. If the tolerance is 0.2 pH is it OK? Conductive path no. 1
If this influence is to be compensated for, the temperature
coefficient of the measuring solution must be known. This value Conductive path no. 2
must be determined in the laboratory since different measuring
solutions have different ion compositions and concentrations.
The values thus determined can be entered in hi-tech measuring Fig. 40
instruments (medium temperature compensation, Liquiline CM42)
and used in computing the pH value. Step 1 detects looseness on conductive path no. 1
(membrane rupture)
Practical significance of this:
The temperature of the measuring solution must always be
specified for pH values to be processed by process control systems.
pH comparisons are only valid for identical medium temperatures. Auxiliary wire

Water (not of low

conductivity)

Conductivity
Fig. 41

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

Fig. 42
Chlorine

I have a tolerance between DPD 2. DO sensor functionality check

and the inline measurements Perform calibration in air (see page 65).
1. pH is not compensated (fluctuations higher than 0.1 pH Perform simple check of the zero point (see page 66).
must be compensated).
2. The pH value is unstable. 3. Degradation of the reference electrode
3. pH > 8.7 Sensors produced before April 2000 can be subject to AgBr
4. The temperature is unstable. degradation when exposed to a medium containing a high amount
5. There is an interference of iron, copper, manganese or high of H2S / NH3.
concentration of combined chlorine to the DPD measurement. Typical behavior: Signal increase up to overflow within 1-3 hours.
6. Organic chlorination chemicals were used instead of inorganic (Check on a recorder if possible!)
chlorination chemicals.
Remedy: Repair at Endress+Hauser.

4. Error possibilities on a handheld meter

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

74 The Endress+Hauser Maintenance Guide

 Pressure measurement

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
application, serve to calculate a flow rate or from your instruments throughout Basics 76
a level. Thus these devices are in frequent their lifecycle and prepare for renewing The Basics chapter includes
use in a broad scope of applications. your equipment gradually. information that is valid for all
measurement principles described in
this section. We therefore strongly
Most of the reported questions occur during recommend that you read it first.
commissioning. Therefore we have decided
to focus on this on the following pages. In Absolute/relative pressure
95% of the cases, proper installation and transmitters 79
cabling enables immediate operation! Differential pressure
measurement 81
Hydrostatic pressure
measurement 83

The Endress+Hauser Maintenance Guide 75

 Basics

Absolute/relative Differential pressure transmitters Hydrostatic pressure transmitters

pressure transmitters Specific information p. 81 Specific information p. 83
Specific information p. 79

The current Endress+Hauser range of pressure measurement In this Basics section, we have put together:
devices includes: Information on installation and maintenance
The Cerabar S and M absolute/relative pressure transmitters that is relevant to all types of pressure sensors
The Deltabar S and M differential pressure transmitters Information on configuration and maintenance
The Deltapilot S and M hydrostatic pressure transmitters that is common to all sensors of the S series
Note: T-class devices are not subject to maintenance and therefore
not included in this guide.

Information common to all types of pressure sensors

Maintenance of Seal for flange mounting Maintenance planning the shorter the acceptable
pressure sensors (fig. 1) time for repair. Thanks to the
Do you know exactly which part of your
The seal is not allowed to press installed instrumentation base is critical
Endress+Hausers spare part
Pressure measurement on the diaphragm as this could to the operation of the plant and how concept, most parts can be
instruments require minimum affect the measurement result. you could maintain or calibrate it more easily replaced by the user thus
maintenance as they are efficiently? Are you sure that your allowing quick repair.
present actions are minimizing the risks
insensitive to the medium and Calibration of unplanned breakdowns? Are you Being more efficient in the repair
have no moving parts. We Hydrostatic pressure sure that your present actions are the process is another way to reduce
recommend you periodically measurement sensors need most cost-effective? downtimes. Our training sessions help
perform a visual check of the calibration at start-up. We can help you to find an answer to you to diagnose quickly any failure and
these questions and move forward in
devices: All pressure sensors require a controlled manner to a maintenance
to apply the most appropriate repair
method. (See Training in the
Check the cap and housings periodic calibration; the plan that improves plant reliability At your service section).
condition calibrations frequency depends while reducing costs
Check the diaphragms on the expected precision. (See Maintenance & calibration
consulting in the At your service
condition Calibration can be performed section).
Spare parts stock
Check the cable gland either on-site or in the laboratory On each part you will find a
is watertight (for greater precision and/or for sticker with the part number, for
Ensure there is accredited calibration). Maintenance performing easy spare parts ordering.
no condensation For each device type, we
inside the housing In case you dont have the suggest you keep a full set of
Endress+Hauser can help you manpower, the right skills or the
Check the connections calculate the right calibration right tools to efficiently perform your electronic inserts in stock.
to the electronic module frequency and perform calibration maintenance, with Endress+Hauser In case of a highly critical
Pressure

either on site or in accredited service contracts, you decide the instrument, you might also
laboratories. right level of maintenance support
Note: Do not clean or touch (See Calibration services in the
consider stocking a complete
you require. We provide regular
diaphragm seals with hard or At your service section). checks on your equipment and new instrument.
pointed objects. warranty extensions providing you
with complete peace of mind and Re-engineering
1 2 cost control. From regular support to
partnership agreements, we offer four
distinct levels of service Want to use an instrument for
(See Maintenance services in the a new application? We can
At your service section). help you check the relevant
parameters. See our online
Corrective maintenance Applicator tool.
Fig. 1: Mounting the versions with flange or diaphragm seal P01-FMD7xxxx-11-xx-xx-xx-002
The more critical your https://wapps.endress.com/applicator
Fig. 11:
Mounting the versions with flange or diaphragm seal
1 Diaphragm 2 Seal instrument is to your process,
1 Diaphragm
2 Seal

76 The Endress+Hauser Maintenance Guide

 S series common features
As members of the Evolution range, CerabarS, Deltabar S and Taking 4-20mA test signal
Deltapilot S use the same electronic modules (for HART output, for A 4-20mA signal may be measured via the positive and test terminal
PROFIBUS output etc), the same housings, caps, display, terminal without interrupting the measurement.
compartment, mounting set and Histo-ROM. Only the sensor is The minimum supply voltage of the device can be reduced by simply
specific. This allows a consistent spare parts stock reduction. changing the position of the jumper. As a result, operation is also
possible with lower voltage sources. Observe the position of the
Setup & configuration jumper in accordance with the following table (fig. 5).

CerabarS, Deltabar S and Deltapilot S use the same interface for Save time and resources
operation with or without display (see details on fig. 3). Our service team can set up any Endress+Hauser level measurement device for you
and thus ensure you immediately get the best from your instrument.
(see Device commissioning in the At your service section)
Quick Setup enables quick and easy configuration of the devices
main functions (units, outputs). The Extended Setup menu gives
access to advanced configuration features. Operation and maintenance
You can also configure the device from a PC using FieldCare software.
Load analog and HART devices
Wiring Load diagram, observe explosion protection. (see fig. 6)
See fig. 4

Jumper position for test signal Description

Taking 4-20mA test signal via plus and test
terminal: possible. (Thus, the output current
can be measured without interruption via the
diode.)
Delivery status
minimum supply voltage: 11.5V DC

Taking 4-20mA test signal via plus and test

terminal: not possible.
minimum supply voltage: 10.5V DC
Deltabar S Cerabar S Deltapilot S

Fig. 2: Overview of the S series Fig. 5

RLmax U 10.5 V RLmax U 11.5 V

RLmax RLmax
23 mA 23 mA
[ ] [ ]
isplay Operation
Operationwithout
withoutdisplay
display Operation without
Operation display
with display Test Operation
1500
Quick with
setup display
menu Test Quick setup menu
1456
Measuring mode pressure Measuring
Externalmode
push pressure
buttons ExternalPressure
push buttons Pressure
1282 1239
Position calibration Lower range value Upper range value Position calibration Lower range value Upper range value First page 10, then First page 10, then
s in the Operating
Pressure is present Desired pressure keys in thepressure is
is Desired Pressure is present Desired pressure is Desired pressure is correct orientation correct orientation
partment at the device electronics
present compartment
at the device present at the device at the device present at the device present at the device 847 of the device (zero)4) of the device (zero)4)
804
+ E Enter+ 4 mAE value Enter 4 mA value
Press -key Press -key Press -key Press -key Press -key Press -key
413 without reference without reference
for 3 seconds for 3 seconds for 3 seconds for 3 seconds for 3 seconds for 3 seconds 369
pressure pressure
LED or Navigation in the picklist or or Navigation in the picklist or
Does the LED Does the LED Does the LED Does the LED Does thethe
editing LEDcharacters
Does the LED Enter 20 mA value
editing the characters Enter 20 mA value
Damping [ ]

light up? light up? light up? light up? light up? light up? without reference U without reference
splay
yes* yes*
Display
yes* yes* and Esc.yes*(cancel), yes* and Esc. (cancel),
30
10.5 20 40 45 11.5 20 30 40 45 U
on Sensor
pressure [V] pressure [V]
Release key Release key Release key Release key Previous menu item
Release key Release key Previous menuEnter
itemdamping Enter damping
off
Conrm entry Conrm entry time
1 2
PC

PC

Pressure for Pressure for Pressure for Pressure for Pressure for Pressure for U 11 V time
U 12 V
RLmax 23 mA
RLmaxitem RLmax RLmax
Histo R O M

Histo R O M

position calibration lower range value upper range value position calibration Next menu
lower range itemupper range value
value [ ]
Next menu [ ] 23 mA
accepted accepted accepted accepted
+ + Reset accepted
all parametersaccepted + + Reset all parameters
1478
4) POS. INPUT VALUE or POS. ZERO ADJUST 4)1434
POS. INPUT VALUE or POS. ZERO ADJUST
* If no, see Operating Instructions (Code
* If no, see 7864)
Operating Instructions (Code 7864)
1260 1217

Fig. 3: Operation with or without display 826 782

Pressure
391 347

nu Quick
Quicksetup
setupmenu
menu Damping
Quick and locking
setup menu 11Damping
20 and
30locking
40 45 U 12 20 30 40 45 U
[V] [V]
Flow6)
Level Flow6)
Damping [ ]

Damping [ ]

st page 10, then Firstpage

First page10,
10,then
then LED First page 10, then LED
rrect orientation correctorientation
correct orientation
420 mA correct orientation Fig. 6: Load diagram
the device (zero)4) (zero)4)
Damping [ ]

Damping [ ]

ofofthe
thedevice
device(zero) of the device (zero)
Test
on Display
1 onJumper for the 4-20mA test signal inserted in Non-test position Display

ter level value for Enter

Enterlevel value for
maximum ow Enter maximum ow
on Sensor on Sensor

wer calibration lower calibration

of primary device Test
1 2
off of primary device 2 Jumper for the 4-20mA test signal inserted in Test position
1 2
off
PC

PC

off 1 2
off 1 2

int5) point5) 3 Supply voltage 10.5 (11.5) to 30V DC for 1/2 G, 1 GD, 1/2 GD, FM IS, CSA IS,
HistoR O M

HistoR O M

ter level value for 4... 20mA Enter

Test level
Enter value for
maximum Enter
HistoROM maximum
/M-DAT IECEx ia, NEPSI Exia
HistoROM and TIIS Ex ia
/M-DAT
per calibration upper calibration
pressure of primary pressure of primary
int5) point 5)
device device 4 Supply voltage10.5 (11.5) to 45V DC for devices for non-hazardous areas,
DIP Switch 1 DIP switch 2 DIP Switch 1 DIP switch 2
ter damping Enter
Enterdamping
damping Pos. off = locked Enter damping
Pos. off = damping off 1/2D,
Pos. off =1/3 locked D, 2 GPos.EEx offd, 3 G EExoffnA, FM XP, FM DIP, FM NI, CSA XP, CSA
= damping
me time
time time
Pos. on = unlocked Pos. on = damping on Dust-Ex, NEPSI ExPos.
Pos. on = unlocked d, on
TIIS Ex d on
= damping
Factory setting: off Factory setting: on (2 sec.)
4... 20mA Test 5 Supply voltage 11 (12) to 45V DC for PMC71, EEx d[ia], NEPSI Ex d[ia] and TIIS
Factory setting: off Factory setting: on (2 sec.)
6) Deltabar S only 6) Deltabar S only
Ex d[ia]
RLmax Maximum load resistance
Fig. 4: Electrical connection 4-20mA HART U Supply voltage

The Endress+Hauser Maintenance Guide 77

 M series common features
CerabarM, Deltabar M and Deltapilot M use the same electronic Taking 4-20mA test signal
modules (for HART output, for PROFIBUS output, etc.), the same A 4-20mA test signal may be measured via the test terminals
housings, caps, display, terminal compartment, mounting set. without interrupting the measurement. To keep the corresponding
Only the sensor is specific. This allows a consistent spare parts measured error below 0.1%, the current measuring device should
stock reduction. exhibit an internal resistance of < 0.7.

Setup & Configuration Save time and resources

Our service team can set up any Endress+Hauser level measurement device for you
and thus ensure you immediately get the best from your instrument.
CerabarM, Deltabar M and Deltapilot M use the same interface for (see Device commissioning in the At your service section)
operation with or without display (see details on fig. 8).

You can configure these devices from a handheld terminal e.g. Operation and maintenance
FieldXpert or DXR375. You can also configure these devices from a
PC using FieldCare software. Load analog and HART devices
Load diagram for non-Ex devices. (see fig. 10)
Wiring
See fig. 9

Cerabar M

Deltabar M
Fig. 9: Electrical connection 4-20mA HART
1 Terminals for supply voltage and signal
2 Test terminals
3 Grounding terminal
4 Supply voltage: 11.5-45V DC (versions with plug connectors: 35V DC)
5 External ground terminal

Deltapilot M

Fig. 7: Overview of the M series

Pressure

Fig. 10: Load diagram

Supply voltage 11.5-45V DC (versions with plug-in connector 35V DC) for other types
of protection and for uncertified device versions
Fig. 8: Operation without operating menu RLmax Maximum load resistance
The operating keys and DIP switches are located on the electronic insert in the device. U Supply voltage
The picture shows an HART electronic insert. Note: When operating via a handheld terminal or via a PC with an operating program,
1 DIP switch for locking/unlocking parameters relevant to the measured value a minimum communication resistance of 250 must be taken into account.
2 DIP switch for switching damping on/off
3 DIP switch for alarm current SW / Alarm Min (3.6mA)
4 DIP switch (not used)
5 Slot for optional local display
6 Green LED to indicate successful operation
7 Operating keys for lower range value (zero) and upper range value (span)

78 The Endress+Hauser Maintenance Guide

 Absolute/relative
pressure transmitters
Cerabar series

The current Endress+Hauser range of absolute/relative pressure

transmitters includes Cerabar M (PMC and PMP5X) and S (PMC and
PMP7X) series. In this section you will find essential information and
advice that is specific to this type of pressure sensor, enabling optimum
follow-up throughout lifecycle.
Please read Basics first (pages 76 to 78).

Cerabar S series - overview Cerabar M series - overview

CerabarCerabar
S S Cerabar S PMC71PMC71 PMC71 PMP71 PMP71 PMP71 PMP75 PMP75 PMP75
CerabarCerabar
M MCerabar
M PMC51PMC51 PMC51 PMP51PMP51 PMP51 PMP55PMP55 PMP55
ProductProduct
family family
Product family
ProductProduct
family family
Product family

P01-PMC71xxx-16-xx-xx-xx-000
P01-PMC71xxx-16-xx-xx-xx-000
P01-PMC71xxx-16-xx-xx-xx-000 P01-PMP71xxx-16-xx-xx-xx-000
P01-PMP71xxx-16-xx-xx-xx-000
P01-PMP71xxx-16-xx-xx-xx-000 P01-PMP75xxx-16-xx-xx-xx-000
P01-PMP75xxx-16-xx-xx-xx-000
P01-PMP75xxx-16-xx-xx-xx-000

PMC71 PMP71 PMP75 PMC51

P01-PMC51xxx-16-xx-xx-xx-000
P01-PMC51xxx-16-xx-xx-xx-000
P01-PMC51xxx-16-xx-xx-xx-000
PMP51
P01-PMP51xxx-16-xx-xx-xx-000
P01-PMP51xxx-16-xx-xx-xx-000
PMP55
P01-PMP51xxx-16-xx-xx-xx-000 P01-PMP55xxx-16-xx-xx-xx-000
P01-PMP55xxx-16-xx-xx-xx-000
P01-PMP55xxx-16-xx-xx-xx-000

With capacitive
With capacitive
measuring
With capacitive
measuring
cell and
measuring
cell andWith
cellpiezoresistive
and
With piezoresistive
With
measuring
piezoresistive
measuring
cell measuring
With
cell diaphragm
Withcell
diaphragm
With
seal diaphragm
seal seal
With capacitance measuring cell and ceramic process isolatingceramic
ceramic
processprocess
diaphragm
(Ceraphire
)
(Ceraphire
ceramic
isolating
isolating
(Ceraphire

)
(Ceraphire
process
diaphragm

)
diaphragm
)isolatingand
diaphragm
metal
andwelded
diaphragm
metaland
welded
process
metal
diaphragmdiaphragm
process
isolating
weldedisolating
process isolating

With piezoresistive measuring cell and metal welded process isolating diaphragm
Fig. 11
With diaphragm seal

Measuring principle

Ceramic measuring diaphragm (PMCxx devices) Metallic measuring diaphragm (PMPxx devices)
The ceramic sensor is a dry sensor, i.e. the process pressure acts
directly on the robust ceramic diaphragm and deflects it. A pressure-
dependent change in capacitance is measured at the electrodes of
the ceramic carrier and the diaphragm. The measuring range is
determined by the thickness of the ceramic diaphragm.

p p

Fig. 13: Metal sensor

Ceramic sensor
P01-PMC71xxx-03-xx-xx-xx-000

Metal sensor
P01-PMP7xxxx-03-xx-xx-xx-000

1 1. Measuring element
Atmospheric vent (gauge pressure only) 1 3. Channel with fill fluid
Measuring element
2
3
2. Measuring
Ceramic substrate
Electrodes
diaphragm with 2
3
4. Process diaphragm,
Measuring diaphragm with Wheatstone bridge
Channel with fill fluid
4 Wheatstone bridge
Ceramic diaphragm 4 metal separating diaphragm
Process diaphragm, Metal separating diaphragm

p For PMP51/PMP71 p

P01-PMC71xxx-03-xx-xx-xx-000 The operating pressure deflects the separating diaphragm and a fill
P01-PMP7xxxx-03-xx-xx-xx-000

Fig. 12: Ceraphire ceramic sensor Ceramic sensor

fluid
Metal sensor
transfers the pressure to a resistance measuring bridge (semi-
Pressure
1. Atmospheric vent (gauge pressure only) 1 3. Electrodes
Atmospheric vent (gauge pressure only) 1 Measuring element

2. Ceramic substrate
2
3
Ceramic substrate
4. Ceramic diaphragm
Electrodes
2
3
conductor
Channel with fill fluid
technology). The pressure-dependent change of the bridge
Measuring diaphragm with Wheatstone bridge

4 Ceramic diaphragm 4
output voltage is measured and processed further.
Process diaphragm, Metal separating diaphragm

For PMP55/PMP75
The operating pressure acts on the diaphragm of the diaphragm
seal and is transferred to the separating diaphragm of the sensor by
a diaphragm seal fill fluid. The process membrane is deflected and
a fill fluid transfers the pressure to a resistance measuring bridge.
The pressure-dependent change of the bridge output voltage is
Video about ceramic measuring
diaphragm available at measured and processed further.
www.endress.com/videos

The Endress+Hauser Maintenance Guide 79

 Installation instructions for devices without diaphragm seals Level measurement
Mount Cerabar S/M below the lowest measuring point.
Pressure measurement in gases Do not mount the device at the following positions: in the fill
Mount the sensor with shut-off device above the tapping point so flow, in the tank outlet or at a point in the container which could
that the condensate can flow into the process. be affected by pressure pulses from the agitator.
The calibration and functional test can be carried out more easily
if you mount the device after a shut-off device.
Fig. 14: Measuring arrangement for
pressure measurement in gases
1. Cerabar S/M
2. Shut-off device

P01-PMx7xxxx-11-xx-xx-xx-001

Pressure measurement in steams

Measuring arrangement for pressure measurement in gases

Mount the sensor with syphon below the tapping point. The
syphon reduces the temperature to almost ambient temperature. Fig. 17: Measuring arrangement for level P01-PMP75xxx-11-xx-xx-xx-000

Fig. 8: Measuring arrangement for level

Fill the syphon with fill fluid before commissioning.
Special instructions for PMP51/71, PMC51/71
If a heated Cerabar is cooled during the cleaning process
(e.g. by cold water), a vacuum develops for a short time,
whereby moisture can penetrate the sensor through the
pressure compensation(1). If this is the case, mount the
Cerabar with the pressure compensation (1) pointing
downwards. Keep the pressure compensation and
GORE-TEX filter (1) free from contamination.

Operation and maintenance

See Basics for general information on the maintenance of pressure

P01-PMx7xxxx-11-xx-xx-xx-002
P01-PMx7xxxx-11-xx-xx-xx-002
sensors (page 76).
Fig. 6: Fig. 6:Measuring
Measuring
arrangement
arrangement
for pressure
for pressure
measurement
measurement
in steams
in steams
Fig. 15: Measuring arrangement for
1
2
1CerabarCerabar
pressure
2Shut-off
S S
measurement
Shut-off
in steams
device device
Instrument and spare parts availability
3 1. Cerabar
3U-shaped S/M
U-shaped
siphon siphon 3. U-shaped syphon
4 4Circular
Circular
siphonsiphon
2. Shut-off device 4. Circular syphon
Your Spare parts New
instrument availability generation
Pressure

Pressure measurement in liquids PMC731 NO - since 12/2010 PMC71

Mount the sensor below or at the same level as the tapping point.
PMP731 NO - since 12/2010 PMP71
Fig. 16: Measuring arrangement for PMP635 NO - since 12/2010 PMP75
pressure measurement in liquids
1. Cerabar S/M
2. Shut-off device PMC631 NO - since 12/2010 PMP75

For further information, use our Device Viewer:

www.services.endress.com/device-viewer

Table 1: Instrument and spare parts availability

P01-PMx7xxxx-11-xx-xx-xx-003

Fig. 7: Measuring arrangement for pressure measurement in liquids

1 Cerabar S
2 Shut-off device

80 The Endress+Hauser Maintenance Guide

 Differential pressure
measurement
Deltabar series

The current Endress+Hauser range of differential pressure

measurement includes Deltabar M and S series.
In this section you will find essential information and advice
that is specific to this type of pressure sensor, enabling
optimum follow-up throughout the lifecycle.
Please read Basics first (pages 76 to 78).

Deltabar S
Deltabar
Deltabar
Deltabar
PMD70 SS
S series -PMD75
overview
PMD70
PMD70
Deltabar S FMD76
PMD75
PMD75
PMD70 FMD77
FMD76
FMD76
PMD75 FMD77
FMD78
FMD77
FMD76 FMD78
FMD78
FMD77
Deltabar
FMD78
M
product family product
product family
family product family

+ ++ +

+ ++ +

P01-PMD70xxx-16-xx-xx-xx-000 P01-PMD75xxx-16-xx-xx-xx-000
P01-PMD70xxx-16-xx-xx-xx-000
P01-PMD70xxx-16-xx-xx-xx-000 P01-FMD76xxx-16-xx-xx-xx-000
P01-PMD75xxx-16-xx-xx-xx-000
P01-PMD75xxx-16-xx-xx-xx-000
P01-PMD70xxx-16-xx-xx-xx-000 P01-FMD76xxx-16-xx-xx-xx-000
P01-FMD76xxx-16-xx-xx-xx-000
P01-FMD77xxx-16-xx-xx-xx-000
P01-PMD75xxx-16-xx-xx-xx-000 P01-FMD77xxx-16-xx-xx-xx-000
P01-FMD77xxx-16-xx-xx-xx-000
P01-FMD78xxx-16-xx-xx-xx-003
P01-FMD76xxx-16-xx-xx-xx-000 P01-FMD78xxx-16-xx-xx-xx-003
P01-FMD78xxx-16-xx-xx-xx-003
P01-FMD77xxx-16-xx-xx-xx-000 P01-FMD78xxx-16-xx-xx-xx-003
PMD70 FMD76 PMD75 FMD77 FMD78 PMD55
With ceramic process With
With metal
ceramic
ceramic
process
process
process With
With
With
ceramic
metal
metal
ceramic
process
process
process
process With
With
With
metal
ceramic
ceramic
metal
process
process
process
process With
With
With
With
metal
metal
metal
ceramic
process
process
process
process With
With
Withmetal
metal
metalprocess
process
process With metal process
isolating diaphragms isolating
isolating
With diaphragms
diaphragms
ceramic isolating
isolating
isolating
process isolating diaphragms
diaphragms
diaphragms
diaphragms isolating
isolating
isolating
diaphragms
diaphragms
diaphragms isolating
isolating
isolating
isolating
diaphragms
diaphragms
diaphragms
diaphragms
With metalisolating
isolating
isolating
process diaphragms
diaphragms
diaphragms
isolating isolating diaphragms
diaphragms
and diaphragm seal and
and
anddiaphragm
diaphragm
capillary seal
seal and
and
andcapillary
capillary
diaphragm seal and capillary
Fig. 18
mounted on one side mounted
mounted
diaphragm on
onseals
one
one side
side diaphragm
diaphragm
mountedseals
seals
on one side diaphragm seals

Measuring principle

Metallic measuring diaphragm Ceramic measuring diaphragm (PMD70 and FMD76 devices)
(PMD55, PMD75, FMD77 and FMD78 devices) The ceramic measuring cell is based on the principle of a plate
The separating diaphragms (3/9) are deflected on both sides capacitor with an electrode on (1) and a movable electrode on the
by the acting pressures. A filling oil (4/8) transfers the pressure interior of the diaphragm (3). Standard silicone oil or mineral oil
to a resistance circuit bridge (semi-conductor technology). The filling oils for this measuring cell.
differential-pressure-dependent change of the bridge output voltage is A differential pressure (p1 p2) causes a corresponding deflection
measured and further processed. The pressure-dependent change of of both diaphragms. Both capacitance values are converted and are
the bridge output voltage is measured and processed further. fed to the microprocessor of the transmitter as a digital signal.

Pressure

Fig. 20: Ceramic sensor

1. Meter body
2. Diaphragm
3. Electrodes
4. Glass frit fixes the diaphragm
onto the meter body
5. Temperature sensor

Fig. 19: Metal measuring cell 10 mbar Metal measuring cell as of 100 mbar
and 30 mbar 6. Sensing element
1. Sensing element 7. Overload diaphragm/middle
2. Silicon diaphragm diaphragm
3. Separating diaphragm 8. Filling oil
4. Filling oil 9. Separating diaphragm
5. Integrated overload protection

The Endress+Hauser Maintenance Guide 81

 Installation instructions Level measurement in a closed tank with FMD78
(capillary diaphragm seals)
Main installation requirements regarding the most frequently used
Level measurement is only safeguarded
applications: between the upper edge of the lower and
the lower edge of the upper diaphragm seal.
Flow measurement in liquids with PMD55/PMD70/PMD75 max. In vacuum applications, it is recommended
Mount the Deltabar S below the measuring point so that the p2 to install the pressure transmitter below
the lower diaphragm seal. This will avoid a
impulse piping is always filled with liquid and gas bubbles can run vacuum load of the diaphragm seal caused
back into the process piping. by the presence of filling oil in the capillaries.
When measuring in media with solid parts, such as dirty liquids,
installing separators and drain valves is useful for capturing and Optimizing measures
In order to avoid additional pressure
removing sediment. fluctuations and a defective instrument,
min. the capillaries should be installed free of
p1 vibrations.
The capillaries may not be installed in the
vicinity of heating or cooling pipes which
would impair exact measuring results.
It is recommended to insulate the capillaries
Fig. 21: Measuring layout for flow
Fig. 23 in a colder or warmer environment.
measurement in liquids with PMD75
In case of two-sided diaphragm seal systems,
1. Orifice plate or pitot tube
the ambient temperature and the length of
2. Shut-off valves
both capillaries should be identical.
3. Deltabar S, here PMD75
Two identical diaphragm seals
4. Separator
(e. g. diameter, material, etc.) should
5. Drain valves
always be used for the minus and plus side.
6. Three-valve manifold
Operation and maintenance

See Basics for general information on the maintenance of pressure

sensors (page 74).
Level measurement in a closed tanks with PMD55/PMD75
(pressure piping)
Instrument and spare parts availability

Mount the Deltabar S/M below the Your Spare parts New
max. lower measuring connection so that instrument availability generation
p2 the impulse piping is always filled
with liquid. PMD230 NO - since 12/2010 PMD70
Pressure

Always connect the minus side above

the maximum level.
A condensate trap ensures constant
PMD235 NO - since 12/2010 PMD75
pressure on the negative side.
Generally speaking, the installation of FMD230 NO - since 12/2010 FMD76
min. separators and discharge valves makes
p1 sense to collect deposits, pollution FMD630 NO - since 12/2010 FMD77
or liquids in pressure piping and to
remove them. FMD633 NO - since 12/2010 FMD78
Calibrate at operating temperature.
Fig. 22

For further information, use our Device Viewer:

www.services.endress.com/device-viewer

Table 2: Instrument and spare parts availability

82 The Endress+Hauser Maintenance Guide

 Hydrostatic pressure
measurement
Deltapilot series

The current Endress+Hauser range of differential pressure measurement

includes Deltapilot M (FMB50, 51, 52 and 53) and S (FMB70) series.
In this section you will find essential information and advice that is
specific to this type of pressure sensor, enabling optimum follow-up
throughout lifecycle.
Please read Basics first (pages 76 to 78).

Deltapilot S Deltapilot M series - overview

Deltapilot
Deltapilot
DeltapilotSS S FMB70
FMB70
FMB70 Deltapilot
Deltapilot
M MDeltapilot
M Deltapilot
FMB50FMB50
M FMB50 FMB50
FMB51FMB51 FMB51 FMB52
FMB51
FMB52 FMB52 FMB53
FMB52
FMB53 FMB53 FMB53
ProductProduct
family family
Product family Product family
T14
T14
T14 T15
T15
T15 T17
T17
T17

T14 housing, T15 housing, T17 housing

P01-FMB70xxx-14-xx-xx-xx-000
P01-FMB70xxx-14-xx-xx-xx-000
P01-FMB70xxx-14-xx-xx-xx-000

optional optional display (hygienic),

FMB70 display on the top optional
on the side display P01-FMB5xxxx-14-xx-xx-xx-000
P01-FMB5xxxx-14-xx-xx-xx-000
FMB50
P01-FMB5xxxx-14-xx-xx-xx-000
P01-FMB5xxxx-14-xx-xx-xx-001
FMB51
P01-FMB5xxxx-14-xx-xx-xx-000
P01-FMB5xxxx-14-xx-xx-xx-001
P01-FMB5xxxx-14-xx-xx-xx-001
FMB52
P01-FMB5xxxx-14-xx-xx-xx-002
P01-FMB5xxxx-14-xx-xx-xx-001
P01-FMB5xxxx-14-xx-xx-xx-002
FMB53
P01-FMB5xxxx-14-xx-xx-xx-002
P01-FMB5xxxx-14-xx-xx-xx-003
P01-FMB5xxxx-14-xx-xx-xx-002
P01-FMB5xxxx-14-xx-xx-xx-003
P01-FMB5xxxx-14-xx-xx-xx-003
P01-F

on the side Compact Rod Cable Cable version with

Compact
Compact
versionversion
Compact version
Compact
Rod version
Rodversion
version Rod version
CableRod
version
Cable
version
version
Cable version
Cable
Cable
version
Cable
version
version
with Cable
with version with
Cable version w
Fig. 24 version version version mounting
mounting clamp clamp
mounting clamp
mounting clampmounting clam

Measuring principle

Due to its weight, a liquid column creates hydrostatic pressure. If

the density is constant, the hydrostatic pressure depends solely on
the height h of the liquid column (see fig. 25).

The CONTITE measuring cell works on the principle of the

gauge pressure sensor. In contrast to conventional gauge pressure
sensors, the precision measuring element (2) in the CONTITE
measuring cell is absolutely protected between the process
diaphragm (3) and the measuring diaphragm (1). Thanks to this
hermetic sealing of the measuring element, the CONTITE
measuring cell is absolutely insensitive to condensate, condensation
and aggressive gases. The pressure applied is transferred from the
process diaphragm to the measuring element by means of an oil
without any loss in pressure.

Two temperature sensors are arranged between the process

Pressure

diaphragm and the measuring element which measures the

distribution of temperature in the cell. The electronics can
P01-FMB70xxx-15-xx-xx-xx-000

Deltapilot S hydrostatic level meas urement and measuring principle

Fig. 25: Deltapilot S hydrostatic level p tot Total pressure = hydrostatic pressure
compensate any measuring errors resulting from fluctuations in 1 measurement
Measuring diaphragm
and measuring principle + atmospheric pressure
2 Measuring element
temperature with these measured temperature values. 3 1.Process Measuring diaphragm
diaphragm (separating diaphragm) p atm Atmospheric pressure
g 2.Gravitational
Measuring element
acceleration p hydr. Hydrostatic pressure
h 3.Level Process
height diaphragm p meas Measured pressure in the measuring
p tot Total pressure = hydrostatic pr essure + atmospheric pressure
(separating
p atm Atmospheric pressure diaphragm) cell = hydrostatic pressure
p hydr.g Hydrostatic
Gravitational
pressure acceleration Density of fluid
p meas Measured pressure in the meas uring cell = hydrostatic pressure
h Density
Level height
of fluid

The Endress+Hauser Maintenance Guide 83

 Installation instructions Operation and maintenance

See Basics for general information on the maintenance of pressure

Weather protection cover
Always recommended for outside
sensors (page 76).
installation to avoid strong
temperature changes of electronics. Note: Do not clean or touch the sensor membrane with hard or
pointed objects.
Installation from the top
(FMB51/52) Corrective maintenance
When installing rod and rope Changing the sensors electronic module Deltapilot M/S requires
versions, please ensure that the no calibration.
head of the probe is at a location
which is as free of flow as possible.
In order to protect the probe Instrument and spare parts availability
against contact by lateral
movements, install probe in a Your Spare parts New
guide tube (preferably of plastics)
or use an anchoring device. instrument availability generation
The length of the carrier cable
or the probe rod depends on the DB50L YES - until 10/2012 FMB50/70
envisaged level zero point. The
tip of the probe should be at least DB50S YES - until 10/2012 FMB50/70
5cm (2) below that.
DB50A YES - until 10/2012 FMB50/70
Tank installations
Obstacles do not affect hydrostatic DB51 YES - until 06/2014 FMB51
level measurement.
DB52 YES - until 06/2014 FMB52

DB53 YES - until 06/2014 FMB53

For further information, use our Device Viewer:

Foam
www.services.endress.com/device-viewer
Foam formation does not have any
noticeable influence on hydrostatic
level measurement. Table 3: Instrument and spare parts availability
Pressure

Installation from below

(FMB50, FMB70)
Always install the instrument
below the lowest measuring point.
It is recommended to install the
pressure transmitter behind a stop
valve to facilitate easy cleaning
and functioning checks.
Do not install the instrument in
the following positions:
in the flow of product as it is filled In case of media which might cure
in the tank outlet as they cool down, the instrument
at a location in the tank which must be included in the insulation.
might be affected by the pressure
impulses of the agitator

84 The Endress+Hauser Maintenance Guide

 Temperature measurement

Calibration: finding the right balance

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 86
Maintenance of temperature measurement cycle and prepare you for renewing your FAQ 90
consists mostly of periodic calibration. This equipment gradually.
is why we have focused on calibration in
the following pages. As experts, we also offer training sessions,
in classroom and on site. We would be glad
Please note that transmitters such as to meet with you and help you to go one
TMT162 include advanced diagnostics step further. See Training in the At your
functions (e.g. drift or corrosion detection) service section .
that can increase the systems performance
and availability.

Video about our competence

in temperature available at
www.endress.com/videos

The Endress+Hauser Maintenance Guide 85

 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 detectors) thermometers
The family of TC (thermocouples) thermometers

Measuring principle thermocouples reference insulated cable, 3 or 6mm

tables (see IEC 50584), the (0.12 or 0.24), including
RTD sensors temperature at the connection 4 or 6 copper or nickel wires
(See figure 1) (measuring junction) can be embedded in stone hard pressed
In RTD-sensors the electrical concluded. Thermocouples MgO powder, surrounded by a
resistance changes with a are suitable for temperature very thin sheath made of stainless
change in temperature. They are measurement in the range steel. On one end of the stem
Fig. 1: Measuring principle of
RTD sensors suitable for the measurement of of 0C to 1800C (32F to the sensing element is welded
temperatures between -200C/ 3272F). They stand out due to to the wires and encapsulated;
-328F and approx. 800C the fast response time and high the sensitive zone of an insert
/1472F and stand out due to vibration resistance. has a length of about 25mm
high measurement accuracy /0.98 from the closed end
and long-term stability. The The mechanical construction (tip). On the other end a
resistance sensor element most of a thermometer used in ceramic terminal board or a
frequently used is a Pt100 process plants is the same for free wires connection system is
which has a nominal value resistance thermometers and mounted on a metal flange; the
of 100 at 0C/32F. Pt100 thermocouples and consists of spring loaded mounting screws,
Fig. 2: Measuring principle of
sensors are manufactured in the following components: integral with the metal flange,
thermocouples different formats: Measurement insert with guarantee the insert coupling to
Wire wound ceramic sensors: ceramic terminal block or the terminal housing and a tight
A spiral of platinum wire is head transmitter (A) contact between the insert end
wound and embedded in Thermowell: The tip and the thermowell.
ceramic powder within a thermowell is the process Inserts are generally equipped
capillary and is fed to the wetted component of the with single or double resistance
outside by platinum wires. thermometer (B) sensing elements.
Thin film sensors: A platinum Process connection: The Twin resistors are normally
layer is vaporized on a process connection is the used to split the destination of
C ceramic plate (sputtered). connection between the the output signals.
The connection wires and process and the thermometer. The use of a double sensing
the platinum layer are Neck: The neck is the element to increase the
encapsulated in glass. extension between measuring point reliability is
As standard, Endress+Hauser connection head and process not recommended because the
RTD sensors fulfill IEC60751 connection / thermowell. two elements are embedded
A B accuracy class A. Connection head with cable in the same point: therefore,
glands: The connection head when a mechanical or electrical
TC thermocouples is fitted to the thermowell or cause damages the insert
(See figure 2) the neck of the thermometer. construction, the complete
A thermocouple is a component resistor might be damaged also.
made of two different metals Insert This can be solved with two
connected with each other at (See figure 3) independent thermometers.
one end. An electrical potential First step of Pt100 protection
(electromotive force) is caused consists in making an insert. Thermowell
due to the Seebeck effect at the This will be used for installation A second protection of
Fig. 3: Construction of temperature
sensors
open end if the connection in the final assembly and thermometer assembly consists
A Insert and the free ends are exposed has the advantage of being of installing the insert in
B Thermowell to different temperatures. interchangeable. The insert appropriate metal thermowells
C Terminal head With the help of the so-called normally consists of a mineral (i.e. thermowells or pockets).

86 The Endress+Hauser Maintenance Guide

 Temperature
This component is normally This component can provide a due to heat dissipation
required for medium and heavy protective housing for built-in through the connection mass
duty applications but it can be transmitters or can act as a that can affect the correct
employed also for light duty junction box if remote mounted measurement: this problem
services whenever the insert transmitters/receivers are used. can be solved with a longer
replacement is possible without The head allows a complete immersion length.
any plant shut-down. compact thermometer assembly Process requirements
In order to reduce the sensor and makes it easier for insert should also be considered to
response time lag due to replacement. guarantee a representative
thermowells, tapered end A wide choice of terminal heads measuring point for sensing
constructions are available. includes general purposes, and for control efficiency.
Fig. 4: Pipe installations:
The thermometer thermowell heavy duty, explosion-proof and For a correct temperature a) at elbows, against the flow
can be mounted in tanks or sanitary applications. A widely measurement the b) in smaller pipes, leant against the flow
pipes by means of threaded, used version of connection thermowell/thermometer c) perpendicular to the flow
flanged or welded connections. heads is constructed in light immersion length must be
Since the thermowell is the metal alloy, usually aluminum, at least 20 times its diameter
component that comes into and conforms to DIN (30times if not MI cable
contact with the process, exact standard 50446 type B. The type). Shorter immersion
specification is most important Endress+Hauser metallic heads lengths can be specified but
as it determines the lifetime of are delivered with gaskets the thermometer requires an
the assembly. The appropriate to withstand a temperature external (process connection,
selection depends upon the of 130C/266F). Some neck and connection head)
chosen method of mounting, connection heads can include thermal insulation.
the space available, the a built-in transmitter and/or Furthermore, if a calibration
pressure, the temperature, the an indicator: in this case the certificate is requested,
flow speed and the nature of temperature has to be checked the probe design (length
the product. considering the electronic and diameter) has to be
Fig. 5: Thermal insulation examples:
Among different international device limits. defined also according to a) insulating material
and corporate standards, the certification laboratory b) pipe
DIN43772 defines a series Installation instructions sizerequirements. c) thermowell with insert
of standard thermowell d) external plate
designs including: Immersion length Pipe installations
Threaded thermowells The thermometers should be (See figure 4 and 5)
type 2G or 3G inserted in the medium where the In small diameter pipes the
Flanged thermowells temperature has to be measured most suitable immersion length
type 2F or 3F at such a depth that a good can often be achieved only
Weld-in thermowells type 4. compromise between different by installing the assembly at
measuring problems is obtained. an angle to the pipe axis or in
Terminal head The heat conducted into bends. In this case the inserted
A terminal head is sensors from environment assembly must be mounted
recommended to protect the may alter the temperature of against the flow.
connections between the insert the sensing tip: for this reason
and the external circuit wires. a small sensing element
The heads are normally is preferable.
provided with two connections, The thermometer/thermowell
one for the thermowell and one process connection may
for the electrical output wiring. introduce a thermal drift

The Endress+Hauser Maintenance Guide 87

 Internal wiring of
Temperature
1xP t10 0 Class Tolerance (C)
Pt100 inserts
A 0.15 + 0.002 ltl
According to IEC751, three
R ed B 0.3 + 0.005 ltl
W hite configurations are possible:
R ed
R ed Notes:
3 w ires
2 wire configuration: ltl = modulus of temperature in C
This configuration generates regardless of sign.
W h ite Tolerance value for each temperature
an error which equals to
point can be calculated with the above
twice the resistance of the formula.
R ed
wire. This configuration is not Example: class A tolerance value at
recommended, except when -50C = 0.15 + 0.002 x 50 = 0.25C
1xP t100 high nominal resistances
(e.g. Pt1000) are in use. Tolerance values vary with the
3 wire configuration: temperature.
W h ite
R ed W h ite This configuration introduces
W h ite
a compensation which reduces We recommend the use of the
4 w ires the error to approx. zero. This 4wire configuration combined
R ed configuration is commonly with class A tolerance for high
R ed
used in the industry today. measurement precision.
4 wire configuration:
R ed W hite Recommended and provided Device configuration
as a standard connection (see fig.7)
Fig. 6: Internal wiring of Pt100 inserts for the single Pt100, this PCP (PC-programmable):
configuration excludes Online configuration with
additional errors in every TXU10 SETUP connector,
condition. Generally in the socket and ReadWin 2000
4wire configuration there is a operating software.
higher guarantee of accuracy. HART: HART signal for
on-site or centralized device
The TPR insert series is available set-up using the handheld
in two basic versions (see fig. 6). Field Xpert (SFX100) or a PC.
The connections of the first one, Operation, visualization and
with free wires for mounting maintenance at the PC using
of in-head transmitters, are FieldCare, AMS, PDM or
shown on the left side of the ReadWin 2000 software.
figure, while the connections of FOUNDATION Fieldbus:
the second one, with ceramic Operation, visualization and
terminal block, are shown on maintenance at the PC using
the right side of the figure. On FieldCare or AMS.
the left side, the internal wiring PROFIBUS PA: Operation,
of Pt100 is shown. visualization and
maintenance at the PC using
Resistances and tolerances FieldCare, AMS or PDM.
IEC 60751 standard
Nominal resistance is the
specified resistance value Operations and maintenance
at a given temperature.
Thermometers of 100 Maintenance mostly consists
nominal resistance value at of periodic calibration. We
0C/32F shall be classified also recommend that you
according to degree of periodically check (visually) the
conformity with the values of installations watertightness.
the complete reference table
of temperature vs. for Pt100 Thermometer calibration
resistance elements. A calibration means the
Class A and B tolerances are determination of a deviation
given in the following table. compared to a reference that
Class A tolerances shall not shows a known uncertainty.
be applied to Pt100 resistance So when calibrating, the right
thermometers at temperatures value of the measurement is
above 450C/842F and it is predefined by a reference with
valid only for 3 and 4 wires which the measurement to
Fig. 7: Device configuration thermometers. be calibrated is compared. In
the case of thermometers, this
happens either at the defined
fixed points of the international
temperature scale (ITS90) or by

88 The Endress+Hauser Maintenance Guide

the comparison with a standard mechanical strains (vibrations,

Temperature
Old generation New Description Spare part
reference thermometer. So jolts etc.) the thermometer availability
a redundant sensor cannot will be exposed to. TST10/TST111/TST221 TR10 RTD sensor No
replace any calibration, because Legal requirements. TST42 TR24 RTD sensor No
both measurements may drift
TST425 TR25 RTD sensor No
and neither of the two sensors As we know, RTDs are affected
TST11/TST211 TR11 RTD sensor No
are a traceable reference. by aging, i.e. their characteristic
curve drifts slightly. This drifting TST12/TST221 TR12 RTD sensor No

An accredited calibration is usually particularly marked TST13/TST131 TR13 RTD sensor No

is carried out under strict with new devices, while later TST140/TST141 TR15 RTD sensor No
compliance with national on a certain stabilization is TST288 TR88 RTD sensor Until 01/2013
or international norms and observed. Therefore, calibration TST44N TR44 RTD sensor No
guidelines. The normals should be performed more TST14 TR45 RTD sensor No
and gauges used as well as often in the beginning (about TST74 TR47 RTD sensor No
the calibration process and every 36 months).
TST76 TR48 RTD sensor No
algorithms of the evaluation and Later on, having gained
TST262 No
measuring accuracy calculation experience with the drifting TR62 RTD sensor
TST264 Until 01/2013
were checked, approved and behavior of one special
confirmed in the accreditation thermometer, the recalibration TST266 TR66 RTD sensor Until 10/2013
authority approval. The intervals may be prolonged TET100 No
RTD sensor,
compliance is regularly (about every 9-12 months). TET102 TPR100
measurement insert
No
supervised by an accreditation TET105 No
authority by audits and tests. Thermocouples: The user TSC110S TC10 Thermocouple No
In Europe, the national might be recommended (if a TSC130S TC13 Thermocouple No
accreditation authorities have particularly high precision of TSC140T TC15 Thermocouple No
united themselves within the measurement is required) to
TSC288 TC88 Thermocouple No
EU (e.g. DKD: Germany, SIT: buy a TC calibrated by us and
TSC262/TSC264 TC62 Thermocouple Until 10/2012
Italy; SCS: Switzerland) to the to recalibrate it theirself, every
EA (European Cooperation of 2-3months in the beginning. TSC266 TC66 Thermocouple Until 10/2012
Accreditation). TEC100/TEC105 TPC100 Thermocouple, No
measurement insert
If the TC turns out to be stable,
The factory calibration is after some time the calibration TMT136/TMT137 TMT180 Head transmitter No
carried out dependent on cycles may certainly be TMD831 TMT181 Head transmitter No
production norms and sets prolonged to 9-12 months. TMD832 TMT82 Head transmitter No
of rules or according to the It depends entirely on the TMD834 TMT84 Head transmitter No
requirements of the customers. individual case. After all, TMT184 TMT84 Head transmitter No
The results are documented in drifting is different with TMD842 TMT112 Transmitter No
a calibration certificate. All test every TC, therefore general TMT122 DIN rail transmitter
equipment used is traceable recommendations regarding TMD833 TMT162 Field transmitter No
to national/international calibration cycles cannot be TMT165 TMT162 Field transmitter No
standards. The measurement made. If precision is of major
TMT165 TMT85 Head transmitter No
accuracy of a device is not importance, the customer
TMT182 TMT82 Head transmitter No
influenced by a calibration. will have to monitor the drift
TMD833T TMT162R Compact No
On the contrary, during an theirself and then decide how
thermometer,
adjustment (defined on page8) often the TC needs to be RTD sensor and
a measurement device is recalibrated - or not. field transmitter
adjusted and calibrated in such TMD833C TMT162C Compact No
a way that the measurement Note: with nearly all thermometer,
deviation does not exceed transmitters drift can be thermocouple and
field transmitter
predetermined error limits compensated via ReadWin
TA10 TW10 Thermowell No
(defined by the user). The 2000 (sensor matching).
following are part of any TA11 TW11 Thermowell No
adjustment: trim, offset and Spare parts TA12 TW12 Thermowell No
sensor-transmitter matching. TA13 TW13 Thermowell No
The insert, the thermowell, the TA573/TA574 TW15 Thermowell No
How often must a terminal head and the transmitter TA250 TW251 Thermowell No
thermometer be calibrated? can be exchanged if necessary. Note: these dates are periodically updated on www.endress.com
At which intervals is
recalibration required? Migration Table 1: Instrument and spare parts availability
How often a thermometer should
be recalibrated depends on: You will find detailed
The users requirements information regarding the new Re-engineering help you check the relevant
regarding precision. generations of temperature Want to use an instrument parameters. See our online
Which thermal (maximum sensors in the following table. for a new application? We can Applicator tool.
temperature, possible thermo https://wapps.endress.com/applicator
shocks, frequent changes
of temperature etc.) or

The Endress+Hauser Maintenance Guide 89

 Frequently asked questions
Temperature

The PLC doesnt display the right temperature value For TMT82/112/122/142/182 (HART products) and TMT162
Check the Pt100 signal using an Ohmmeter. (HART version only), ensure that the load resistance at the
Thermocouple: Commuboxs terminals equals 250. If the loop is overloaded
Is the right thermocouple selected? (due to the PLCs impedance or the presence of a recorder) the
Is the right temperature for the reference junction used? load resistance can be much higher thus reducing the signals
Is the right extension or compensating cable used? intensity.
Ensure that both 4-20mA ranges of the transmitter and the PLC You are using TXU10:
correspond. Is the USB driver installed in the PC? The driver is stored on
Check or calibrate the thermometer. the Readwin 2000 CD-ROM. You can download the latest
Check the installation (see fig. 4 and 5 on the previous pages). version from www.readwin2000.com
To install the driver you need admin rights on your PC.
Also take care of the selected communication port:
I have no communication to the transmitter from From Windows, START/CONTROL PANEL/SYSTEM/
Readwin2000 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 in 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 TMT82, TMT112, TMT122 (HART), TMT142, TMT162
(HART) and TMT182 (HART), switch of the FIFO active setting.
In order to do this proceed as follows:
Windows NT Version 4.0:
Using the menu START/SETTINGS/SYSTEMCONTROL/
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/DEVICEMANAGER/
PORTS (COM and LPT)/COMMUNICATION PORT
(COM1)/PORT SETTING/ADVANCED menu.
Deactivate Use FIFO buffer.

90 The Endress+Hauser Maintenance Guide

 Recorders

The advantages of paperless recorders

Today, maintenance of strip chart recorders As paperless recorders are maintenance- Contents
is considered too high. The need for many free, in the following pages we focus on
consumables (paper and pens) and the fact suggestions for improved operation. Basics 92
that data isnt stored electronically are a real FAQ 94
inconvenience in the process world. Nevertheless paper recorders still
constitute a pretty large part of the
This is why electronic (paperless) recorders market and Endress+Hauser will keep
have rapidly become very popular. Whereas providing consumables for its recorders.
the first generation stored the data on
diskettes, the new range uses Compact As experts, we also offer training sessions,
Flash or Secure Digital cards for even more in classroom and on site. See Training in
reliability and storage capacity. the At your service section.

The Endress+Hauser Maintenance Guide 91

 Basics
Information common to
any type of modern recorders
The current Endress+Hauser range of recorders includes:
Ecograph T RSG30 multi-channel electronic (paperless) recorder
Memograph M RSG40 system compatible data manager with a unique
safety concept for critical applications. Compliant with the high FDA
requirements laid down in 21 CFR Part 11.
Recorders

Measuring principle Display of historical data New generation (RSG30/ However, set up using a PC is
and main features on site RSG40): To achieve and much simpler.
Display of statistics analyze a higher amount of
The electronic recorders carry Various display modes data, we recommend the FDM Setup using a PC
out the electronic acquisition, software (Filed Data Manager) You can use the PC software
display, recording, analysis, Memory (fig.1) that supports a SQL database. ReadWin 2000 provided with
remote transmission and Redundant memory the device to put the device into
archiving of analog and digital ensures safe data recording: 21 CFR 11 service / configure it via PC.
input signals. internal Flash memory + CF Memograph M together with
(CompactFlash)(RSG30) or ReadWin2000 fulfill the You can also download the
Communication SD (Secure Digital) cards and requirements of 21CFR11 latest software version directly
Communication interfaces USB stick + data transfer to a concerning electronic from the internet under the
available: USB, RS232, RS485, PC (RSG40). documents and electronic following address:
Ethernet, PROFIBUS DP and Note: Please use the signature. www.readwin2000.com
MODBUS (RSG40) original memory cards from For further information on
Endress+Hauser, as these are Installation instructions ReadWin2000, refer to
Input/Outputs industrially proved. the operating manual of the
Galvanically isolated universal Installation software (BA137R/09).
inputs (U, I, TC, RTD, Analysis/archiving The front side seal should be
frequency and pulse <10kHz) Long-term archiving is carried correctly positioned to ensure Advantages of configuration
Digital input (high/low) out at the PC, whereby the watertightness and avoid any via PC:
Digital output (relay) data is transferred to the problems due to condensation. The device data is saved in a
Mathematical channels for database, via Ethernet or database and can be accessed
calculations serially to the PC. The rear should also be again at any time.
Using the supplied PC protected against humidity. Text entries can be carried out
Display of measured values software package, the devices more quickly and efficiently by
Electronic recorders are easy can be operated, read-out and Electrical connection keyboard.
to program via the Set up the measurement data can be Please cable the unit with care. Measured values can also be
window or from a PC archived and visualized. Many reported errors come read out, archived and displayed
from wrong connections. We on the PC with this program.
remind you that the terminal
diagram is printed on the rear Operations and maintenance
of the recorder.
Please use shielded cables. Electronic recorders are
maintenance-free.
Surge arrester
We recommend the use of Using the screensaver mode
surge arrester(s) (HAW56x increases the displays lifetime.
Copy saved on
family) to protect the
Compact Flash instrumentation against Tips for safe and
or SD card overvoltage. comfortable operation
Use Readwin 2000 to analyze
Data transfer Setup and print the recorded data.
using CF Note: the operating instructions
or SD card
Setup can be performed at documentation related to
the unit by using the Set Readwin 2000 is available on
Fig. 1: Measuring system on new generation recorders up window at main menu. the accompanying CD.

92 The Endress+Hauser Maintenance Guide

 Recorders
Use the Safely remove Ethernet or USB. Start the Interface connection
CF/SD/USB function (on provided PC software. Select
Ecograph T and Memograph Read out -> Read out memory
M) to ensure safe removal of card by interface/modem.
the memory card: all internal Select the appropriate unit
access is ended and you from the PC database. Select
receive a message when the Unit -> open unit(s). The
card can be safely removed. connection is established.
To prevent possible loss of Select the appropriate file on
data, this function must be the memory card and confirm CompactFlash or SD Secure Digital
the only method used to with OK. The measured memory card

remove the card. values are read out. The Fig. 2: Data transfer to the PC
measured values remain on
Data transfer to the PC the memory card.
(see fig.2) Migration delivered with the recorder
We recommend to periodically We recommend the following for professional, tamper-
transfer the recorded measured procedure for saving data: The shift to electronic recorder proof data processing
data and the configuration data Always have a memory card offers many advantages: Flexible: direct access to
to a PC. Data can be transferred inserted Economical: electronic archived data also with
to the installed PC software in Periodically read out the recording replaces strip MS Excel or in ReadWin
one of the following ways: memory card with the PC chart recorder, saves 2000 for example
Using USB, RS232/485 or software on consumables
Ethernet. Communication Protect access to the Versatile: up to 6 (RSG30) or Re-engineering
and download of data to PC recorders configuration 20 (RSG40) universal inputs
using the function Read out via your personal code or record all measuring signals Want to use an instrument
-> Read measured values a password (21 CFR 11) Clear layout: multi-colored for a new application? We can
using interface/Modem. to prevent unintentional display, digital, bargraph help you check the relevant
Save the data to modification. and curve display parameters. See our online
CompactFlash in the unit Note: the data on the memory Compact: low installation Applicator tool.
using the function: for RSG40 card is compressed (10 to 1). depth, saves space and money https://wapps.endress.com/applicator
Extras -> SD Card -> ... or Safe: reliable data archiving
Extras -> USB Stick -> ..., Calibration with internal memory and
for RSG30 Main menu -> Calibration must only be separate memory card
CompactFlash (CF) functions carried out by skilled and (mechanically locked) on the
-> Update CF trained personnel. Malfunctions recorders. No data loss even
Now insert the memory card are possible if calibration is not in the event of power failure!
into the PC and read the data performed correctly! Communication interfaces:
using the function Read out see table 1 (next page)
-> Read out measured values Spare parts stock Available worldwide:
using PC card drive. integrated web server function
Read out the memory card We recommend to keep a power for remote monitoring
with the PC software: in supply board in stock if you have e.g. with Endress+Hauser
principle the values can no surge arrester installed to Fieldgate Viewer
be read out directly from protect the instrumentation. Reliable: inputs are galvanically
the memory card. The isolated from the system
connection to the unit is Complete: ReadWin2000
made by RS232/RS485, PC software package

The Endress+Hauser Maintenance Guide 93

 Recorder How to export data from Readwin 2000 to Excel?

Profibus

MODBUS

MODBUS

MODBUS
Ethernet
To display the data, click Display/Display measured values from

Master
RS232

RS485

RS485
RTU

TCP
USB

DP
database
Choose the unit to be displayed, then the data timescale etc.
Ecograph T RSG30 Click Tabular at the bottom left of the screen then click on the
Memograph M RSG40 Display tag at the top left then choose Save table (choose .txt
or .xls file format)
Table 1: Communication interfaces available

How long can we store measured values on the external and

Old generation New Description Spare parts internal memories?
availability Please refer to your devices operating instructions.
RSG12 RSG40 Paperless recorder Until 01/2017
RSG20 RSG30 Paperless recorder Until 01/2013 The display of the % of external memory is not correct after
RSG22 RSG30 Paperless recorder Until 01/2013 read out to a PC
RSG24 RSG40 Paperless recorder Until 01/2013
The displayed percentage will be refreshed after the first new
memory block is sent to the external memory.
RSG10 RSG40 Paperless recorder Until 01/2014
Note: These dates are periodically updated on www.endress.com
I have no communication via USB to the recorder
Is the USB driver installed in the PC? You can download the latest
Recorders

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 Windows,
START/CONTROL PANEL/SYSTEM/HARDWARE/DEVICE
MANAGER/PORTS
Frequently asked questions From this window, use the port number that corresponds to the
connected communication interface (FXA195 if you are using a
HART modem).

How to start with Readwin 2000? (see also BA137R) Will the database of measured values be deleted after an
Create a unit Group/plant update of Readwin 2000?
Unit\Display/Change unit setup/Add new unit\Unit group plant No.

How to insert and configure the unit? (see also BA137R) Will the configuration and the measured values be deleted
Unit\Display/Change unit setup/Add new unit\Unit\ after a software update of the unit?
Add new unit Yes. Please read out and save data before.

How to store and display measured values on the PC? Can I define different levels of user rights in Readwin 2000?
There are two ways to read out data: Yes: Extras\Program options\Set-up\Security\Password protection
Via the Compact Flash card must be activated.
Click Read out/Read out measured values using PC card drive
then New unit and give it a name. Data will then be transferred. The terminals on the rear side of the unit are missing
Via the interface Only the terminals that correspond to the options you have ordered
Click Read out/Read out measured values using interface/modem are delivered.
then New unit and give it a name. Data will then be transferred.
Installation of the operating software
To display the data, click Display/Display measured values from Please do not install the operating software in the Program folder if
database you have only restricted admin rights. Install the operating software
Choose the unit to be displayed, then the data timescale etc. e.g. under C:\ReadWin32

94 The Endress+Hauser Maintenance Guide

 Field communication

New picture

An introduction to the maintenance of fieldbus networks

The use of digital communication We have issued Guidelines for planning Contents
and fieldbus networks provides many and commissioning for both PROFIBUS
advantages for maintenance. and FOUNDATION Fieldbus networks. For Networks using the
further details, please refer to Operating HART protocol 96
Digital instrumentation allows Instructions manuals BA034S (PROFIBUS) WirelessHART 99
simultaneous, bidirectional exchange of and BA013S (FOUNDATION Fieldbus). You
data with controllers and computers. Once can download these documents from our Profibus DP/PA networks 101
the instruments have been installed, they website. Foundation fieldbus
can be parametrized remotely, from a networks 104
workshop, a control room or at any point in As experts, we also offer training
the network with a laptop - very convenient sessions at our training center or on site. Tools 107
in the case of hazardous environments or We will be glad to meet you and help FAQ 108
difficult access. This is even easier since you improve your knowledge of digital
WirelessHART devices are available. communication. See Training page in
the At your service section.
For troubleshooting, the diagnosis can
also be performed in the same way, even
over long distances, thanks to gateways
or modems.

Video about FDT available at

www.endress.com/videos

The Endress+Hauser Maintenance Guide 95

 Networks using
the HART protocol
46%* of the 69.2 million devices installed worldwide by the end of 2010 were
HART-enabled devices. As a result, HART (Highway Addressable Remote
Transmitter) is a global industrial standard with an installed base of 32million
devices* in 2010.

HART is a smart technology,

i.e. it supports simultaneous
communication over two Field Xpert
channels on the same wire PLC PLC
including power supply for
the devices:
An analog 4-20mA signal A) B)
ensures the fastest possible 420 mA
data transfer of control signal 420 mA
HART Fieldgate Fieldgate
HART digital signals provide
HART FXA520 FXA520
for read/write access to all
device data HART/Bluetooth HART multidrop
Modem (up to 15 devices)
420 mA
Typical architectures /HART
HART is a master-slave protocol
Field communication

for point-to-point and multidrop

communication. Several
architectures are possible to
meet all kinds of requirements
(see Fig. 1 from left to right): Fig. 1: Typical HART architectures
Point-to-point parametrization
and diagnosis via Field Xpert
Point-to-point asset Common practice the higher rate until it instructs of approximately 23 data
management using FieldCare commands offer functions the slave to stop bursting. updates per second without
Point-to-point or centralized that are optional but that interrupting the analog signal.
parametrization and diagnosis are supported by many Frequency shift keying
via multiplexer using HART instruments. The HART communication Basic parameter set
FieldXpert (with WLAN Manufacturer-specific protocol is based on the Bell Thanks to the common practice
or Bluetooth connection) commands are for proprietary 202 telephone communication commands, all HART devices
or FieldCare functions not covered by standard and operates using offer a basic parameter set
Centralized plant asset the HART specification, the frequency shift keying that ensures interchangeability
management via remote I/O e.g. linearization, advanced (FSK) principle. The digital and fulfils the requirements
(with DTM) using FieldCare diagnosis functions, etc. signal is made up of two for process control and asset
Centralized plant asset frequencies 1,200Hz and management. The parameters
management via Fieldgate Burst mode 2,200Hz representing bits include:
FXA520 (for remote access) Some HART devices 1 and 0, respectively. Sine Device identification (device
using FieldCare support the optional burst waves of these two frequencies tag, supplier, device type and
communication mode. are superimposed on the revision, device serial number).
System integration Burst mode enables faster direct current (DC) analog Calibration data (upper
HART determines how data is communication (34 data signal cables to provide and lower range values,
to be presented and transferred updates per second). In burst simultaneous analog and digital upper and lower sensor limits,
between master and slave. Three mode, the master instructs the communications. Because the process value damping, last
command classes are defined: slave device to continuously average value of the FSK signal calibration date).
Universal commands offer broadcast a standard HART is always zero, the 420mA Process variables (primary
a basic set of functions reply message (e.g., the value analog signal is not affected. variable plus secondary
and are supported by all of the process variable). The The digital communication measurements and multi-
HART instruments. master receives the message at signal has a response time variable parameters).

* According to a recent study by the ARC Advisory Group

For more information on HART technology, please visit: www.hartcomm.org

96 The Endress+Hauser Maintenance Guide

 Installation instructions easily, with the transparency
demanded by Good
Standard 4-20mA cables Manufacturing Practice.
are used. A minimum loop
impedance of 250 is required Nested communication
e.g. for digital communication. with iDTM-HART
PROFIBUS DP
Currently there are two
Ethernet Set-up different technologies for
Remote
I/O device integration available:
Device Parametrization FDT/DTM (Field Device
using FieldCare Tool/Device Type Manager)
420 mA
HART FieldCare supports HART e.g. and EDDL (Electronic Device
HART Multidrop (up to 15 devices)
via Fieldgate FXA520, via Description Language).
FXA195 HART/USB modem iDTM-HART (interpreter
or via a HART remote I/O or Device Type Manager)

Field communication
multiplexer with CommDTM. combines both technologies
It can configure all intelligent effectively and allows the
field devices in your plant, integration of HART devices
including devices without a in FieldCare that have no
native DTM and supports you appropriate DTM at hand.
in managing them. By using HART devices from about
status information, it also 90 manufacturers are supported
Device Descriptions (DDs) Field Device Tool provides a simple but effective so that you can choose the best
HART uses DDs to describe Field Device Tool provides means of checking their health. device for your application.
the parameter set carried by the protocol-independent FieldCare ensures that
device to the HART master. operation of digital field devices can be integrated iDTM-HART is handled in
Device configuration tools use devices. It maps all device and configured quickly and FieldCare as any other DTM
either DD or FDT technology, functions, including advanced
both based on the original diagnostics such as Time of
HART DDs. Flight envelope curves. PLC

- FieldCare
- ToF Tool - FieldTool
A Connection Commubox FXA195

Electronic Device Description The information is contained Package

EDDs are the successors of in a Device Type Manager

DDs and are used in Asset (DTM), a software module Commubox 270
Management Solution that runs in a FDT frame
Off

On

FXA191/195
EX Switch Commubox FXA195
(AMS), Process Device application, e.g.:
A
Manager (PDM), 375 Field FieldCare Transmitter power-
EX
Communicator and other DD Yokogawa FieldMate supply unit,
e.g. RMA422
Measured Value

64.50

supported applications. In the PACTware

%

or RN221N
(with communication
future, Field Xpert will also ABB Composer, Control resistor)
3 PV
4 SV
DELTABAR: * * * * * * * *
ONLINE
1 QUICK SETUP
2 OPERATING MENU
352 mbar
0 C
dsdmdm
df das.
asdas fa
asas la.

Display and
operating module
support enhanced graphics Builder, Fieldbus builder, etc.
HELP SAVE

Bksp
Page
Up

Delete
(optional)
FXA191/195
Page
On

ENDRESS + HAUSER
RMA 422

in the Device Description. Invensys I/A Series

#%& ABC DEF
1 2 3
Copy Paste Hot Key

or
GHI JKL MNO
4 5 6
Insert + Hot Key

PQRS TUV W XY Z

HART handheld terminal

7 8 9

DXR375
,() _<> +*/
. 0 -

DXR375
Endress+Hauser provides EDDs Other FDT frame applications
375
FIELD COMMUNICATOR

for all its devices and also Endress+Hauser fully

Fig. 2: The measuring system.
supports their integration in supports FDT technology The communication resistor (270) integrated in the Commubox FXA195 (see A)
Emerson AMS and Siemens and offers DTMs for all should not be connected in parallel to a power supply point greater than 15V. If the
PDM applications. Endress+Hauser devices. communication resistor is used, it should always be looped into the 4-20mA circuit.

The Endress+Hauser Maintenance Guide 97

and available within seconds Operations and maintenance
in online mode. It is based on
an EDD (Electronic Device As the HART signal modulates
Description) interpreter of the 4-20mA current, if the latter
the HART Communication operates, the former should also
Foundation (HCF) and contains operate. You just need to check
over 600 registered HART the presence of the current with
EDDs of the HCF Library, a multimeter.
which is updated regularly.
Device Xpert offers the range of
iDTM-HART combines diagnosis supported by the
basic device functionality Device Description (DD). Basic
with the familiar DTM information such as device
user interface. EDD-based status can be seen at a glance,
devices can use nested making diagnosis easy.
communication thanks to FDT.
Diagnosis Fig. 3: Options for remote operation via HART protocol
1 PLC (programmable logic controller)
Device parametrization If you are facing a problem
2 Transmitter power supply unit, e.g. RN221N (with communication resistor)
using Field Xpert during commissioning 3 Connection for Commubox FXA195
Every parameter is easy to or troubleshooting of a 4 Computer with operating tool (e.g. FieldCare, AMS Device Manager, SIMATIC PDM)
find and to configure. If the HART device, you can 5 Commubox FXA195 (USB)
6 Field Xpert SFX100
location of a specific function solve it as follows:
7 VIATOR Bluetooth modem with connecting cable
is unknown, the integrated 8 Transmitter
Function Finder locates it in all By using a Commubox FXA195,
you should see the instrument from
HART devices. This is especially FieldCare, otherwise there is a
useful with complex devices problem with the cabling.
with many parameters. Ensure that the load resistance at the
Commuboxs terminals equals 250.
If the loop is overloaded (due to the
More information on FieldCare at: controllers impedence or the presence Also take care of the selected Make sure you have the right DD /
www.automation.endress.com/fieldcare communication port: DTM installed in your configuration
of a recorder) the load resistance can
be much higher thus reducing the From Windows, software
More information on Field Xpert START/CONTROL PANEL/S
signal strength.
on page 107. Switch off the FIFO active setting. In YSTEM/HARDWARE/DEVICE
MANAGER/PORTS
Re-engineering
order to do this, proceed as follows:
Our service organization can set up Windows XP: From this window, use the port
any Endress+Hauser device for you to Select Port settings from number that corresponds to the Our Projects teams can help you
ensure you immediately get the best connections Port (Com 1)/ST connected communication interface from the start of your revamping
from your instrument. ART/SETTING/SYSTEM (FXA195 if you are using a HART project. Please contact us.
(See Device commissioning in the /HARDWARE/DEVICE modem).
At your service section). MANAGER/PORTS (COM Check the minimum voltage required
and LPT)/COMMUNICATION for your HART communicating
PORT (COM1)/PORT transmitter(s); the voltage (usually
SETTING/ADVANCED menu. 16V) is related to the device.
Deactivate Use FIFO buffer.

98 The Endress+Hauser Maintenance Guide

 WirelessHART

WirelessHART is the wireless standard of the HART Communication Foundation for

use in process automation. It adds wireless capabilities to the HART protocol while
maintaining compatibility with existing HART devices, commands and tools.

WirelessHART protocol The Fieldgate SWG70 is

The HART protocol has until the master device in the
now used the wired 4-20mA WirelessHART network.
loop with a superimposed Acting as network manager, Host applications
digital signal as as physical it recognizes other devices
layer. Although full digital wanting to join the network.
communication is available in It makes contact with each
multidrop mode, the majority in turn and initiates the Ethernet
of transmitters are connected procedures required for them
WirelessHART Fieldgate
to analog I/O cards and digital to join. The network organizes with network and
communication is used only for itself without any intervention security manager
parametrization, diagnosis and on the part of the user.
maintenance purposes.
Fieldgate SWG70 also acts as
WirelessHART now allows security manager.
for the wireless transmission
of HART data. For worldwide Finally and most important,
use, WirelessHART utilizes the it collects the data sent by
2.4GHz Band (IEEE 802.15.4 the network participants,
wireless network) as physical converting it into a form which
layer. The WirelessHART can be used by other systems
devices form a mesh network connected to it.
in which every device is not
just a measurement point, but Installation instructions
also a repeater. This results in
a wider range for the whole Positioning
network as well as increased Please consider the following
reliability through redundant points when planning a
communication paths. WirelessHART network: Field devices with
The positioning is good Wireless Adapter SWA70
A WirelessHART network when the network
comprises (see fig. 4): participants are within Fig. 4: WirelessHART network WirelessHART adapters (either
Wireless field devices the antennas emission The network may comprise three types connected to 4-20mA/HART
of devices: devices or acting as repeaters)
Non-wireless field devices angle (see fig. 5). WirelessHART gateway In a mesh network, all devices
enhanced by using a The most power is in the (e.g. Fieldgate SWG70) communicate with each other, allowing
WirelessHART adapter horizontal plane, decreasing WirelessHART field devices alternative communication paths should
Gateways that enable to 50% at an angle of 39. the shortest path be broken.
communication between Almost no signal will be
devices and host applications radiated directly above and
Network and Security below the antenna.
Manager software responsible The height differences
for configuring, managing and between wireless devices in a PWR
COM
FLT

monitoring the network network should not be too big.

The Endress+Hauser solution The schematic is valid height
includes a gateway and an only for an antenna placed
distance
adapter (see next page). outdoors with no metal
surfaces nearby. Fig. 5: Good positioning

For more information on WirelessHART technology, please visit: www.hartcomm.org

The Endress+Hauser Maintenance Guide 99

 Set-up Operations and maintenance
WirelessHART solutions
There are two ways to set up
Fieldgate SWG70: via web
Network optimization
a) Verify connections: from Endress+Hauser
server or via FieldCare. Check that each device has
The Fieldgate SWG70 has an joined the network and is Endress+Hauser WirelessHART solutions allow users to make
integral web server that can be communicating properly. If you a quantum leap in plant availability and transparency.
used to set up and monitor both cannot establish a connection to
the SWG70 and the network. a device, the device is probably
The structure of the parameter too far away or an obstacle
blocks and parameters is blocks the radio waves. In this
identical to that of the Fieldgate case, add an additional device to
SWG70 DTM. Connection to bridge the gap.
the web server is established
via an internet browser. b) Make sure that each
device has a minimum
FieldCare Setup via FieldCare of two neighbors.
differs from the web server
in that it is also possible to c) Eliminate bottlenecks:
parameterize the WirelessHART If all messages sent by several
adapter SWA70 as well as any devices have to pass through
connected HART devices. A a single device to get to the
prerequisite is that the field gateway, the network has a
devices already have the same bottleneck. This means that WirelessHART adapter WirelessHART fieldgate
join key and network identifier if this device fails, whole The WirelessHART adapter The Fieldgate SWG70 serves
as the Fieldgate SWG70 and parts of the network get cut SWA70 is a battery-powered as a gateway device for
have joined the network. off from communication interface module that connects WirelessHART networks.
Attached devices can be because there is no alternative HART and 4-20mA devices to a It enables WirelessHART
configured via their DTMs. path to route messages. To WirelessHART network. devices to communicate with
eliminate a bottleneck, add each other and manages
For more information, please at least one device near the Features and benefits security and connectivity.
HART devices quickly upgraded
refer to WirelessHART bottleneck to provide redundant to WirelessHART technology
Fieldgate converts and stores
Fieldgate SWG70 Operating communication paths (see fig. 6). One 4-20mA or up to four HART wireless device data in a
Instructions (BA064S). devices can be connected (in format that is compatible with
multidrop mode) to one adapter other systems. It has Ethernet
Burst mode and event notification
Field communication

supported for adapter and

and serial interfaces for
connected devices connection to host applications
PWR
COM
FLT

Remote and difficult-to-access HART such as SCADA tools.

devices connected to the plant control
room without expensive cables Features and benefits
Tanks and silos integrated at Gateway, network manager and
minimal cost into e.g. SupplyCare network access point capabilities
Inventory Control software according to the WirelessHART
Endress+Hauser and third specification: works with all
1 party devices maintainable WirelessHART adapters and devices
with open FieldCare Plant RS-485 and Ethernet interfaces
Asset Mangement software with support of HART and
Network configuration also Modbus: network data easily
2
PWR
COM
FLT
done within FieldCare Plant integrated into existing system
3
Asset Management software Configuration and parameterization
Supports configuration with FDT via FDT/DTM, EDDL or a web
PWR
COM
FLT

and DD-based network tools interface: clear presentation

of network, measured values
Fig.6: Eliminating a bottleneck by adding a device and diagnosis information
1 Device situated at a bottleneck Local or remote antenna
2 Fieldgate options: easily adapted to local
3 Additional adapter adds alternative routes installation conditions

100 The Endress+Hauser Maintenance Guide

 PROFIBUS DP/PA networks

With more than 40 million devices installed at the end of 2010 and with over
5.4million of these in the process industries, PROFIBUS has established itself as the
leading communication technology in the field of process automation. PROFIBUS
can be used in all industrial automation applications: process automation, factory
automation, motion control and safety.

The technology was introduced DP/PA systems the baud rate FieldCare P View
in the early 1990s and has supported by the segment Plant Asset
Management
Process Operation
and Visualization
been developed continuously coupler can be a limiting factor. Ethernet

ever since. PROFIBUSDP and PROFIBUS master for PROFIBUS master for
PROFIBUSPA technologies are PROFIBUS PA is used at field acyclic communication
e.g. Fieldgate FXA720
cyclic communication
of process data
e.g. AS-Interface
specified in the international level. A segment coupler or link
e.g. Field Controller SFC173
PROFIBUS DP

standards EN50170 and serves both as interface to the

IEC61158 and are suitable for PROFIBUS DP system and as
Devices from third-party vendors
replacement of discrete and power supply for the PROFIBUS (Remote I/O, drives, pumps, etc.)

analog signals in control systems. PA field devices. Depending PROFIBUS PA

upon the type of segment

Typical PROFIBUS DP/PA coupler, the PROFIBUS PA
architecture (Fig. 7) segment can be installed in safe
or hazardous areas.
Safe Area
The process is controlled by Hazardous Area

Field communication
a process control system or a PROFIBUS PA and DP have the PROFIBUS PA

programmable logic controller same communication protocol.

(PLC). The control system or
PLC serves as a Class 1 master. Transmission standards
It uses the cyclic services to PROFIBUS supports three
acquire measurements and different transmission Fig. 7: typical architecture of a Profibus DP/PA network
output control commands. The technologies: RS485, fiber
asset management program, optics and MBP (Manchester
e.g. FieldCare, serves as a Coding/Bus Powered). System integration Where an FDT-frame is
Class 2 master. It uses the Both RS485 and MBP make Devices are integrated into used for acyclic configuration
acyclic services and serves provision for intrinsically safe a PROFIBUS network using of the device, another type of
to parameterize the bus transmission in hazardous areas. two files: file is used:
participants during installation General Station Data Device Type Manager (DTM):
and normal operation. The maximum length of a DP file (GSD): describes the is a software component used
network ranges from 1200m communication behavior for accessing specific functions
The PROFIBUS DP system (copper, RS485) to several and supported features of of a field device via a user
is used to handle the kilometers (fiber optics) for a a PROFIBUS device. The interface, for parametrization,
communication at the control transmission rate range from GSD file includes the format diagnosis and maintenance of
level. Drives, remote I/Os, etc 9.6kBit/s to 12MBit/s. of input/output data that the device as well as for the
may all be found on the The maximum length of may be exchanged cyclically integration in FDT engineering
bus. At this level, field a PA network using MBP between the device and the tools or control systems.
devices such as Promass (Manchester Coding/Bus master as well as diagnostic
and Promag flowmeters Powered) is 1900m in a safe data as plain text*. Installation instructions
are externally powered. area and 1000m in a hazardous Electronic Device
area. The transmission rate is Description (EDD): is used PROFIBUS is considered a very
PROFIBUS DP ensures that 31.25kBit/s. in parametrization or in asset robust way of communication.
data is quickly exchanged, management tools to adjust Nevertheless, wiring, cabling
whereby in mixed PROFIBUS the device. The EDD contains and shielding is a crucial
information on the device part of the installation and
parameters. as every form of digital
For more information, you can download our Guidelines for planning and commissioning
Profibus DP/PA field communication (ref. BA034S) from www.endress.com
communication, this has to
* GSD files may be downloaded from www.endress.com be performed carefully.

For more information on Profibus technology, please visit: www.profibus.com

The Endress+Hauser Maintenance Guide 101

Cabling If the bus is extended by intelligent field devices in the equipotential bonding are
When installing a PROFIBUS the use of a repeater, then your plant and supports you very difficult to locate, you
network, particular attention the extension must also be in managing them. By using should check all equipotential
must be paid to the cabling. terminated at both ends. status information, it also bonding connections.
This covers both choice of provides a simple but effective
cabling and the way in which Termination (PROFIBUS DP) means of checking their health. 2) Checking the connection
the cables are laid in the The start and end of the FieldCare ensures that devices of DP/PA slaves
plant. By careful routing, e.g. PROFIBUS DP segment can be integrated and configured The quality of the wiring should
avoidance of potential sources must be terminated. Some quickly and easily, with the be checked at the slaves side
of intense electromagnetic connectors that are available transparency demanded by Good and at the junction boxs side.
interference, use of metal trays on the market are fitted with Manufacturing Practice. On a PROFIBUS DP bus,
or separation of power and terminating resistors that must communication losses may be
bus cables in the cable tray, a be switched in. Our service organization can set up caused by:
any Endress+Hauser device for you to
significant contribution can be Note: branches are allowed in ensure you immediately get the best
A cable inversion
made to the fault-free running Profibus PA segments but not from your instrument. (the PROFIBUS DP bus
of the bus. in Profibus DP segments. (see Device commissioning is polarized)
Note: never use Profibus DP in the At your service section) The presence of a PA device
cables for cabling PA devices Set-up A short-circuit
and vice versa.
General instructions Operations and maintenance As a PROFIBUS PA bus is not
Termination (PROFIBUS PA) The bus parameters and polarized, communication
The start and end of every baudrate must be set when Since FouNdation fieldbus H1 losses may be caused by:
PROFIBUS PA segment must the PLC is configured. The and PROFIBUS PA use the same The presence of a DP device
have a bus terminator. For non- baud rate to be set depends electrical signal and encoding, A short-circuit
hazardous areas, some T-boxes upon the segment coupler used. only the protocol differs low
have an integrated terminating Pepperl+Fuchs SK1: level maintenance is identical 3) Verifying bus terminators
element that can be switched 93.75kBit/s in both networks. For the bus connection two
in when required. If this is not Siemens coupler: types of errors can occur,
the case, a separate terminator 45.45kBit/s Diagnosis both of which cause a signal
must be used. PA-link (Siemens IM If you are facing a problem reflection:
The segment coupler at the 153/157): freely selectable during the commissioning Too many terminators
beginning of the segment has Pepperl+Fuchs SK2 and or troubleshooting of a are switched on.
a built-in terminator. SK3: freely selectable PROFIBUS device, you One (or more)
The terminator in the T-box at The bus parameters can solve it as follows: terminator is missing.
the end of the segment must require adjustment The reflection strength depends
be switched in, or a separate As PROFIBUS DP is sensitive 1) Checking the on the error.
terminator must be used. to polarity, line A and B cabling infrastructure Note: Combining three
Currently, T-boxes with should never be reversed. Checking the cabling resistors, a PROFIBUS DP
switchable terminators are infrastructure should be one terminator differs from a
not allowed in explosion Device parametrization of your first troubleshooting PROFIBUS PA terminator
hazardous areas. However, this using FieldCare steps. In addition to testing that combines a resistor and a
will change in the near future. FieldCare supports PROFIBUS, the actual cabling, you should capacitor.
For a segment with a tree e.g. via ControlCare SFC173 also test the cabling of the
architecture, the bus ends at controller, Fieldgate FXA720 or equipotential bonding. An error 4) Verifying PROFIBUS
the device that is the farthest other PROFIBUS communication in the equipotential bonding station addresses
from the segment coupler. interfaces with CommDTM. can result in communication PROFIBUS stations that
FieldCare can configure all malfunctions. Since errors in incorporate setting of the

102 The Endress+Hauser Maintenance Guide

address over PROFIBUS 6) Oscilloscope measurements
a) Data core B b) Data core A
are often delivered with a Oscilloscope measurements
pre-set address of 126. It are a very effective means of Ideal form Ideal form

is important that no two troubleshooting PROFIBUS.

devices have the same address With a little practice different
on the network otherwise statements about errors and
communication is impossible. signal quality can be derived
from the signals displayed. You
The address of a PROFIBUS can also use the ProfiTrace
station can be set in one of two network analyzer.
ways:
A local binary dip switch on In order to check the
the device. The new address PROFIBUS DP signal, we
In practice In practice
will be valid after switching recommend to use a battery-
on the device. powered oscilloscope tuned on c) B - A Fig. 8: PROFIBUS DP
Software setting of device DC mode. See details on fig. 8. Ideal form The signals are transmitted
address over the PROFIBUS concurrently on both cores.
However, the signal on data line B is
network using a configuration For PROFIBUS PA, switch to
transmitted reversed to data line A.
tool (called a Class 2 master) AC mode. See details on fig. 9.
e.g. FieldCare. a) Measuring data line A
See the FAQs at the end of this against data ground
5) Checking PA networks section.
b) Measuring data line B
There are three ways for against data ground
checking PROFIBUS MBP (PA) Re-engineering
wiring: using a multimeter, a c) Measuring data line B against data
line A (shows you the actual signal
Pepperl+Fuchs SK3 with the Our Projects teams can help you
from the start of your revamping waveform on the PROFIBUS)
ADM or the lateste version of
project. Please contact us.
the PROCENTEC Profitrace. In practice

With the multimeter it is

possible to detect and locate a) Ideal signal b) Defective bus terminator c) Signal affected by noise
errors such as:
Simple inversion
in the data lines
Interruption of one of
the two data lines
Cable shielding interruption
Short circuit between
the data lines
Short circuit between the
data lines and the cable shield Ideal form Ideal form (grey: terminator is missing, A: noise amplitude B: amplitude of affected signal
black : too many terminators)

In addition, the DC voltage

Fig. 9: PROFIBUS PA
on the PROFIBUS MBP (PA) a) Ideal signal. Note: The signals
cable should also be measured. amplitude may slightly differ
This should be at least 9V and from one bus end to another.
not more than 32V at each
b) Defective bus terminator
station. A typical value for
non-hazardous installations c) Signal affected by noise due
is 19V. For intrinsically safe to: bad connection quality,
installations where there is an In practice In practice (terminator is missing) bad connection of shields,
static due to devices
explosion hazard, the value
should not be more than 13.5V.

The Endress+Hauser Maintenance Guide 103

 Foundation fieldbus networks

With FOUNDATION fieldbus, field device data becomes an integral

part of the control and operating system. The technology provides
the optimum interface for planning and maintenance programs running
in your plant.

FouNdation fieldbus is standard, defines four

Visualization Network
an open fieldbus standard to cable types: A, B, C and D, and Monitoring engineering
IEC61158 and IEC 61784-1 allowing different maximum e.g. P View e.g. ControlCare
Configurator
(Part 5). The Foundation permissible bus lengths of
fieldbus system architecture 1900m (6232ft), 1200m
is designed to promote (3936ft), 400m (1312ft) and
interoperability between 200m (656ft) respectively High Speed Ethernet
and among devices of (in the case of a safe area
different manufacturers. application). The transmission FOUNDATION fieldbus controllers
The standard specifies two rate is 31.25 kBit/s. Type A is
communication levels: recommended.
A high speed communication
level (HSE) on which System integration SFC162 Controller
(as visitor)
traffic between controllers, Devices are integrated into
FOUNDATION fieldbus H1
computers, frequency a FOUNDATION fieldbus
Field communication

converters and other network using two files:

instruments is handled. Common File Format (CFF):
A low speed communication is a software file used by the
level (H1) on which traffic host to map the detailed FF
between the process sensors capabilities of a device without
and actuators is handled. requiring its physical presence Fig. 10: standard Foundation fieldbus architecture
(offline project).
For more information, you can download Device Description (DD):
our Foundation fieldbus Overview
(BA013S) from www.endress.com
provides an extended integration in FDT engineering analog output and discrete
description of each object tools or control systems. output blocks have the
Typical Foundation in the Virtual Field Device same respective function for
fieldbus architecture (Fig. 10) (VFD) and includes Function blocks switches, actuators and for e.g.
information needed for a Every FOUNDATION fieldbus reset functions on a flowmeter.
Since Foundation fieldbus control system or host to device has function blocks: Control blocks: allow control
supports both a high speed understand the meaning of Resource block: describes the to be performed by fieldbus
and low speed network, two data in the VFD. The DDs are attributes of the fieldbus device, devices. Manufacturers are
architectures exist. These composed of two files: the e.g. device name, manufacturer free to implement the blocks
provide the same basic .SYM file which is a symbol and serial number. they prefer. For example,
functionality but differ in the file in text format, and the Transducer block: contains Endress+Hauser offers PID
physical layer. The H1 layer is .FFO file which gives a detailed all device information such control, input selection, etc.
IEC 61158-2 based and the description of the device. as calibration data and sensor according to the application for
high speed layer uses High type. A device may have which the device is designed.
Speed Ethernet (HSE). Linking Where an FDT frame is used for several transducer blocks,
For more information on function
devices, bridges or gateways configuration of the device, an e.g. diagnostic, process blocks handling, you can download
interface the communication additional file is required: variable or display. our guideline ref. BA00062S from
between the two levels. Device Type Manager (DTM): Analog input block: puts the www.endress.com.
is a software component used process variable including
Transmission standards for accessing specific functions status information on the Installation instructions
Foundation fieldbus HSE of a field device via a user fieldbus. It ensures that
uses the Ethernet 100BASE-T interface for parametrization, all devices publish their Cabling and termination are the
standard. FOUNDATION diagnosis and maintenance of information in exactly the sources of most of the reported
fieldbus H1, the IEC 61158-2 the device as well as for the same way. Discrete input, problems, see below.

For more information on Foundation fieldbus technology, please visit: www.fieldbus.org

104 The Endress+Hauser Maintenance Guide

Cabling counted in the total cable Device parametrization their virtual counterparts in
When installing a FOUNDATION length. The maximum using FieldCare the offline project. The project
fieldbus H1 segment, particular length of the individual FieldCare supports is then downloaded to the
attention must be paid to the spurs is dependent upon the FOUNDATION fieldbus, e.g. controller(s) in the network.
cabling. This covers both choice number of participants. via ControlCare SFC162 FOUNDATION fieldbus
of cabling and the way in which controller (as visitor), Softing supports distributed control
the cables are laid in the plant. Set-up FF Gateway or other FF linking systems (DCS), which have
By careful routing, e.g. avoidance devices with CommDTM. several controllers connected
of potential sources of intense There are several ways to set Today Endress+Hauser together by the HSE backbone
electromagnetic interference, use up a FOUNDATION fieldbus provides its own DTMs for and even down to the device.
of metal trays or separation of device, whereby the following all FOUNDATION fieldbus
power and bus cables in the cable points must be considered: devices from 2010 onwards. Operations and maintenance
tray, a significant contribution can All device parameters are These offers device diagnosis
often be made to the fault-free mapped in the controller: a based on the NAMUR NE 107 Since FOUNDATION fieldbus
running of the bus. Similarly, the parameter changed directly at recommendation. H1 and PROFIBUS PA use

Field communication
number of network branches a device may be overwritten Moreover, with more than the same electrical signal and
should be kept as low as possible. on project download if this 400 registered devices from encoding, only the protocol
change has not been registered about 80 manufacturers, the differs, low level maintenance
Termination by the controller. specific iDTMs-FOUNDATION is identical in both networks.
The start and end of every To prevent accidental changes, fieldbus catalog allows FOUNDATION fieldbus HSE
FOUNDATION fieldbus all FOUNDATION fieldbus full, quick and transparent can be fixed in the same way as
H1 segment must be fitted devices have a hardware write parametrization capabilities. an industrial Ethernet network.
with a bus terminator. For lock that must be disabled
buses with a branched before configuration. Our service organization can set up Diagnosis
structure, the end of the any Endress+Hauser device for you to If you are facing a problem
ensure you immediately get the best
bus is considered to be the Device parametrization from your instrument. during the commissioning
network node that is farthest using an engineering tool (see Device commissioning or troubleshooting of a
removed from the start of the A FOUNDATION fieldbus in the At your service section) FOUNDATION fieldbus
segment. For non-hazardous system allows both offline and H1 device, you can
areas, some T-boxes have online configuration of devices solve it as follows:
an integrated terminating from the engineering tool, System configuration
element that can be switched e.g. ControlCare Application A FOUNDATION fieldbus 1) Checking the
in when required. Designer, NI_FBUS Configurator, project is engineered offline cabling infrastructure
If the bus is extended by Delta V, etc. All blocks, i.e. with the tool provided by the Checking the cabling
the use of a repeater, then resource, transducer, I/O and control system, e.g. Application infrastructure should be one
the extension must also be control are accessible. Designer. This allows a network of your first troubleshooting
terminated at both ends. of virtual devices to be built steps. In addition to testing
Max. four repeaters are Device parametrization up and a control strategy to be the actual cabling, you should
allowable between a using a handheld created by linking the device also test the cabling of the
participant and the linking Field Xpert, FC375 or FC475 function blocks together. The equipotential bonding. An error
device (or H1 I/O card). can be used to configure device engineering tool is also used to in the equipotential bonding
resource, transducer and I/O parameterize the control blocks. can result in communication
Limitations on spurs blocks. The new configuration malfunctions. Since errors in
The cable between the T-box/ must always be uploaded to the During commissioning of the equipotential bonding are
junction box and the field controller (via the engineering the plant, the project is put very difficult to locate, you
device is called a spur. Spurs tool). For more information on online, and the actual devices should check all equipotential
longer than 1m (3.3ft) are Field Xpert, see page 107. in the plant are assigned to bonding connections.

The Endress+Hauser Maintenance Guide 105

2) Checking the connection Using a handheld (e.g. Field Measurement with a be derived from the signals
of FOUNDATION fieldbus Xpert or DXR375) or FieldCare, multimeter is one possibility displayed. You can also use
H1 slaves you can configure the tag, available for checking analyzers such as FieldConnex
The quality of the wiring should address and specific parameters FOUNDATION fieldbus wiring. from Pepperl+Fuchs, FBT6 etc.
be checked at the devices side of FOUNDATION fieldbus
and at the junction boxs side. devices from the field. In addition, the DC voltage In order to check the
As a FOUNDATION fieldbus After connection to the host on the FOUNDATION fieldbus FOUNDATION fieldbus signal,
H1 bus is not polarized (device network, this data must cable should also be measured. we recommend using a
dependent), communication be matched and uploaded This should be at least 9V and battery-powered oscilloscope
losses may be caused by to the controller using not more than 32V at each tuned on AC mode to
a short-circuit or a bad the engineering tool. station. A typical value for non- ensure that the grounding
shielding connection. hazardous installations is 19V. of the oscilloscope is not
5) Measurement For intrinsically safe (FISCO) disturbing the measurement.
3) Verifying bus terminators with a multimeter installations where there is an See details on fig. 11.
For the bus connection two With the multimeter it is explosion hazard, the value
types of errors can occur: possible to detect and analyze should not be more than 13.5V. See the FAQs at the
Too many terminators problems such as: end of this section.
are switched on. Interruption of one of 6) Oscilloscope measurements
One (or two) terminator the two data lines Oscilloscope measurements Re-engineering
is missing. Cable shielding interruption are very effective ways of
Short circuit between troubleshooting FOUNDATION
Our Projects teams can help you
4) FOUNDATION fieldbus the data lines fieldbus. With a little practice from the start of your revamping
station addresses Short circuit between the different statements about project. Please contact us.
There are dedicated data lines and the cable shield errors and signal quality can
address ranges set for the
FOUNDATION fieldbus stations:
Addresses 0 to15 are reserved. a) Ideal signal b) Defective bus terminator c) Signal affected by noise
Addresses 16 to 247 are
available for permanent
devices. Some host systems
may further subdivide
this range. This range
is typically shortened to
reduce cycle time.
Addresses 248 to 251 are
available for devices with
no permanent address Ideal form Ideal form (grey: terminator is missing, A: noise amplitude B: amplitude of affected signal
such as new devices or black : too many terminators)

decommissioned devices.
Fig. 11: FOUNDATION fieldbus H1
Addresses 252 to 255 are a) Ideal signal. Note: The signals
available for temporary amplitude may slightly differ
devices, such as handhelds. from one bus end to another.

b) Defective bus terminator

FOUNDATION fieldbus
stations are identified on the c) Signal affected by noise due
network through their: to: bad connection quality,
Tag name In practice In practice (terminator is missing) bad connection of shields,
static due to devices
Device ID (which is unique)
Bus address

106 The Endress+Hauser Maintenance Guide

Tools

Endress+Hauser service teams use tools that

have been designed for specific commissioning
and maintenance tasks. Commubox FXA195 and
FieldXpert are also available for maintenance teams.

Commubox FXA195

Field Xpert

The Commubox FXA195 HART/USB conversion

connects intrinsically safe Intrinsically safe interface
smart transmitters with HART for smart transmitters.
protocol to the USB port Converts HART protocols
of a personal computer. to USB signals.
This makes the remote Power is supplied
commissioning and operation via the USB port.
of the transmitters possible via Reactionless in accordance Profibus PA/DP
HART modem
Endress+Hausers operating with IEC 61508 for
program FieldCare. connection to 4-20mA
SIL2 loops.

Configuration/
parameterization
PROFIusb of HART devices
High performance
industrial PDA meeting
needs and requirements
4-20mA HART
of the process industry
Operates both inside
and outside of explosion
hazardous areas
Protection from static
electricity, water and dust
with shockproof housing
PROFIusb is a PROFIBUS PC PROFIBUS/USB conversion Device Xpert - Configuration
interface. PROFIusb gives you Converts PROFIBUS Software: Supports all
high performance access to protocols to USB signals. Fig. 12 registered HART devices
PROFIBUS, allowing you to Power is supplied via the Connectivity to WiFi,
perform such tasks as network USB port. Bluetooth, USB, InfraRed
configuration or device The bus line to which you MS Windows Mobile 5
parameterization in PROFIBUS connect PROFIusb is not operating system
systems. PROFIusb acts as a extended. You thereby avoid
PROFIBUS master class 1 or reflection-induced noise.
class 2 at all data transfer rates
up to 12Mbits/s.

The Endress+Hauser Maintenance Guide 107

 Frequently asked questions

Profibus networks - Commissioning Instructions on how to adjust the parameters PV_SCALE and
OUT_SCALE in the function block can be taken from the device
How can I assign an address to a device? operating instructions.
With the exception of the analysis device Mypro, Note: we recommend that you use FieldCare for this adjustment.
all Endress+Hauser devices have an address switch
that allows hardware or software addressing. Profibus networks - Data transmission
Software address changes can be made via the PROFIdtmDPV1
CommDTM of FieldCare, the DPV1-DDE server of Commuwin II or How is data transferred to the PLC?
any other PROFIBUS operating tool. See also Chapter 6.6 of BA034S. The measured values are transmitted in 5 byte long data blocks.
4 bytes are used to transmit the measured value. The fifth
Where is the device termination switch? byte contains standardized status information. Error codes for
PROFIBUS PA: Endress+Hauser device faults, e.g. E 641, are not transmitted
There is no termination switch on the device itself. with the status.
The bus is terminated by using a separate terminator or a For limit switches, the information is transmitted in two bytes:
T-piece/junction box with a switchable terminating element. signal condition and status information.
PROFIBUS DP:
Termination switches are located in the devices. We recommend How can the PLC switch on the positive zero return of the
the use of PROFIBUS connectors with integrated terminators Promag 53?
(in cabinet). If you use the termination of the plugs, the Via the output word of the cyclic services.
termination of the segment is lost as soon as you unplug them.
The best way would be to use external terminations, as in How can the totalizer of the Promag 53 / Promass 83 be reset?
here the plugs are usually not pulled. The same is valid for Via the output word of the cyclic services for the totalizer in
terminations inside of the devices. If the device gets damaged or question, see corresponding operating manual.
replaced, the termination is gone at least for this timeframe.
How can I suppress a measured value in cyclic communication?
When a device is added to the bus, the segment fails. By using the placeholder EMPTY_MODULE or FREE_PLACE
If too many devices are connected to the bus, the segment can fail. during configuration. Note: You have to set the EMPTY_MODULE
The segment coupler supplies a defined maximum output current placeholders in the hardware configuration to keep the order of the
to the segment. Every device requires a particular basic current (see slots. Some systems may not work if this is not set correctly.
Chapter 5.3 of BA034S). If the sum of the basic currents exceeds
the output current of the coupler, the bus becomes unstable. How can I write a value to the local display?
Field communication

Diagnosis: Measure the voltage at the device farthest from the By using the Display_Value model from the GSD (if supported).
segment coupler (should be > 9V DC). General note: You can refer to Chapters 7.2 and 7.3 of BA034S
Remedy: Reduce the electrical load on the segment concerned, (Profibus) for more details.
i.e. one or more devices must be disconnected.
Profibus networks - Using FieldCare
PROFIBUS PA slave with address 2 cannot be found.
If a Siemens DP/PA-link Type IM 153/157 is used, the internal FieldCare cannot open connection to the PROFIBUS PA
address must be taken into consideration. On the PROFIBUS PA devices
side, the link has the fixed internal address 2. For this reason, the FieldCare is a Class 2 master that allows the transmission of
addresses 1 and 2 may not be assigned to any of the PROFIBUS acyclic values. The PROFIBUS-DP baud rate to be set depends
PA slaves connected to the link. upon the segment coupler used. FieldCare is synchronized with
Two devices (slave or master) have the same address. Disconnect the PLCs parameters.
the slave with address 2 from the bus and check whether there
are others on the bus with the same address (e.g. with FieldCare). The connection to the devices can not be opened.
Readdress as appropriate. Check the settings of the PROFIBUS If the PLC and FieldCare are used in parallel, the bus parameters
master as to whether the address 2 has been allocated twice. must be mutually compatible. The bus parameters must be
identical for all connected masters.
Profibus networks - PLC planning If FieldCare is used, the Token Rotation Time (TTR) calculated by
the PLC configuration tool must be increased by 20,000 bit times
The measured value in Siemens S7 PLCs is always zero and the corresponding value entered in the FieldCare Profibus
The function module SFC 14 must be used. The SFC 14 ensures configuration and in the PLC.
that for e.g. 5 bytes can be consistently loaded into the SPS. If the The HSA parameter (Highest Station Address) must permit
SFC 14 is not used, only 4 bytes can be consistently loaded into the FieldCare address. The HSA specifies the highest address
the Siemens S7. permitted for active participants (masters) on the bus. Slaves can
Newer versions of the S7 series can access the I/O buffer directly. have a higher address.
The SFC 14 is no longer required. Is the FieldCare address free or is it being used by another device?
Check that cyclic communication to the device is active. Have the drivers and cards been correctly installed? Is the green
LED on the TAP of the Proficard or PROFIusb lit?
The measured value at the device display is not the same as
that of the PLC. A device does not appear in the live list.
The parameters PV_SCALE and OUT_SCALE are not set correctly. Device is not connected to segment.
OUT_SCALE_Min. = PV-Min. Address used twice.
OUT_SCALE_Max. = PV-Max.

108 The Endress+Hauser Maintenance Guide

Device cannot be fully operated. the ControlCare SFC162 controller (as visitor). For the older
The device version is not supported by FieldCare. An appropriate generation, the envelope curve can only be read out through the
DTM is necessary. The default parameters of the PROFIBUS PA Service interface.
profile are offered.
I cannot access HistoRom data via the FF interface.
HistoRom data can only be read out with FieldCare through the
Service interface.
FOUNDATION fieldbus networks - Technology
How to replace a device?
Where can I find the DDs? Use pre-defined routines in the DCS or use FieldCare and the DCS
DDs can be found at www.fieldbus.org, www.endress.com or the database reconciliation (Delta V) or DCS database equalization
specific DCS vendors website. (To be recommended, as the DD files (Yokogawa).
can differ slightly. The DD from the DCS vendor has been tested and
approved by that vendor for use in a particular version of the DCS. Can I replace a device without touching the DCS?
Additional DCS specific drivers may be required.) No. You have to set a tag and make a download with the DCS.
In the DCS from Emerson, there is the possibility for an automatic
A DD from www.fieldbus.org or www.endress.com cannot replacement.
be installed in the DCS.
Use the DD from the DCS vendors website. Can I replace a device with a device with a higher
device revision?
The backup LAS function cannot be activated in DeltaV. In general, yes, but manual work is needed.
Download the DD from www.easydeltav.com
FOUNDATION fieldbus networks - Troubleshooting
Can I integrate any Endress+Hauser device into any DCS?
Yes for the major DCSs! However, there are specific commissioning The transducer block cannot be set to AUTO.
issues (e.g. preconfiguration) with every DCS. Please ask for more Check the mode of the resource block (AUTO) and the settings in
information from Endress+Hauser for the DCS considered. the transducer block (Config. error).

I cant find any FF-specific parameters in the device manual. Analog input block can not be set to AUTO Mode.
FF-specific parameters are described in the following Check the scaling, linearization and channel settings (and units for
Endress+Hauser manual: BA013S/04/en DeltaV). It could be that this block is not included in the schedule.

Field communication
FOUNDATION fieldbus networks - In work My device is not working properly. In the transducer block
Ican only see Block Error. Maintenance Needed.
The parameters are not displayed very well. I cannot interpret Look for the parameters Actual Error and Last Actual Error.
the meaning of the parameters. These parameters can be found in the diagnostic transducer block.
If available, install specific PAM Tool drivers and applications e.g.
Emerson AMS drivers or Yokogawa PRM Device Viewer Files. Communication between the device and the DCS doesnt
seem stable. What should I do?
I cannot find all the parameters for a basic set-up. Where can Find out if the FF communication is OK (termination, signal quality,
I find them? lost pass token telegrams) or if the device was set up incorrectly
In the transducer block. The easiest way is to use Methods. Methods (e.g. bad PV status because of bad echoes on a level device).
contains automated procedures for set-up, diagnostics, etc.
Can you recommend any diagnostic tools?
I cannot find the envelope curve module in the DD or device Several tools are available. There are software oscilloscopes, test
online via the FF interface. handhelds and diagnostic modules. Check with Endress+Hauser for
For the new generation of devices, the envelope curve can more information.
be read out with FieldCare through the Service interface or

The Endress+Hauser Maintenance Guide 109

110 The Endress+Hauser Maintenance Guide
 At your service
Experienced and qualified people
whatever the level of support

Contents

Our services 112

Project services 113
Maintenance
Repair and Operation
(MRO) services 122

The Endress+Hauser Maintenance Guide 111

At your service

Services throughout your plants life cycle

Endress+Hausers life cycle approach to service means that were As your long-term partner, we pride ourselves in taking an active
with you every step of the way: from initial project preparation part in your success - read on to discover how our complete service
in the engineering phase right through to effective maintenance portfolio will help you achieve your goals.
practices during the MRO phase.

MRO Maintenance Repair & Operation

Training Maintenance and calibration consulting

p. 120 p. 124

Calibration and maintenance

Device commissioning management agreement
p. 118 p. 126

Efficiently manage your assets

Preparing smooth transition p. 129
to the operational phase
p. 116 Calibration services
p. 132

Commissioning site Maintenance services

management p. 134
p. 114
Support services
p. 136
PROJECTS

112 The Endress+Hauser Maintenance Guide

Project services

At your service
Starting production on time
to quickly meet your goals

The Endress+Hauser project team has four main goals:

1. Execute commissioning as efficiently as possible
2. Deliver quality workmanship
3. Provide professional documentation
4. Provide efficient knowledge transfer

The key to any successful project is to have the right people

following the right plan. Understanding that every commissioning
project is unique in some way, an integral step in the process Having the right people on the job
is to define a commissioning strategy. The right strategy will Endress+Hauser has well trained, technically qualified
optimize the commissioning process while implementing a tools service engineers equipped with the right tools to
infrastructure that will allow you to maximize plant uptime and efficiently manage all of the challenges they will face
reduce maintenance costs over the lifecycle of your assets. throughout the project. For international projects,
Endress+Hauser has a global team of qualified people.
Poor handover on capital projects
has a lasting impact on new operations In addition, Endress+Hauser has experienced Site Project
One of the keys to a successful handover is having critical Managers that can manage the instrumentation from installation
documentation at your fingertips. The documentation is to start-up and optimization. This team will also help with staff
normally stored in a CMMS or a lifecycle management tool. training to manage the assets during the operational phase or
Endress+Hausers strategy is to take advantage of the work that is assist with a strategy where Endress+Hauser takes on partial
done during the commissioning phase and efficiently use it to create or full responsibility for management of your installed base.
a package that will become the documentation cornerstone for the
maintenance and operations group. Our solution is effective as a Endress+Hauser commissioning teams have access to
stand-alone or can be easily integrated into your IT landscape. our strong internal technical resources to quickly resolve
any issues on site and links to our worldwide network
and databases for instrumentation and controls.

Proven results

Production starts on time at Connacher Commissioning management for ArcelorMittal All under control at the Aitik mine
Endress+Hauser has been highly responsive Above all, what counts in the relationship with Besides Endress+Hausers own instruments,
from the quoting of equipment through to Endress+Hauser is the human quality. We need 3,000 products made by third party manufacturers
commissioning and start-up. The staff has been solutions and not people who simply pass the have also been included in the W@M Portal. This
helpful, knowledgeable and supportive buck, blaming problems on other people helps us to keep engineering under control
Dean Bannister, Instrument Technologist Mr Divol, Project Manager at ArcelorMittal Michael Sirkka, Technician at Aitik Mine,
atAMEC BDR, Canada Fos-sur-Mer, France New Boliden, Sweden

The Endress+Hauser Maintenance Guide 113

 Commissioning site management
At your service

Achieving efficient plant commissioning while minimizing costs

Starting production on time and meeting operational targets value added service that will help to achieve overall project
is essential. Therefore a competency is required to manage targets including saving both time and money.
and control the plant commissioning phases, providing a

Typical commissioning and operational challenges

Realizing start-up timing objectives
Compliance to Health & Safety, environmental
and quality standards
Ensure optimum performance of the
production process from the start
Lack of resources and inadequacy of
instrumentation/solution knowledge
Meet project budget expectations
Seamless transition into plant operational phase

How does Endress+Hauser meet these requirements?

We engage the right level of expertise at the right time to meet
project deliverables. Our on-site resource is strongly linked and
has access to the Endress+Hauser organization to ensure all issues
on site are resolved quickly and effectively. The site manager
coordinates with all other contractors and provides status reports
on commissioning progress. All commissioning and instrumentation
documentation is coordinated for a seamless transition and
handover to the plant operational staff at time of start-up. Commissioning Project Group

Typical project scope for plant commissioning and start-up site

management includes managing the full I/O for instruments, Off-site Repair Technicians Off-site Support Administration
digital points and third party devices. This service can also include
management of installation (mechanical and electrical), training,
system commissioning, logistics, technical support and any other Off-site Product Specials Off-site Global Support Network
relevant requirements linked to commissioning.

Working closely with you we will: Project Lead

Look for ways to speed up the commissioning process
Propose ways to avoid project delays
Define QA/QC processes Calibration Engineers Commissioning Engineers
Define the scope of supply
Define a life cycle management strategy
Define project and maintenance documentation Support Technicians
Identify all required tooling Tubing/Piping
Manage and control project commissioning issues

Coordination & Reporting Our commissioning team will consist of project leads for on-site management,
The Endress+Hauser commissioning team will coordinate with service engineers & calibration engineers for commissioning at site and additional
support from the head office for administration and technical issues, including
all the project groups to enable the most efficient transfer of our vast network of instrumentation and control specialists worldwide.
information for commissioning activities. The Endress+Hauser
commissioning staff will report to the project lead on-site, and
our commissioning site manager will handle all reporting and
scheduling activities for the group. The commissioning site manager
will liaise with the other site contractors and project manager(s)
to facilitate commissioning timelines and issue resolution with the
other stakeholders.

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Commissioning site management involves a lot of documentation: W@M - Life Cycle Management enables project data structuring.

The complete package... Your benefits

Endress+Hauser will strive to provide EPCs and end users with Safe, efficient and effective management
a commissioning documentation package that meets or exceeds of the commissioning process
expectations. The commissioning turnover package for the project Consistent on-site presence with access to key resources to
will contain the basic data required for the optimal operation meet project commissioning quality, budget and timing targets
and management of the plants instrumentation and controls Shared responsibility for project risk
infrastructure. The turnover package will include the following Partner that has strong motivation to ensure instrumentation
documents: is commissioned optimally for operation over its entire life cycle
1. As-left device settings Coordination of training and documentation
2. As-built loop drawings for a seamless handover to the operational staff
3. As-built P&IDs
4. Original and/or on-site calibration and verification certificates
5. Additional documents as required for the IQ/OQ protocol Discover how to speed up your commissioning
project while achieving a smooth transition
for smooth transition to the operations phase to the operational phase
Endress+Hausers W@M Portal or W@MEnterprise is
our documentation solution. This format allows for greater
detail and access to all device information, e.g. manuals,
commissioning parameters, spare part information, service/
troubleshooting information, technical information, etc. Device Pre-Comm
Order Startup,
Installation (Instruments,
Review & WP Calibration Optimization, Handover
(Electrical & System,
The flexibility of the W@M Portal allows for the plants criticality Project Plan
Mechanical) Solution)
SAT

matrix to be defined during the commissioning phase and for

operations staff to have access all the manufacture information for Initial Asset Database Setup

Endress+Hauser devices and imported information for all third party Infrastructure Management

devices. Whats more, W@M has the ability to interface with other Project Management

CMMS software or software related to plant maintenance activities. Resource Management (+Training)

Document & Record Management

Commercial Management

Time Registration

Change Management

HSE Management

Tool Management

Spares Management

Risk Management

Project commissioning with W@M Life Cycle Management

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At your service

Speed up your commissioning project

while achieving a smooth transition to the operational phase
with Endress+Hausers Plant Asset Management platform

Commissioning the
instrumentation and electrical
components in a large project
can be a daunting task if
a well-defined process is
not established. One often Endress+Hausers Plant
over-looked aspect of this Asset Management solutions
process is to ensure all the use a combination of tools
necessary documentation is to support commissioning
in place for the operational workflows to not only correctly
staff at start-up. In addition to configure and calibrate the
potential start-up delays related instrumentation but also to
to missing and inaccessible seamlessly link this information
documents, the task to collect with other instrument-relevant
this data in the operational documentation in one platform
phase is much more costly, that is easily accessible for Configuration/parameterization of field devices
incomplete and inaccurate. customers and their systems. As many commissioning and maintenance actions require direct
intervention at the measuring point, Endress+Hauser uses handheld
Here is a typical use case tools, amongst others a Personal Digital Assistant (PDA), to increase
example to speed up your productivity and improve the quality of the data collection. After the
commissioning project: reception of the instruments list from engineering, this mobile tool
serves as an asset collection tool to easily organize and populate all
the assets and related data according to the plant topology.

This offers the opportunity to shorten data entry time not

only to save money, but to speed up the entire process of plant
commissioning and start-up. Project quality is therefore ensured
through standardized data collection and storage, providing accurate
documentation for quality control audits at any time. The information
once organized is then used to efficiently plan the work to be
completed in FieldCare which allows managing configuration of all
registered HART and/or FOUNDATION Fieldbus devices.

TOOLS
116 PLATFORM The Endress+Hauser Maintenance Guide
Storage of device data for future

At your service
optimized preventive maintenance
Once all the devices are set up with the FieldCare
configuration and asset management tool, configurable and
printable reports of device settings, plant configuration, loop
checks are generated and stored under the device tag.

By using status information and initiating regular

communication with the monitored devices and checking
device diagnosis and performance information, FieldCare
optimizes maintenance tasks offering clear diagnostic
information for fast reaction to any problems.

Centralized access to all life cycle

device information facilitates maintenance
Operators and maintenance technicians need to have complete,
accurate, comprehensive and timely information about their
physical assets in order to use them effectively and safely during
the operations phase. The device information produced during
the commissioning phase by using FieldCare is stored in the
W@MPortal or W@M Enterprise application, providing a historical
record of device settings. Thus, the W@M data for a specific
instrument can be displayed by simply clicking on the instrument
node in FieldCare. The configured device data is available over the
entire life cycle, which helps to optimize further device replacement
during the operations phase.

This information can be integrated into your CMMS system and

Endress+Hausers CompuCal calibration management system so
that all life cycle asset information is accessible in one place.

W@M allows archiving of all device data and documentation:

hook-up diagrams, installation and commissioning reports,
calibration certificates, P&ID, electrical connection diagrams,
IQ/OQ documentations, operating manuals, etc can be
easily added to W@M during the commissioning process
to streamline the transition to the operational phase.

Further information on W@M Life Cycle Management and

FieldCare at:
www.automation.endress.com/asset-management

Jmtkraft reduces costs of ownership

With the tree structure in FieldCare, finding the right
instrument is easy. And the Key Performance Indicators in
the W@MPortal show us exactly where we should focus our
maintenance efforts
Anders Gjerstad,
Instruments Manager at Jmtkraft

TOOLS
The Endress+Hauser Maintenance Guide
PLATFORM 117
 Device commissioning
At your service

Getting your process up and running - on time and on budget!

Correct commissioning of process instrumentation is maintenance staff higher than ever before, time, human
of paramount importance for optimum performance. resource and specific skills become critical factors when a
Whats more, with the demands on your engineering and project is nearing completion.

Device commissioning typically includes a check of the installation

and mounting and cabling of your installed instrument. We power
up the instrument, perform its complete configuration and give the
users all the necessary training to achieve optimum operation. Finally,
everything is documented in a detailed report.

Commissioning packages offer cost-effective solutions to all cases:

Standard commissioning is the ideal start-up solution for

instruments with common features and functionality in standard
applications:
Cost and time saving - Optimum set-up by qualified people
means less effort and potential reduction of time loss for your
teams.
Efficient transfer of knowledge - On-site instruction during
commissioning is a quick and practical method to pass on
information on how to set-up and operate instrumentation.
Extended warranty - Choose Endress+Hauser to commission
your instruments and open the door to extended warranty!

Extended commissioning is the best start-up solution for Competence ensures success
sophisticated instruments in complex applications and/or with With more than 50 years experience in process instrumentation
additional documentation requirement: and a global team of experts at your disposal, you can rely on us for
Peace of mind - Optimization and confirmation of the all your commissioning needs.
performance of the measuring point in order to minimize
breakdown potential. Endress+Hauser service technicians perform the set-up of the
instruments according to defined Standard Operating Procedures
No investment needed - Provision of specific tools and
(SOP) this ensures constant performance quality whatever the
software provides traceable reference and ensures optimum
location and whatever the technician. They are trained to application-
performance and functionality.
specific regulatory requirements and are keen to share their
Conformity to the internal standards - Detailed reports and application know-how with your staff.
backup files for every device guarantee traceability.
Our teams use special tools designed to ensure quick and efficient
Advanced commissioning is the solution if a complete system commissioning of instruments and confirm the function of the
check from field to your control room is required: device through the delivery of standardized reports.
Totally reliable measurement results up to system
level - Complete multi-point check from sensor to the system Full traceability of certificates
ensures the correct signal integration into the system, including After Endress+Hauser has performed the commissioning service,
conformity statement. a full report is issued detailing equipment set-up and advising on
Loop validation included in the individual device report future maintenance requirements. The reports and documents are
and the backup files stored either on your server or on the Endress+Hausers servers
accessed via Internet on the W@M Portal. The documents are
Installation Qualification of your device - Experienced and available shortly after the job is performed.
qualified service engineers will support your requirements.

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Commissioning packages that meet your needs whatever the application

Standard Extended Advanced

Component
commissioning commissioning commissioning
Mounting/wiring check
Environmental conditions
Configuration
Output value check
On-site instruction
Provision of device set-up parameter files
Service report (i.e. MSE report)
Instrument conformity
Functional test
Device related extended report
Loop test
Device related advanced report
Instrument warranty extension Optional Optional Optional

Typical application Conventional continuous Complex measurements Instruments with digital

measuring points such as: or specific applications communication networks
Level such as: such as:
Flow Photometric analyzer FOUNDATION Fieldbus
Pressure Automated pH system PROFIBUS PA/DP
Temperature etc. Density measurement Ethernet
Concentration HART
measurement
Samplers
Tank linearization, etc.

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 Training
At your service

Mastering instrumentation and fieldbus networks

to maintain your competitive edge

People provide an essential contribution to your companys Endress+Hauser trainers put all of their expertise at your
overall performance. This is all the more true for people disposal, helping you to produce more, at a higher quality,
who are invested in production processes and maintenance. in a safe and profitable manner.

Training is essential to fulfill your commitments:

It allows you to get the best from your measurement devices and
thus optimize your investment.
Thanks to a better knowledge of the instrumentations behavior,
your technicians will be able to minimize downtime.
A better knowledge of appropriate maintenance methods will
contribute to make your assets durable.

We conduct training sessions to your needs and where it is most

convenient (at your site, in your local Endress+Hauser sales center or
in specialized tranining centers). Competent and totally equipped, our
trainers ensure an efficient knowlegde transfer to your teams.

Training sessions for commissioning and maintenance engineers

How do you improve or update your personnels skills in We provide training for: Training topics include:
process automation? With the continuous updates of the Engineers and technicians Theoretical and hands-on
production processes, many challenges are faced by your Plant operators knowledge
people, such as: Maintenance engineers Installaton advice
Selecting the most efficient device for your application New recruits, apprentices, Start-up and maintenance
by considering all required regulations and legislations refresher courses diagnostics
such as ATEX, SIL, FDA, IFS Troubleshooting tips
Maintaining and optimizing critical measurement points Practical exercises using a
Finding untapped opportunities to improve range of working instruments

Our specialists will provide your maintenance staff with the technical
product knowledge they require to run the plant efficiently and Your main benefits
cost-effectively. Get the best out of your equipments
Extend your assets life cycle through
Training is performed in-house or on-site. Your maintenance increased maintenance knowledge
personnel will benefit from professional, up-to-date and hands-on Reduce breakdown time thanks to qualified people
training, using a range of working instruments. Increase your personnels efficiency

The training programme will be pre-defined according to your For more information please contact your local sales center.
requirements and participants will receive supplementary
literature and a certificate of attendance.

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Fieldbus technology training Application Training Center

Endress+Hauser places great score on having trained fieldbus Offering consulting, services and complete automation solutions,
engineers and technicians. They are well prepared to offer you Endress+Hauser ensures that as the People for Process Automation,
advice and support on the implementation of fieldbus systems we have a real understanding of our customers applications.
at your plant and are also available to help with information on
specific fieldbus devices. To meet this requirement our Application Training Center
in Reinach, Switzerland. The sub processes of an industrial
The same support is also offered to you at our training center production are replicated and offer fully functional modules. This
in Reinach, Switzerland, at your local sales center or at your creates a very realistic training environment from the sensor up to
site. Courses are arranged by your local sales center and can be the control system.
customized to your specific requirements.
A mix of professional trainers and technicians with extensive
practical experience in the field guarantee up-to-date information
PROFIBUS training and high quality knowledge transfer.

PROFIBUS technology The training portfolio covers:

Basic Basics of process control
Advanced Basics of process automation
Professional Process automation: mixing, blending and CIP
Certified* PROFIBUS PA Engineer Plant Asset Management
Theory and practice on PROFIBUS PA Measurement technology and PAM in life sciences
Parts on PROFIBUS DP Energy monitoring
Final exam for certificate
For more information please contact your local sales center or visit
FOUNDATION Fieldbus training www.endress.com/atc

FOUNDATION Fieldbus technology

Basic
Advanced
Professional
Certified** FOUNDATION fieldbus Engineer
Theory and practice on FOUNDATION Fieldbus
Final exam for certificate

ach
Take a virtual tour of our fieldbus test and located in Rein
competence center System World in Reinach, Switzerland:
www.fieldbuslab.endress.com

*recognized by PROFIBUS International

**recognized by Fieldbus Foundation

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 MRO services
At your service

Maintenance Repair & Operation

Revealing the true sense

of partnership

How can we help you to perform your work in a more

convenient way? We can support you at three different levels
according to your needs:

With consulting services, looking at your situation with

fresh eyes, we provide our expertise to identify the areas of
improvements and to help you to take a step back and look at
things from a distance. We also bring you the recommendations
to manage and perform efficiently your maintenance and Due to increasing demands linked to quality industry standards
calibration activities. By collecting the relevant data, the (such as ISO 9002.4.10b, GAMP, IFS 5.0), customers within the
optimization services allow you to improve either your process industry are requesting that suppliers document their
maintenance business process or the manufacturing process. quality efforts from start to finish. With calibration being our core
competence for more than 50 years, we are in the best position to
If you consider outsourcing management activities, the define calibration cycles on quality critical measurement points.
relationship with Endress+Hauser can range from simple
supplier up to strategic partnership. A Service Agreement Where plant productivity is at stake, fast resolution to any
allows you to focus on your core activities and eliminate a smaller potential production downtime is required to minimize costs. Our
or larger part of these challenges by outsourcing well defined maintenance and support services are on hand to quickly diagnose,
tasks or even responsibilities. These can range from simple repair or even exchange a complete device to keep your processes
loop checks and instrument calibration right through to partial up and running!
functions of maintenance management.
Our objective is to sustainably generate outstanding value for our
Of course, we can offer a whole range of execution services based users. Our Added Value Services mostly use existing competences
on our maintenance and calibration competence. These services of the Endress+Hauser Group such as metrology, system and IT
have the objective to keep the original or promised performance know-how and excellent skilled people! We use our competence
of your application. to work on third party equipment as well as our own products.

Proven results

ALGAR accesses manufacturer-level information JAMTKRAFT makes sustainable investment One-stop shop saves time
Every time equipment-specific details are We need to use the tools available to make our and money at Coca-Cola Beverages
required, I realize how powerful and time-efficient work easier. This is why we have opted to invest in Endress+Hauser calibrates 66 measuring points from
this web-based portal is. The way this was a technology which makes us feel were very well a wide variety of manufacturers, some up to four
implemented was nothing short of effortless. equipped for the future. times a year We are very satisfied with the service.
Herve Laforest, Maintenance Coordinator Johan Storm, Maintenance System Manager Rolf Bieri, Executive Producer of Coca Cola
at the Algar plant (Connacher) at Jmtkraft in Brttisellen, Switzerland

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Our strengths at a glance
In-depth knowledge of instrumentation maintenance,
maintenance management and consulting capabilities Competence of the Staff behind the
for the best solution to the broader problem Services Worldwide in numbers
Qualified and motivated people, a robust organization,
a sustainable global partner More than 800 dedicated service staff
Innovative technologies for an efficient and seamless approach including 150 highly trained and qualified
(e.g. remote access and business process integration) calibration technicians around the world
A mature, well developed and globally available
metrological competence for reliable performance More than 19 ISO 17025 accreditations
Information provided through Endress+Hausers own in calibration (in laboratory or on-site)
web-based collaborative platform W@M (Web-enabled delivered by different accreditation bodies
Asset Management) reduces overhead costs (COFRAC, A2LA, SCS, DKD, EMA,...)
A standardized global approach for processes and tools
to perform our service portfolio with the same quality all More than 100,000 calibrations
over the world. This approach is supported by a service (on-site or laboratory) performed
management system that integrates all of our systems every year by our service centers
and processes into one complete framework, enabling
us to work as a single unit with unified objectives.

Heineken takes care of critical instrumentation Auditable documentation for Punica A maintenance strategy for the
With the W@M Portal, we are able to cross-check Auditors also pay more attention to verification instrumentation at Nestl Waters Supply Est
the criticality of our instruments versus their measures for individual measuring points. In this We now have a clear view of our installed base and
maintainability and to use this to determine suitable respect, much progress has been made in recent have implemented a relevant maintenance plan. We
maintenance strategies for each instrument. years in the calibration of measuring points. also reduced the number of types of sensors
Steve Sherborne, Maintenance Manager Dr. Birte Gerken, Quality Manager Mr Antoine, Methods Officer at Nestl Waters
at Heineken UK Limited, United Kingdom at Punica Getrnke GmbH, Germany Supply Est, France

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 Maintenance and calibration consulting
At your service

Auditing and analyzing your installed base of process instrumentation

Do you want to minimize your maintenance efforts, reduce Endress+Hausers maintenance and calibration expertise can
the complexity of your installed base and be supported in help you to achieve these objectives, and much more
terms of quality and safety requirements?

Your primary benefit is a clear view and status of your installed

Total cost
base. Thanks to the inventory, you get an exhaustive database
providing traceability for your installed instrumentation.
Target zone:
By involving your production, quality and maintenance Optimized relationship,
departments representatives, our consultant delivers you the minimum cost
keys for making the right decisions in terms of focusing your
maintenance and calibration efforts according to your available
resources and production requirements.

This service called Installed Base Audit reduces the complexity of No Too much
an older plant that includes different makes of equipment and large maintenance maintenance
variety of instrument types.
Degree of preventative maintenance
According to your needs, consulting services can help you to reach
various additional objectives: Finding the right balance
Our objective is to help you reach the optimum point where the
Reduction of spare parts stocks overall costs are at their minimum level. We understand that too little
maintenance and no back-up can result in costly downtime, but on
Competence analysis of your maintenance the other hand, too much maintenance is unnecessary and leads to
and metrology personnel additional expense.
Optimization of methods and intervals
for maintenance and calibration
Minimization of process downtime
Definition of a complete maintenance and calibration plan
with all master data to fill a plant asset management system.
Availability of extended documentation online,
including quality evidences for internal and external
audits, calibration certificates, people qualification, etc.
Get a clear proposal for a scheduled replacement
plan by providing order codes, pricing and
logisitical solutions for longer term etc.
Just tell us what you need!

Achieving efficient data management

Installed Base Audit gives you an access to the W@M Portal. The data
collected during the on-site inventory are presented here in a structured
format. The W@M Portal also includes additional information linked to
the serial number of the instrument.

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Towards a maintenance plan with Installed Base Audit

Step 1 - Collecting data in the plant

Equipped with a dedicated Personal Digital Instrument data (serial number, tag, order
Assistant, the Endress+Hauser audit technician code, manufacturer, type and model, location,
collects and records: age, measuring principle, process conditions)
Application data (pressure, temperature,
medium)

Step 2 - Revealing process critical instruments

During a meeting involving the production, and the maintainability of all your installed
quality and maintenance departments, our instrumentation. Each measuring point is
consultant asks the right questions in order then assigned with the criticality level
to define the critical measuring points (High, Medium, Low).

Step 3 - Highlighting potential improvements

Our consultant studies the data collected improvement recommendations regarding

during steps 1 and 2 and provides the the different areas of your maintenance
status report giving you an overview of the activities (preventive and corrective
status of your installed base with global maintenance, standardization, migration).

Step 4 - Analysis and recommendations

Based on the maintenance activities you decided He then defines the recommendations
to develop in the step 3, our consultant completes for maintenance improvements
a thorough study of the activities to improve.

Step 5 - Presentation of the results and action plan

Your Endress+Hauser consultant will present At the conclusion of step 5, we deliver

you with a detailed analysis and the the final Installed Base Report.
different options available for maintenance
optimization. This meeting leads to the
definition of an action plan.

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 Calibration and maintenance
At your service

management agreement
Discover the next level of maintenance

Relieve your calibration and maintenance headaches and trust us with the
management of your activities, freeing you up to focus on your core business -
with total peace of mind!

Plant managers seek to continuously

improve their operations competitiveness
Plant peroformance/availability

Continuous improvement
by improving productivity and flexibility
while maintaining regulatory compliance.
Therefore the demands on the maintenance Design
performance
of the plants automation system are rising.
Target availability/efciency
The management challenges include a
high degree of cost pressures, step-wise
tightening of regulations, a lack of skilled
people ready to work in a process plant
and the complexity of a multi-vendor Endless re-ghting
installed base with a mix of new and old
technologies. Project Operation

On top of that, the typical plant asset

management systems in place are often not
suited to the management of automation Outsourcing contributes Endress+Hauser has opted for this next
components: either they were installed to to your bottom line level where the focus is no longer only on
take care of complete assemblies and lack In order to better focus on their core maintaining but also on improving your
the crucial master data of the automation activities more and more companies try to maintenance/calibration and manufacturing
components or they dont support the achieve the outsourcing of maintenance processes. It is not just about cost savings
business processes required, such as and/or calibration function(s). If you are but also about contributing to your bottom
calibration management. in this position, you can select from two line. This outsourcing model is a unique
types of maintenance suppliers: those and strategic partnership where both
who concentrate solely on cost reduction, partners can also jointly commit on targeted
and those who take maintenance to the metrics achievable through a continuous
next level. Usually, next level means improvement program.
maintenance that improves sustainably and
continuously the operational equipment
effectiveness.

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At your service
entrusted to true specialists
When you choose a service level agreement, Endress+Hauser takes
over the full maintenance and/or calibration function of the field
instrumentation of your plant.

As your single point of contact, Endress+Hauser manages

multi-vendor support and subcontractors who maintain other
components of the control loops such as valves, drives or other
system components. By driving this function, Endress+Hauser
offers a maintenance/calibration program that turns routine
maintenance activities into a profit source by focusing on
maintenance costs optimization and quality improvement.

Once both partners have agreed on an effective and efficient

corrective and preventive maintenance program to optimize
the plants manufacturing operations, the maintenance team
uses standardized workflows to manage the maintenance and
calibration function, enabled by a planning and execution system.

A clear view of the activities Partnership for continuous improvement

This Plant Asset Management system allows transparency and This partnership development generally takes place when the
clarity of information about the activities that Endress+Hauser maintenance and the calibration management services are
team is performing on-site. If requested, the relevant data developed to set the strategy for maintenance and reliability
sources are integrated in your ERP system, for example to at the site. Due diligence is performed for finance, human
close your work orders or to enhance the accounting. resources (HR), health and safety, mutual responsibility (incl.
liability), technical issues, including any agreed performance
This data integration is the start to getting the complete picture objectives. The partnership agreement is signed prior to the
and the key to facilitate your decision-making process. The initiation of the implementation phase. During this phase,
connection between of your ERP to the W@M collaboration systems and networks are installed, the new maintenance
platform allows to share Key Performance Indicators (KPIs) and organization is announced and implementation plans are finalized
other key data, including up-to-date and complete information for HR, facilities, supply management and accounting.
on all your Endress+Hauser and other suppliers assets. The
Endress+Hauser contract manager is therefore able to continuously The maintenance agreement execution phase begins
identify, analyze and improve existing processes within the with start-up and training, and the introduction of any
maintenance organization to meet new goals and objectives. new processes. The management process governs the
relationship, and the introduction of continuous improvement
programs can help improve performance on site.

Via this performance-based partnership, we work with you to

achieve a common goal. The results are measurable in terms
of cost savings, performance improvements and higher quality.

Proven results

Heineken Netherlands subcontracts LyondellBasel outsources metrology activities

instrumentation workshop At its Marseille site, Endress+Hauser manages and
With the current performance of Endress+Hauser, performs 900 metrological interventions. Today,
there are a number of advantages that make it possible people at the production become conscious of the
for us to fully concentrate on our core business benefits of metrology
Ron Verweij, Maintennace Engineer at Heineken Mr Porta Y Santacreu, Metrology department
Den Bosch, The Netherlands coordinator in Marseille, France

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 Calibration management service
At your service

supported by a proven process

Step 1 - Kick-off meeting

In cooperation with the customer, the This allows optimization of calibration scheduling,
definition of the measuring points to be resulting in a reduction of downtime.
calibrated, the presentation of the tasks
and processes and the creation of the work
breakdown structure is carried out.

Step 2 - Perform calibration job

On-site calibration is performed by specialized and All around the world, Endress+Hauser service
highly trained staff. For you this means reliable engineers are trained and qualified to execute
advice, optimum instrument performance and calibrations in line with your quality requirements.
true cost-effectiveness. (See p. 132 Calibration services)

Step 3 - Analysis of calibration results

After calibration, results are gathered and analyzed, Out of the figures we provide advices to optimize
providing an overview of the job performed and calibration strategy in the plant.
qualification of metrological performance and
installed base health.

Step 4 - Documentation management

In addition to calibration certificates, All records are included such as master list, SOP,
a W@M Portal is created and populated. Calibration Masterplan report, qualifications,
accreditations

Step 5 - Review meeting

This meeting brings the opportunity to review the Improvements are documented in an action list
job performed, identify any weak spots and define and used for the next review meeting.
improvements for future.

Proven results

A comprehensive calibration strategy

guarantees that quality standards are met
Endress+Hauser offers utmost flexibility when
carrying out calibrations. Measures which are
decided upon can be implemented without delay.
Thomas Eggimann, Head of repair shop at GABA
International AG, Switzerland

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Efficient calibration and maintenance management
supported by suitable Plant Asset Management platform

The more that is known about your plants assets, the Depending on the scope of our partnership agreement,
easier it is to avoid expensive production shutdowns. the following use cases could be combined and
monitored to meet your performance objectives and
Preventive maintenance including calibration, i.e. regular to ultimately increase your competitiveness:
replacement of devices regardless of their condition can be
extremely expensive, while fail and replace strategies can lead to
unscheduled shut-downs, particularly if a component has been
phased out and there is no identical replacement. Within the
scope of a calibration and maintenance management agreement,
our Plant Asset Management Platform offers the ideal tools
to efficiently manage your assets while meeting your quality
requirements.

By monitoring the condition of critical plant components with

FieldCare, a predictive maintenance strategy can be evolved,
which helps extend their service life and reduces maintenance
costs. In addition, calibration is key to gain confidence that the
instrument measurement is accurate and within the limits you
need to produce a quality product. Nevertheless, calibration can
be a major cost factor if not managed properly. Requirements
for detailed and traceable records mean that much time can be
lost with inefficient manual paperwork processes. By managing Predict your maintenance
the calibration and maintenance activities with Compucal,
Endress+Hauser takes care to continuously fulfill the highest Predictive maintenance makes most sense where the failure
quality demands from your auditors, while reducing complexity, or malfunction of devices leads to unsafe conditions, loss of
time and associated costs. quality or a shutdown of the plant. Examples are overspill
protection of hazardous materials or devices with a control
Poor asset information management has a huge impact on function. The health of such measuring points must be
operating costs. Therefore timely, complete, consistent and continuously monitored, so that any tendency to failure
compliant asset and activity information about the performed can be countered before a critical situation develops.
activities is key to monitor progress and overall performance.
This may require that your plant asset management system be Condition Monitoring with NAMUR color-coded status
connected with the information sources of Endress+Hausers information and a valve diagnosis map help to quickly
Plant Asset Management platform. identify and resolve maintenance requirement. Viewable
from any work station via a web browser, the plant
overview allows quick localization of device alerts.

TOOLS
The Endress+Hauser Maintenance Guide
PLATFORM 129
 Efficient maintenance
At your service

and calibration management

Planning and scheduling Verify data and close

Select Due Routine from the work screen list. The work screen Prior to the data entry being closed, the calibration data entered is
displays the technicians current workload and provides easy verified by the supervisor.
access to technical information.

Issue calibration
Add additional tasks, assign reference instruments and issue the
work order. Issue scheduled or unplanned work orders
for instruments and loops for both calibration and maintenance
activities. Once the calibration is issued, the work order including
the relevant data is sent to the mobile reference tools used by our
technician.

Carry out the work

Carry out the work according to the Standard Operating
Procedure.
Streamline your processes
Maintenance organizations fail not because of the people
themselves but because the people lack the systems, process,
methodologies and disciplines to be successful. Operators and
maintenance technicians need to have complete, accurate,
comprehensive and timely information about their physical assets
in order to use them effectively and safely. In practice many loose
up to 70% of their day hunting for asset information. Information
management, therefore, is fundamental to improving performance.

Endress+Hausers W@M Life Cycle Management concept allows

users direct access to the equipment records of over 20 years
of instrument production. Simply by typing in the device serial
number you can access:
Common equipment record giving details of the device you
Automatic filling of calibration results have purchased
Once the work is performed, the calibration and maintenance data Automatic registration of all device events and related
is sent back to CompuCal. This is color-coded for easy recognition documentation to get its full history during its life cycle
of failures, e.g. yellow for re-adjustment (percentage of process Spare parts list for the device
tolerance) and red for deviations when errors exceed process Current availability of the a device with risk analysis and
tolerance values. Calibration results may be displayed immediately replacement strategy for phase-out products
in graphical form for checking. Certificates, operating manuals, device drawings etc.

TOOLS
130 PLATFORM The Endress+Hauser Maintenance Guide
 The KPI (key performance indicators)

At your service
dashboard in CompuCal enables
the quality manager to check the
calibration status at a glance.

and reduces the maintenance costs. It can also provide remote

access capabilities through a highly secure connection between
your business systems and ours, allowing our experts to provide
continuous support to maximize plant uptime and deliver
innovative support services.

Thanks to BPI, Endress+Hauser is able to integrate data into

Plant Asset Management, CMMS systems and ERP environments
enabling you to optimize your business processes by integrating
and sharing key data across various departments. W@M (Web-
enabled Asset Management) is used as the collaborative platform
to visualize and share Key Performance Indicators and other
Enrich your business systems relevant kind of information, including up-to-date, timely,
complete, consistent and compliant plant asset information.
through relevant data integration
Like business managers, plant managers demand real-time data
integration and visibility to execute critical business decisions. To
be successful, your organization must run its operations effectively
and efficiently which requires the ability to analyze operational
performance. If you cant see how youre performing, how do you
know you are making the right business decisions? You need to be
certain that you can take appropriate actions to build upon your
successes, initiate any corrective measures, and effectively plan
Endress+Hauser officially collaborates with SAP AG in Dresden, Germany,
proactive actions for the future. helping to foster research and development in the process industry
Endress+Hauser and SAP are working together to facilitate information exchange,
It is why integrating data, connecting information and people helping to make the information more valuable to our customers, for example
through efficient technologies to business processes are today an through condition monitoring and predictive maintenance.
important business strategy to ensure a smooth and seamless plant One of our major goals is to overcome the typical limitations of the automation
workflow. pyramid model data confinement and complexity to map and access all
relevant asset information in the plant. We would like to achieve it via open,
Endress+Hauser offers a range of services to enrich your business scalable, lean and secure process automation and IT platforms and prove that
real-time asset data with transaction information may be merged and transformed
systems with integration of relevant information. The Business in more than one place, in fact wherever it makes sense, and make information
Process Integration (BPI) approach enables the transfer of accessible whenever it is needed.
information between different IT platforms, as it is common to use
different business systems these days.

It connects the systems to make it easy to retrieve relevant Further information on W@M Life Cycle Management,
information and critical data when required. It improves the FieldCare and CompuCal at:
business performance regarding to quality, safety and reliability www.automation.endress.com/asset-management

Proven results

Kolb saves time The single source for inventory control, Information technologies are vital
with W@M-Ultimo integration calibration and documentation to correctly manage assets
The link between Ultimo and W@MPortal The W@M portal will act as a centralized Endress+Hausers highly experienced and certified
saves us a lot of time. We see this immediately, measuring device database for follow-up audits. calibration and maintenance people combined with
both in finding information and in The database basically maintains itself the innovative Plant Asset Management system bring
management of all asset information worldwide maximum value to our customers.
Thorsten Woyand, Coordinator Technical Support
Jorn Mulders, Instrumentation Technician at Punica Getrnke GmbH, Germany Stefan Schulze - Endress+Hauser
at Kolb Netherlands Product manager Tools and Software

TOOLS
The Endress+Hauser Maintenance Guide
PLATFORM 131
 Calibration services
At your service

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, high quality, testing through to fully accredited factory calibration. We
traceable and accredited? Do you need clear and concise calibrate your equipment at just the right time to ensure
calibration certificates? optimal process performance at minimum cost.

Endress+Hauser performs instrument calibrations across a variety

of measuring principles. We even extend our calibration service to
third party equipment to reduce time, effort and cost in terms of
coordination and documentation.

Accredited facilities
Thanks to accredited laboratories installed in our factories and our
service organization, we can offer the accredited calibration of:
Flow: SCS (CH) + A2LA (US)+ ASNITE (J) + CNAS (CN)
+ EMA (MX) accreditation
Pressure: DKD (DE) + SCS (CH) accreditation
Temperature: SIT (I) + COFRAC (F) + DKD (DE) + SCS (CH)
accreditation
Humidity: COFRAC (F) accreditation
Voltage, current: COFRAC (F) accreditation

On-site calibration
Having also invested in mobile reference tools and in the
deployment of a powerful service organization in many countries,
Endress+Hauser can also perform on-site calibration of the Parameter Equipment type Calibration location
following parameters:
On-site Laboratory
Flow Weight Speed
Pressure Density Conductivity Resistance thermometer
Temperature Time Voltage, current Probe + temperature
Temperature transmitter
pH Length
Probe + display

Please contact your local sales center to discuss specific requests.

Manometers
Pressure Pressure sensors
Pressure transmitters

Electromagnetic
flowmeters
Vortex flowmeters
Flow Coriolis flowmeters
Ultrasonic flowmeters
Thermal flowmeters
Mechanical flowmeters

Conductivity measuring
Conductivity chain including cell,
transmitter and cable

pH measuring chain
pH including cell, transmitter
and cable

Other On request, we can calibrate other parameters. Please contact

parameters your local Endress+Hauser sales center for further information.

132 The Endress+Hauser Maintenance Guide

 Calibration specification

At your service
Endress+Hauser will help you to establish your

1 metrology plan by fixing your calibration specifications

per parameter (maximum permissible errors, 1
Calibration
SOPs
2
Test
periodicities) or by defining the right reference tools Calibration Equipment
according to their uncertainty. specification

Together, we will work out which parameters have to

be calibrated on site and, in the case of high accuracy
3
requirements, which need calibrating in the laboratory. 7 Circle of quality
calibration Trained
Calibration Employees
software
Calibration SOPs
We offer a full range of Standard Operating Procedures 4
2 to support our on-site work. SOPs ensure that our work
is repeatable all over the world. We also provide site-
specific SOPs noting which measuring parameters have
6 Calibration
Documentation
5
Calibration
Work

to be calibrated on-site and in case of high acccuracy

requirements, which need calibrating in the laboratory.

Test equipment Calibration work

Local service centers provide a one-stop calibration and All of our primary calibration facilities operate and

3 repair service to a wide range of test, measurement and

process control instrumentation. So whether you need
pressure, analytical, temperature or flow calibration, 5
are accredited to ISO17025 and are located around
the world. We own and operate more calibration
laboratories than any other instrumentation supplier.
look no further. As a leading supplier of field instrumentation we not only
All of our facilities are traceable to national and can calibrate but also quickly and efficiently adjust, repair
international standards. This means you are guaranteed or replace equipment that is failing to meet the specified
the highest level of service compliant with the criteria. Our specialists have the necessary skills and
ISO17025 standard. equipment to calibrate all makes of instruments.

Calibration documentation
Trained employees
We support our service with certified and traceable
On-site calibration is performed by specialist, highly

4 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
6 documentation.
A calibration certificate compliant with the ISO17025
standard is issued. It details all required data in form
that is easy to understand. Importantly, it also satisfies
means reliable advice, optimum performance of your
all relevant authorities.
instruments and true cost-effectiveness. Our service
engineers are trained in accordance to GMP and we can
offer full validation services if required.
Calibration management software
Compucal is a high performance scheduling

7 and electronic software tool that helps

to control the scheduling activity around
your installed base, providing traceable and
auditable records.

Proven results

One-stop shop saves time Gerolsteiner puts its trust in the manufacturer Auditable documentation for Punica
and money at Coca-Cola Beverages Endress+Hausers calibration service is defined by Auditors also pay more attention to verification
Endress+Hauser calibrates 66 measuring points from the high level of professionalism and expertise. These measures for individual measuring points. In this
a wide variety of manufacturers, some up to four strengths are very much in evidence throughout the respect, much progress has been made in recent
times a year We are very satisfied with the service. entire service capabilities of Endress+Hauser years in the calibration of measuring points.
Rolf Bieri, Executive Producer of Coca Cola Guido Moll, Coordinator Calibration Management Dr. Birte Gerken, Quality Manager
in Brttisellen, Switzerland at Gerolsteiner Brunner at Punica Getrnke GmbH, Germany

The Endress+Hauser Maintenance Guide 133

 Maintenance services
At your service

Evidence of total support

It would be nonsense to offer you a whole range of value Total support from Endress+Hauser means that we strive to
added services if we werent able to sustain you in case of prevent any breakdown caused by process instrumentation
trouble or emergency! and, if need be, minimize downtime through quick diagnosis
and prompt repair.

Technical support
Within the scope of the technical support, we offer for
our products, softwares and solutions a broad
spectrum of services tailored to your needs. Our technical
support specialists advise and support you if you have
any questions concerning functions, handling and
application of our assets installed in your plant.

You will benefit from:

Easier and quicker diagnosis
Reduction of carbon footprint by avoiding an on-site vist
Recommendations for products and software installation
Advice on the regular maintenance of our equipment

A dedicated phone line and a system that records your

calls ensures reliability, traceability and efficiency.

Preferential processing of urgent cases, availability outside

working hours, support via remote diagnosis can also be
proposed within the framework of an agreement.

For more information on our remote capability, see p. 128.

Returning material
On-site diagnosis and repair
Our team of dedicated troubleshooters are always on
hand for situations of breakdown and on-site repair.
At their disposal are special tools that help them
provide fast and efficient diagnosis and repair.

Within the scope of a service level agreement, we offer Ensure safe and secure return of instruments from the outset
call-out times dependent upon your level of urgency. Typically for repairs, laboratory calibrations or wrong orders/deliveries you will
need to return your instrument(s) to us.

Workshop services
Because we value your time and strive to minimize possible downtime, we
provide guidance to ensure that your request is registered and processed as soon
as possible, sometimes even before we physically receive your return.
Sending back an instrument to our workshop is an opportunity to In order to guarantee that your returned device is proactively taken into
benefit from various services such as technical checks, preventive consideration and handled according to safety standards, you might have to
maintenance, repair followed by functional or even metrological provide important information such as safety statement certificate for example.
tests and laboratory calibration.
The requirements for safe returns may differ according to device type or country
legislation.
Our goal is to have your instrument returned to you within five
working days after the receipt date in our workshop. If the standard You will find detailed information at www.services.endress.com/return-material
turnaround time is not acceptable, we can propose an or you can call our technical support for more information.
emergency service in the scope of a service level agreement.

134 The Endress+Hauser Maintenance Guide

 At your service
Preventive maintenance

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

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. This parts in the event of equipment these with a tailor-made service
regulatory requirements. covers any call-out 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 a scheduled package of services
(SOP) can be combined with costs for new instruments within a predefined quick and guarantee we meet all your
annual replacement of worn under contract agreement will response time. maintenance needs and provide
parts or consumables, telephone be covered by Endress+Hauser. a bespoke service solution.
support during non-opening Your additional benefits For example, this kind of
hours. An independent report Your additional benefits Commissioning spares contract can include calibration
confirms the instruments Reliable back-up and call-out covered activites, remote services,
performance and reliability. instrument operation Complete control of your maintenance of software
between preventive maintenance budget updates etc.
Your benefits maintenance visits
The necessary maintenance Any pre-arranged extra visits Your additional benefits
tasks to ensure an optimal for the commissioning of Endress+Hauser support
instrument performance newly contracted equipment services perfectly complement
The delivery of documented are included in the costs your internal resources.
reports to ensure you comply
to audited quality procedures

The Endress+Hauser Maintenance Guide 135

 Support services
At your service

Keep your application up-to-date and running at optimum

Reliable, up-to-date application is a critical part of your Instead of focusing on our core business, we get distracted with
process. Is yours getting the attention it deserves? trying to solve IT problems that should ideally be resolved by
We have all been confronted with software-related system problems experts. The solution? Entrusting Endress+Hauser with the support
- and all experienced how it can completely cripple our processes. of your software and hosted applications.

Rapid and professional

To get the most out of your Endress+Hauser application, simply
choose the level of support you need. All our packages include
professional service and software updates:

Software Update Support Service: the ideal way to keep your

software solutions continually up-to-date.
Application Support Service: a wider scope of support for your
application with your choice of appropriate response time.

Your benefits with Endress+Hauser

Our support services will:
Reduce your operating costs and increase your efficiency
Achieve a quick return on your investment through support
and regular software updates
Minimize the time and effort involved in solving
your application issues
Minimize your risk of process interruption

Endress+Hausers vast product expertise can help your organization The information below provides food for thought when considering
to quickly resolve even the most complex application-related issues a support service that will guarantee that the newest hardware is
and thereby keep operations functioning efficiently. integrated, all available operating systems are supported and that
your application can still be supported. What you get is direct access
to competent support when you need it.

A typical crisis scenario Constantly up-to-date software Tailor-made support

The four-year-old PC on which your preferred The latest software helps you to commission new Your personal guide through todays technology
PAM software was running crashes what now? instruments! Having the latest software drivers jungle! Regardless of the infrastructure system
Can you still find the same PC hardware? Probably (DTMs) for your Endress+Hauser devices running components you connect through, our support
not. What about your operating system? Try finding in FieldCare can help you commission the device service provides the necessary information to
a PC running Windows XP when Windows 7 is as fast as possible. The result is a faster start-up establish a successful connection to your intelligent
todays standard! time for your process and, in turn, your plant. components, for e.g. the correct bus parameters of a
PROFIBUS topology or the configuration setting of a
The settings you were using were probably based We deliver the latest driver packages as soon as remote I/O driver during setting up a project within
on a serial interface. Can you switch it to the they are released. Simply insert the DVD you FieldCare.Our support service could also help if your
current standard USB interface or even imagine receive as part of our support service for FieldCare automation infrastructure prompts you to access the
having it with Bluetooth or wireless technologies? and update the existing driver library with the new HART or PROFIBUS information vertically through
DTM package. the corresponding system components.

136 The Endress+Hauser Maintenance Guide

 At your service
Get the most out of your system and processes
with Endress+Hauser solutions

Software Update Support Service - what does this cover? Application Support Service
Following the initial release of a major software version, a software Application Support Service includes all the features of the Update
update is developed to enhance, modify or fix any minor issues Support Service plus technical support for usage and configuration
associated with the initial release. Endress+Hausers Update Support for your application.
Service ensures that you always get the latest update of your software.

With FieldCare software for example, the update includes new With our Application Support Service, you get a rapid response to
frames and DTM updates. By having the latest DTM update, any questions you may have related to your FieldCare software such
you minimize the risk of a process interruption during device as how to handle projects, how to create device documentation and
configuration. Moreover, phone and email support is provided for even how to link to the W@M database and to establish a W@M
update-related information. connection. Better still, you can also choose the response time that
best fits your requirements (see table below).

Software Update Application

Features
Support Service Support Service
Applicable for Software Solution

Software update (if applicable)

Support by phone and/or email

Support availability 8 hours a day, 5 days a week

Guaranteed response time Within 1 working day Within 1 hour*

Support availability 8 or 24 hours a day, 7 days a week Optional

Direct contact to expert team

Assistance for installation, use and configuration

of the supported application

Direct contact for on-site field service planning

* 2 hours outside working hours

The Endress+Hauser Maintenance Guide 137

 Maximize uptime
At your service

through cost-effective support

Reducing our carbon footprint and supporting a sustainable

environment is a growing concern for Endress+Hauser. And
we know that many companies that call upon our services
share this concern. This is why we are heavily investing in
remote capability.

Endress+Hauser support services with remote capability provide

secure, direct connections between your Endress+Hauser applications
and our experts teams. Remote technical support is an innovative
service that helps maximize system uptime and improve your
business processes.

Seamless support for your solutions via remote capability

Through in-depth knowledge of instrumentation services and
automation solutions, Endress+Hauser develops long-term and
reliable partnerships with companies that employ the same strategy.
We combine our strengths and competence in understanding your
business challenges and translate them into support services with real
benefits. Whenever possible, we utilize state-of-art IT platforms such
as W@M, remote access with support of KPI dashboards to provide a
cost-effective, efficient and sustainable way with the smallest carbon
footprint and that delivers a great experience.

These support services with remote capability contribute to generate

value regarding cost savings, enhanced application support, workflow
efficiencies with increased operational usage time and improved
experience, such as quicker problem solving via remote connection to
our customer service system. supplementing on-site maintenance personnel. Preventing asset
failures and quickly resolving those that may occur, increases the
With equipment diagnostic information at their fingertips, our overall system reliability, availability, and operational performance.
technical support team can quickly understand the scope of a support
issue, and significantly reduce the resolution time. Endress+Hauser For more information, please contact your local Endress+Hauser
support services are therefore an economically sound approach to sales center.

138 The Endress+Hauser Maintenance Guide

Three complementary tools to help with everyday problems The Maintenance Guide

The Maintenance Guide - 3rd edition

Tips and reference information
The Maintenance Guide: this manual is the reference text for to keep your installed base up and running
your production, metrology and maintenance teams. Keep a
printed copy on your desk all year round and have a shortcut to
the PDF version on your computer desktop for quick reference.
The content is updated on a regular basis.

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. It 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.

Find these maintenance publications at

www.services.endress.com/maintenance_publications

Instruments International Other locations

Endress+Hauser Please visit:

Instruments International AG www.endress.com/worldwide
Kaegenstrasse 2
4153 Reinach
Switzerland
Tel. +41 61 715 81 00
Fax +41 61 715 25 00
http://www.endress.com
info@ii.endress.com
Endress+Hauser

EC00003H/29/EN/01.11

PF/INDD CS4